JCBPS; Section A; February 2017 – April 2017, Vol. 7, No. 2; 301-319.

E- ISSN: 2249 –1929

Journal of Chemical, Biological and Physical Sciences

An International Peer Review E-3 Journal of Sciences
Available online atwww.jcbsc.org
Section A: Chemical Sciences

CODEN (USA): JCBPAT Research Article

Beneficiation of Low-Grade Phosphate Ore Using Desliming

and Gravity Separation Technique
Hanaa A. El- Boraey1, Ashraf A. El-shennawy2, Ahmed M. Masoud3, Hady S.Gado4
and Ahmed A.Bekair5.

1
Prof. of Inorganic Chemistry, Menoufia University, Shebin El-Kom, Egypt.
2
Lecturer of Geology, Nuclear Materials Authority, Cairo, Egypt.
3
Lecturer of organic chemistry, Nuclear Materials Authority, Cairo, Egypt.
4
Prof of Geo-Chemistry, Nuclear Materials Authority, Cairo, Egypt.
5
B.Sc. applied Chemistry (2005), Egypt

Received: 13 January 2017; Revised: 26 January 2017; Accepted: 01 February 2017

Abstract: Gravity separation technique has been adopted to upgrade the Egyptian low-
grade phosphate ore (22.71%) from East Siba'eya area as an alternative method to the
existing calcination method, which is not friendly environment and has several
disadvantages and low reactivated final product. Shaking table is a gravity separation
device was used for separating phosphate ore with respect to the factors influencing
effective mineral separation include particle size, density and shape, riffle design, deck
shape and slope, water flow, feed rate shaking motion and speed. Prior to gravity
separation experiments, the feed phosphate ore was prepared by washing and desliming
to remove fine clay from ores. The phosphate concentrate obtained under the optimum
conditions (particle size was less than 150 mesh (100 μm), the optimal deck slope of
shaking table was 10°, the optimal feed water flow rate was 8 liters per minute and the
dressing water flow rate was 10 liters per minute. The results show promise for the
produced grades of 29%–33% P2O5 with 68.51% recovery.
Keywords: Beneficiation; Calcination; Low grade Phosphate ore; Egypt; East Siba'eya ;
Gravity separation technique; Shaking tables; Desliming.

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Beneficiation … Hanaa A.Elboraey et al.

INTRODUCTION

Phosphate plays a significant economic role in developing countries because of the increasing demand on
phosphate rock for fertilizer production and its importance in animal feed stocks, as well as food-grade
phosphates and other industrial uses. The high demand for phosphate is typically fulfilled through mining
and processing1, an industry which, globally, produced 224 million tons in 2013 and is expected to reach
260 million tons2 in 2017. Phosphoric acid is a widely used basic raw material in many areas. However,
can be produced by two main commercial methods: wet process and thermal process. Wet process is by
far the most common route and the acid can be used in phosphate fertilizers production such as; single
super phosphate (SSP), and treble super phosphate (TSP). Thermal process is used in the manufacture of
high grade phosphoric acid used in the manufacture of pharmaceuticals, detergents, food products, and
other non-fertilizer products3,4. Phosphate ore is an important economic deposit in Egypt. Phosphate
deposits in Egypt are a part of the Middle East to North African phosphogenic province of Late
Cretaceous-Palaeogene age. Phosphate ores occur in Egypt in three main provinces, Western desert, Nile
valley, and Red sea. Added to these are some phosphate-bearing sediments are present in Kurkur and
Dungol, Bahariya Oasis, WadiQena, WadiAraba, and Sinai but with limited extent as shown in
(Figure1)5.

Fig. (1): Location map of the phosphorite deposits in Egypt5.

