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38 Journal of Mineral, Metal and Material Engineering, 2019, 5, 38-50 E-ISSN: 2414-2115/19 © 2019 Scientific Array Upgrading of Egyptian Talc Ore for Different Industrial Applications Sabreen H. Mourad 1 , M.K. Abdel Rahman 1,* , N.A. Abdel Khalek 1 , S.A. Sayed 2 , K.A. Selim 1 and B.A. Salah 2 1 Central Metallurgical Research & Development Institute, P.O. box 87, Cairo, Egypt 2 Chemistry Department, Faculty of Science, Helwan University Abstract: Talc mineral is widely used in many industrial applications, including paper making, plastic, paint, coatings, rubber, pharmaceuticals, cosmetics, and ceramics. This work aims to upgrade Egyptian talc ore to meet the required specifications for different industrial applications through physical separation techniques. Characterization showed that it contains 76% talc, 13% chlorite, 9% dolomite and 1.5% quartz. It classified as grade C which can be used as filler in rubber, plastic and paints after ultra-fine grinding. A concentrate of 23% weight with 6.37% loss of ignition (L.O.I) and 88% whiteness was achieved by natural floatability of talc while its weight is increased to 59% by using 250 g/ton pine oil at pH 8. It can be classified as talc grade "B" which can be used as a filler for paper, textile and ceramics. A second concentrate of 47% weight with 5.86% L.O.I and 90.26% whiteness was obtained by magnetic separation followed by flotation. Its talc content is 94%, while chlorite is 6.7%. It can be classified as grade A, which is suitable for paper coating, cosmetic and pharmaceutical industries. A third concentrate of 30% weight with 4.9 % L.O.I and 92% whiteness was obtained by flotation followed by magnetic separation. Its talc content is 95%, while chlorite is 1.8%. Keywords: Talc, Flotation, Attrition scrubber, Magnetic separation, Filler. 1. INTRODUCTION Talc is used in many industries, including paper making [1] plastic, paint and coatings, rubber, food, electric cable, pharmaceuticals, cosmetics, ceramics and construction materials [2]. It is also often used in basketball to keep a player's hands dry. Most tailor's chalk, or French chalk, is talc, as is the chalk often used for welding or metalworking [3]. Generally it is classified into A, B, C and D grades [4]. Grade A is pure white to slightly green with whiteness ranges from 90 to 95%. It is used in producing pharmaceuticals and cosmetics [5]. Grade B is pale-greenish to white with whiteness range 85 to 90%. It is used in producing superior-grade paper, textile and ceramics. Grade C is light greenish-grey with whiteness range 78 to 85%. It is used in paper (inferior grade), paint, rubber, plastic and detergent industries. China is the key world talc producing country with an output of about 2.2M tones (2016), which accounts for 30% of total global output. The other major producers are Brazil (12%), India (11%), the U.S. (9%), France (6%), Finland (4%), Italy, Russia, Canada, and Austria (2%, each). Talc deposits are found in different localities in the Eastern Desert of Egypt such as Atshan, Abu Gurdi, Darhib and Kashira [6-8]. *Address correspondence to this author at the Central Metallurgical Research & Development Institute, P.O. box 87, Cairo, Egypt; Tel: (0202) 25010642, Int. 185; Email: [email protected] Talc was processed using wet attrition scrubber as a substitution of the conventional ball or rod milling in talc beneficiation plants because of its friable nature. Flotation scheme was carried out for talc beneficiation [9]. Piga and Marruzza, [10] reported that carbonates are harder than talc; they are used as a grinding medium for the slurry formed of the ore to be treated. So the fine fraction should be enriched in talc and the coarser fraction enriched in carbonates. This product may be floated for further removal of carbonates and chlorite. Flotation is used to remove impurities from talc [11] Various factors that control flotation process of talc include particle size, pH values, collector dosage, depressant dosage, pulp density and frother dosage has been studied [9, 12-14]. Beneficiation of talc at the Governor district in New York was studied by Combination of froth flotation and high intensity magnetic separation for the removal of iron–bearing minerals [15]. Yehia and Al-Wakeel [16] applied flotation process at 25% solids, airflow rate of 1000 L/min, pH 7, and using 0.1 kg/ton of polypropylene glycol as a frother. Al-Wakeel and Roe [12, 17] have treated the final cleaned product with a diluted hydrochloric acid having a concentration of 10% and SnCl 2 (300 ppm) to produce talc free from carbonates. The iron content was nearly removed and the whiteness increased to 93%. Their last product was suitable for different purposes for paper, cosmetic, paint, roofing, ceramic and rubber filling industries.
Transcript
Page 1: 38 Journal of Mineral, Metal and Material Engineering ...cyclosizer. Figure 4 represents a relation between cumulative operational weight percent passing and the particle size. The

