Mohamed G. Farghaly

@azhar.edu.eg

Mining and Petroleum Engineering
Faculty of Engineering, Alazhar University, Egypt



           

https://researchid.co/mgalal

RESEARCH INTERESTS

Mineral processing
Ore dressing
wastewater treatment
Hydrocyclone separation

17

Scopus Publications

Scopus Publications

  • 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, and El-Sayed R. E. Hassan
    Faculty of Mining, Geology and Petroleum Engineering
    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, and Mohamed A. Abdel-Khalek
    Walter de Gruyter GmbH
    Abstract 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, and Samah M. Elsayed
    Faculty of Mining, Geology and Petroleum Engineering
    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, and Jung Gyu Kim
    Dnipro University of Technology
    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.

  • From waste to treat waste: exploitation of marble dust as a harmful pollutant to a green adsorbent for dyes and heavy metals from industrial wastewater
    Hamada Attia, Mohamed Farghaly, Abdel-Hady Saleh, and M. Abdel-Khalek
    Politechnika Wroclawska Oficyna Wydawnicza

  • Optimizing the separation characteristics of the waterinjection hydrocyclone using mathematical modelling
    Leonid Minkov, Johann Dueck, Mohamed M.A Hassan, Mahrous.A.M. Ali, and Mohamed G Farghaly
    Dnipro University of Technology
    Purpose. Although the hydrocyclone separator has many advantages, it still has some limitations which decrease its separation efficiency in many mineral processing applications because of fine particles which are miss separated to the coarse product in the underflow. Water injection in the conical part of the cyclone was recently implemented to solve this problem. The water injection mechanism and the way in which the injected water affects the separation are still not clear and need to be more investigated. Methods. New design of water injection hydrocyclone was tried using a modified conical part with a water injection range consist of five equal distance injection openings open directly on the periphery of the cone part. Findings. This study presents a mechanical mathematical model that simulates the water injection to give a clear indication of the injection mechanism impact on the classification process. It could also predict the dependence of the basic characteristics of the classification on the amount of the injected water and the influence of different operating and design parameters of the hydrocyclone. Originality. The model accounts for the fluid flow, the particle motion, the turbulent particle diffusion, and particle settling. Particle interactions and fine particle entrainment by settling coarse particles are also included in the model. The model was found to predict well the injection effect and agrees with the experimental results. Practical implications. The results showed also that the increase in water injection velocity leads to an increase in both the cut size and the minimal value of the separation curve. It was found also that the hydrocyclone length has an important effect on the injection process, and the separation sharpness is directly proportional to it at higher values of water injection velocity.

  • Effect of Polyacrylic Acid Molar Mass as a Surface Modifier on Rheological Properties of Calcium Carbonate Suspensions
    Samah Abdullah, Khaled Selim, Mohamed Abdel-khalek, and Mohamed Farghaly
    Politechnika Wroclawska Oficyna Wydawnicza



  • A combined hydrocyclone - electrocoagulation treatment for different types of industrial wastewater
    Mohamed Farghaly, Hamada Attia, Abdel Hady Saleh, Atef Ramadan, and Mohamed Abd elkhalek
    Politechnika Wroclawska Oficyna Wydawnicza

  • Physicochemical study and application for pyrolusite separation from high manganese-iron ore in the presence of microorganisms
    Mohamed Farghaly, Nagui Abdel-Khalek, Mohamed Abdel-Khalek, Khaled Selim, and Samah Abdullah
    Politechnika Wroclawska Oficyna Wydawnicza

  • Using a high pressure hydrocyclone for solids classification in the submicron range
    Th. Neesse, J. Dueck, H. Schwemmer, and M. Farghaly
    Elsevier BV
    Abstract A 10 mm hydrocyclone was operated using a barite suspension with a maximum particle size of dmax = 7 μm. The test rig was equipped with a piston diaphragm pump for pressures up to 60 bar. At 40 bar and 20 °C, cut sizes d50 were obtained down to 0.7 μm; increasing the temperature to 50 °C resulted in d50 values down to 0.5 μm for a throughput of 0.6 m3/h. Another experiment was conducted at 40 bar using a batch hydrocyclone technology. Only the overflow was recirculated to the feed box, whereas the underflow was discharged via a collection box. Increasing the number of recirculations increased the separation of fines in the submicron range. The results showed that after 20 min particles with dmax = 1 μm were obtained in the hydrocyclone overflow. After 120 min, the particles size distribution had a dmax = 0.5 μm and a mean size of d50 = 0.2 μm. This procedure requires high energy consumption and is thus suitable only for fractionating small quantities of particles in the submicron range.