Phosphoric acid is mainly manufactured by the wet process, decomposing the phosphate rock either with
sulfuric acid, hydrochloric acid or nitric acid. The sulfuric acid route is widely used, but suffers from the
fact that the used phosphate ore must have (i) P 2O5≥ 30 % (ii) CaO/ P2O5 ratio < 1.6 (iii) MgO< 1% and
Fe2O3 and Al2O3content: maximum 2.5 %. Therefore, the low-grade phosphate rocks, which do not fulfill
these specifications, are not usually suitable for direct use in sulfuric acid acidulation plants and require
some beneficiation6,7. To concentrate low-grade phosphate ore to a marketable grade (~30% P 2O5)8,

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Beneficiation … Hanaa A.Elboraey et al.

several pre-processing and processing methods are defined1, 9, 10. These are based on the ore type,
associated gangue minerals and the amount of impurities, as well as factors such as the degree of
liberation of apatite minerals, the cost of the beneficiation method1,9.
Phosphate rocks have various chemical and mineralogical compositions in the gangue phase11 and,
therefore, based on the major associated minerals, gravity separation is an effective method for separating
minerals of significantly different densities instead of the existing calcination method, which is not
friendly environment and has several disadvantages12,13, such as high energy costs, the high initial capital
cost of calcination plants9, furthermore, calcination produces low reactivity of the resulting phosphate 14.
This is undesirable because it reduces the rate at which phosphoric acid can be produced. Reduced
reactivity can be attributed to the chemical and physical changes that, the phosphate ore goes through
during the calcination.
Gravity separation is a method for separating two components from a suspension or any other
homogeneous mixture where separating the components with gravity is sufficiently practical. It is a unit
process in which gravity removes settle able solids and associated pollutants, floatables and dispersed
petroleum products. The effectiveness of separation is also mainly dependent on particle size, not just
density. In some cases of separation may be effective down to 50µm15.
There are numerous advantages to gravity separation: low startup cost, low energy consumption during
the crushing process, high efficiency, lack environmental impact and high selectivity compared with other
methods, such as flotation16. The gravity separation method is not applicable to all mineral compounds
and requires the determination of a concentration criterion (C.C) based on the relationship between the
specific gravity (S.G) of heavy and light minerals and the fluid (water or air) in which they are found 17,
as follows:
S.G.of heavy mineral-S.G. of Fluid
Concentration Criterion (C.C.) =
S.G.of Light mineral-S.G. of Fluid
Mineralogical studies have shown that calcite, quartz, apatite and glauconitic with specific gravities of
2.7, 2.65, 3.2 and 2.4 gm./cm3, respectively, are the primary minerals of the phosphate ore. Consequently,
the C.C, based on the equation of Taggart 17 `is 1.29, a value which indicates that gravity separation will
not be commercially viable and cannot be used as the only pre-concentration method because carbonate is
very finely dispersed in phosphate18, so that gravity separation technique was applied in this work
together with washing and desliming as an effective process to concentrate the low-grade phosphate ore
of the Egyptian phosphate ore from East Siba'eya area.
During using gravitational methods in beneficiation of low-grade phosphate ore, the use of shaking tables
such as (wifely table) is considered an efficient method for ore concentration. In this method, a solid-
liquid separation process is based on cross flow of light and heavy particles on an inclined, riffled table as
the particles simultaneously spread out. As the table shakes the differential motion, riffled deck and cross
flowing water causes particle separation, with the riffles helping to transmit the shaking motion to the
particles as well as preventing direct washing of particles off the table. The vibration is asymmetrical,
being slow in the forward direction and quick in the reverse direction. The particle feed enters at the
corner of the table along with dressing water introduced from the upper edge to aid separation and
displacement across the table. Finally, the particles move diagonally as shown in (Figure 2)19.

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Beneficiation … Hanaa A.Elboraey et al.

