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Magnetite Magnetic separators Screens Coal characteristics Separation Density control Medium bleeds Circuit design
Magnetite
Manufacture
Wet ball mill & cyclone closed circuit Low Intensity Magnetic Separators Vacuum filtration Susceptibility Coercive force Saturation Moment Size dependence
Magnetic properties
Magnetite
Chemical analysis
Size distribution
Magnetic Separators
Counter-current vs co-current Fluid level control Water draining Flow rates Magnetite concentration in feed Squeeze pan gap Feed pan gap Magnet angle Drum speed
Magnetic separation
Co-current separators
Slurry level
If too high dilutes the concentrate Too low and magnetite recovery reduced
Squeeze pan gap - wider than OEM spec. Feed pan gap
Large gap will increase losses but capacity increased Small gap reduces capacity Rarely (if ever) measured
Magnetic separation
Co-current separators
Tub design
Some designs limit adjustment ability Side overflow is poor choice for level stability
Primary separators
Aim for high density concentrate Wide squeeze pan and lower water level Magnetite recovery is low priority
Secondary separator
Magnetite recovery so high water level needed
Magnetic separation
Co-current separators
Magnet angle
Not as critical as other parameters Higher angle reduces magnet availability in the feed area Magnet does however need to be lifted from parked or transport position
Counter-current separators
Higher magnetite recoveries Higher density concentrate Higher flow rates Caveats
Higher flow rates cause higher losses High feed magnetite concentration causes preferential loss of finer magnetite
Screens
Sieve bend turning more art than science Sieve bend life vs magnetite loss
Banana screens
Feed arrangement
Too much water = high magnetite losses Too little water = high magnetite loss Multiple small additions
Rinsing
Screens
Only effective for flat particle shapes Major factor in magnetite recovery
Screen loading Aim for maximum stratification on the screen Scale formation blinds screens but not apparent from above
Influencing Factors
Coal size distribution Coal density distribution Particle shape Clay Mining influences Product drying Screen apertures Desliming or Drain & Rinse
Separation
Factors
Medium density Magnetite sizing Amount of near density Coal sizing Medium contamination Cyclone operating conditions Medium differential cyclone underflow/overflow
Density Control
Water Addition
Direct from separators Metered via control valve Screen carry-over Medium bleed
Medium Bleeds
Loose finest magnetite fraction Lower density concentrate Removal of stabilising clays
Recirculating load of fine coal & reject Reduced medium/coal ratio Increased viscosity (clay buildup)
Circuit Design