38 Journal of Mineral, Metal and Material Engineering, 2019, 5, 38-50

E-ISSN: 2414-2115/19 © 2019 Scientific Array

Upgrading of Egyptian Talc Ore for Different Industrial Applications

Sabreen H. Mourad1, M.K. Abdel Rahman1,*, N.A. Abdel Khalek1, S.A. Sayed2, K.A. Selim1 and B.A. Salah2

1Central Metallurgical Research & Development Institute, P.O. box 87, Cairo, Egypt 2Chemistry Department, Faculty of Science, Helwan University

Abstract: Talc mineral is widely used in many industrial applications, including paper making, plastic, paint, coatings, rubber, pharmaceuticals, cosmetics, and ceramics. This work aims to upgrade Egyptian talc ore to meet the required specifications for different industrial applications through physical separation techniques. Characterization showed that it contains 76% talc, 13% chlorite, 9% dolomite and 1.5% quartz. It classified as grade C which can be used as filler in rubber, plastic and paints after ultra-fine grinding. A concentrate of 23% weight with 6.37% loss of ignition (L.O.I) and 88% whiteness was achieved by natural floatability of talc while its weight is increased to 59% by using 250 g/ton pine oil at pH 8. It can be classified as talc grade "B" which can be used as a filler for paper, textile and ceramics. A second concentrate of 47% weight with 5.86% L.O.I and 90.26% whiteness was obtained by magnetic separation followed by flotation. Its talc content is 94%, while chlorite is 6.7%. It can be classified as grade A, which is suitable for paper coating, cosmetic and pharmaceutical industries. A third concentrate of 30% weight with 4.9 % L.O.I and 92% whiteness was obtained by flotation followed by magnetic separation. Its talc content is 95%, while chlorite is 1.8%.

Keywords: Talc, Flotation, Attrition scrubber, Magnetic separation, Filler.

1. INTRODUCTION

Talc is used in many industries, including paper making [1] plastic, paint and coatings, rubber, food, electric cable, pharmaceuticals, cosmetics, ceramics and construction materials [2]. It is also often used in basketball to keep a player's hands dry. Most tailor's chalk, or French chalk, is talc, as is the chalk often used for welding or metalworking [3]. Generally it is classified into A, B, C and D grades [4]. Grade A is pure white to slightly green with whiteness ranges from 90 to 95%. It is used in producing pharmaceuticals and cosmetics [5]. Grade B is pale-greenish to white with whiteness range 85 to 90%. It is used in producing superior-grade paper, textile and ceramics. Grade C is light greenish-grey with whiteness range 78 to 85%. It is used in paper (inferior grade), paint, rubber, plastic and detergent industries.

China is the key world talc producing country with an output of about 2.2M tones (2016), which accounts for 30% of total global output. The other major producers are Brazil (12%), India (11%), the U.S. (9%), France (6%), Finland (4%), Italy, Russia, Canada, and Austria (2%, each).