Fig. (2): Schematic illustration of the arrangement of a riffled shaking table19

2. Conditions of Effective Gravity Separation15
There are some factors and conditions that must be considered during ores upgrading process:
Proper water balance with concentrators has an optimum feed pulp density; the Feed must be prepared
carefully. Primary grinding where possible for a suitable fraction size. No slimes wherever gravity
separation is negatively impacted by slimes, as well as slimes increase viscosity of fluid. Also, 10 μm
particles should be removed from feed and particle sizes should be relatively close. Screening, then
separation of the screened fractions will improve results.
The present work is an attempt of using wifely shaking table as a gravity separation technique route to
upgrade the Egyptian low-grade phosphate ore from East Siba'eya area to decrease the content of
carbonate impurities and produce marketable phosphate (P 2O5% ≥30%) as an alternative route for the
calcination process that is currently, to produce phosphoric acid by wet process, which increase the
economy of the process.
2.1. Background of the study: As 75% of the world’s phosphate carbonate reserves are of sedimentary
origin20, much research has been done involving the use of calcination, direct-reverse flotation, and spiral
gravity or using a combination of two methods, to reduce carbonate gangue. In each of the cases
described in this section, new methods were used to concentrate phosphate carbonate ore.
Sinirkaya et al.21 examined the changes of P2O5 in samples of phosphate rock from Turkey during
simultaneous sulfidation-calcination. The ore had an initial P2O5 grade of 23%–27% and consisted
primarily of calcite, Fluor apatite and quartz. In this case, a fluidized bed reactor was used for calcination,
and the results showed a temperature decrease during calcination, a reduction in particle size as well as
rapid quenching of sulfated samples, which resulted in an increase of P 2O5 to more than 36%. Xin Liu et
al.22, examined phosphate rock samples was collected from yihua group CO., Ltd. Yichang, China that
have an average P2O5 grade of 21.54% and consist of apatite, quartz, pyrite and dolomite. Using a
combination of spiral gravity and direct-reverse flotation, a high concentration of 30.41% P 2O5 and
recovery of 91.5% was obtained. It was found that pre-recovery of collophanite by spiral separation could
significantly reduce the flotation reagent consumption and lead to improvement overall collophanite
recovery.

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Beneficiation … Hanaa A.Elboraey et al.

Experimental Work
3.1. Material: The examined sample is collected from East Siba'eya area, Nile Valley, Egypt. The degree
of crushing to generate a representative sample for mineral liberation and concentration purposes had to
be considered. The material was then well dried and crushed for separation studies.
3.2. Methods
3.2.1.Sample preparation: The phosphate ore sample of (5300 gm.) received from East Siba'eya mine
was dried and crushed in an elaborator jaw crusher to pass on 1000 µm (1ml) sieve then, after ore
homogenization, identical sample of (300gm.), was separated for chemical and qualitative mineralogical
analysis.
3.2.2. Chemical and mineralogical analysis: Mineralogical analysis was done by using X- ray
diffraction (XRD) type (Shimadzu XRD7000). The (XRD) was recorded at 40 kV and 30 mA for a Cu-
target tube. According to Shapiro and Brannock23, major oxides (SiO2, Al2O3, TiO2, P2O5, and soluble
SO4) were determined colourmetry by Meterch Inc. (SP-8001), single beam spectrometer; cover the U.V.
visible range 200-650nm. Uranium contents was determined calorimetrically using Arsenazo III as
indicator by the Spectrophotometer, while CaO, MgO and total iron as Fe2O3 contents were determined
volumetrically by the complex titrimetric techniques.
Potassium and Sodium were determined by Sherwood flame photometer 410 (England). Soluble fluoride
ion concentration was determined by Jenway pH meter with Orion F - ion selective electrode.
Determination of the trace elements in the rock samples was carried out by X-ray fluorescence technique
using PHILIPS X` Unique-II spectrometer with automatic sample changer PW 1510, (30 positions)
Holland. The results of XRD analysis are presented in (Figure 3) and the results of major and traces
element are presented by (Table 1) and (Figure 4).

Fig. (3): XRD pattern of examined low grade phosphate sample before beneficiation

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Table (1): Chemical analysis of major oxides and trace elements of East Siba'eya Phosphate ore before
beneficiation

oxides Content (%) trace elements Content (ppm)

P2O5 22.71 Cr 36.0
CaO 47.50 Co 3.0
MgO 2.99 Ni 9.0
SiO2 10.18 Cu 10.50
Na2O 0.67 Zn 73.50
K2O 0.36 Zr 29.0
SO4-- 2.15 Rh 91.0
Al2O3 1.11 Y 203.0
Fe2O3 2.80 Ba 13.0
MnO 0.01 V 104.0
Cl 0.55 Sr 354.0
F- 1.34 Mn 814.0
L.O.I 10.10 U** 44.0
L. O. I. = loss on ignition ** Analyzed by spectrophotometer technique.

