Induced Roll Magnetic Separator Research Articles

Quality Improvement of Low-Grade Calcium Carbonate Using Induced Roll Magnetic Separator

Quality Improvement of Low-Grade Calcium Carbonate Using Induced Roll Magnetic Separator

Induced roll magnetic separator applied for high grade ilmenite separation from mining tailing

This article aimed to separate ilmenite (FeTiO3) mineral from tin tailing applying a single splitter IRMS (Induced Roll Magnetic Separator). Ilmenite mineral is the substantial main source for TiO2. This work used air table middling for feeding. The mineral components of middling feeding from air table using grain counting analysis were found as follows: cassiterite (48.61%), ilmenite (21.36%), monazite (18.56%), pyrite (4.60%), zircon (5.85%), quartz (0.71%), anatase (0.27%), and tourmaline (0.02%), It was found that electrical current and opening of single splitter affected the degree of separation addressing to ilmenite recovery and ilmenite grade. The finding showed that current of 15 Ampere and single splitter with opening 4.25 cm yielded ilmenite recovery more than 74%. The high grade ilmenite (90.46 %) and recovery of 29.38% was obtained using 5 Ampere with single splitter opening of 1.0 cm. Up to date, the study on ilmenite separation from tailing only focused on the effect of current, however, the effect of single splitter magnetic separator to enhance ilmenite recovery from other paramagnetic minerals such as monazite, siderite, xenotime and tourmaline has not yet been reported.

High-intensity magnetic separation for recovery of LiFePO4 and graphite from spent lithium-ion batteries

Numerous end-of-life LiFePO4 batteries will emerge soon due to their limited lifespan. High reagent cost and environmental pollution of hydrometallurgy are the main factors that prevent the economic recycling of spent LiFePO4. In this paper, an environment-friendly physical method, that is, high-intensity magnetic separation (HIMS), was introduced for the first time to demonstrate its feasibility in preconcentrating the LiFePO4 from spent LiFePO4 batteries. Numerical simulation combined with laboratory experiments of two typical HIMS separators, namely high gradient magnetic separator (HGMS) and induced roll magnetic separator (IRMS), were conducted. Simulation analysis indicated that the separation performance was related to the magnetic field strength. In the HGMS experiments using − 0.21 mm electrode powder (after grinding) as feed, the concentrate grade and recovery of LiFePO4 were 74.54% and 96.60%, respectively. By contrast, in the IRMS experiments using electrode pieces (after shredding) as feed, the concentrate grade and recovery of LiFePO4 cathode pieces were 93.30% and 98.69%, respectively. Surface morphological analysis of electrode powder implied that superfine LiFePO4 particles produced by grinding adhered to or were embedded in coarse graphite particles, which seriously deteriorated the separation performance. By contrast, electrode pieces were considerably larger size, and the generation of superfine LiFePO4 particles can thus be avoided.

Optimization of ilmenite ore processing using induced roll magnetic separator

PT Timah Tbk has been processing residual ore (SHP) with a low tin grade of ± 10-30% wt. To increase tins grade and associated mineral products to be a high grade (> 70% wt), an evaluation and optimization process is needed on Induced Roll Magnetic Separator processing equipment. The evaluation and optimization process was carried out on magnetic products, especially ilmenite minerals. Sampling is done on the feed and the product based on the tool parameter settings. The feed rate is set at 380, 320, 250, 420, and 470 gr/10s. The splitter opening is set at 10, 15, 20 mm of magnetic rollers. While the electric current is set at 2, 4, 6, 8, 10, 12, 14 amperes. Mass and grade data are then analyzed by regression and variance statistical methods and optimized by the response surface method. The evaluation results show that only the splitter opening parameters and electric current strength are significant in explaining the product results obtained with a level of hypothesis error of 5%. The results of IRMS optimization show that the best parameter conditions are in the 2-4 ampere of electric current and 10-15 mm of splitter openings with illmenite grade capable of> 80% wt in the second order of central composite design.

Evaluation of Dry Processing Technologies for Treating Low Grade Lateritic Iron Ore Fines

ABSTRACT Dry processing options, involving the use of a circulating air classifier and thermal roasting (advanced microwave-assisted magnetizing roasting), followed by magnetic separation using an Induced Roll Magnetic Separator (IRMS), were evaluated for upgrading low-grade hematite-goethite iron ore fines. The novel magnetizing roast was conducted under reducing conditions using CO/CO2 gas mixtures which converted the initial goethite-rich ore into a magnetite-rich ore. From a feed sample containing 54.5% Fe, 2.10% SiO2, 7.97% Al2O3, 0.97% TiO2 and 0.13% P with a density of 3.87 g/cm3 and 80 wt% passing 675 µm, a high-grade IRMS magnetic product of 62.0 wt% Fe was obtained with a yield of 71.6 wt% and around 82 wt% recovery of iron units.