Talc deposits are found in different localities in the Eastern Desert of Egypt such as Atshan, Abu Gurdi, Darhib and Kashira [6-8]. *Address correspondence to this author at the Central Metallurgical Research & Development Institute, P.O. box 87, Cairo, Egypt; Tel: (0202) 25010642, Int. 185; Email: [email protected]

Talc was processed using wet attrition scrubber as a substitution of the conventional ball or rod milling in talc beneficiation plants because of its friable nature. Flotation scheme was carried out for talc beneficiation [9]. Piga and Marruzza, [10] reported that carbonates are harder than talc; they are used as a grinding medium for the slurry formed of the ore to be treated. So the fine fraction should be enriched in talc and the coarser fraction enriched in carbonates. This product may be floated for further removal of carbonates and chlorite. Flotation is used to remove impurities from talc [11]

Various factors that control flotation process of talc include particle size, pH values, collector dosage, depressant dosage, pulp density and frother dosage has been studied [9, 12-14]. Beneficiation of talc at the Governor district in New York was studied by Combination of froth flotation and high intensity magnetic separation for the removal of iron–bearing minerals [15]. Yehia and Al-Wakeel [16] applied flotation process at 25% solids, airflow rate of 1000 L/min, pH 7, and using 0.1 kg/ton of polypropylene glycol as a frother. Al-Wakeel and Roe [12, 17] have treated the final cleaned product with a diluted hydrochloric acid having a concentration of 10% and SnCl2 (300 ppm) to produce talc free from carbonates. The iron content was nearly removed and the whiteness increased to 93%. Their last product was suitable for different purposes for paper, cosmetic, paint, roofing, ceramic and rubber filling industries.

Page 2: 38 Journal of Mineral, Metal and Material Engineering ...cyclosizer. Figure 4 represents a relation between cumulative operational weight percent passing and the particle size. The

Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 39

This work aims to upgrade Egyptian talc ore to meet specifications for paper industry application through flotation and magnetic separation techniques.

2. MATERIALS AND METHODS

Representative sample of about 1/2 ton run of mine from Eastern Desert delivered to Central Metallurgical Research and Development Institute (CMRDI), by El-Nasr for Mining Company.

2.1. Characterization, Chemical Analysis and Optical Properties

The mineralogical investigation was carried out by X-ray diffraction (XRD) analysis using diffractometer model (D8 ADVANCE Cu-Target 40 kV. 40 mA). Chemical analysis was carried out by X-ray fluorescence analysis. XRF diffractometer model advanced axios, Netherlands, was employed to determine oxides content. Ignition loss is determined by heating talc sample at 1000°C, for 2 hours in a muffle furnace. A 10 g of ignited sample is mixed and pressed with 2 g of wax as a binder in aluminum cup, and then exposed to X-ray as a disk. An accompanied computer unit with software program calculated the element in oxide forms.

The optical properties such as brightness, whiteness, iso-brightness, redness and yellowish were determined using “UV whiteness and color-meter model JY 9800”. About 10 g of dried sample was compressed in a mold. The smooth surface of compressed sample exposed to UV lamp in the measuring port.

2.2. Crushing and Attrition Scrubbing

The primary crushing of talc sample to less than one inch was carried out using Denver jaw crusher. The crushed product is used as a feed for attrition scrubber. Attrition scrubber was charged by 30 kg representative crushed talc sample with 20 liters of water (pulp density 60%). Effect of attrition time and pulp density was studied. Attrition product is screened on 75 micron screen. The product was discharged and screened on 75 micron sieve. The oversize and under size fraction were dried, weighted and loss of ignition was determined.

2.3. Flotation Process

Flotation was carried out on the size of less than 75 micron with and without flotation collector. A "Denver" flotation machine (D-12), was employed to study parameters affecting the flotation process such as pH and dose and type of collectors and depressants.

A batch of 250 g of (−0.075 mm) was subjected to flotation in a tank of one liter capacity. The conditioning process is performed at 1800 rpm and 50% solid/liquid ratio, and then depressant is added for 5 min. Sodium carbonate, sodium silicate and sodium hexameta phosphate were used as depressants while sodium hydroxide is used as a pH modifier. Pine oil and methyl isobutyl carbinol were used as frothers. Flotation is carried out at 1200 rpm after dilution to 25% solid. A Cleaning step was carried out on the concentrate of the first stage without adding more surfactant. A frother

(a) X-ray diffraction of talc ore (b) Mineral composition.

Figure 1: (a & b) X-ray diffraction and mineral composition of talc ore.

