MAGNETIC SEPARATION

N. Chakravorty
le Introduction:
Magneticseparationemploys thedifferencein
magneticproperties of minerals to effect separation
betweenthem. Themagneticseparationmay befor removing
oreparticles which aremagneticor conversely to remove
magneticimpurities froma product which is non-magnetic.
Examples areMagnetitefromQuartz or Magnetiteand
WolframitefromCassiterite.
All materials areaffectedinsomeway whenplaced
ina magneticfield, although with most substances the
effect is too slight to bedetected. Materials canbe
classifiedinto two broadgroups, accordingto whether
they areattractedor repelll by a magnet.
Diamagnetics arerepelledalongthelines of magnetic
forceto a point wherethefieldintensity is smaller.
Theforces involvedherearevery small anddiamagnetic
substances cannot beconcentratedmagnetically.
Paramagnetics areattractedalongthelines of
magnetic force to points of greater field intensity.
Paramagnetic materials can he concentrated inhigh-
intensity magnetic separators. Examples of paramagnetics
which are separated in commercial magneticseparators are
ilmenite(FeTiO3' )rutile(TiO
2
)wolframite(Fe,Mn)W0
4
),
monazite(rare earth phosphate), siderite (FeCO3),pyrrhotite
(FeS), chromite(FeCr204),hematite (Fe203), and
manganeseminerals.
Some elements are themselves paramagnetic, such as
Ni,Co,Mn,Cr,Ce,Ti3 O, and the Pt group metals, but in most
cases the paramagnetic properties of minerals are due to
the presence of iron in some ferromagnetic form.
- 2 -
Ferromagnetismcanberegardedas a special caseof
paramagnetism, involvingvery high forces. Ferromagnetic
materials havevery high suscei)tibility to magneticforces
andretainsomemagnetismwhenremovedfromthefield
(remanence). They canbeconcentratedinlow-intensity
magneticseparators andtheprincipal ferromagnetic
mineral separatedis magnetite(Fe304),although hematite
(re2 03)andsiderite(FeCO3)canberoastedto produce
magnetiteandhencegivegoodseparation. Theremoval of
"tramp"ironfromores canalso beregardedas a formof
low-intensity magneticseparation.
Theunit of measurement of magneticfluxdensity
or magneticinduction(thenumber of lines of forcepassing
through unit area of material)is thetesla. Despitethe
fact that thec.g.s. systemis nowobsolete, theunit
most commonly usedis thegauss (G), which is 10
-4
tesla, andit wouldappear that for many years to come
a knowledgeof the"electromagneticc.g.s."unit (e.m.u.)system
will bea necessity for workers inmagnetism.
Themagnetisingforcewhich induces thelines of
forcethrough a material is celledthefieldintensity,
andby conventionhas theunits oerstedinthee.m.u.
system(amperemetre
-1
inSI units),although one oersted
is numerically equal to onegauss. Whendealingwith
magnetic fields in air, thevalueof thefieldintensity
is virtually thesameas that of fluxdensity, andthe
termmagneticfieldintensity is thenoftenloosely
used. Ontheother hand, when dealingwith themagnetic
field inside materials,particularly ferromagnetics that
concentratethelines of force, thenthevalueof the
inducedfluxdensity will bemuch higher thanthefield
intensity, andit must beclearly specifiedwhich term
is being referred to. A Table giving the magnetic properties
of somecommonminerals is giveninTable-1. This indicates
theinductionrangerequired Eor separationof theseminerals
- 3
Thecapacity of a magnet to lift a particular
mineral is dependent not only onthevalueof thefield
intensity, but also onthefieldgradients i.e. therate
at which thefieldintensity tncreases towards themagnet
surface.
It canbeshownthat
dH
FH
Where F is the force on the particle, H is the field
intensity, and dif/dt is th- rLeld gradient.
Thus in order to generate a given lifting force,
there are an infinite number of combinations of field and
gradient which will give the same effect. Production of
a high field gradient as well as high intensity is
therefore an important aspect of separator design.
2.
Magnetic Separators
2.1 Design Principles:
In the design of any type of magnetic separators,
therefore besides a field a gradient in the field strength
has to beprovidedto enhancemovement of particles inthe
desireddirections. Ina fiell of uniformmagneticflux
magneticparticles will convercir, thefluxandorient
i-ionof flux
themselves so that thereis a concentrateinits body but it
will not move. Ontheother hand, by producinga converging
fielda resultingpull ontheparticles towards thehigher
fluxarea (Fig. 1. ). Thesimplest methodof producinga
convergingfieldis by reducingthepolearea of one
poleina magnet or a Vshei)ed poleover a flat pole.
Thesmall area of onepoleconcentrates themagneticflux
into a very small area givinghigh intensity. Thecorres-
pondingpolewith a larger area has sametotal magnetic
fluxdistributedover a larger area. Thus thereis a steep
fieldgradient across the gap dueto thedifferent
intensity levels.
1
Fig.l. Convergence of magnetic flux due to
inequal pole pairs.
Besides the inhomogenity created by the geometry
of the pole shape and size design, arrangements areprovide,1
to alter the intensity by varying the pole gap or by
varying the current in coils of electromagnetic separators.
the latter usually being the operating variable.
Commercial magnetic separators are continuous-process
machines and operation is carried out on a moving stream
of particles passing into and through the magnetic field.
Closecontrol of the speed of passage of the particles
through the field is essential, which rules out free fall
as a means of feeding. Belts or drums are very often used
to transport the feed through the field.
Theintroductioninto a magneticfieldof particles
which are highly susceptible concentrates the lines of
forceso that they pass thQugh them.
Since the lines of force converge to the particles,
a high field gradient is produced which causes the particles
themselves to behave as magnets, thus attracting each other.
Flocculation, or agglomeration, of the particles canoccur
if they aresmall and highly susceptible and if the field
is intense. This has great importanceas thesemagnetic
"flocs" can entrain gangue and can bridge the gaps between
magnet poles, reducing the efficienilly of separation.
Flocculationis especially serious with dry separating
machines operating on fine material. If the ore can be fed
through the fieldina monolayer,f the effect is much less
serious, but, of course, thecapacity of themachineis
drastically reduced. Flocculation is often minimised by
passingthematerial through consecutivemagneticfields,
- 5
