In China, direct-reverse flotation is proved to be applicable to most phosphate ores. However, because the ratio of froth product is generally high, current direct-reverse technology faces challenges in terms of high reagent consumptions and cost. A new gravity and flotation combined process has been developed for the recovery of collophanite from sedimentary phosphate ore from the beneficiation plant of Hubei, China. In this process, 53% of the collophanite was firstly recovered by gravity separation, reducing the mass flow to direct flotation. The gravity tailing was the feed for the direct flotation. The flotation concentrate, mixed with gravity concentrate, was then subjected to reverse flotation. A final concentrate with a grade of 30.41% P₂O₅ at a recovery of 91.5% was produced from the feed analyzing 21.55% P₂O₅. Compared to the conventional direct-reverse flotation 86.1% recovery at 31.69% P₂O₅, it was found that pre-recovery of collophanite by spiral separation could significantly reduce the flotation reagent consumption and lead to improved overall collophanite recovery. The benefits of the new process in terms of cost savings were also discussed.

Phosphate ore is a valuable strategic resource. Most phosphate ore in China is collophane. Utilization of mid-low grade collophane is necessary to maintain social sustainable development. The gravity-flotation combination separation process can be utilized to separate mid-low grade collophane, but the process consumes a large quantity of acid in the reverse stage. Sodium dodecyl sulfate (SDS) was used as a dolomite collector in this study to reduce the acid consumption of collophane flotation. SDS effectively removed dolomite from the gravity concentrate when no other reagents were present. Flotation test results showed that, compared to the conventional gravity-flotation process, the proposed SDS-based process reduced phosphoric acid dosage from 6.1 kg/t to 3.9 kg/t with similar separation results. The SDS action mechanisms on dolomite were further investigated by zeta potential analysis, single mineral flotation tests, infrared spectrum detection, and theoretical analysis. The results indicate that the SDS adsorption on dolomite is mainly physical adsorption, and that favorable separation effects between collophane and dolomite may be attributed to physical adsorption and entrainment. In addition, it also indicates that the physical adsorption can be utilized to remove dolomite from phosphate on account of zeta potential differences when the separate feed is coarse.

Due to the low grade of V₂O₅ in stone coal, the existing vanadium extraction technologies face challenges in terms of large handling capacity, high acid consumption and production cost. The pre-concentration of vanadium from stone coal before the extraction process is an effective method to reduce cost. In this study, detailed mineral characterization of stone coal was investigated. It has been confirmed that the vanadium mainly occurs in muscovite and illite. A significant demand for an effective pre-concentration process with simple manipulation for discarding quartz and other gangue minerals is expected. Based on the mineralogical study, a new vanadium pre-concentration process using a fine mineral spiral was investigated. The experimental results showed that the separation process, which was comprised of a rougher and scavenger, could efficiently discard quartz, pyrite and apatite. A final concentrate with V₂O₅ grade of 1.02% and recovery of 89.6% could be obtained, with 26.9% of the raw ore being discarded as final tailings.

Detailed characterization and recovery of apatite from a sedimentary phosphate ore slime of a gravity plant of Yichang, China, were investigated. The phosphate ore slime consisted mainly of apatite, quartz, dolomite, and clay. To start with, the ore slime was characterized in sufficient detail to reveal that it is extremely fine in distribution with a d₅₀ of 65 μm. Other different characterizations, such as apatite grain size distribution, apatite liberation, particle density distribution, and theoretical grade recovery, were also analyzed by mineral liberation analyser (MLA). Based on the results, a new gravity-flotation process, which was comprised of spiral gravity and reverse flotation, was proposed to process the slime. In the new process, the apatite was firstly recovered by two-stage spiral gravity, avoiding direct flotation. The gravity concentrate was the feed for the reverse flotation. A phosphate concentrate of 30.51% P₂O₅ with a P₂O₅ recovery of 89.00% can be produced from the slime analyzing 24.25% P₂O₅. Compared to the conventional direct-reverse flotation process, it was found that the reagent cost of the new gravity-flotation process was lower a quarter than that of the direct-reverse flotation flowsheet.