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40 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

was added stepwise and flotation continues to reach demineralized froth.

2.4. Magnetic Separation

Magnetic separation was carried out using Boxmag wet high intensity magnetic separator. The process was carried out by down passing the feed through stain less-steel wool matrix. The canister was filled with 176 g stainless steel wool. The non-magnetic fraction represents talc concentrate. The magnetic and non-magnetic fractions were dried, weighted and chemically analyzed. 3. RESULTS AND DISCUSSION

3.1. Characterization Studies

XRD pattern and mineral composition, Figure 1 (a and b), shows the associated gangue minerals with talc are chlorite, dolomite, and quartz. Talc ore contains about 76% talc, 13% chlorite, 9% dolomite and 1.5% quartz. Table 1 shows the chemical analysis of talc ore. It contains about 47% SiO2, 28% MgO, 6%CaO and 1% Fe2O3. Thus, the talc ore is considered as low grade and it was necessary to increase its grade to be suitable for different industrial applications.

3.2. Crushing of Talc Ore

Figure 2 illustrates size distribution of jaw crusher product. It was noticed that the d90 and d50 were 15.6 mm and 9 mm, respectively. This crushed product was used as a feed for attrition scrubber.

Table1: Chemical Analysis of Talc Ore

Minor Elements

% Constituents % Constituents

0.069 TiO2 0.332 Na2O

0.008 Cr2O3 28.184 MgO

0.078 MnO 2.705 Al2O3

0.004 NiO 47.432 SiO2

0.009 CuO 0.134 P2O5

0.298 ZnO 0.083 SO3

0.006 SrO 0.031 K2O

0.003 MoO3 6.234 CaO

0.010 PbO 0.939 Fe2O3 0.243 F 13.2 L.O.I

Figure 2: Crushing of talc ore using jaw crusher.

3.3. Attrition Scrubber of Talc

3.3.1. Effect of Pulp Density

Attrition scrubbing was carried out at different pulp density 60%, 40% and 25% for 30 min. Figure 3 represents the size distribution of attrition scrubber products. At 60% pulp density the attrition product size was finer than that of 40% and 25% pulp density. The attrition scrubber product was screened on 75 micron screen. The size fraction less than 75 micron at 40% and 60% pulp density was about 70% by weight of the talc ore with ignition loss about 9%. Classification of less than 75 micron fraction was carried out using cyclosizer. Figure 4 represents a relation between cumulative operational weight percent passing and the particle size. The product at 40% pulp density is finer than that at 60% pulp density. The less than 11 micron fraction is 38% compared to 31% at pulp density 60%. The loss of ignition is decreased from 14% to 7.6% with decreasing the 11 micron fraction.

Figure 3: Size Distribution of attrition scrubber at different pulp density.

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Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 41

Figure 4: Size distribution of less than 75 micron fraction.

3.3.2. Effect of Attrition Time

The attrition scrubbing was carried out at solid/liquid ratio 60% for different times from 30 to 90 min. Figure 5 represents the results of size distribution and loss of ignition of attrition products at different time as well as the LOI for 30 min. The attrition increased with increasing attrition time. The weight percentage of less than 75 micron size fraction is increased from 70% to 78% with increasing time from 30 to 90 min. There is no change in ignition loss at varied times. The coarser size has high ignition loss compared to finer size. The ignition loss for - 1160 micron size fraction is 24% compared to 8.7% for -75 micron size fraction.

Figure 6 illustrates the size distribution of classification of - 75 micron size fraction for studied times at pulp density of 60%. The size distribution at 45 min and 90 min are nearly the same while at 60 min is finer. The size distribution at 30 min is the finest one and the - 11 micron size fraction is 46% as operational weight% compared to 36% at 45, 90 minute and 26% at 60 min. This may be attributed to that feed for attrition scrubber was - one inch and increasing time increased grinding of coarse talc and increase the weight of - 75 micron size fraction with less fines. The weight of - 75 micron size fraction is at 90 min with high fines.

Figure 5: Attrition scrubbing of talc ore at 60% pulp density for different time.

Figure 6: Size distribution of - 75 micron fraction.