Application of Artificial Neural Networks to Predict Dry Magnetic Separation of Low-Grade Hematite Fines

An artificial neural network model to predict the performance of induced roll high-intensity magnetic separator while upgrading low-grade iron ore fines is presented in the present investigation. Key process parameters of induced roll magnetic separator operation, i.e., applied current, speed of rotor, splitter position, particle size, and feed rate, are used as the network input. A feedforward ANN is designed with one hidden layer, with units varying from 9 to 40 and capable of estimating the separation performance (iron content, silica content, iron recovery, and silica rejection of the magnetic product) in an induced roll magnetic separator. Simulated results obtained using the neural network modeling correspond closely to the actual results with a correlation of coefficient (R2) > 0.95 in training and testing stages. The developed models are further used to understand the sensitivity of the studied variables. The effects of speed of the rotor and splitter position are found to be more sensitive to the separation. Furthermore, an optimized solution is designed to predict the best achievable grade-recovery curve for this pre-concentration.

Influence of particle size on dry high-intensity magnetic separation of paramagnetic mineral

Dry high-intensity magnetic separators are one of the most common magnetic separation methods extensively used for the concentration of paramagnetic minerals based on their magnetic susceptibility, particle size, particle density, and shape. In this paper, the influence of particle size on the separation of the garnet particle in Induced Roll Magnetic Separator (IRMS) was investigated by varying the magnetic field intensity, rotor speed, feed rate, and splitter position. The influence of particle size on a magnetic fraction of Induced Roll Magnetic Separator was analysed as the D50 (μm) and D80 (μm) size. The results show that segregation of the coarser particle is segregated in non-magnetic fraction while finer sized particles are at the magnetic fraction. To understand further, particle size distribution is analysed by Rosin-Rammler equation and the variation of the constants are explained by statistics. Also, the influence of individual variables and their interactions on the segregation pattern is described by analysis of variance method along with response surface plots.

Effect of desliming on the magnetic separation of low-grade ferruginous manganese ore

In the present investigation, magnetic separation studies using an induced roll magnetic separator were conducted to beneficiate low-grade ferruginous manganese ore. The feed ore was assayed to contain 22.4% Mn and 35.9% SiO2, with a manganese-to-iron mass ratio (Mn:Fe ratio) of 1.6. This ore was characterized in detail using different techniques, including quantitative evaluation of minerals by scanning electron microscopy, which revealed that the ore is extremely siliceous in nature and that the associated gangue minerals are more or less evenly distributed in almost all of the size fractions in major proportion. Magnetic separation studies were conducted on both the as-received ore fines and the classified fines to enrich their manganese content and Mn:Fe ratio. The results indicated that the efficiency of separation for deslimed fines was better than that for the treated unclassified bulk sample. On the basis of these results, we proposed a process flow sheet for the beneficiation of low-grade manganese ore fines using a Floatex density separator as a pre-concentrator followed by two-stage magnetic separation. The overall recovery of manganese in the final product from the proposed flow sheet is 44.7% with an assay value of 45.8% and the Mn:Fe ratio of 3.1.

Physical separation for upgradation of valuable minerals: a study on sands of the Someswari river

The study is carried out to develop a physical separation method for upgradation of valuable minerals from sands of the Someswari River. Understanding the morphology and mineralogy of the heavy minerals may allow development of processing methods that produce the higher grade products. For this purpose, grain size analysis, microscopic, spectroscopic study and feasibility of physical separation by shaking table, electrostatic plate separator and induced roll magnetic separator have been done. Considering the huge quantity of sandy materials of the studied river sands and separation of heavy minerals magnetite, ilmenite and garnet from the bulk sands and further treatment of the light mineral quartz to remove iron coating could be use as glass-sands; either the light mineral quartz or heavy minerals will be the main product. From the overall study by physical separation method, the Someswari River is identified as potential resources for mineral processing.Bangladesh J. Sci. Ind. Res. 50(1), 53-58, 2015

Prediction of Separation Performance of Dry High Intensity Magnetic Separator for Processing of Para-Magnetic Minerals

High intensity dry magnetic separators are gaining popularity for the separation of para-magnetic minerals due to the cost economic factor. Induced roll magnetic separator is found to be an effective dry separator for the separation of fine particles. Separation efficiency of this separator depends on mineral characteristics and the design features of equipment along with the optimization of process variables. Present investigation focuses on the prediction and validation of separation performance of minerals while treating in induced roll magnetic separator. Prediction of the separation is expressed in terms of separation angle at which a particle leaves the rotor surface by using a modified particle flow model derived by Cakir. The validation of the model is carried by capturing the particle trajectory using an image analyzer. It is found that Cakir’s mathematical model produces reliable results and a new model is proposed to increase the reliability of separation angle prediction by including the particle shape factor.

