Outputs Track 1 &2 : Technology Transfer for Improving the Specifications of Kaolin and white sand for Production of Competitive Chemicals

Transcription

1 Outputs: Track 1 &2 : Technology Transfer for Improving the Specifications of Kaolin and white sand for Production of Competitive Chemicals Generally, the outputs of track 1 and 2 of the project are: Prototype Know-how Feasibility study Process development: Semi-industrial production Technology Transfer Specifically, the outcomes are as follows: 1. Production of Functional Prototypes: Production, on lab level at CMRDI, of high grade kaolin with different specifications and their testing and application in a wide scope of chemical industries such as ceramic, porcelain, sanitary-ware, glaze, cement, paper making, paint manufacturing, plastic production, fiber glass, water purification chemicals, cosmetic industries. Production, on lab scale level at CMRDI, of high grade sand, on pilot scale level, with different specifications and their testing in the plants of our industrial partners such as glass, fine glass, crystal and optical glass companies, and as a filler in paint, plastic, and fiber glass production companies. 2. Semi-Industrial Production Production, on pilot scale level at CMRDI, of high grade kaolin with different specifications and their testing and application in a wide scope of chemical industries. Production, on pilot scale level at CMRDI, of high grade white sand with different specifications and their testing and applications in production lines of the above mentioned industrial partners. 3. Process Development: Flow-sheets design for upgrading both Egyptian kaolin and white sands of Sinai that satisfy the required specifications for different industrial applications. 4. Preparing Prefeasibility Studies: A techno-economic prefeasibility study will be prepared for establishing new plants for upgrading a kaolin beneficiation plant and white sand upgrading plant either or in Sinai (beside the mines) or/and in any of the industrial cities (beside the chemical industries). These feasibility studies will include; technology with the required capacity and annual production, environmental assessment, investment required, startup costs, operating costs, return of investment (ROI) and payback period (PBP), risks, what-if-scenarios, etc. Track 3: Production of Manganese Rich Slag and Pig Iron from Egyptian Low Grade Manganese Ore Market study Development of technology package for treatment of low grade manganese ore into high added value products of high manganese content without phosphorous and pig iron with lowest content of manganese. Semi-industrial production of rich manganese slag and pig iron. The produced high manganese slag will reduce the cost production of 1

2 manganese ferroalloys. The produced high manganese slag will reduce the need to the hard currency for importing manganese ores and sinter. Utilization of huge amounts of Egyptian low grade manganese ores Feasibility study Track 4: Production of Silicomanganese from local ores at Sinai Manganese Company Development of a suitable technical and economical process for producing silicomanganese from local raw materials. Local producing of needed SiMn on industrial scale at Sinai Manganese Company. Provide a sustainable and effective tool to raise and channel resource to Egypt's innovation priorities as the impact of implementing of innovation into industrial sector. Strengthening cooperation between research and industry sectors. Increase the competitiveness of SMC through introducing a new product that uses the traditional production by-product and optimize the low grade ores. The proposed production technique improves the energy efficiency of the company. Reviving the Egyptian identity through introducing a new product in the heavy industry with the slogan; made in Egypt. Socio-economic development of Sinai. Creating new jobs Saving hard currency by reducing the import Partners Partner Name Logo Partner Name Logo Sinai Manganese Company (SMC), Abu Zennima, Sinai Cairo University Ezz Steel Company Housing & Building National Research Center, HBRC 2

3 Asfour for Mining and Refractories Arab Pharmaceutic al Glass Company, (A.P.G), El-Obour Paints and Chemical Industries "PACHIN" Aluminum Sulphate of Egypt Co Prima Ceramic Co Nile for Chem. Supplies Co The National Company for Glass & Crystal Chamber of Metallurgical Industries Engineering Company for Industrial Services (EINS) General Syndicate of Industrial Investors TESSRA Technologies News: Visit to Sinai Manganese Company, Abou Zenima, South Sinai On Thursday, 3/8/2017 a team of the Alliance represented by Prof. Mamdouh Eissa, the Principal Investigator, Prof. Mahmoud Nasr, the Executive Manager, Prof. Nagui Ali Abdelkhalek, the Co-principal Investigator of Kaolin Track and Prof. Taha Mattar, the Chairman of Central Metallurgical Research and Development Institute (CMRDI) and the Co-principal Investigator of Silicomanganese Track visited Sinai Manganese Company (SMC), Abu Zenima, South Sinai. A meeting was held with a team of the company represented by: Prof. Mohamed Adel Yehia, Chairman of SMC. Geo. Gamal Hendawy, Managing Director of SMC Eng. Magdy Oraby, Head Sector of Ferromanganese 3

4 Eng. Aly Farghly, Head Sector of R&D Geo. Hamdy Sabna, Head Sector of Mining Geo. Hassan Saad, Technical Consultant Eng. Saeed Mohamed Ahmed, General Manager of Production, Chem. Walid Ahmed Abd El-Fatah, General Manager of Laboratories, Geo. Mohamed Abd El-Daiem, General Manager of Kaolin Tech. Tarek Kamel, General Manager of Workshops and a member of Board of Directors. In this meeting, the various activities of the project were discussed. It was also agreed to supply the research team with the necessary ores: Kaolin, white sand, low grade manganese ores, in addition to reducing agent and fluxing materials needed for performing the pilot plant runs. It was also agreed on periodic meetings to determine the progress of the project. 4

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7 Participation in EGYCAST 2017 Conference A team of the Alliance has participated in EGYCAST 2017 Conference which has been held in Sharm El-Shiekh during the period October 2017, where Prof. Dr. Mamdouh Eissa, the Principal Investigator of Alliance, presented a paper about the project entitled: "Utilization of Egyptian Low Grade Manganese Ore to Produce Silicomanganese and Pig Iron at Sinai Manganese Company" Four members of the management of Sinai Manganese Company (SMC), the principal industrial partner of the Alliance attended the conference: Geo. Gamal Hendawy, Managing Director Eng. Magdy Oraby, Head Sector of Ferromanganese Eng. Aly Farghly, Head Sector of R&D Geo. Hamdy Sabna, Head Sector of Mining Representatives of Egyptian steelmaking companies attended the conference and expressed great interest in the local production of silicomanganese alloy in Egypt, where this alloy of great importance in the steelmaking process, and is currently imported from abroad with the negative impact on the balances of hard currency. 7

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