New Valley (Abutartur) Phosphate Project

One of the major mining projects in the Egyptian western desert, 60 kilometers from Kharga, major city in the New Valley Governorate. Mining of raw phosphate is exploited in manufacturing fertilizers and intermediary chemicals to meet the demand locally and abroad.

The preliminary studies and replacement plan were made by consultants from Russia, Ukraine, Britain, French- Swiss and USA. The design of line production was made by Former Soviet Union. The design and supply of standard equipment were executed by Russian and Ukrainian bodies, and nonstandard equipment by Egyptian companies. Replacement of mining equipment carried out by the English Joy Company. Infrastructure executed by Egyptian Contracting Co.

Project’s initial operation and handing over:

Initial operation carried out in May 1999.

The project includes the establishment of a phosphate mine producing 4.5 million tons of raw material annually, and a factory to produce and process 2.2 million tons/ year of phosphate concentrate. The project serves a group of complementary projects and promotes exportation.

Ground mine occupies 14 km2 per preliminary layout. It consists of four long walls of a design length of 150 m each and a productivity of 800- 850 thousand tons annually.

The mine consists of 2 underground mining complexes using long wall method, linked by three loop tunnels. The long wall consists of a 150 m face, with a height of 3.2 m and a length of 1100-1250 m. Each wall is served by three tunnels, main tunnel to transfer the raw material, a tunnel for the use workers and transfer of equipment and for ventilation and end of face tunnel for electric and hydraulic supply. Long wall includes self-moving support, crusher, belts and ventilators.

Main platform consists of air compressors, pumps of supplying water for dust suppression, firefighting and drinking, maintenance workshops, water tanks and administrative building.

Raw material silos consist of 5 silos, 1000-ton capacity each, crushing and sorting units including:

• Two 60 mm. sieves
• Rotary crushers, 240 ton/h
• Two storage yards, 40000 ton each.
• Stacker, 1000 ton/h
• Reclaimer, 1000 ton/h

The plant consists of 3 similar lines for processing phosphate raw material to upgrade its concentration to commercial levels, with a capacity of 750000 tons of concentrate annually per each line. A line is loaded by 1.5 million tons of material annually. An experimental semi industrial concentration unit of 2 ton/h capacity was carried out to measure concentration results, assess the effect of operation process on equipment and items, and test prospected kinds of raw materials. The plant is served by storehouses and phosphate loading stations.

Three drying furnaces with a design capacity of 114 ton/hour each. One furnace was established.

It consists of 2 silos, 400 ton each. Raw material is transferred by railway wagon, 65-ton capacity each.

There are 7 specific complementary projects working as an infrastructure for the basic industrial project:

• High voltage supply line extending between Naga Hamadi and Abutartur cities, with two transformers.
• Water wells: 15 wells, 200 m3/h each, at depths reach 800 m. The wells are for supplying drinking water and industrial water as well as for cultivating areas of 60 fedans up to 2000 fedans in future.
• Roads network
• Housing project: including administrative buildings; 2000 units. Residential city lies to the south on an area of 800 fedans including 5000 units.
• Farm
• Abutartur/Qena/Safaga railroad: 680 km, including a Nile river bridge at the city of Qena.
• Safaga seaport, Red Sea: Established for handling and exporting phosphate concentrate. Port capacity is 2.2 million ton/year up to 6 million tons/year in future. Ship tonnage is estimated at 65000 tons.