which areusually arrangedwith successivereversal of
thepolarity. This causes theparticleto turnthrough 180',
each reversal tendingto freetheentrainedgangueparticles*
Themaindisadvantageof this methodis that fluxtends
to leak from pole to pole, reducing the effective field
intensity.
Provision for collection of the magnetic and non-
magneticfractions must beincorooratedinto thedesignof
theseparator. Rather thanallowthemagnetics to contact
the pole-pieces, which would cause problems of detachment,
most separators aredesignedso that themagnetics are
attractedto thepole-pieces, but comeinto contact with
someformof conveyingdevice, which carries themout of
theinfluenceof thefield, i, ito a binor belt. Non-
magneticdisposal presents no problems, freefall from
a conveyor into a binoftenbeingused. Middlings are
readily producedby usinga moreintensefieldafter the
removal of thehighly magneticfraction.
,0111-1g21: 5aE2L2La:
Though thecommercial magneticseparators areseen
inmany forms andnames, a broadgroupingcanbemade
for theseas below:
a) LowIntensity
b) High Intensity
both couldbeeither wet or dry operationtype. Amongthese,
dependinguponfunctionit couldbesubdividedinto
1) Guardmagnet to removetrampironetc.
2) To removemagnetics of value
3) To removedeletrious impurities,
The
magneticfieldmay begeneratedby oneof theseveral_
ways as 1)permanent magnet, 2)Electromagnet with ironyoke,
3)Solenoidand4)Superconductingmagnet. After some
ME,
6
stagnation, recently there has been new spurt in the magnetic
separation machine design and manufacture - notable among
which are the Wet high intensity magnetic separation(WHIMS)
and high gradient high intensity separation (HGMS),Rare
Earth magnet permanent magnet separators(Permaroll).
Last to join the system is superconducting magnets
developments on which are now in just beginning. A current
trend in the design of magnetic separators is towards
higher capacities per unit so as to obtain lower capital
and operating cost per tonne of material treated. Two
other parameters for evaluating magnetic separators are
the energy consumption per tonne of material treated and
the mass per tonneof a machine.
3.(1) DRUM Separator:
Dry Drum magnetic separators are most common -
lowintensity units in operation used for separation of
strongly magnetic particles. The unit consists of a rotating
non-magneticdrumcontaininga number of stationary magnets
of alternate polarity, of electromagnets, which are now
mostly madewith permanent magnets. (Fig.2a-a).Thematerial
to be separated is fed at thetopof therotatingdrum
surface, thenon-magneticfractionleaves thedrumby
centrifugal throwwhilethemagneticfractionis retained
on the surface and is dropped outside the magneticfield,
and are thus deflected. A splitter makes a suitable cut.
Usually besides the magnetic andnon-magnetic fraction, an
intermediate product is sometimes obtained depending on
the material characteristics and interlocking and are
called middlings. Commercially available drum separators
have a wide range of diameters from 300 - 1500 mm and
length from 300 to 4000 mm. Coarsely crushed material as
large
as 8mmdia canbetreatedeconomically at feedrates
over 150 T/h per metre of lenyth. Typical radial magnetic
induction values for current drum separators are of the
order of 500 to 1500 gauss (0.05- to 0.15T). Singleor
multipleunits incascadehavebeenbuilt.
3.2. Wet drum Separators:
Magnetic separators most commonly in use are wet
drum low intensity type used in concentration of magnetite
ores, and can be of concurrent and countercurrent design.
Thedrumconstructionis similar to dry drumseparator,
havinga number of electromagnets with 6-8poles inside
a non-magneticrotatingshell with locationinsidea tank
havingarrangement for feedanddischargeof products as
shown in Fig.3 a,b,c. Material is fed in the submerged
tank in a slurry form which passes across the face of the
drum, whenthemagnetics arepickedupby therotating
drum and discharged in a separate chute. Water spray is
usually provided to facilitate discharge at places where no
field exists. The feed in these machines are usually ground
to below 1 mm rarely exceedincf 3 mm for handling and
blockage in the discharge orifice.
The tank design varies in the manner of presentation
of feedanddischargeof products. Onthebasis of pulp
flow, theunits aretermed(i)Concurrent, (ii)Counter-
current and(iii)Counter rotation. Thepulpas a slurry
is fedas shown(Figs. 3a,b,c)anda level is maintained
inthetank by adjustableweir pieces andtailingdischarge
orifices so that about 10-20%of total tailings volumeoverflows.
The Counter rotationdrums areusually usedinroughing,
wheremaximumrecovery is eFC'ectecl, whiletheconcurrent
units may beusedinroughingor cleaningoperations
andthecountercurrent ones for finishingseparators.
TheCrockett lowintensity separator is anearly
model wherethemagnet tank is submergedina tank over
which a belt runs betweentwo drivepulleys (Fig. 3e).
Themagnetics aredrawnupagainst thebelt andare
carriedout to theconcentratedischarge. Inboth drum
andbelt separators, themagnet poles arealternateso that
thepickedupmagneticparticles rotateto dropout the
entrainedgangueparticles dueto bridging.
3.3Designof thedrum:
Theseparatingdrumconsists of two mainparts: a
stationary magneticcircuit anda shell, madeof non-magnetic
material, which freely rotates roundthemagnets. The
capacity of such a separator is determinedby themagnetic
inductiononthesurfaceof thedrum, by thegradient of
themagneticfieldinthepulpandby thesizeof thedrum.
Nowadays, designof thedrumis closely associated
with thedevelopment of thepermanent magnets usedto
generatethemagneticfield. With bariumferritepermanent
magnets, of theenergy product of 20 - 22 kJm
3
(2.6- 2.8
thethickness of thewall of thedrumcanbea maximum
of 2.0 - 2.5mm. Therefore, thelength of thedrumis
limitedto about 1500 mm. With theincreasedquality of
thebariumferritewith theenergy product of 2.8- 3.2
MGOe(22 - 25kJm3)thewall thickness couldhavebeen
increasedto 3.0 - 3.5mm, andtherefore, thediameter and
thelength of thedrumcouldhavebeenincreasedto 900 and
3000 mm, respectively.
By combiningthestrontiumandbariumferrites,
thewall thickness canbeincreasedto 4 - 5mmanddrum
diameter andlength to 1500 mmand4000 mm, respectively.
Thecapacity of thethreetypes of drummagnetic
separators discussedabove, dependingondrumdiameter,
is showninFig. 3f. andTable2- .
Table2. Capacity of drummagneticseparators
DrumConcurrent Counter rotationCounter current
diameter drum

