Mineral processing
Ore dressing
wastewater treatment
Hydrocyclone separation
20
Scopus Publications
Scopus Publications
Optimization of Parameters for the Reduction Process of Um Nar Iron Ore Using Sawdust Biomass Mostafa A. Metwally, Mohamed G. Farghaly, A. M. Ramadan, El-Sayed R. E. Hassan Journal of Sustainable Metallurgy, 2026 The Um Nar banded iron formation (BIF), one of the largest occurrences within the Pan-African basement rocks of Egypt’s Eastern Desert, represents a significant target for iron ore exploration. However, no commercial mining operations have yet been established due to its high-silica content, as high-silica iron ores adversely affect the production of pig iron and steel. This study focused on investigating the reduction of Um Nar BIF by biomass sawdust as a green reducing agent. Key reduction process parameters, such as reductant concentration, reduction temperature, and reduction time, were investigated in the study. Reduction experiments were designed and analyzed using the Box–Behnken Design (BBD) to identify the most significant variables, assess their interactions, and determine the optimal conditions for the process. At the optimum conditions, i.e., reducing the Um Nar BIF under reducing conditions at 796 °C with a 10% concentration of sawdust for 30 min in a muffle furnace after wet low-intensity magnetic separation (WLIMS), a concentrate containing 59% total Fe and 6% SiO 2 was obtained, with an 83% total Fe recovery. Additionally, the economic feasibility of the processed ore was also assessed. Upgrading Um Nar BIF using sawdust demonstrated a profitable and eco-friendly approach, with over $20 net profit per ton of raw ore under moderate conditions. This method provides an efficient and sustainable solution for recovering good quality iron concentrate from Um Nar BIF. Graphical Abstract
The limitations of flotation technique in processing complex Um Nar BIF: exploring sustainable alternatives Mostafa A. Metwally, Mohamed G. Farghaly, Atef M. Ramadan, Ahmed S. Abdel-Fattah, El-Sayed R. E. Hassan Tenside Surfactants Detergents, 2025 Iron is essential for industry and the economy. It is used in construction, transport, and manufacturing. However, its extraction remains challenging due to geological complexity. Iron ore is tightly interlocked with silica, which limits the efficiency of conventional beneficiation methods. This study investigated the upgrading of the Um Nar Banded Iron Formation using froth flotation, including micro-scale tube and column flotation. Both anionic and cationic reverse flotation routes were explored. It was found that using anionic reverse flotation is more effective than cationic reverse flotation for upgrading the Um Nar Banded Iron Formation (BIF). Under optimal conditions (i.e. collector type: oleic acid, dosage: 1 kg t−1; calcium oxide dosage: 0.25 kg t−1 (as activator); pH 11; and starch dosage: 0.75 kg t−1 (as depressant)), a concentrate with 58 % total Fe grade, 71 % total Fe recovery, and 10.75 % SiO2 was produced at superficial air flow rate of 2.00 cm s−1, which was attributed to the intricate mineralogy of the ore. To overcome the limits of flotation, the study used reduction roasting with biomass sawdust as a green reductant. After roasting, a low-intensity wet magnetic separation was applied. This two-step process yielded improved results, achieving a Fe grade of 59.55 %, a Fe recovery of 78 % and a SiO2 content of 5 % in the concentrate, rendering it suitable for processing complex iron ores.
Processing complex Egyptian banded iron formation: Geological challenges, experimental approaches, and sustainable innovations Mostafa A. Metwally, Mohamed G. Farghaly, A. M. Ramadan, El-Sayed R. E. Hassan Mineral Processing and Extractive Metallurgy Transactions of the Institute of Mining and Metallurgy, 2025 Iron is crucial for industry and the global economy, essential for construction, transport, and manufacturing. However, extracting iron from complex ores, such as those in Um Nar BIF, is challenging due to the interlocking of iron with silica and other minerals, making conventional beneficiation inefficient. This study investigates upgrading Um Nar Banded Iron Formation (BIF) using the Falcon SB-40 concentrator. The Box-Behnken Design (BBD) optimized conditions: g-force of 60, water pressure of 7 psi, and feed rate of 25 g/min, achieving 61.3% Fe grade, 59.29% Fe recovery, and 8.28% SiO 2 grade. Given the limits of gravity separation, reduction roasting with biomass sawdust was explored, enhancing results to 59.55% Fe grade, 78% Fe recovery, and 5% SiO 2 . This research highlights that reduction roasting offers a more effective strategy for processing complex iron ores, contributing valuable insights to the field of mineral processing and sustainable extraction technologies.
