Document Details
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Document Type |
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Thesis |
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Document Title |
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BENEFICIATION OF SAUDI LOW– GRADE PYROPHYLLITE ORE FOR FILLER INDUSTRIES تركيز خام البيروفلايت السعودي منخفض النقاوة لصناعات المواد المالئة |
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Subject |
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Faculty of Engineering |
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Document Language |
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Arabic |
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Abstract |
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With its unique properties, pyrophyllite ((AI2Si4O10(OH)2)) has become an economical alternative to many essential minerals such as talc, kaolinite, and feldspar in many applications, especially as fillers. The pyrophyllite price depends mainly on its alumina (Al2O3) content and impurities, particularly iron-bearing minerals. Iron causes several problems in the final product, such as coloring and decreasing mechanical strength, which affects the quality of the product. Globally, high-grade pyrophyllite ores are very rare in nature, and there are large quantities of low-grade pyrophyllite ores. Therefore, industry seeks to treat them and raise their purity to fit different applications. In this purview, this thesis investigates the beneficiation of low-grade pyrophyllite ore to be used in filler industries. The Saudi low-grade pyrophyllite samples were collected from the SAMIROCK ltd company site (Yanbu, Saudi Arabia). The representative samples were characterized using Microscopic studies, X-ray fluorescence (XRF), Energy Dispersive X-Ray Analysis (EDX), X-ray Diffraction (XRD), and Scanning Electron Microscope (SEM). The crushing and grinding processes were optimized before beneficiation approaches. Several beneficiation approaches were investigated for enriching Saudi low-grade pyrophyllite ore. An economic evaluation was conducted on obtained pyrophyllite concentrates. The results of chemical and mineralogical characterization showed that pyrophyllite is a major constituent associated with quartz and feldspars associated with rare amounts of muscovite, chlorite, impurities, and sericite. Furthermore, impurities are evident in the form of altered pyrite and hematite. The results of dry high-intensity magnetic separation(DHIMS) revealed that using Outotec-induced roll at optimum conditions can produce pyrophyllite concentrate having 0.40 % Fe2O3 and 26.04 % Al2O3 which can be used as a filler for paper, plastic, and paint industries. The results indicated that applying wet magnetic separation optimum conditions using Outotec high gradient magnetic separator can lead to a pyrophyllite concentrate having 0.38 % Fe2O3 and 26.32 % Al2O3, which is also suitable for filler industries. The results indicated that the combined microwave treatment and dry magnetic separation at optimum conditions would provide high purity pyrophyllite having 0.18 % Fe2O3 and 27.22 % Al2O3 for filler industries. The results showed that using the combined dry magnetic separation and collectorless flotation at optimum conditions led to high purity pyrophyllite concentrate having 30.25 % Al2O3 and 62.90 % SiO2. This product can have different filler applications due to its high alumina and low iron and silica contents. The results showed that using chemical treatment with oxalic acid at optimum conditions could provide concentrate having 0.13% Fe2O3 and 27.77 % Al2O3 as well as significantly increase the whiteness index of Saudi pyrophyllite samples to 88 %, which is fit filler industries. The thermogravimetric analysis (TGA) showed no noticeable difference between the leached product and bulk ore. The economic evaluation results showed that concentrate obtained by combined dry high-intensity magnetic separation (DHIMS) and collectorless flotation approach has a high price (470 US$/t) due to high alumina and lower silica content. In contrast, concentrates obtained by high-intensity magnetic separation, either dry or wet, have a low price (280 US$/t) compared to other approaches. However, results showed that all the concentrates obtained under optimum conditions by the beneficiation approaches have a high market value for filler grade.
Key words: (Beneficiation, Low-grade, Pyrophyllite, Filler, Purity) |
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Supervisor |
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Prof. Dr. Hussin Abdelbary M. Ahmed |
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Thesis Type |
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Doctorate Thesis |
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Publishing Year |
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1444 AH
2023 AD |
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Added Date |
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Tuesday, June 6, 2023 |
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Researchers
| معاذ عبدالمنعم نور الدائم | Noureldaim, Maaz Abdelmoniem | Researcher | Doctorate | |
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