drumdrum
(mm)Capacity Capacity

Capacity
(t/mh) (1/mh) (t/mh)
600
900
1200
1500
35
50
40
60
85
100
20
30
35
Thedevelopment of ne,,r, permanent-magnet materials
has increasedthemagneticinductionavailableonthedrum
surfaceandinsidetheseparationtank. For instance, the
earlier systemgenerated0,0_6T on the drumsurfaceand
0.06T at 40 mmfromthedrumsurface, whilenewmagnetic
circuits create0.22 T onthesurfaceand0.09T at 40 mm.
Theimprovement inparameters of themagneticcircuit
andinthedesignof theseparationtanks producedanincrease
in
1) thediameter andlength of thedrumandtherefore,
thecapacity of themachine
2) thegradient of themagneticfieldandthus an
increaseintheefficiency of recovery of fine
ferromagneticparticles
3) thedepth of themagneticfieldandeasier
recovery of larger grains.
4.0 High Intensity_lia2E2LicL;c2parators :
Weakly magneticmaterials canonly beremovedfrom
anorefeedinmagneticfields much greater thanthose
availableinlowintensity magneticseparators. Dry high-
intensity magneticseparationhas beenusedcommercially
sincethebeginningof thecentury, whilewet, high-intensity
andhigh-gradient magneticseparators weredevelopedonly
recently.
Threetypes of dry high-intensity magneticseparators
are in commonuse, viz;
(1) thecross-belt type
(2) theinducedmagneticroll type
(3) thepermanent magneticroll type.
4.1Cross-belt magneticseparator
This is oneof theoldest types of separator usedto
concentratemoderately magneticores (Fig.-
3a).
- 10 -
Dry material is fed in a monolayer onto theconveyor
belt and is carried between the poles of the magnetic
system.
The belt, with its load, passes between the poles of two
or more electromagnets. The lower pole-pieces are flat and
immovable, but the corresponding upper pole-pieces are
shaped and may be raised or lowered as required for the
material undergoing treatment. An endless cross-belt
runs around a series of pulleys and across each upper
pole-face surface at right angles to the conveyor belt.
As the material passes, the magnetic particles areattracted
to thecross-belt, are carried with it towards the discharge
side and fall into a suitably placed bin. The material may
be passed successively between several pairs of magnet poles
when it is desired to make several products in one pass.
Anon-magnetic tailing discharges as the conveyor belt
passes over its end pulley. Machines with two to eight
pairs of poles are available, and each pair can be adjusted
independently by regulatin:i t'lepositionof the upper poles
andby alteringthecurrent through thecoils. The height
of the upper pole-pieces above the belt should be set at
least 2.5times the size of the largest particle in thefeed.
The conveyor belt width ranges from 100 to 600 mm, the
distancebetweentheconveyor belt surfaceandthe upper
belt surface being from 3 to ?5 mm, depending on the si7=-3
and magnetic properties of the feed. Particles ranging
from 4 mm to 75 um may be treated successfully, but they
should preferably be sized into several fractions.
The main advantage of the cross-belt separator is
that several types of magnetic products can be recovered
in one pass at increasing magnetic field strength while
several separate passes are needed in other dry magnetic
separators. Since the electromagnets are independently
adjustable the selective removal of different magnetic
minerals is possible. Low-intensity magnet- can be
installed to scalp off any ferromagnetic particles present.
For estimatingmagnetics ina sample, a standard laboratory
test unit is the Davies rube Tester (Fig. 3 b).
- 1~ ~
4.2 Inducedma neticroll separator
Theinducedmagneticroll (IMR)separator consists
of a revolvinglaminatedroll formedof alternatemagneti-
zableandnon-magneticdiscs. Theroll is placedbetween
specially shapedpoles (Fig. 4 )of anelectromagnet.
Theelectromagnet induces a magneticfieldinthemagnetic
laminations of a roll forminglocal regions of high
magneticfieldgradients as showninFig.
I..
Material to betreatedis fedina controlledthin
stream by a vibratory feeder to the top of theroll. As
theroll revolves, thematerial passes through a narrow
gapbetweenthepoleof themagnet andtheroll andthe
non-magneticparticles aredischargedfromtheroll. The
magneticparticles areattractedto theroll, anddischarged
into a separatechutewhenthey enter a non-magnetic
region. Ferromagneticmaterjal canberemovedwith a s-par
ma(Ineticscalper beforefeeditlgto MR, to prevent plugging
thegap.
Thegapbetweenthefeedpoleandroll is adjustable
andalso thesettingof thesplitter is of great importance,
Thetypical values of magneticinductiononthesurfaceof
a laboratory IMR as a functionof the gap width.
It is a general practiceto ensurethat each
successiveroll is of greater magneticinductionthanthe
precedingroll. This is achievedby adjustingthepoles
so that a smaller gapbetweenthepoleandtheroll is
producedoneach successiveroll.
Becauseof variations inthecharacter andsizeof
thematerials it is difficult to express capacity interms
of mass. However, inmost applications capacity ranges
from2 to 3t h
-1
per metreof roll length. Material to he
treatedmust bedry, free-flowingandfor best results
shouldbewithinthesizer. anleof 2 mmto 100 um. Thegap
shouldbeadjustedinsuch a way that It is approximately
equal to 2.5times theaveragegrainsize.
- 12 -
Inducedmagneticroll s?parators aremarketedby
several manufacturers, e.g. Carpco,Eriez andReading.
Themaximumlength of theroll is 0.75m, except for the
Carpco separator which is 1myinlength. This separator
uses hollowrolls which reducetheeddy currents during
rotation, (most other IMR usesolidrolls). Fig.; 4cshows
a -roll IMR.
Although therecovery of ilmenitefrombeach sands
is thebiggest application, IMR separators havebeen
successfully appliedinnumerous other branches of minerals