Enhancing Iron Separation and Recovery from Egyptian Banded Iron Formation Using Paper Industry Sludge: A Sustainable Reduction Roasting Approach Mostafa A. Metwally, Mohamed G. Farghaly, A. M. Ramadan, El-Sayed R. E. Hassan Rudarsko Geolosko Naftni Zbornik, 2025 This paper proposes an innovative method to upgrade Um Nar Banded Iron Formation (BIF). The method consists of three stages: reduction roasting using paper industry sludge and sawdust, sulfuric acid leaching, and magnetic separation. The effects of CaCO3/sawdust concentration and magnetic field intensity were examined. This approach not only provides an effective means of processing complex and low-grade iron ores but also offers a sustainable solution for recycling industrial waste. Additionally, it utilizes biomass sawdust as a green reducing agent, a new type of clean energy source with low sulfur content, which does not pollute the environment. Adding paper industry sludge as calcium carbonate (CaCO3) led to its reaction with Si and Al minerals, forming grossular (Ca3Al2(SiO4)2(OH)4). This prevented SiO2 from reacting with iron oxides, thereby enhancing iron recovery. The resulting iron concentrate meets the quality standards necessary for steel production. The iron concentrate obtained through this method, i.e. reduction roasting conducted with 10% dosage of reductant, followed by acid leaching and magnetic separation at 2000 gauss, contains 67.23% total Fe and 1.5% SiO2 with a total Fe recovery of 73.82%, meeting the iron ore quality requirements of the steel and iron industry.
Production of high value-added filler from harmful dust of marble industry using N-sodium lauroyl sarcosinate surfactant as a new flotation collector Hamada A. Attia, Mohamed G. Farghaly, Abdel-Hady M. Saleh, Mohamed A. Abdel-Khalek Tenside Surfactants Detergents, 2023 In the stone industry, about 73% of the total production is generated as solid waste. In the processing phase, only 20% is produced as harmful ultra-fine sawdust sludge. In the Turah area, Cairo, Egypt, an estimated 448,000 tons are produced annually. About 60% of the total production of dimension stones is carbonate stones. The objective of this study is to properly dispose of the ultrafine pollutants and produce value-added products. The ultrafine marble waste was characterized by different methods such as XRD, XRF, FTIR, particle size analysis and zeta potential. Calcite and dolomite minerals were the main constituents of this waste (91%). The average particle size was 6.656 µm. The fine fraction with a particle size of less than 25 µm contains 97.6% calcite with 81% weight. Sodium N-lauroyl sarcosinate (SNLS) was used as a selective flotation collector for calcite as a calcium mineral. A flotation concentrate with a purity of 99.6% and an overall yield of 80% was obtained at a pH of 9. The bleached product meets ASTM standard specifications for paint and paper applications.
Bioprocessing of natural phosphate ore with Staphylococcus aureus bacteria Samah S. Abdallah, Khaled A. Selim, Mohamed M. A. Hassan, Atef El-amir, Mohamed G. Farghaly, et al. Rudarsko Geolosko Naftni Zbornik, 2022 Phosphate ores are in high demand around the world because they are the primary raw materials used in the manufacturing of phosphatic fertilizers and other chemicals. Since the grade of the ore is gradually declining, it is becoming economically viable to mine and beneficiate numerous lower-grade deposits, and a significant number of precious minerals are discarded due to the inadequacy of new technological advances. Thus, biological processes are becoming more appealing in mineral processing due to their lower operating costs and potential applications to beneficiate low-grade complex ores through the interaction of bacteria and mineral surfaces, resulting in surface modification and mineral separation via bio-flotation. Staphylococcus aureus was supplied by the mineral bioprocessing lab, CMRDI. Bacterial adhesion measurements revealed a higher affinity for apatite than quartz. A binary mixture containing 12.5% P2O5 and 42.5% SiO2 yielded a concentrate containing 20.15% P2O5 and 33.5% SiO2. Using the bio-flotation process with Staphylococcus aureus and the optimal conditions on natural phosphate ore, a concentrate with 30.25% P2O5 was obtained from a feed containing 21.89% P2O5.
Evaluation of gold ore properties and their impact on grinding operations Mohamed M. A Hassan, Mahrous A. M Ali, Mohamed G Farghaly, Wael R Abdellah, Jung Gyu Kim Mining of Mineral Deposits, 2022 Purpose. The purpose of this paper is to evaluate the efficiency of grinding operations in terms of how mechanical properties (e.g., strength properties and ore texture) affect the Bond Work Index. Methods. The specimens have been collected in the Eastern Desert of Egypt, namely Abu Marwat, Hamash and Al Sadd. As a result, strength parameters such as compressive strength, cohesiveness and hardness have been assessed. Ore texture, mineral content and bonds between tiny fabric units have been examined using X-Ray Diffraction (XRD) and thin section. Findings. This research shows that as the strength properties of the rock increase, the Bond Working Index also increases. Moreover, the results indicate that the level of cohesion of ore minerals with the surrounding tailings, on the one hand, and the variance in the tailing content, on the other hand, play a significant role in the processing operation, given the discrepancy in the Bond Work Index for the six Abu Marawat gold ores of 18.8%. Originality. This research attempts to develop a methodology for assessing the efficiency of grinding operations as a function of rock strength properties and ore texture in relation to the Bond Work Index. Practical implications. Ore texture is one of the most important factors influencing the grinding process. Since grinding consumes a considerable amount of energy, the economic evaluation is based on increasing the grinding efficiency. According to previous research, the petrographic, which varies from sample to another, has an impact on the mechanical properties as well as the grinding operations.
