Apple - Cannot erase SD card with Disk Utility (El Capitan)
A better and simpler solution would be using the command-line.
Execute the following command to identify the mount name of SD card following the pattern /dev/diskX, e.g., /dev/disk2
diskutil list
Say the disk name is /dev/disk2
. Now format the card to FAT32 by running the following command:
sudo diskutil eraseDisk FAT32 MYSD MBRFormat /dev/disk2
I had the same exact problem. Format your card using this application: https://www.sdcard.org/downloads/formatter_4/index.html
Worked perfect for me.
Cheers.