treatment, viz. theproductionof high-quality (i.e. low-
iron)materials for theglass andceramics inlustry. They
oftenconstitutethefinal finishingpart intheflowsheet,
and theremoval of magneticimpurities fromandalusite,
Leldspar,wollastoniteandother: minerals is well proven.
IMRs arealso usedfor , oncentrationoE theinrlurip,1
min2rals (chromite, ironores, monazite,wolfrarniteetc.).
Therearetwo principal technical limitations for
IMRs, namely: relatively lowcapacity per unit andlimited
partictesizerange. Thelimitations arerelatedto the
maximumallowableair-gapandto theneedto feeda thin
streamof particles. To permit unobstructedflowthrough the
separator it is desirableto increasetheair gapfor larger
material flowandfor increasingparticlesize. It should
benoted, however, that increasingtheair-gapmeans reducing
themagneticfield, thereby limitingthethickness of the
material layer fedonto theroll, andreducingthecapacity.
4.3Permanent Mq.9122Iic roll separator :
Themost recent development inthefieldof permanent
magnet separators, conductedby E.L. BatemanLtd., resulted
inthedesignandmanufactureof thePermroll separator.
Theactivepart of this separator is a roll consistingof
disks of Sm-Co, or Nb-Fe-Bpermanent magnets interleaved
with mildsteel disks. Themost favourableratio of the
widths of themagnet andof thesteel is 4 : 1. Mildsteel
gives themost satisfactory results andspecial steels
- 13-
usually do not improvetheperformanceof theseparator.
Themagnet inthis configurationgenerates magneticinduction
upto 1.6T onthesurfaceof theroll andfieldgradients
of theorder of 300 T m. For aneasy removal of magnetic
particles theroll is covered
by.
a thinbelt supportedby
a second(idler)roll, as shownschematically inFig. 4 e
Belowtheconveyor is a hopper which collects thedis-
chargingmaterial whileadjw:table-splitters divert the
different fractions into collectionpans placedbeneath
thehopper.
4.4 g p2ep-t Submeredrollear rm :
Theneedfor a wet separationfor diamondrecovery
ledto thedevelopment of a Sm-Co permanent magnet sub-
mergedroll separator. (Fig. 4E)Thefeedis discharged
as a thinfilmby thefeed17.nler over thebelt travelling
over themagneticdrum. Thedrumis partially submerged
inwater wherethemagnetics clingto thebelt andare
transportedto themagneticcollectionchamber discharged
by separatingbelt.
1.5Ferrous Wheel Oekarator
Inthis unit a magnetic: matrixcontainedina vPriicai
rotatingringwhich passes over permanent magnets at the
feedpoint belowandat washingpoint higher up.
Magneticparticles infeedenteringbelowaretrapped
inthematrixandcomeout, dischargingat thetopwhereno
magneticfeedexist. Theadvantageis that it combines some
capability of high gradient matrixseparator, wherenot too
largefieldis neededbut thepower consumptionis lowfor
driveonly.
5.1Wet Hi .h Intensit Hi h-Cr-alient MagneticSearators :
Several factors andlimitations indry magnetic
separationhas ledto thedevelopment of wet high intensity
andhigh gradient magneticser3rators; amongthemare-
(1) Needto dry materials, which arecommonly wet groun-J;
(2) Sizingrequirement andfeedinginmonolayers;
(3) Limits of separationat very finesizes;
(4) Dust pollution;
(5) Needfor a sufficiently high field.
- 14
Jones in1955developedthefirst unit usingtheFrantz'
matrixwhich was thestartingpoint ona series of development-
basically dependingongenerationof high gradient ina
matrixplacedinmagneticfield. A simpletypeis shown
inFig. 5(a)whereexpandedmetal magneticelements are
packedina container betwe=enhepolepieces of a electro-
magnet. Material is fedat th- top, whenthemagnetics are
trappedandnonmagnetics flush out alongwith theslurry
flow. Themagnetics aretakenout by switchingoff the
current andflushingagain. A continuous versionof the
sameunit is shown in Fig.(5c). Herethemagneticelements
arehousedinanannular carTis,7,,1(rotor)runningbetween
thepoles of anelectromagnet. Thefeedenters thepoint
betweenthemagnet poles, wherethenon-magnetics flowalit-
Thetrappedmagnetics move; alongwith therotating
matrixandareflushedout outsidethemagnet poles at a
point of minimumfield. Theintermediatemagneticproducts
dischargebetweenthis andthetails port. Theproducts are
collectedby annular launders, with splitters placedsuitably.
A number of units areoffered, basically working
onthesameprinciples. Theonly differencebeinginthe
manner of magnetic_matrixmaterial, generationandconfigurat
of magneticfield, rotor arrah, 4ements etc. (Fig. 6,7). The
units may haveone,two,four or larger number of poles and
stackedmultiples of rotors to effect roughing-scavenging
-cleaningoperations as desired. Thematrixmay beof groved
plates, punchedsheets, steel balls,steel wool etc. Thefree
gapshouldbe2-3times thelargest particles inthepulp.
Themagnetisingcurrent may bevariedandmanufacturers
usually providemagneticinductioncharts dependingon
pole/matrixconfigurations use-1,(Fig.8).
Theunits havelargec.Fl-city usually oE theorder
of 1-5tonnes/H for laboratory/Pilot models to over 100/150
tonnes/H for largemodels. Most wideapplications havebeen
foundfor Jones magneticseparators, manufacturedby
Humboldt WedagAg,mainly for ironores'
15-
5.2 ,Soleno pato.y
Frantz ferrofilter was the first ironclad
solenoid magnetic separator. The matrix consists essentially
of screens fashionedfromthinsharpribbons of magnetic
stainless steel. It works in cycles, with magnetic trapped
material is backwashed,used for Kaolin industry, for
magnetic contaminant removal from industrial slurry,wastes.
5.3 Cyclic high:Lgradient Magnetic Separator:
The first industrial high-gradient magnetic separator
which grew from Frantz's concept and from an investigation
into the removal of weakly magnetic discolouring agents
from clays was designed and built by Magnetic Engineering
