Mining Solutions

Development of fatty acid modifier for beneficiation of the igneous apatite ores of Kovdor depositRostislav Kamkin, Alexej Michailovski, Pavel Alexandrov, Pasi Mikkola

MEI Flotation`17 conferenceCapetown 2017

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Kovdor mining plant: brief information

Kovdor mining plant: Situated in the Murmansk region (town of Kovdor);

Part of EuroChem Group AG;

Second major Russian apatite concentrate producer –

2,8 million tons/year ~ 20 % of total production;

The only baddeleyite concentrate producer;

Big iron concentrate producer: 5,7 million tons / year.

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Kovdorskiy plant:Apatite flotation technologyOre types: igneous apatite and staffeliteUsed method: direct flotation (2 rougher, 2 cleaner, 2 scavenger stages)Сollector: fatty acids of tall oilsCollector modifier: mixture of high and low ethoxylated nonylphenols (NPEO)Frother: ethylhexanol distillation bottomsTarget concentrate grade: 37,0 % P2O5, MgO ≤ 2,2 %

Flotation mixture composition:

Ways of process improvement: Increasing of concentrate quality and P2O5 recovery; Reducing costs for reagents; Search for NPEO-free collector modifiers

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Surfactants: Sustainable substitution of NPEO-based collector modifiers

Sustainable solution from BASF:

Since mid-1990s, BASF has developed a range of sustainable alternatives for alkylphenol ethoxylates, biodegradable and non-toxic. These have been proven to be suitable to all typical NPEO applications.

Ethoxylated fatty alcohols show good performance as substitutes of NPEOs in apatite flotation: combination of surfactants with low and high HLB allows to improve performance of fatty acid based collectors and lead to:• Higher selectivity & recovery• Lower effective dosage

APEO-based fatty acids modifiers are well known and effectively used for more than 40 years, but: Alkylphenol, generated during APEO degradation path was found to be a weak estrogen; According to [EU REACH No 1907/2006]: APEOs not allowed to use in most of

applications unless they are used in a closed system; Phase-out in EU until 2018; other key economies follow a similar timetable.

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Lupromin® FP A 105:Laboratory and pilot trials cycle

Initial lab screening

Pilot trials:Step I

Pilot trials:Step II

Initial screening among products with different hydrocarbon length, degree of ethoxylation & branching

Product composition adjustment:[A] – Initial: hi ethoxylated fatty alcohol [B] – Adjusted: mix. of hi- and low-Ethoxylated fatty alcohols

Comparison with incumbent product Approval for industrial trials

READY FOR INDUSTRIAL TRIALS

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Lupromin® FP A 105:Industrial trials cycle

1 «small» section(100 t\h), 3 days

1 «big» section(230 t\h), 30 days

Whole flotation(~1700 t\h), 30 days

Several trials periods covered: Ore grades range: P2O5: 8,2÷11,3 %; CO2: 7,5÷22 %, apatite and apatite-staffelite ores Work during all 4 seasons – impact of seasonal changes

in water composition & temperature checked

Positive feedback from the factory staff: Easy reagent preparation procedure Stable froth layer and concentrate quality

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Lupromin® FP A 105 industrial trials:Main results

Parameters Average valuesTrials period Sep.2016 Nov. 2016Used modifier Incumbent Lupromin FP A 105Р2О5 content in flotation feed, % 10,4 10,2Ratio of CO2/Р2О5 in flotation feed 1,0 1,0Apatite concentrate grade, % of Р2О5 37,3 37,3MgO content in concentrate, % 2,3 2,1Р2О5 recovery, % 77,0 79,9Modifier consumption, g/t 235 147Frother consumption, g/t 134 133

Results of 30-days trials:

Recovery gain >3,5 %

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Conclusions and acknowledgements

Specific tailored for Plant conditions Lupromin® FP A 105 allow to improve process…

…economics: increasing P2O5 recovery up to 2,5 % at the same concentrate grade reducing total modifier consumption up to 37 % at the same flotation feed lower MgO content at the same concentrate grade

…ecology: NPEO-free product, biodegradable and non-toxic

…sustainability: one product instead two → easy of preparation and dosing more stable flotation process maintenance

Acknowledgements: BASF`s Mining Solutions team, on behalf of BASF, expresses deep gratitude to managementand technologists of Kovdor plant for possibility to try our products, and for support and openness in the field of flotation reagent regime improving.

Mining Solutions 150 years