  • The theoretical partition curve of the hydrocyclone
    Johann Dueck, Mohamed Farghaly, and Thomas Neesse
    Elsevier BV
    In many cases, the hydrocyclone partition curve exhibits a non-monotonic course in the fine particle range. The so-called fish-hook effect indicates an increased separation of the fine fraction, which is of practical interest and has a positive effect on solid/liquid separation. However, for classification purposes, the separation is less distinct. In this contribution an equation of a partition curve containing a fish-hook is derived considering the laws of disturbed settling in dense, polydisperse suspensions. The following effects are considered: the entrainment of fine particles in the boundary layer of the coarse settling particles, the hindered settling due to the increased effective density and viscosity of the fluid, and the counter flow of the displaced fluid caused by the settling particles. The calculations indicate that the fish-hook effect is primarily caused by fine particle entrainment, which is influenced by the feed solid content and the feed particle size distribution. An approximated analytical solution for the partition curve is presented for aRosin–Rammler–Sperling–Bennet (RRSB)-distributed feed. Experiments using 25-mm hydrocyclone confirm the calculations.

  • Higher kaolin recovery with a water-injection cyclone
    V. Golyk, S. Huber, M.G. Farghaly, G. Prölss, E. Endres, T. Neesse, and M.A. Hararah
    Elsevier BV
    Abstract In kaolin classification, the final product is isolated from the overflow of a 50 mm hydrocyclone with an underflow containing fine sand and residual kaolin. For a higher kaolin recovery, the underflow is usually further treated using a washing cyclone. This paper presents a new development in fine sand washing using water injection in the conical section of the classifying cyclone. This washing results in a 45–50% reduction of the kaolin fraction (

  • Mechanism of hydrocyclone separation with water injection
    J. Dueck, E. Pikushchak, L. Minkov, M. Farghaly, and Th. Neesse
    Elsevier BV
    Abstract In hydrocyclones, the particle separation efficiency is limited by the suspended fine particles, which are discharged with the coarse product in the underflow. It is well known that injecting water in the conical part of the cyclone reduces the fine particle fraction in the underflow. This paper presents a mathematical model that simulates the water injection in the conical component. The model accounts for the fluid flow and the particle motion. The stationary concentration distributions result from superpositioning the turbulent particle diffusion and particle settling. Particle interaction, due to hindered settling caused by increased density and viscosity of the suspension, and fine particle entrainment by settling coarse particles are included in the model. Water injection in the conical part of the hydrocyclone is performed to reduce fine particle discharge in the underflow. This added water transports the fine particles of the sediment to the center, where they are directed to the overflow. The model demonstrates the impact of the injection rate, injection velocity, and injection location on the shape of the partition curve. Under optimal conditions, the so-called “fish hook” of the curve is reduced without changing the cut size. The simulations are compared with experimental data of a 50-mm cyclone.

  • Controlled wash water injection to the hydrocyclone underflow
    M.G. Farghaly, V. Golyk, G.A. Ibrahim, M.M. Ahmed, and Th. Neesse
    Elsevier BV
    Abstract In hydrocyclones, the classification efficiency is limited by the fines, which are discharged together with the water in the underflow. It is well known that the injection of water in the conical portion of the cyclone reduces the fines in the underflow. This paper presents an improved technique, which is done via an injection at the upper end of the apex or the conical end. This results in a greater washing effect and reduced consumption of wash water. The process is stabilized by controlled water injection specific to the underflow shape. This controlled wash water injection is applied to kaolin processing for the reduction of kaolin losses in the cyclone underflow. A series of tests using 50-mm cyclones was conducted in this work, which demonstrates the marked improvement of the partition curves using controlled water injection.

  • Performance of a three-product hydrocyclone
    Mahmoud M. Ahmed, Galal A. Ibrahim, and Mohamed G. Farghaly
    Elsevier BV
    Abstract Conventional (two-product) hydrocyclones have a wide range of applications in most of the mineral plants. The design of various hydrocyclones differs depending on the application but the most common one is the cylindrical-conical shape with variations in its cylindrical length and cone angle. In this paper, the design and operation of a three-product hydrocyclone which generates two-underflows and one-overflow is described. This type of the three-product hydrocyclone was tested successfully in the solid–liquid separation processes. The influence of opening diameters; overflow diameter ( d o ), middling flow diameter ( d m ), and underflow diameter ( d u ) on the solid and water recovery in the three products was also investigated and general prediction equations were estimated. Some potential applications of the new type three-product hydrocyclone were studied.