Sulfonated modifiers for froth flotation

Abstract

Improved sparge compositions for reverse froth flotation separation and uses thereof, and methods of reverse froth flotation are described. The sparge compositions comprise sulfonated polymeric modifiers which can act as dispersants and depressants, and the compositions are suitably used in the reverse froth flotation of particulate material containing ultrafine particles. For example, the compositions and methods can be used in the separation of phosphate beneficiary from ores comprising phosphates, dolomite, calcite, clay, silica, silicates, carbonates, and mixtures thereof.

What is claimed is: 
     
         1 . A sparge composition comprising:
 (i) a medium;   (ii) a phosphate ore comprising a phosphate beneficiary and a gangue;   (iii) a collector; and   (iv) a sulfonated polymer comprising
 (a) a monomer residue having the structure 
   
       
         
           
           
               
               
           
         
         
           and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
           (b) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           (c) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           wherein n is 1, 2, or 3, and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
           (d) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           wherein n is 1, 2, or 3, 
           (e) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           (f) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
           (g) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           wherein R 4  is alkyl, 
           (h) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           wherein R 4  is alkyl, and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
           (i) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           (j) a monomer residue having the structure 
         
       
       
         
           
           
               
               
           
         
         
           and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, or 
           (k) any combination thereof, 
           wherein the phosphate beneficiary comprises a phosphate. 
         
       
     
     
         2 . The sparge composition of  claim 1 , wherein the gangue comprises a silicate, silica, a carbonate, or any combination thereof. 
     
     
         3 . The sparge composition of  claim 1 , wherein the sparge composition further comprises a sulfonated lignin, a sulfonated starch, a sulfonated cellulose, a sulfonated guar gum, a sulfonated xanthan gum, or any combination thereof. 
     
     
         4 . The sparge composition of  claim 1 , wherein the sulfonated polymer has a weight average molecular weight of from about 300 g/mole to about 100,000 g/mole. 
     
     
         5 . The sparge composition of  claim 1 , wherein the sulfonated polymer further comprises a residue of acrylic acid, methacrylic acid, acrylamide, vinyl alcohol, maleic acid, a maleic acid ester, or any combination thereof. 
     
     
         6 . The sparge composition of  claim 1 , wherein the phosphate beneficiary comprises an apatite. 
     
     
         7 . The sparge composition of  claim 1 , the sparge composition further comprising phosphoric acid. 
     
     
         8 . The sparge composition of  claim 1 , the sparge composition further comprising a pH adjusting agent, wherein the pH of the sparge composition further comprising the pH adjusting agent is from about 4 to about 7. 
     
     
         9 . A method of reverse froth flotation comprising:
 forming a sparge composition comprising
 (i) a medium, 
 (ii) a phosphate ore comprising a phosphate beneficiary and a gangue, 
 (iii) a sulfonated fatty acid, and 
 (iv) one or more sulfonated polymers; 
 sparging the sparge composition to yield a sparged composition,
 the sparged composition comprising a froth and a sparged slurry, 
 wherein the sparged slurry comprises a concentrate of the phosphate beneficiary and the froth comprises tailings of the gangue; and 
 
 separating at least a portion of the concentrate from the sparged slurry. 
   
     
     
         10 . The method of  claim 9 , wherein at least one of the one or more sulfonated polymers comprises a residue of sulfonated vinyl alcohol, sulfonated acrylamide, sulfomethylated acrylamide, 2-acrylamido-2-methylpropane sulfonate, styrene sulfonate, or any combination thereof. 
     
     
         11 . The method of  claim 10 , wherein the at least one of the one or more sulfonated polymers further comprises a residue of acrylic acid, methacrylic acid, acrylamide, vinyl alcohol, maleic acid, a maleic acid ester, or any combination thereof. 
     
     
         12 . The method of  claim 9 , wherein the one or more sulfonated polymers comprises a sulfonated lignin, a sulfonated starch, a sulfonated cellulose, or any combination thereof. 
     
     
         13 . The method of  claim 9 , wherein the phosphate beneficiary comprises an apatite. 
     
     
         14 . The method of  claim 9 , wherein the sparge composition further comprises phosphoric acid. 
     
     
         15 . The method of  claim 9 , wherein the sparge composition further comprises a pH adjusting agent and the pH of the sparge composition is about 4 to about 7. 
     
     
         16 . A method of froth flotation comprising:
 forming a sparge composition comprising
 (i) a medium, 
 (ii) a phosphate ore comprising a phosphate beneficiary and a gangue, 
 (iii) a collector, and 
 (iv) a sulfonated polymer comprising
 (a) a monomer residue having the structure 
 
   
       
         
           
           
               
               
           
         
         
           
             and a counterion selected from NH 4   − , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
             (b) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             (c) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             wherein n is 1, 2, or 3, and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
             (d) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             wherein n is 1, 2, or 3, 
             (e) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             (f) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
             (g) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             wherein R 4  is alkyl, 
             (h) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             wherein R 4  is alkyl, and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, 
             (i) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             (j) a monomer residue having the structure 
           
         
       
       
         
           
           
               
               
           
         
         
           
             and a counterion selected from NH 4   + , Na + , K + , primary organic ammonium, secondary organic ammonium, tertiary organic ammonium, and quaternary organic ammonium, or 
             (k) any combination thereof, and 
           
           sparging the sparge composition. 
         
       
     
     
         17 . The method of  claim 16 , wherein the sulfonated polymer further comprises a residue of acrylic acid, methacrylic acid, acrylamide, vinyl alcohol, maleic acid, a maleic acid ester, or any combination thereof. 
     
     
         18 . The method of  claim 16 , wherein the phosphate beneficiary comprises an apatite. 
     
     
         19 . The method of  claim 16 , wherein the sparge composition further comprises phosphoric acid. 
     
     
         20 . The method of  claim 16 , wherein the sparge composition further comprises a pH adjusting agent and the pH of the sparge composition is about 4 to about 7.