3.3.3. Preparation Feed for Flotation and Magnetic Separation Using Attrition Scrubber

The feed for upgrading of talc ore is prepared at pulp density 60% for 30 min. Table 2 shows that the - 75 micron size fraction weighs about 69% with 8.8% loss of ignition and 87% whiteness which can be categorized as talc grade B which can be used in paper and ceramics [4]. The size fraction larger than 75 micron was about 30% with high ignition loss and 79% whiteness, which can be classified as talc grade C which can be used in rubber and plastics and detergent industries [5]. Figures 7 show X-ray diffraction patterns

Table 2: Attrition Scrubbing of Less than one Inch Size at 60% Pulp Density for 30 min

Size, µm Weight % L.O.I Whiteness Brightness

-75 69.46 8.76 87.38 70.31

+75 30.24 20.37 79.54 56.85

Total 99.7 12.24 85.9 67.56

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42 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

and mineral composition of attrition scrubber products. The gangue minerals such as dolomite and quartz peaks are increased in the size fraction larger than 75 micron meanwhile the chlorite peaks is increased in the size fraction less than 75 micron. Talc is increased in size fraction less than 75 micron to 86% compared to 76% and 80% in talc ore and size larger than 75 micron, respectively. The size fraction less than 75 micron contains 2.4% dolomite and 10.4% chlorite compared to 12.4% dolomite and 6.3% chlorite in the size fraction larger than 75 micron. Table 3 represents the chemical analysis of attrition scrubber products. The silica and magnesium oxide are increased in the size fraction less than 75 micron to 52% and 29% compared to 47% and 28% in the size larger than 75 micron. The size fraction - 75 micron can be used as a feed for upgrading processes.

Table 3: Chemical Analysis and Mineral Contents in Attrition Scrubber Products

Size Fraction

+75 micron −75 micron Constituents, %

0.308 0.222 Na2O

22.658 29.889 MgO

2.693 3.900 Al2O3

36.274 52.022 SiO2

0.149 0.102 P2O5

0.083 0.040 SO3

0.131 0.035 K2O

13.284 2.685 CaO

0.195 0.007 Fe2O3

21.1 9.4 L.O.I

(a) less than 75 micron (b) larger than 75 micron

(c) Mineral composition

Figure 7: X-ray diffraction and mineral composition of attrition scrubbing products.

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Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 43

3.4. Flotation for Upgrading of Talc

Based on hydrophobicity nature of talc, flotation was carried out on attrition scrubbing product of less than 75 micron (Table 2) with and without flotation frother.

3.4.1. Flotation of Talc without Frother

Rougher flotation of attrition scrubber feed of talc was carried out for different speeds and flotation time at pH 8 without frother. Table 4 shows that, a total concentrate weighs 23% overall of talc with 6.37% loss of ignition and 88% whiteness was obtained at 15 min.

The flotation of talc was carried out at 1200 rpm and continuous skimming until no mineral float to improve the yield of talc concentrate. Table 5 represents the results of flotation at different pH and 1200 rpm. Loss

of ignition is decreased from 9% to 6.4% and whiteness is increased from 85% to 88%. Also, at pH 8 about 59% overall weight of talc with 6.4% loss of ignition and 88% whiteness is obtained which can be classified as grade B which can be used in paper industry [5]. The effect of collector type is carried out in order to increase the quality of talc.

3.4.2. Flotation of talc with different frother

3.4.2.1. Flotation of talc with pine oil and methyl isobutyl carbinol

The flotation of talc was carried out using pine oil and methyl isobutyl carbinol with different dose and pH8. Table 6 shows that at 250 g of pine oil for ton of ore, a concentrate weighing 59% with 6.4% loss of ignition and 88% whiteness. A similar concentrate was