Associates (new Sala Magnetic) in 1969. Fig.10ashows
schematically the essential elements of such a separator.
The system comprises a canister filled with a matrix
formedof compressedmats of magneticstainless steel wool.
Thecanister is placedinaniron-cladsolenoidwhich
generates a magneticinductionof upto 2 T. Thethin
fibres of thematrixcreatea high degreeof the non-homo-
genity of themagneticfieldandproducea largemagnetic
forceactingonthemagnetizableparticles.
Theslurry is pumpedvertically upwards through the
matrixwith themagneticfieldswitchedon. Themagnetic
particles fromtheslurry aretrappedonto thesurfaceof
themagnetizedfibres, whilenon-magneticparticles
pass through thecanister Whenthematrixhas become
loadedwith magneticparticles theflowis halted, the
magneticfieldis reducedto zero andthemagneticfraction
flushedfromthematrix.
Other units availableire(a)Carpco high grarli--
magneticseparator, (b)Eriez high-gradient magnetic
separators, (c)Boxmag-Rapidmagneticseparators. A new
designwherethecarousel rotates betweenvertical pole
process is designedby OreResearch Institute,Prague
called MRVK unit. The matrix is made up of rods. Cpacity of
these units are given in Fig, '
- 16-
Such cyclicdevices ar- very useful inapplications
wherea pulpto beprocessedcontains a small fractionof
magneticparticles, preferably very fineso that their
mechanical captureby strainingis avoided, andvery wealy.
magneticso that theblockageof thematrixby magneticFlocs
is avoidedandlowflowrates canbeused. Intheopposite
casetheduty cycleof such a cyclicmachinewouldbevery
lowandthefilamentary matrixwouldbesusceptibleto
cloggingas a consequenceof thestrainingmechanism. Thf-2
machines founda wide-spreadapplicationinthekaolin
industry andinwastewater trfi,atment.
5.4 Continuous Solenoidmagneticseparators:
Theseincludethefirst unit development Sala-HGMS
Carousel separator which has beenimprovedfurther and
multipolemachines havebeenbuilt. Inthesemachine
thecoil is a saddletypecoveringthematrix, which mini-
mises stray fieldas no ironc2reis used. They arealso
less heavy for thesamereason. Theinductionclaim
is upto 2 T with 250 KWper bradandcapacities upto 2)0 T.
TheSOLmagneticseparator developedby Krupp
GmbH havingaxial solenoidth,lt generates a magnetic
fieldinthedirectionof motionof thecarousel. It has
comparatively lowmass andgiveless strainonthe
rotatingsystem.
The VMS separator developed by Ore Research Institute
in Prague has the magnetic ffel ,-1 generated by horizontally
orientedsolenoidwoundwith a watercooledhollowcopper
conductors anda vertical rotor to carry thematrixmaterial.
6.0 Super ConductingMagneticSepara
Although high--gradient magneticseparators that use
theresistivemagnets meet thetechnological requirements
of themininginlustry, their -ost-effectiveness is impa'ter?
by high energy consumptionandby considerablemass owing
to massiveironyokes or cladding. Thesedisadvantages however
canbeovercomeby usingsuperconductingmagnets which offer
a number of advantages.
17
a) Superconductingmagnets canproducehigh magnetic
inductioninlarge'Volumeat lowenergy consumption. If
operatedinpersistent mode, they consumeno energy at all,
whileinnon-persistent modethey consumeonly a small
amount of energy as a consequenceof energy dissipationin
theresistiveleads that sup)ly theelectriccurrent. A
factor of fiveto teninpower reductionis easily possible
for a superconductingmachine, compared with a conventional
machineof thesameprocessingcapacity. Thepower is
requiredmainly for liquifactionof heliumrather thanfor
ohmiclosses inthecoil of themagnet.
b) Sinceironcladdingis not needed the machine can be
madephysically smaller.
c) Thesuperconductingcoils canbearrangedinsuch a
way that a sufficiently largefieldgradient canbegenerated
without usinga matrix,whilestill maintaininghigh magnetic
inductionoutsidethemagnet.
Although theadvantages of superconductingmagnets
seemto beconvincing, a number of problems still hamper a
genuinelarge-scaleapplicationof superconductivity in
mineral processing, viz:
1) Theactual savingof energy is not as high as was
assumed, dueto theenergy neededfor cooling.
2) Themethodof coolinghas not yet beenproved:
refrigerationis still unreliable, evenunder laboratory
conditions, anddirect coolingby liquidhelium, though
reliable, is expensiveandcomplicated, sincethehelium
vapours must berecoveredif theprocess is to beeconomically
viable.
3) Sincea magneticseparator is usually a small part of
a complexflowsheet, any savinginenergy canbeeasily
offset by increasedunreliability andunexpectedexpenses
causedby forcedshut-downs.
4) Theneedfor magneticinductiongreater than2 T
has never beenconvincingly demonstratedinmatrix
separators, andit seems improbablethat, except for some
isolatedapplications induction greater than 2 T will be
required. It is claimedthat by enhancingmagneticinduction
- 18-
to well over 2 T it wouldbepossibleto increasetheflow
velocity voat thesamerate(andthereby theproduction
rate)by keeping B/v0 constant. Although this outcomeof
a simpletheoretical model has beensupportedby isolated
experiments, it is doubtful whether this rulewouldbe
generally valid, eveninthoseapplications inwhich non-
magneticfractionis thevaluable product, and it is certainly
not truefor thoseapplications inwhich a magneticfraction
is theuseful product.
TableComparisonof resistiveandsuperconducting
magnets for magneticseparators.
ResistivesolenoidSuperconducting
magnet magnet
Energy consumptionHighLow
MagneticinductionLimitedby theavail Upto 15T
-ablecooling,usual-
ly upto 2 T
HighLow
Hollowcopper Superconductor (11b-T.L:
conductor
Direc.:water coolingTo 4 K(liquidhelium)
Important for short Not required
coils
Mass
Conductor
Cooling
Ironreturnframe
Reliability of

