Electromagnetic Hydrocyclone for Magnetite Separation During Coal Beneficiation

Grady Paxton, Justin Hammond, Colin Smith Team Sponsor: Mike Nave Consol Energy Background
Problem: Unsafe nature of current magnetite recovery technology Magnetite is a crucial material used in coal beneficiation. Industry currently uses large permanent magnetic drum separators to recover magnetite, but this equipment poses serious safety issues. Electromagnetic hydrocyclones are a potential alternative. Objective: Optimize the magnetite recovery efficiency of an electromagnetic hydrocyclone
Figure 3: Pico 1760 Microcontroller Figure 2: Process of magnetite separation in hydrocyclone

System Level Design

Microcontroller
Function Controls on/off patterns and frequencies of electromagnets cycling the electromagnets prevents buildup and clogging inside the hydrocyclone

Pattern 1

Pattern2

Figure 1: Electromagnetic Hydrocyclone

Operation Overview 1.) Slurry enters the hydrocyclone from the pump 2.) Slurry is separated by centrifugal force into heavy particles going to the underflow and light particulates going to the overflow 3.) Electromagnets aid in the separation of magnetite via magnetic forces in the direction of centrifugal force 4.) Slurry is recombined in the sump, then mixed, and recycled by the pump

1 4 3 2 1

1 2 2

*Pattern 1 was primarily used, but pattern 2 shows merit for future studies
4

Sampling Procedure
Efficiency of Prototype

Power Supply
Function Provides current to four electromagnets which causes magnetic forces to be generated on hydrocyclone

Results
Table 3: Separation efficiency using pattern 1 and the evaporation/boiling sampling method

Samples were simultaneously taken from the underflow and overflow for a set period of time various methods were tried to determine the amount of magnetite in each sample Density Method Fast method, but does not have enough resolution with standard lab equipment

Specifications Boston Gear: 120VAC, 90VDC, 10ADC Provided Current vs. Magnetic Force
Table 1: Magnetic force increases with input current Results show that separation efficiency is best when current is high. Also, the optimal Magnet ON time is highly dependent on the current and resonance time

Conclusions
Goal: Provide maximum current that is safe Limitations of Electrical System
Figure 4: The density equation is theoretically a good method Table 2: Electromagnetic strength was limited by our system

Filtration Method Magnetite has a diameter less than 50um, making it nearly impossible to filter Evaporation/Boiling Method Most time consuming, though most accurate method as almost all of the magnetite in the sample is measured

Additional Comments A 240VAC, 27ADC power supply application was attempted to increase current to the electromagnets relays could not handle voltage and so we decided to pursue the Boston Gear power supply

More robust electrical equipment needed to increase current to electromagnets Sampling needs to be performed at precise time intervals Samples need to be measured at high volume and mass resolutions Slurry needs to be continuously mixed with an impeller when sampling Future teams should test a greater variety of electromagnet patterns, polarities, and strengths while taking into account magnetic strength degradation with heat and time A special thanks to: Mike Nave, Dan Yanchak, Consol Energy, PSU CUL Team & Liz Kisenwether
References: Pico 1760 picture nhp.com.au Hydrocyclone picture waterrenewaltech.com