Table 4: Flotation of Talc without Frother at pH 8

Weight % Time, min

Rpm Product Operation Overall L.O.I % Whiteness

2 900 Conc. 1 6.62 4.59 6.2 88.14

4 900 Conc. 2 8.12 5.63 6.8 87.77

10 900 Conc. 3 10.01 6.94 6.1 88.3

15 1200 Conc. 4 8.38 5.81 6.4 88.8

Total Concentrates 33.13 22.97 6.37 88.26

Tail 66.88 46.40 9.8 83.9

Total 100.00 69.38 8.66 87.38

Table 5: Flotation of Talc without Frother at Different pH and 1200 rpm

Weight % pH Product

Operational Overall L.O.I % Whiteness

Conc. 63.80 44.27 7.1 87.1

Tail 36.20 25.12 13.1 82.18 6

Total 100.00 69.52 9.2 84.64

Conc. 85.01 58.98 6.40 88.30

Tail 14.99 10.40 18.09 60.61 8

Total 100.00 69.52 9.11 74.45

Conc. 57.08 39.69 6.9 87.71

Tail 42.92 29.84 11.5 82.9 10

Total 100.00 69.52 8.87 85.305

Conc. 46.94 32.64 6.6 87.88

Tail 53.06 36.89 11.1 83.81 12

Total 100.00 69.52 8.99 85.845

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44 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

obtained without collector. The pine oil enhances the flotation process through decreasing flotation time. Figure 8 represents X-ray and mineral composition of flotation products. Talc is increased from 76% to 85% while there is no change in chlorite content. Thus, whiteness does not improve. In order to improve the whiteness of talc, cleaning of flotation should be carried out to reduce chlorite mineral. Table 7 depicts the results of cleaning flotation. A final concentrate weighing about 29% with 6% loss of ignition and 90% whiteness is obtained. It can be classified as talc grade (A) which can be used in cosmetics [4]. To increase yield and whiteness, magnetic separation followed by flotation or flotation followed by magnetic separation are studied.

Table 8 illustrates the results of flotation using a 250 g per ton methyl isobutyl carbinol as frother at pH8. A concentrate weighing 47% with 7.1% loss of ignition and 88% whiteness is obtained. It can be classified as

grade (B) which can be used in ceramics [15]. The results of pine oil (Table 6) is better than that for methyl isobutyl carbinol.

3.5. Wet High Intensity Magnetic Separation Followed by Flotation

Chlorite contains iron in its chemical formula (Mg,Fe)5(Al,Si)5O10(OH)8 which deteriorates whiteness. A wet high intensity magnetic separation is used to remove chlorite. Table 9 illustrates the results of magnetic separation followed by flotation. The magnetic fraction was about 2% overall weight with 10% ignition loss. Figure 9 depicts X-ray diffraction and mineral composition of magnetic separation product. The chlorite peak is decreased in nonmagnetic fraction and increased in magnetic fraction. The talc mineral is increased in nonmagnetic fraction from 76% to 90% and chlorite is 5% compared to 15% in magnetic fraction. The whiteness of nonmagnetic does not

Table 6: Flotation of Talc with Pine oil at pH 8

Weight %

Dose, g/ton Fraction Operational Overall L.O.I % Whiteness

Conc. 62.28 43.21 7.02 87.36

Tail 37.72 26.17 12.6 82.06 125

Total 100.00 69.38 9.12 84.71

Conc. 85.01 58.98 6.40 88.30

Tail 14.99 10.40 18.09 81.86 250

Total 100.00 69.38 9.11 85.08

Conc. 66.05 45.83 7.2 87.52

Tail 33.95 23.55 12.9 81.51 375

Total 100.00 69.38 9.13 84.515

Conc. 63.51 44.07 7.1 87.29

Tail 36.49 25.32 12.07 81.93 500

Total 100.00 69.38 8.91 84.61

Table 7: Cleaning of Flotation Concentrate using Pine Oil at pH 8

Pine Oil Weight %

Fraction Operational Overall L.O.I % Whiteness

Conc. 1 50.74 29.01 6.01 90.36

Conc. 2 16.37 9.36 6.8 87.52

Tail2 32.89 18.80 12.8 84.04

Total 100.00 57.16 8.37 87.30

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Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 45

increases due to the presence of chlorite mineral. Therefore, nonmagnetic fraction can be concentrate with another technique such as flotation.

Results of rougher flotation of nonmagnetic (Table 9) showed that a concentrate weighing 56% with 6.93% loss of ignition and 89% whiteness is obtained. It is cleaned by another flotation step.