High

Lowto modest
operation
Capital costs
Magnet

High

High
Power supply

High

Low
Cooling

Lowto medium

High
Running costs

High

Lowto medium
Cyclic matrix

Well proven

Inoperation
separator
Continuous matrix

Well proven

Not designil, yet

separator
Open-gradient

Not suitable

Two types
separator

a)drumseparator
b)split-pair
separator
- 19-
Although superconductingmagneticseparators have
beenbuilt invarious laboraLories, andlarge-scalecyclic
HGMS andreciprocatingcanister HGMS machines arein
operation, superconductivity has madeno considerableimpact
onmineral processingas yet-,
Classificationof magneticseparationprocess and
its selectionbasis as givenby J.Svoboda is givenin
Figs. 11&12. A fewtypical examples of magneticseparation
applicationflowsheets are(votedinFigs. 15&16. Comparison
of different types of magneticseparators for a specific
applicationinphosphaterecovery is giveninFig.17.
For a good study coverage
onthedevelopments in
MagneticSeparators includingSuperconductingmagnetic
separators, excellent referenceis availableinthe
book entitled, 'Magnetic Methods for the Treatment of
Minerals' by J. Svoboda publishedby Elsevier,Amsterdam
in1987intheseries 'Developments inMineral Processing',
fromwheremany materials for thepresent write-uphas
beendrawn.
ece
REFERENCES
1. Principles of Mineral Dressing. A.M.Gaudin
Tata McGrawHill PublishingCo., NewDelhi.
2. Mineral ProcessingTechnology. B.A,Wills
PergamonPress, Oxford, NY.
3. Handbook of Ore Dresing. A.F.Taggart,John.Wiley & Sons, NY',,
4. Magnetic Methods for the. Treatment of Minerals,
J, Svoboda, Elsevier SciencePublishers, Amsterdam, 1987
5. Wet Separationof ParamagneticMaterials. I.S.Wells,
Chemical Engineer, Nov.1982.
PAHAMAGNIA If: MINERALS
Table 1.7-Magnetic Induction In Gauss Required to Extract Discrete Minerals
MAGNETIC
INTENSITY
MINERAL
1000
2000
3000
4000
5000
6000
7000
9000
9(XX1
10000
11000
12000
13000
14000
15000
16000
17000
10000
19000
20000
21000
22000
23000
24000
ALAB AND1TE
PP'
lall11111 ILI" I
ANK ERITE
APATITE
1;011
INIIII
Emu
.,
B AST NASITE .
B IO TITE

open
B RAUNITE
CHRO MITE
mblqi
CHRYSO CO LLA
-
,._
wig
1 -.41
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-.el
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M E -
li
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DAVIDITE
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F ERO ERITE
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GO E1IIITE
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ILMENITE
i 1111
ILMENO -RUTILE
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,
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PYRIIHO TITE
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NI
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. ar
STAURO LITE
MINE
MS
alumworelm
iii
MIN
SERPENTINE
XENO TIME

TANTALITE
T1TANIF ERO US-MAGNETITE -44--).-
_
101MMALINE
____ ..___ _.. ____
U RANINITE
,. .
WO LF RAMITE
THE CHEMICAL ENGINEER;NO VEMB ER 1982
(1!I
4.25
Mops
t.aHI
rig. AAL
pry drumnetnirntor.

Tht.
counter-current or Steffenson
21-
F EED
CO NCENTRATE
REPUVING HEADEM
CO NCENIRAIE
DISCHARGE
WATER
LINE
F ig.Ast
CO UNTER-RO TA} IO N
IAII 1110C
DISC l/
DRUM
FEfb
kA/411
ONE
Flp4
CONCURRENT
/AMP!, III
111.1.01,1I
( (111(AIIIIIME
\ ()VI I.I WW1
I/
/
RI::
DISCO IANA
Drive pulley
Tailings.
Middlings
\
Conce ntrate
F eed
F IG.
t
Crockett low- intenstt) maroctic
separator.
Fig. 2. LowIntensity Magnetic. Separator.
(a)Dry drumtype; (b)Counter-current;
(c)Concurrent and(d)Counter-rotation
typewet drumseparator
- He) submergedbelt
separator.
IMT
ER117 M(111 MIENS! TY
.)1)
MAGIV IS P. CRO SS B ELT ASSEMB LY
ft!
ETLIEZ VO LUMATIC
F EEDER MACHINE
(O PTIO NAL) ),1
Ii
MAIN CO NVEYO R B ELT
UPPER
SEPARATO R PO LE
O NETO TO UR EDGES
MAIN
CO NVEYO R B ELT
TAK E UP
O MEN TAIL PULLEY MAGI IT TIC
CO NCENTRATETIO rPF P
B O TTO MPO LENO NMAGNETIC
ADJUSTMENT ." DISCHARGEPO INT
/ L
MMIN( I IC
CO NCENTRATE
' TO PPER
VARIAB LESPEED
MO TO R DRIVE
U
END
VIEW
C
13'
14_61.1
26' MAXIMUM
- 22 -
Fig. 3 (a) Laboratory cross-belt
type separator
Dry high intensity
Fig. 3 b. Laboratory navies Tube tester.
3-1.
939-80
4 (b)
4(a)
-fcE0
FF.EDI RAY
BACK
FOULE
813USI-1
A

MAGNETICS tsON-MAGNETICS
MIDDLINGS
cr.
11
0
10
9
UI II
0
7
6
Ei 5
cr.
4
(r)3
- 2
C9
GAUSS CURVES
20
819
18
x
17
a.
r
(9
CC
rr:
16
15
14
13
12
hGNP
AM,.
IDI nun
UAU
est III ear
Mmrsim.
ooartI/18"1
I mm
2 3415
D.C. FIELDSUPPLYAMPS.
IACAt
32mm
m
WAIR CAP
9 $vrost

4 (c)
Fig.