16.0 4

14.0
Ca

12.0

Count
s[x1.E 10.0
+3]
8.0

6.0 Rh
Rh
P
Si Rh Fe
4.0 S Ca Fe
Sr Rh Mn Rh
S Ti Mn Zn Sr Rh Rh
2.0 Ti Zn Sr Rh Rh

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Fig. (4): XRF pattern of phosphate raw material

4. Mineral composition and characterization: The results of the chemical composition of phosphate
raw material used in this work were shown in (Table1). It can be seen that the phosphate ore is a low P 2O5
content 22.71% and high in CaO and MgO%. From the data in (Table1) the CaO: P 2O5 weight ratio was
calculated and found to be 2.09. The given values and that of P 2O5% and MgO (2.99%) are beyond the
requirements (P2O5 ≥ 30%, CaO/P2O5 ≤ 1.6 and MgO < 1%) of the phosphate grade for industrial uses 24.
More ever, the chemical analysis results showed that the phosphate ore sample contains relatively high
amounts of Fe2O3, Al2O3 and SO4--, the results show that low-grade phosphate sample has uranium
concentration is (44 ppm). In addition, the results of X-ray diffraction analysis of the phosphate ore
sample are shown in (Figure 3), this figure indicates that, apatite (Ca 10 (PO4, CO3)6(F,OH)2) is the
predominant phosphate mineral, whereas calcite (CaCO3) is the main carbonate gangue mineral
associating the ore with some dolomite CaMg(CO3)2 mineral. This could explain the high CaO/P2O5 value
of the ore and low uranium concentration.

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4.1. Physical treatment technique: After the primary crushing and sample preparation stages, the feed
phosphate ore was prepared by washing and desliming operations, to remove fine clay minerals and dust
from the low-grade phosphate samples. This clay will cause many difficulties during separation because
of their high surface areas. In addition to clay can coat the phosphate particles and significantly reduce
separation process 25. The studied low-grade Phosphate sample (5000gm.) is typically washed by water
then dried and deslimed (shook) for 15 minute using sieve of 354 µm (-45) mesh (British standard). The
screen products, over size (separation feed), were conducted in shaking table and under size (slimes) were
calculated together with dried clay resulting from the washing process as percent on weight bases and
analyzed for their P2O5 and other contents. The rejected slimes are characterized with a weight of
(600gm.) from the total sample, and low P 2O5=1.18% losses in the slim with a significant increasing in
SiO2 content = 31%, loss on ignition (L.O.I) = 32.95% and CaCO3 content =30.83%, as shown in
(Table 2).

Table (2): Full chemical analysis of slims

Content Concentration (%)

P2O5 1.18
CaCO3 30.83
F 0.05
SiO2 31.0
Na2O 0.19
K2O 0.03
SO4-- 0.47
MgO 0.56
Al2O3 0.31
Fe2O3 0.75
Cl NIL
L.O.I 32.95

5. RESULTS AND DISCUSSION

After Physical treatment, shaking table studies performed by assigning values to variables such as particle
size, deck slope, feed water flow rate, dressing water flow rate and finally base on four mentioned
parameters, the grade and recovery variation were investigated accordingly, the examined sample was
divided into various fractions (<100, 100–270, 270–500, 500–1000 μm) with weights of (2000gm,
800gm, 800gm and 800gm) respectively, before testing. The following comparative experiments were
carried out, and the numerous produced spices of various concentrations in each experiment taken as a
bone of phosphate lime (BPL) differ in color according to its concentration, homogeneity and density.
5.1. The first experiment: For the fraction of 500–1000 μm, the deck slope 6°, the feed water flow rate of
8 liters per minute and table water flow rate 6 liters per minute lead to the high grade of P2O5 and low
recovery of 40.75% and 6.19%, respectively (Table 3).
5.2. The second experiment: For the fraction of 270–500 μm, the results of shaking table tests denote
that, separation considering the parameters such as the slope of deck as 8°, feed water flow rate of 7 liters

