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<p>Pyrophyllite is preferred for many industrial applications because of its distinctive properties. It is essential to achieve the required purity level because it is rarely found in nature. In this study, a high-alumina product from a low-grade pyrophyllite was produced not only by removing iron but also by increasing the alumina content to more than 30% to meet the industrial specifications with the highest quality and price. The dry high-intensity magnetic separation (DHIMS) was followed by a collectorless flotation process based on the hydrophobic surfaces of the pyrophyllite under different operating conditions. The results showed the effectiveness of the DHIMS in removing a high percentage of iron-bearing impurities, where the iron content decreased from 1.4% in the feed to 0.4% in the concentrate. The roll speed was a critical controlling factor. Additionally, the collectorless flotation increased the alumina content in the pyrophyllite concentrate to about 31% using 100&#xa0;g/t MIBC as a frother at a pulp density of 20% and particle size fraction of − 125 + 45&#xa0;µm. The frother dose and particle size controlled the final flotation product.</p>

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Achieving High-Alumina Pyrophyllite by DHIMS and Collectorless Flotation

  • 期刊论文

  • 发表日期：

    2025年3月18日

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  • Maaz A. Ali,
  • Hussin A. M. Ahmed,
  • Ayman A. El-Midany,
  • Reham M. Farag

摘要

Pyrophyllite is preferred for many industrial applications because of its distinctive properties. It is essential to achieve the required purity level because it is rarely found in nature. In this study, a high-alumina product from a low-grade pyrophyllite was produced not only by removing iron but also by increasing the alumina content to more than 30% to meet the industrial specifications with the highest quality and price. The dry high-intensity magnetic separation (DHIMS) was followed by a collectorless flotation process based on the hydrophobic surfaces of the pyrophyllite under different operating conditions. The results showed the effectiveness of the DHIMS in removing a high percentage of iron-bearing impurities, where the iron content decreased from 1.4% in the feed to 0.4% in the concentrate. The roll speed was a critical controlling factor. Additionally, the collectorless flotation increased the alumina content in the pyrophyllite concentrate to about 31% using 100 g/t MIBC as a frother at a pulp density of 20% and particle size fraction of − 125 + 45 µm. The frother dose and particle size controlled the final flotation product.