4. Induced roll magnetic separator..
(a) operating principle; (b) Lab model;
(c) Pilot Plant 3 high unit
(d) Typical induction curve.
SPRAY
.-
ADE ES IONTO
ROL L , ------
REMOVAL
-NATE It--tiE VE
strums
NONM AC,
RE M OVAL
GRAVE L ,
TRANSPORT
S I EVE 13END
SL IM E S
A 11R L I FT TO
S.f E VE BE ND
CHUTE
AIR L IFT TO
S I E VE 13 E ND
- 24
ST11(...,ING WEAKNON-
VIA(3)MAGS MAGS
Fig.4 e Operation cat ri-
mroll magnetic separator (conrtcsy
IF
Ore SorLers
rig. 4 f
The schematic diagrnm of a wet submerged roll permanen
magnetic separator (aUer HylAnd (11331).
25
502)
51c)
Fig.5. Wet high intensity magnetic separator
(a) Bench .
:;cale unit. (b) Matrix elemenLs
(c) Contirmous carousel model of
Eriez :lagnetics.
6 ,4 1 2 P o : o , sJONISSchel. .
IP lf s( 5 5
TYYTT7( ;,
ttS tf
tftt
It
KAI tkti.,4' ,
us.,) 4 .." .1 4 1 1 1 1 1 1 1 01 1 0.1 1 .
60)
2 6 6-
Fig.6. Jones Wet high intensity seprator(a) Rotor(hf c)
matrix plate arrangement(d) Schematic of a ? pole 2-v,tage unY.
(Atter Humboldt Wedag)
-2'
1
11 12
r
ani ,.Icfq!
:CI
:.
1
W 13
-(
11
!
.11g11
b.
.i
Fig.7. Cross Section 1 - ew of the Z pole 2stage
Jones Separator.( fter Humboldt Wedag??
F LO AT
RINSE
CO IL F EED
Fig. 7c.
Single-headEriez high-gradient magneticseparator
courtesyof Eriezflagneticsi Int)i
28

CIRCUIT
SPRAY
RINSE HEAD tolARTMENTED
RO T TING RING
STATIO NARY
CO LLECTING TRAY
EXPANDED
STEEL SHEETS
STEEL B ALLS
GRO O VED STEEL
PLATES
REMO VEAGLE aO ttkO N
EACH CO MPARTMENTT
1" x 2" (25 x 51 nn)
CO MPARTMENTS
3
O PTIO NAL
MATRICES
- .
"- OpetatiOn of eight- feed- point separator: t
feed pip; 1
rotor; 3 A 7 g4
h- pressutv water jet; 4 Low- pressure water fel; S oitter coil;
6 matrix; 7 non- magnetics discharge; 8 magnetics discharge; 9 middl-
ings discharge; 10 trough; 11 inner coil
29
f--- -- ---- -4---: ,
. . :
,
i ;!, ,
:;1
:
I-7
qt tit I 4'
Int. :
0
ci
CZ)
Cl.
ci
ci-
ci
ci
F
C LY1
(r)
0 :1-
-
0
4- )
(I)
Its
(0 t4.4
( 1 )0
0 0
C:
0
c
4)
0
10
v
..tru- 1
i
(ti
rr.:4 >to
10
Co
U- '
g
r
o
o
v
e
s

(,/),Types of Jones double-rotor high-gradient Magnetic separators
Type Capacity
(t/h)
Mass
(t)
Rotor diameter
or 335 180 114 3.35
DP 317 120 98 3.11
DP 250 75 70 2.50
DP 180 40 41.7 1.80
DP 140 25 29.2 1.40
DP 112 15 22.4 1.12
DP 90 10 16.2 0.9
DP 71 5 13.4 0.7
1 A Eriez carousel magne:ic sepa::at r!',
iht '
Model Capacity Ring
diametel
Input
power
Mass
(t/h) (in) (kW) (t) .
CF-'10 1 0.76 3 5.7
CF-50 5 0.90 12 11.
CF-100 10 1.24 32 13t6
CF-200 20 1.69
70
20
CF-400 40 2.70 140 30.
CF-600 60 3.10 180 46
CF-1200 120 3.10 360 90 *)
Y
*) two-deck unit
Boxmag-Rapid carousel magnetic s,,paratort
Model Capacity i'!ss
Input power
(t/h) (I ) (kW)
HIWI
5 8
HIW2 10 to 16
HIW4 20 1.53 18
HIW8 40 32 65
O. The specifications bf MRVK magnetic separators
MIIVK - 2 MRVK - 4 MRVK 6
HackgkoUnd magnetic
induction (T) 0.9 0.9 0.9
ThroUghput (t/h) 10 - 14
20 - 30 30 - 45
Water consumption (m3/h) 32 24 36 .
Masi; (t) 3. 8 45 55
F1g.9.
Capacities of WHTUI ;15_ suggested by Manufaci.
,linr
(a) Jones 2 rotor. (L) Eriez, (c) Boxmag Rapi*
4, FE E D
to valvpc
tI
D
CONTROL L E R
-4
4 --
M AG PRODUCT
RINSE WATE R
4
M AGNE T
POWE R
SUPPL Y
4
FL USH WATE R
M ATRIX
NONM AG. PRODUCT
Fig. 2-.-42, Schematic
diagramof a small cyclicSALA-HGMS magnetic
separator (courtesy of Sala Magnetics).
- 31
TABLE 2.10
Technical characteristicsof variouscyclichigh-gradient magnet
separators, for kaolinbeneficiation(matrixheight 150 to 500 m
max. magnetic induction2 T)
Model Mass Matrix
diam.
Matrix
area
FeedPower
throughput input
Manufactut
(t) (m) (m2 ) (kVA)
EO-20-84 340 2.1 3.6 115m3h-1400 Eriez
107-30-20 1.07. 0.9 Sala
152-30-20 1.5 1.8 Sala
214-50-20 2.1 3.6 Sala
5PEM 0.13 0.01 200 PEM
84 PEM 2.1 3.6 100th-
1
400 PEM
120PEM 3.0 7.1 200th-1 PEM
Fig. 10. SALA- HGMS Schematic diagram and Table.
showing particulars of various units.
Strongly
magnetic
. ,, - 7.1%,-,
We
, agnetic
,.... .
Strongly
magnetic
Drum
HGM S
Wet
Drum
Particle
size
Weakly
!nag 11etic
Strongly
Inagnetic
Weakly
magnetic
Imn
OGM S
Cross- bell
HGM S
Permroll
Drum
HGM S
HGM S
rig. jj Classificati.onof magneticseparationprocesses.
11
Fig.1
2 Selectionof themagneticseparationtechnique.
f
HGMS cleaner)
Mids Tails Conc .
G(%Fo) 45.2 20.7 59.:i
R
m
(%) - - 21.4