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per minute and dressing water flow rate of 7 liters per minute, produces a concentrate with the
concentration of 39.22% P2O5 and recovery of 7.16% (Table 3).
5.3. The second experiment: For the fraction of 270–500 μm, the results of shaking table tests denote that,
separation considering the parameters such as the slope of deck as 8°, feed water flow rate of 7 liters per
minute and dressing water flow rate of 7 liters per minute, produces a concentrate with the concentration of
39.22% P2O5 and recovery of 7.16% (Table 3).
5.4. The third experiment: For the fraction of 100–270 μm, the table slope was decreased to 4° and the
feed water flow rate and dressing water flow 6 and 5 liters per minute respectively. These changes lead to
an increase in concentrate of 40% P2O5, but the recovery decreased to 4.6 % (Table 3).
5.5. The fourth experiment: For the fraction of <100 μm. To attain a higher grade, slope of deck was
increased to 10°, the feed water flow rate was set up to 8 liters per minute and dressing water flow rate
was raised to 10 liters per minute. As a result, it was found that, the ideal shaking table parameters (10°
deck slope, feed water flow rate of 8 liters per minute and dressing water flow rate of 10 liters per minute)
lead to production of a concentrate with a P 2O5 grade of 29.70% and recovery of 68.51%. However, the
results of shaking table separation are provided in (Table 3).

Table (3): Result of shaking table recovery of phosphate ore various fractions

sample Particle size Weight. (gm.) Weight. (%) Recovery (%)

P2O5 (%)
(µm)
Feed 500-1000 800 100 21.53 100
Concentrate 49.52 6.19 40.75 6.19
Middling waste 597.10 74.63 13.0 74.63
153.37 19.17 9.81 17.55
Feed 270-500 800 100 21.53 100
Concentrate 57.29 7.16 39.22 7.16
Middling waste 495.40 61.92 15.69 61.92
247.30 30.91 8.66 29.33
Feed 100-270 800 100 21.53 100
Concentrate 36.86 4.6 40.0 4.6
Middling waste 248.18 31.02 16.35 31.02
514.95 64.36 8.41 63.11
Feed <100 2000 1370.33 100 21.53 100 68.51
Concentrate …….. 68.51 29.70 …..
Middling waste 629.67 …….. ……
31.48 11.99

From (Table 3), the results showed that, the effectiveness of separation is mainly dependent on particle
size, not just density. Where the fraction size of less than 100 µm with respect to separation factors that
the slope of the deck was 10°, a feed water flow rate of 8 liters per minute and a dressing water flow rate
of 10 liters per minute are the optimum condition of upgrading with recovery of 68.51%, 29.70% P2O5
content and weight of 1370.33gm. However, the upgrading efficiency reduced by increasing the particle
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size diameters (500-1000, 270-500, 100270 µm) with changing separation parameters as mentioned in
(Experiments 5.1, 5.2 and 5.3).
These experiments have shown that, despite the high concentration of phosphate up to 40.75, 39.22 and
40% P2O5, respectively, the recovery a few of phosphate ore up to 6.19, 7.16 and 4.6%, respectively, with
low concentrate`s weight 49.52, 57.29 and 36.86gm from total experimental weights of phosphate ore
compared with (Experiment 5.4). The total loss of phosphate ore through experimentation was estimated
as 1.63, 1.59, 1.27 and 3.22 % respectively which show the amount of loss affected with the degree of
crushing (fraction size), i.e., the ore`s loss was relatively increased with fraction size of less than 100 µm
and decreased with fraction sizes of (500-1000, 270-500, 100-270 µm) as shown in (Table 3).
6. Optimization of Phosphate Ore Upgrading by Shaking Table: The concentrate of the fraction less
than 100 μm (1370.33gm.) was separated another time by shaking table with considering the optimum
foregoing ideal separation parameters (experiment5.4). The result of shaking table phosphate ore
concentration provided in (Table4).

Table (4): phosphate ore optimization by shaking table

Produced Weight.(gm.) Weight. recovery

(P2O5 )%
concentrated (%)

1370.33 100 29.70 More than

Spices 99.0%
Concentrate-A 53.5 3.90 29.23

Concentrate-B 25.40 1.85 30.20

Concentrate-C 122.0 8.90 29.33

Concentrate-D 209.0 15.29 26.96

Concentrate-E 82.5 6.02 32.52

Concentrate-F 64.0 4.67 33.0

Concentrate-G 68.55 5.0 29.30

Concentrate-H 744.78 54.36 32.80

Table (4), shows the optimum efficiency of the different upgraded phosphate ore spices. It shows that,
applying shaking table as a gravity separation technique, the overall phosphate losses in produced
concentrated spices is about 1% of all samples weight with a higher P2O5 content (29.23%-33.0 %), and
variant weights (25.40-744.78 gm.). This can be attributed to two main reasons, the first one is the
optimum factors influencing effective mineral separation on a shaking table include particle size, density
and shape, riffle design, deck shape and slope, water flow, feed rate and shaking motion and speed, in
addition to the compact closed-circuit between shaking table and losses reservation tank adjacent table.