Figure 8: X-ray and mineral composition of flotation product with pine oil. Table 8: Flotation of with Methyl Iso Butyl Carbinol at pH 8

Weight %

Dose, g/ton Fraction Operational Overall L.O.I % Whiteness

Conc. 67.17 46.70 7.1 88.24

Tail 32.83 202.82 13.08 81.86 250

Total 100.00 69.52 9.06 85.05

Conc. 65.33 45.42 7.3 88

Tail 34.67 24.10 12.5 81.7 500

Total 100.00 69.52 9.10 84.85

Conc. 65.90 45.82 7.1 86.8

Tail 34.10 23.71 12.4 82.47 750

Total 100.00 69.52 8.91 84.64

Conc. 69.27 48.16 7.1 87.28

Tail 30.73 21.36 13.05 80.02 1000

Total 100.00 69.52 8.93 83.65

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46 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

Figure 10 shows X-ray diffraction of flotation products. The gangue minerals are increased in tails 1

and 2. Talc is increased from 76% to 97% and 91% in concentrate 1 and concentrate 2, respectively.

Table 9: Wet High Intensity Magnetic Separation followed by Flotation

Weight % Products

Operational Overall L.O.I % Whiteness

Magnetic separation

Non-magnetic 97.07 67.48 8.10 86.11

Magnetic 2.93 2.04 10.30 73.21

Total 100.00 69.52 8.16 85.73

Rougher Flotation of Non-magnetic

Concentrate 83.51 56.35 6.93 88.91

Tail 1 16.49 11.13 14.80 80.23

Total 100.00 67.48 8.23 87.48

Cleaning of Concentrate

Conc. 1 37.05 20.88 5.60 90.92

Conc. 2 46.60 26.26 6.07 89.74

Sum concentrate 1 and concentrate 2

Final Concentrate 1 83.65 47.14 5.86 90.26

Tail 2 16.36 9.22 12.40 81.98

Total 100.00 56.35 9.85 88.91

Mineral composition Figure 9: X-ray diffraction and mineral composition of magnetic separation products.

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Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 47

The concentrate 1 is about 21% weight with loss of ignition 5.6% and 91% whiteness. The concentrate 2 has 26% weight with 6% loss of ignition and 90% whiteness. Both concentrates are mixed to increase yield. Thus, a final concentrate weighing 47% of talc ore with 5.86% loss of ignition and 90.26% whiteness is obtained. It is considered as a high grade and can be used in different industrial applications. Mineral composition of final concentrate (Figure 12) showed that talc mineral is increased from 76 to 94% while chlorite is decreased from 12.7 to 6.7%.

3.6. Flotation Followed by Wet High Intensity Magnetic Separation

Rougher flotation, flotation cleaning and wet high intensity magnetic separation for flotation concentrate were investigated for obtaining high grade talc. Table 10 represents the results of flotation followed by magnetic separation. The rougher flotation is about 52% overall weight percentage with 6.9% loss of ignition and 89% whiteness. Cleaning of rougher concentrate gave two concentrates. The first is about

Mineral composition

Figure 10: X-ray and mineral compositions Flotation Products.

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48 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

26% weight with 5.6% ignition loss and 91.4% whiteness while the second has10% weight with 5.8% loss of ignition and 92% whiteness. Both two concentrates are considered as high-grade talc. A mixed concentrates weighing about 36.54% with 5.7% loss of ignition and 91% whiteness. Wet high intensity magnetic separation was employed to remove chlorite mineral. Figure 11 shows results of X-ray diffraction and mineral composition of magnetic separation products. The gangue minerals are increased in the magnetic fractions while talc is increased in non-magnetic products. Talc mineral in non-magnetic fractions 1 and 2 are 95.8% and 91%, respectively compared to 76% in talc ore. Talc mineral in the final concentrate is increased from 76% to 95% and chlorite mineral is decreased from 12.7% to 1.8%.

Table 11 illustrates chemical analysis of the final product. Figure 12 shows the size distribution of final product. The d50 and d90 are 18.24 and 55.74 micron, respectively.

