Iron Removal from Low-Grade Pyrophyllite Ore by Microwave Irradiation and Dry Magnetic Separation

Owing to its unique properties, pyrophyllite is an economical alternative to many minerals in different applications. The presence of iron-bearing minerals in Saudi pyrophyllite hampers its industrial uses. The aim of this study was to examine the removal of iron from Saudi low-grade pyrophyllite ore using two approaches. The first approach involves dry high-intensity magnetic separation, whereas the second approach involves microwave pretreatment of the ore before dry magnetic separation. For the first approach, the studied operating parameters were roll speed; feed rate, field intensity, and feed particle size. For the alternative approach, microwave treatment followed by dry magnetic separation, the microwave irradiation time and the magnetic field intensity were studied. The results show that the combined microwave treatment and dry separation method could provide high-purity pyrophyllite for filler industries. Microwave irradiation for 30 min was optimal to change impurity phases (i.e., pyrite, hematite) into ferromagnetic phases in microwave-treated pyrophyllite samples. At a magnetic field intensity of 2000 Gauss, the 30 min microwave-irradiated pyrophyllite sample achieved an iron recovery of 11.2% in non-magnetic fractions, with a removal efficiency of 89% with an alumina recovery of 91.31%.