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The full chemical analysis of concentrated spices and waste of fraction < 100 μm were obtained as shown
in the following Tables 5-13 and Figures 5 to 13.

Table (5): Chemical analysis of major oxides of concentrate-A

oxides Content (%)

P2O5 29.23
CaO 45.12
MgO 0.65
SiO2 7.20
Na2O 0.26
K2O 0.16
SO4-- 1.61
Al2O3 0.38
Fe2O3 2.19
Cl 0.47
F- 2.42
L.O.I 10.50
L. O. I. = loss on ignition

1
16.0

14.0

Ca
12.0

Count
s[x1.E 10.0
+3]

8.0

6.0 Rh
P
Y Sc
Si Ca
4.0 Fe
Rh Ba Rh
Sr Rh Ba Fe Y Rh
Rh Rh
Rh Ba Mn Zn Sr Y Ba Ba
2.0 Sr Y Ru
Sc Mn Zn Ru Rh Ba Ba

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Figure 5: XRF pattern of concentrate-A

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Table (6): Chemical analysis of major oxides of concentrate-B

oxides Content (%)

P2O5 30.20
CaO 45.71
MgO 0.37
SiO2 8.10
Na2O 0.42
K2O 0.09
SO4-- 1.64
Al2O3 0.31
Fe2O3 1.45
Cl 0.01
F- 2.92
L.O.I 9.54
C
16.0

14.0

12.0
Ca
Count
s[x1.E 10.0
+3]
8.0

Rh
6.0 Rh
Si S
Fe
P Mn
4.0 Ca
Y Cr
Rh
Sr V Mn
Rh Y Rh
Ti Cr Zn Y Rh
2.0 Al S Ti V
Fe
Zn
Sr
Sr Y
Rh
Rh Rh

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Figure 6: XRF pattern of concentrate-B

Table (7): Chemical analysis of major oxides of concentrate-C

oxides Content (%)

P2O5 29.33
CaO 45.60
MgO 0.41
SiO2 7.15
Na2O 0.29
K2O 0.22
SO4-- 1.30
Al2O3 0.39
Fe2O3 1.96
Cl 0.47
F- 2.80
L.O.I 10.12

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2
16.0

14.0

12.0 Ca

Count
s[x1.E 10.0
+3]

8.0

6.0 Rh
P
Si Ca
4.0 Rh Fe
Y Cd Fe Cd
Sr Rh Rh
Rh Mn Y Rh
Rh Ti Mn Zn Sr Y Rh Rh Cd
2.0 Sr Y Ru Ru
Ti Zn Cd Cd

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Figure 7: XRF pattern of concentrate-C

Table (8): Chemical analysis of major oxides of concentrate-D

oxides Content (%)

P2O5 26.90
CaO 44.38
MgO 1.43
SiO2 8.12
Na2O 0.51
K2O 0.20
SO4-- 2.48
Al2O3 0.33
Fe2O3 2.39
Cl 0.51
F- 2.29
L.O.I 11.0
The high content of MgO indicates the presence of dolomite in the sample

Figure 8: XRF pattern of concentrate-D

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Table (9): Chemical analysis of major oxides of concentrate-E

oxides Content (%)

P2O5 32.52
CaO 46.0
MgO 0.50
SiO2 6.64
Na2O 0.10
K2O 0.07
SO4-- 0.93
Al2O3 0.57
Fe2O3 1.52
Cl 0.03
F- 3.0
L.O.I 9.06

16.0 5

14.0

12.0

Coun Ca
ts[x1 10.0
.E+3]
8.0

6.0
Rh
Si Mn
Fe
4.0 P Rh Ca Mn
Sr Rh Rh
Cr Rh Rh
Rh Ti Zn Sr Ru Rh
2.0 Ti Cr Fe Zn Sr Ru Rh

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Figure 9: XRF pattern of Concentrate-E