4. CONCLUSIONS

Egyptian talc is associated with chlorite, dolomite and quartz as gangue minerals. It contains about 76% talc, 13% chlorite, 9% dolomite and 1.5% quartz. It classified as low grade talc ore. The attrition scrubbing product less than 75 micron was weighing about 69% by weight with 8.8% loss of ignition and 87% whiteness which can be categorized as talc grade B. Flotation of talc without frother gave concentrate of 23% weight with 6.37% loss of ignition and 88% whiteness. In case of using 250 g/ton pine oil at pH 8, a concentrate of 59 % weight with 6.4% loss of ignition and 88% whiteness is obtained compared with 47% weight with 7.1% loss of ignition and 88% whiteness in case of methyl iso butyl carbinol. The pine oil frother is better than methyl isobutyl carbinol frother.

By applying magnetic separation followed by flotation, a concentrate of 47% by weight with 5.86% loss of ignition and 90.26% whiteness is obtained. Talc content is increased from 76 to 94%, while chlorite is decreased from 12.7 to 6.7%. It can be classified as

Table 10: Flotation followed by Wet High Intensity Magnetic Separation

Weight Percentage Product

Operational Overall L.O.I % Whiteness

Rougher Flotation

Conc. 74.10 51.52 6.89 89

Tail 1 25.90 18.00 15.40 77.85

Total 100.00 69.52 9.09 83.4

Cleaning Flotation of Concentrate

Conc. 1 51.24 26.40 5.64 91.37

Conc. 2 19.68 10.14 5.83 90.77

Sum concentrate 1 and concentrate 2

Conc. 1 + Conc. 2 70.92 36.54 5.69 91.21

Tail2 29.07 14.98 9.80 83.61

Total 100 51.52 6.89 89

Magnetic separation for concentrate 1 and concentrate 2

Non-mag.1 86.93 22.95 5.50 92 Conc. 1

Mag. 13.07 3.45 6.60 87.15

Total 100.00 26.40 5.64 91.37

Non-mag.2 66.67 6.76 5.50 91.73 Conc. 2

Mag. 33.33 3.38 6.50 88.85

Total 100.00 10.14 5.83 90.77

Sum Non-magnetic (Non-mag.1+ Non-mag. 2)

Final Concentrate 2 29.71 4.91 91.94

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Upgrading of Egyptian Talc Ore for Different Industrial Applications Journal of Mineral, Metal and Material Engineering, 2019 Vol. 5 49

grade "A", which is suitable for paper coating, cosmetic and pharmaceutical industries.

In case of flotation followed by magnetic separation, a concentrate of 30% by weight with 5.5% loss of

Figure 11: X-ray diffraction and mineral compositions of magnetic separation and flotation products.

Table 11: Chemical Analysis of Talc Ore and Final Product

Percentage

Final Concentrate Talc Ore Constituents

31.64 28.184 MgO

62.65 47.432 SiO2

0.21 2.705 Al2O3

0.1 0.134 P2O5

0.083 SO3

0.01 0.031 K2O

0.07 6.234 CaO

0.30 0.939 Fe2O3

4.91 13.2 L.O.I

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50 Journal of Mineral, Metal and Material Engineering, 2019, Vol. 5 Mourad et al.

ignition and 92% whiteness was obtained. Talc content is increased from 76 to 95%, while chlorite is decreased from 12.7 to 1.8%.

ACKNOWLEDGMENT

The support of “Grant of Scientists of Next Generation (SNG-5) from Academy of Scientific Research and Technology” is gratefully acknowledged.

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Received on 25-9-2019 Accepted on 6-10-2019 Published on 10-10-2019

DOI: https://doi.org/10.31437/2414-2115.2019.05.5

© 2019 Mourad et al.; Scientific Array This is an open access article licensed under the terms of the Creative Commons Attribution Non-Commercial License (http://creativecommons.org/licenses/by-nc/3.0/) which permits unrestricted, non-commercial use, distribution and reproduction in any medium, provided the work is properly cited.

Figure 12: Particle size distribution of final concentrate.


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