Improvement of water recovery from phosphate sludge at the M'Dhilla Mine, Tunisia

In Tunisia, phosphate beneficiation from ores by the Gafsa Phosphate Company (GPC) is a water-intensive process that generates large amounts of sludge. Responsible mining minimizes water use and prioritizes its recycling and reuse to limit the impact on water resources. Recovery of water from the phosphate sludge (PS) using the densification with adapted flocculants—a low-energy consuming process—is plausible for efficient management of water resources. The objective of this study was to improve low-cost water recovery from PS produced at the M’Dhilla Mine plant operated by GPC in Tunisia. Representative samples of PS were first collected and characterized for physicochemical and mineralogical properties. To maximize water recovery, densification based on flocculation was then performed using two different flocculants (Slim Floc vs Flomin 905) with different doses (0.1 g/L vs 0.3 g/L), consumption (100–1200 g per ton of dry sludge g/tds), sludge concentration (50 g/L vs 60 g/L), and settling time (15–1200 s). Results showed that PS particles were fine-grained and contained carbonates, silicates, and significant residual fluorapatite (59%) that could be valorized. Up to 91% of water was recovered using anionic flocculant Flomin 905. These findings show an improvement of 24% relative to the current water recovery at M’Dhilla plant (66%) while using a flocculant dose three times lower than the conventional flocculent Sim Floc (0.1 g/L vs 0.3 g/L). The best sludge settlement conditions were obtained with 0.1 g/L Flomin 905 at 600 g/tds and 10 min of settling time. The densification process using Flomin 905 proved efficient in maximizing water recovery (91%) with a consumption of flocculant that could be decreased by up to 70% annually in comparison with Slim Floc, thus decreasing treatment costs by 63%. Results will help to prevent exhaustion of groundwater resources and limit land exploitation while decreasing the volume of settling ponds. Graphical abstract