Table (10): Chemical analysis of major oxides of concentrate -F

oxides Content (%)

P2O5 33.0
CaO 46.0
MgO 0.79
SiO2 6.50
Na2O 0.18
K2O 0.10
SO4-- 1.0
Al2O3 0.50
Fe2O3 1.45
Cl 0.02
F- 2.78
L.O.I 9.45

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16.0 3

14.0

12.0

Coun
ts[x1. 10.0 Ca
E+3]
8.0 Rh

6.0 S
P
Si Rh Fe
4.0 Ca Mn
Y Rh Cr
Sr Rh V Mn Y Rh
S Ti Cr Zn Sr Y Rh Rh
2.0 Al Ti V Fe Zn Sr Y Rh Rh

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00

Figure 10: XRF pattern of Concentrate-F

Table (11): Chemical analysis of major oxides of concentrate-G

oxides Content (%)

P2O5 29.30
CaO 45.43
MgO 0.35
SiO2 8.14
Na2O 0.36
K2O 0.12
SO4-- 1.61
Al2O3 0.31
Fe2O3 2.24
Cl 0.22
F- 3.20
L.O.I 9.45

Figure 11: XRF pattern of Concentrate-G

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Beneficiation … Hanaa A.Elboraey et al.

Table (12): Chemical analysis of major oxides and trace elements of concentrate -H

oxides Content (%) trace elements Content (ppm)

P2O5 32.80 Cr 33.0
CaO 46.20 Co 10.0
MgO 0.47 Ni 8.0
SiO2 6.18 Cu 9.50
Na2O 0.18 Zn 71.0
K2O 0.03 Zr 29.0
SO4-- 1.29 Rh 112.0
Al2O3 0.71 Y 181.0
Fe2O3 1.18 As 5.50
Cl 0.01 Sr 354.0
F- 2.50 Mn 757.0
L.O.I 8.97 U** 102.0

Figure 12: XRF pattern of Concentrate-H

From the obtained results (Table12) and (Fig-12) it is possible to conclude that the concentrate-H was
characterized by amount of calcite which represented by chemical analysis as CaO=46%. As it
characterized by slightly amount of silica (SiO2=6.1%), low amount of alumina (Al2O3=0.71%) and low
content of alkali (Na2O, K2O) = 0.18 and 0.03% respectively. The results revealed low iron oxide content
(Fe2O3 =1.18%). On the other hand, the peak intensity of calcite is relatively less than in the raw material
(Figure-4), where the concentration of calcite associated with the phosphate concentration in the sample.
Also the XRF peak intensities of silica and iron are significantly reduced to acceptable levels of
concentration. The loss on ignition (L.O.I) reduced to 8.97%; this may be due to decreasing of organic
matter after beneficiation. The sample was contained a repletion of different trace and rare earth elements
that Ru (Ruthenium), Rh (Rhodium), Y (Yttrium), Sr (Strontium), Ti, Cd, Mn, P and Zn.
The uranium concentration in raw material grew after beneficiation (102 ppm), where there is a direct
correlation between the percentage of phosphate concentration and concentration of uranium, whereas the
radioactive content increases with the concentration of phosphorus, It is worth mentioning that the (U)
takes place (Ca) in apatite26 Which reaches maximum in the high-grade of phosphate (P2O5=32.80%)

315 J. Chem. Bio. Phy. Sci. Sec. A, February 2017 – April 2017, Vol. 7, No. 2; 301-319
Beneficiation … Hanaa A.Elboraey et al.

compared to the low-grade of phosphate (P2O5= 22.71%). This clearly shown in chemical analysis and
peaks of XRF pattern, which could explain the high value of P 2O5 content in phosphate ore after
beneficiation.
Table 13: Content analysis of (waste) of fraction less than 100 μm from shaking table

Content (%)
P2O5 11.99
CaO 46.01
MgO 0.72
SiO2 9.24
SO4-- 0.78
TiO2 0.102
MnO 0.012
ZnO 0.06
Al2O3 0.85
Fe2O3 1.06
Cl 0.29
L.O.I 27.36

