Hydrodynamics and Response Analysis of a Cutting-Edge Pulse Bed Mineral Scrubber (PBMS) Featuring U-Type Motion, Pulsation Bed, and Fluidization for Low-Grade Iron Ore Processing

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ABSTRACT A novel compact and efficient pulse bed mineral scrubber (PBMS) has been designed. The scrubber has a hybrid design incorporating a U-type particle flow path, bed pulsation like a jig and fluidization. The hydrodynamic characteristics and response of this scrubber for the scrubbing of low-grade iron ore fines have been reported in this article. The response methodology with a central composite design was used to evaluate the hydrodynamics of the PBMS hutch section. The results indicate that the hydrostatic head increases with an increase in solid percentage in the hutch section and decreases with an increase in pulsation frequency. The pressure and load model prediction matched the experimental data well. The model predicts that at 54 rpm pulsation frequency and a 25% solid percentage, the pressure will be 0.0285 bar and the motor load 25.54 W. The R2 of the pressure and load model are 0.9536 and 0.9936, respectively. Scrubbing performance on −10 mm iron ore fines with 54.17% Fe, 8.15% SiO2 and 12.75% Al2O3 at 10, 15, and 20 l/min water rate has been validated with characterization of products after scrubbing. The desliming efficiency of the particle in the range of 0.045–0.3 mm is ± 88% at a water rate above 15 l/min. The best cleaning and segregation of fines are reported at a 15 l/min water rate. The Fe value of clean coarse products increases from 54% to 59%. The scrubbing improves the grade of ore, and the alumina and silica content reduction is 19% and 40%, respectively.