I 1
Total (aids HGMS rougher
G " 23.3 % Fa
Mids Tails Conc.
G(*-e) 24.8 15.6 55.b
O.)
Tailings thicP,..-c, inderflow

I
str o tot I
F
FSM scroonT:1
OS "--
El-1T;
---- --
.Conc .
p
ms cloanor, I
Conc.
'Thickener 1
1
I llics' filter]
1
[Rotary dryel------1
col lectors
I
__ Dust:7-1
I
TO loadout ]
I !ails
Thickener
Undor-
flow
Cleaner
food
a ltator
liGMS machines
1

r
ougher
feed
agitator
1--T
Cleaner i

corm
T
To plant * Rougher
tailings conc.
I ,
T
I
nistrib. utor]
4
'Screens I
I
OS I US
f
il
Screens 1
US

OS -4
To spiral
circuit
I .THS cleaner I
Cone. j Ta
Fig. 13 Flowsheet showing magnetic separation process at 4 T;110).i
Mines 0334j.
Tailings thickener undcrflow
G ^ 27.0 %la
ASH screen
Tails
G('/,F0) 20.4
R (%) 2.7

Tails Conc.

G( :Fe) 25.6 40.7

R (%) 93.9 6.1

1
I
LI MS cleaner
Conc.
64.9
3.4
hy.141, Metallurgical
performance of ,a magnetic separation circuit
at Wabush Mine 1104].
G-52.5%F e
R-84.3%F e
Classification
90%-45 m
t_ 1115
G,,G8.13% F e
R-3.3% F e
F eed14 t/hr
0.15 % H 03

Drumwasher
L INS
HOM S
Classifier
Tables
ri
yagnetIcs
.Von-magnetics
Non-magnetics
H ags
H ags
44B elt separator
Siderite
Conceilrnfo
0.07 n HO
3
C
F lotation
Sulphides
4
Drier
1
-
Comp
phos
e.
12
34 -
F eed
G.-37.5 % F e
L
C1 ass I f I catI od
c, assI ficat on
BO% -74
L IH S
G..57.4%Fe
R-72.13V8
L H GMS I
G.,5 4,14rm
R..72.134F e
[ ThIckelIng
i
Thicker-11n
.
O verflow
1 HGMS III 1
i.
... 1 * -- 2-:61 7 / F a
-4--
ThIckenln
Overflow
fiGMSII
G.-11.1% F t
R.-0.4% re
Overflow
G-11.7% in
R-15 .7% F e
r HGHS IV
0.-58.3%F e
R-12.9%F e
G-29,3%F e
R-I2%F n
G-60.4' /.F e G .l8.9% F e
R..72.3% F e R..27.7% F el
C oncentrate hallin
Fig. 15Flowsheet showing recovery of oxidized quartzites (Yrivoi
Rog) by 11GMS using electromagnet with iron yoke. Pm - mass
yield (%), G - grade (% Fe), R -recovery (% Fe). (After
Many et al. (M271).
Fig. 16
Recovery of wolframite at Puquio Cocha plant (1)1,0
1W361.
Type of separator
Induced-
magnetic roll
Very high
Proved
L ow, 4 t/h
Very complex
2190
2,0
L ow, scalper
required
None, rolls severely
damaged
By air
Plant requires air
conditioning
lligh onrolls and
bearings
Permanent-
fit agnct roll
Early
Afewprototypes
inplant service
.nw, , 8 t/h
en, complex
440
0,6
Low, scalper
required
1 m()cryiOUSto
',vet-size
islrprie required
None
(:onldbe high on
rolls, lowon
bearings
1..ow
Very poor
. H igh-gradient
matrix
High
A fewmachines in
plant service
Very high. 100t/h
Very simple
4116
5 ,6
H igh, no scalper
required
L ow, matrix clogs
By water
Slight heat output
L ow
( )pen-tar arli,f0
Stir! C olufw
dy
Norte
High, lit)vh
simph:
0,5
Very low, se:Opt--
required
Very high
13y litluicl helimv
Slight heat cola ' .
Low
Attribute
1. Stage of development
' 2 Track recordinpractice
' 1. C apacity per machine
. Orr distributionsystemin
plant
5 . Mass, kg/(t/h) of feed
6. Power consumption, kWh
per onof ore
7. Toleranceto ferromagnetics
8. Tolerance to oversize
partic les
9 Met hodof cooling
111. Ett.ixt onenvironment
II. IsAaintenance
12. Metallurgical performance
12.1. Sensitivity to ore
variation
12.2. Recovery of fine
apatite
H igh
Poor
L ow
Good
Very high
Very poor
J0,7
comparison of different types of magnetic separators, as applied
phosphate recovery (after. Roux et al. (R3))
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