Magnetic separation studies on ferruginous chromite fine to enhance Cr:Fe ratio

The Cr:Fe ratio (chromium-to-iron mass ratio) of chromite affects the production of chrome-based ferroalloys. Although the literature contains numerous reports related to the magnetic separation of different minerals, limited work concerning the application of magnetic separation to fine chromite from the Sukinda region of India to enhance its Cr:Fe ratio has been reported. In the present investigation, magnetic separation and mineralogical characterization studies of chromite fines were conducted to enhance the Cr:Fe ratio. Characterization studies included particle size and chemical analyses, X-ray diffraction analysis, automated mineral analysis, sink-and-float studies, and magnetic susceptibility measurements, whereas magnetic separation was investigated using a rare earth drum magnetic separator, a rare earth roll magnetic separator, an induced roll magnetic separator, and a wet high-intensity magnetic separator. The fine chromite was observed to be upgraded to a Cr:Fe ratio of 2.2 with a yield of 55.7% through the use of an induced roll magnetic separator and a feed material with a Cr:Fe ratio of 1.6.

Separation analysis of dry high intensity induced roll magnetic separator for concentration of hematite fines

In this study, a three level Box–Behnken factorial design combined with response surface methodology was used for modeling and optimization of process parameters of induced roll dry high intensity magnetic separator. The influence of magnetic field intensity, roll speed and feed rate was analyzed for the separation of hematite minerals. Second-order response functions were produced for the grade and recovery of the hematite minerals in the magnetic fraction. Taking advantage of the quadratic programming, optimized levels of the process variables have been determined as optimum levels to achieve the maximum grade of 51.2% Fe, and maximum level of recovery was 97.8% Fe whereas minimum grade of 23.9% SiO2 in the magnetic product was predicted. Further optimization was carried out by targeting the Fe (%) content and recovery of the magnetic product of above 50%. The influence of the process variables of the induced roll high intensity magnetic separator on grade and recovery of the hematite mineral in the magnetic fraction were presented as 3D response surface graphs.

Particle flow modeling of dry induced roll magnetic separator

Abstract Magnetic separators have unrestricted industrial application and are widely used in mineral beneficiation, food, textiles, plastic and ceramic processing industry. Separation efficiency of magnetic separator depends on material characteristics and the design features of equipment along with the optimization of process variables. This study is based on a novel application of image processing technique to capture the particle trajectory on induced roll in an electromagnetic separator while treating magnetic particles. Three different minerals of different magnetic susceptibility were selected to investigate this approach. Trajectories of 3 mm diameter balls of mineral fines were captured using an image analyzer at different operating conditions. The particle trajectory captured was compared with the trajectory predicted by Cakir mathematical model. The separation angle between roll and particles was considered as a separation performance measure. It was found that Cakir mathematical model produce reliable result and a new model was proposed to increase the reliability of separation angle prediction by including the particle shape factor. The proposed model can be utilized to optimize the magnetic separation process while treating paramagnetic minerals.

The Processing of Beach Sand from Sri Lanka for the Recovery of Titanium Using Magnetic Separation

An investigation has been carried out to study the mineralogical and chemical characteristics of beach sand deposits from Sri Lanka and application and optimisation of different magnetic separators (induced roll magnetic separator and disc magnetic separator) to improve the recovery of titanium from the deposit. Commercial grade titanium concentrates could be achieved employing both induced roll and disc magnetic separators. However, the titanium recovery increased greatly in the magnetic fraction with a titanium content of commercial grade (up to 63.9% TiO2) when paramagnetic titanium‐bearing minerals were separated from beach sand using the disc magnetic separator. The results of the mineralogical and chemical analysis tests for the beach sand deposit indicated that 71% of beach sand was smaller than 355 μm in particle size and more than 99% of titanium content of the deposit was contained in this fraction.

Quantification of induced roll magnetic separation of mineral sands

In the present work the effect of variables and forces acting on a magnetic particle passing through induced roll magnetic separator has been discussed. The sensitivity of important variables, namely input current, roll speed and feed rate have been assessed and quantified using statistical techniques.