Characterization and development of beneficiation prospects of sedimentary phosphate ore from the Kef Essenoun deposit (Algeria) by reverse flotation

Phosphate is one of the most important natural resources because it is so crucial to the production of fertilizers and phosphoric acid. However, many undesirable elements are present in raw phosphate ores, which need to be refined in some way to boost their market value is the objective of this work. The most efficient technique for upgrading phosphate ores by the selective removal of gangue minerals is reverse flotation. This study aims to determine the physicochemical properties and the flotation behavior of sedimentary phosphate ore from the Kef Essenoun deposit (Tebessa, Algeria), with the intention of developing an effective beneficiation process. To develop the processing parameters for the medium grade phosphate ore, a thorough investigation was conducted to ascertain its mineralogical composition, particle size distribution, and degree of impurity elimination. Particle size distribution measurements, XRF, XRD, SEM/EDS analysis, and petrographical evaluation were used to describe these phosphates. 69.64% of the total mass of the phosphate raw ore sample fell between the –0.5 and +0.1 mm range, which also showed a reasonably acceptable particle size distribution. In addition to the related impurities of MgO and SiO₂, chemical analysis revealed that the phosphates had P₂O₅ values ranging from 24% to 26%. According to mineralogical analysis, dolomite, calcite, and quartz were the related gangue minerals, whereas hydroxyapatite and fluorapatite were the predominant phosphate minerals. The traditional coprolitic and bioclastic characteristics of sedimentary phosphates were observed when examining the details on a smaller scale. Reverse flotation studies revealed that the produced concentrate reached 30% P₂O₅, confirm the effectiveness of this method for the perspective of valorization of sedimentary ore from the Kef Essnoun at Djebel Onk deposit and that this technique can increase the value of the ore. These findings support the idea that Algerian phosphate ore processing could benefit economically and environmentally from reverse flotation.