Phosphate ore is an important raw material for manufacturing fertilizers and phosphorous chemical products. While most of the phosphate resources cannot be directly treated as feed stock due to the low grade of P₂O₅ and high content of impurities. In order to obtain a qualified phosphate concentrate, the beneficiation of the low-grade phosphate ore is, hence, of great necessity. Many beneficiation techniques can be employed to upgrade the P₂O₅ grade of phosphate ores based on their characteristics in chemical composition and texture. The flotation process is most widely applied to balance the P₂O₅ recovery ratio and cost. In this review, the dominant techniques for the beneficiation of phosphate ores are introduced. Moreover, the factors that affect the flotation of phosphate ore, including the properties of mineralogy, flotation reagents (depressants and collectors) and flotation medium, were systematically analyzed.

The effects of Ca²⁺, Mg²⁺, Al³⁺, and Fe³⁺ on the flotation behaviors of apatite, dolomite and quartz were investigated through a micro-flotation test, and the influence of calcium ions on the flotation of these minerals was further elucidated by solution chemistry study, zeta potential measurement, and X-ray photoelectron spectroscopy (XPS) analyses. The results indicate that an appropriate amount of Ca²⁺ and Mg²⁺ can improve the floatability of apatite but had a negligible effect on the flotation performance of dolomite, whereas Al³⁺, Fe³⁺, and excessive amounts of Ca²⁺ decreased the recovery of apatite and dolomite. The studied metal cations can activate quartz at a particular pH. It can be inferred from solution chemistry and zeta potential measurement that the influence of metal ions on the flotation of different minerals should be attributed to the adsorption of various hydrolysis species on the mineral surfaces. XPS analyses reveal that calcium ions can enhance the adsorption of anionic collector on apatite and quartz surfaces, and there are no apparent changes to be observed on the surface of dolomite in the absence and presence of calcium ions at a concentration of 2.5 × 10⁻³ M, which was in good agreement with the micro-flotation results.

The mid-low grade sedimentary phosphate ore, abundant in silicate and carbonate gangue minerals, exhibits a poor processability. It is conventionally enriched using high temperature flotation to remove silicate gangues with fatty acid as a collector. Cottonseed oil has been proved to be an efficient collector for achieving ambient temperature flotation of the sedimentary phosphate ore used in this study. Flotation kinetics was investigated to ascertain the excellent collecting performance of cottonseed oil, as compared with oleic acid, and the phosphate flotation fitted well with the first-order flotation model. Based on the analysis of flotation reagent effect on the direct flotation process using the response surface methodology (RSM), a closed circuit of direct-reverse flotation for stepwise removing silicate and carbonate gangues from the sedimentary phosphate ore was established. Consequently, a required high quality of phosphate concentrate containing 30.16% P₂O₅ was obtained, with a recovery of 90.90%. Scanning electron microscopy (SEM) and X-ray diffraction analysis (XRD) of the flotation products confirmed that the majority of silicate and carbonate gangues were effectively removed from the concentrate products.

Bauxite residue is a hazardous solid waste produced in the alumina production process and has also become a significant rare earth resource. The extraction behaviors of La, Ce, Sc and Y solubilized in the phosphoric acidic leachate of bauxite residue were investigated in this study with di-(2-ethylhexyl) phosphoric acid as the extractant. With a relatively low concentration of 2% at an aqueous solution pH of 1.5, 90% Sc and 98% Y were extracted by di-(2-ethylhexyl) phosphoric acid. Less than 5% La and Ce and impurities of Fe, Al, Ti and Ca were extracted in this situation. As the concentration of di-(2-ethylhexyl) phosphoric acid increased to 20%, almost all the Sc and Y were extracted and the extraction ratios of La and Ce were 87% and 95%, respectively. A good separation of REEs against impurities was simultaneously obtained in the solvent extraction process and their separation coefficients were much higher than 1. A stepwise extraction process was proposed and established to extract Sc/Y and La/Ce sequentially from the phosphoric acidic leachate. It was further revealed that the Sc and Y in the acidic leachate were extracted by di-(2-ethylhexyl) phosphoric acid through an ion exchange process, and that the extraction of La and Ce was due to an antagonistic process where both an ion exchange reaction and a solvation reaction occurred.