C
16.0

14.0

12.0
Ca
Counts
[x1.E+ 10.0
3]

8.0

Rh
6.0 Rh
Si S
Fe
P Mn
4.0 Ca
Y Cr
Rh
Sr V Mn
Rh Y Rh
S Ti Cr Zn Sr Y Rh Rh
2.0 Al Fe Sr
Ti V Zn Y Rh Rh

0.0
0.00 5.00 10.00 15.00 20.00 25.00 30.00 35.00 40.00
keV

Figure 13: XRF pattern of waste of fraction less than 100 μm obtained from shaking table.

The obtained results Table13 and Fig-13 were shown that the waste of fraction less than 100 μm obtained
from shaking table was characterized by a high amount of calcite represented by chemical analysis as
CaO=46.01% and a maximum peak of XRF-pattern. In contrast, the sample contains small amount of
apatite as P2O5 content does not exceed 11.99%. As it characterized by moderate silica content
(SiO2=9.24%), low amount of alumina (Al2O3=0.85%) and absence of alkali (Na2O, K2O) and the results
of chemical analysis revealed low iron oxide content (Fe2O3 =1.06%) evident by a slightly peak of XRF-
pattern. The loss on ignition (L.O.I) was extremely increased to 27.36%; this may be due to presence of
organic matter, large amount of calcite and dolomite. The sample was contained a repletion of different
heavy and trace elements that Ru (Ruthenium), Rh (Rhodium), Y (Yttrium), Sr (Strontium), Ti, Cd, Mn, P

316 J. Chem. Bio. Phy. Sci. Sec. A, February 2017 – April 2017, Vol. 7, No. 2; 301-319
Beneficiation … Hanaa A.Elboraey et al.

and Zn. These results confirm the success of desliming and shaking table process to upgrade and reduce
the calcareous impurities in East Siba'eya phosphate ore.
From the foregoing data it is noted that, after applying shaking table as a gravity separation technique on
particle size of less than 100 µm, as the P 2O5% increased, CaO% increased somewhat Figure-14, due to
increasing the content of apatite where calcite is existing basically as a cementing agent between apatite
crystals.

46.5

46.0

45.5
CaO
%
45.0

44.5

44.0
26 27 28 29 30 31 32 33

P 2O 5%

Figure 16: the proportional relationship between CaO% and P2O5% in phosphate upgraded samples

In any case, it is suggested preparing the ore feed to the shaking table separation in a way having < 100
µm particle size ranges after desliming.

Based on the test results of this work, the following conclusions can be achieved:

 The phosphate ore under study is of a low P2O5 grade 22.71% calcareous type with carbonates
impurities mainly calcite, and from the size distribution analysis, it is noted that, the P2O5 is mostly
concentrated by shaking table as gravity separation technique in the size fractions of less than 100
µm with a P2O5 grade of ≥29.23% and recovery of ≥ 68.51% as a pre-processing and higher P2O5
content (29.23%-33.0%), with more than 99.0% of recovery as a final processing with respect to
shaking table mineral separation optimum condition that, the slope of the deck was 10°, a feed
water flow rate of 8 liters per minute and a dressing water flow rate of 10 liters per minute. Under
these parameters the Egyptian phosphate ore from East Siba'eya region can be potentially upgraded.
 Washing and desliming are a necessary step to achieve concentration feed assaying of P 2O5 by
removing most of the gangue materials and some of the dolomite in the fine particles using sieve
of 354 µm (-45) mesh (British standard).
 In conclusion, it has been shown that it is possible to effectively employ a technical method of
phosphate upgrade after desliming that overcomes the inherent problems of the ore, including
low-grade, slimes generation and physical property similarities between constituents.

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Beneficiation … Hanaa A.Elboraey et al.

Additionally, this method does not incur a high operational cost compared with other methods as
calcination and flotation, and hence it is possible to acquire a marketable product of appropriate
grade for further processing into fertilizer, or to produce technical or food-grade phosphoric acid.

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Corresponding author: Ahmed A. Bekair;

B.Sc. applied Chemistry, Egypt; chebak_83@yahoo.com
On line publication Date: 01.02.2017

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