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How Does A Magnet Work?: Mine 410 Mineral Processing Ii

Magnetic separators exploit differences in magnetic properties between ore minerals. They are used to either separate valuable magnetic minerals from non-magnetic waste, or remove magnetic contaminants from non-magnetic valuable minerals. A magnet produces its own magnetic field that interacts with other magnetic fields, represented by field lines starting at the north pole and ending at the south pole. Materials can be classified as diamagnetic, paramagnetic, or ferromagnetic based on whether they are repelled or attracted to magnetic fields. Paramagnetic minerals like ilmenite, rutile, and wolframite can be concentrated using high-intensity magnetic separators.

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0% found this document useful (0 votes)
119 views12 pages

How Does A Magnet Work?: Mine 410 Mineral Processing Ii

Magnetic separators exploit differences in magnetic properties between ore minerals. They are used to either separate valuable magnetic minerals from non-magnetic waste, or remove magnetic contaminants from non-magnetic valuable minerals. A magnet produces its own magnetic field that interacts with other magnetic fields, represented by field lines starting at the north pole and ending at the south pole. Materials can be classified as diamagnetic, paramagnetic, or ferromagnetic based on whether they are repelled or attracted to magnetic fields. Paramagnetic minerals like ilmenite, rutile, and wolframite can be concentrated using high-intensity magnetic separators.

Uploaded by

abd ullah
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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4/17/2014

MinE 410 Mineral Processing II [3] MAGNETIC SEPARATION


Dr. Ishaq Ahmad
Assistant Professor • Magnetic separators exploit the difference in
Dept. of Mining Engineering magnetic properties between the ore minerals.
University of Engineering and Technology, They are used :
Peshawar 1. To separate valuable magnetic minerals from the
Magnetic and High Tension Separation non-magnetic gangue (i.e., magnetite from quartz)
2. To remove magnetic contaminants from non-
Spring Semester, 2014 magnetic valuable mineral (i.e., magnetic impurity
[Ref. Wills, B.A 6th Edition, Chapter 13] from clay or cassiterite or wolframite)
e.g. Hematite from Bauxite etc
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Ahmad

How does a magnet work? • All materials are affected in some way when placed in a
magnetic field. ( Sometimes , it may be too slight to be
• A magnet is any object that produces its detected).
own magnetic field that interacts with other • Materials can be classified according to whether they are
magnetic fields. Magnets have two poles, attracted or repelled by a magnet.
a north pole and a south pole. The magnetic Diamagnetics :
field is represented by field lines that start at Repelled along the lines of magnetic
force to a point of minimum field
a magnet’s north pole and end at the south
intensity
pole.
• Materials
Paramagnetics:
Attracted along the lines of
magnetic force to a points of
greater field intensity.
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Magnetism
• Magnetism: It is a magnetic force experienced between two • Paramagnetic minerals : They can be
magnets. The magnetic force is caused by the magnet’s concentrated by high-intensity magnetic
magnetic field and points in the direction of the field lines. If separators.
you have two magnets next to each other and their north poles
are facing each other or their south poles are facing each other, • Ilmenite : FeTiO3
you can see that the field lines move away from each other, so
you feel a repelling force between the two magnets.
Rutile : TiO2
Wolframite : (Fe,Mn)WO4
• If you put the north pole of one magnet next to the south pole
of the other, then the field lines go straight from the north pole Monazite : (Ce,La,Th,Y) PO4
of the first magnet to the south pole of the second, and you Siderite : FeCO3
feel anattractive force between the two magnets. Pyrrhotite : FeS
Chromite : (FeO)(Cr2 O3)
Hematite : Fe2 O3
Manganese minerals
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• Some elements are themselves paramagnetic, such as


Ni, Co, Mn, Cr, Ce, Ti and Pt group metals without the
presence of Fe
• The value of field intensity (H) is virtually the
• Ferromagnetism : special case of paramagnetism. Have
same as flux density (B), and the term magnetic
very high susceptibility to magnetic forces. Can be
field intensity is then often loosely used.
concentrated in low-intensity magnetic separators. (i.e.,
Fe3O4 – Tramp iron (staples, nails etc))
• Remanence : magnetism retained when removed from • However, particularly ferromagnetics, the value of
the magnetic field (Ferromagnetic minerals show flux density B is much higher than field density (H)
remanence property) which term is used should be specified.
• Hematite (Fe3O4 ) and siderite (FeCO3) can be roasted
to produce magnetite.
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• Magnetic Susceptibility (S) is the ratio of the


intensity of magnetisation produced in the
material to the magnetic field.
• The unit of measurement of magnetic flux density (or
magnetic induction )(B) is the Tesla (T). • i.e. S = M/H
• Tesla is the no. of lines of force passing through a unit Therefore,
area
• B = µ0 ( H + M )
• B = Nm of lines of forces passing through a unit area of
B = µ0 ( H + SH )
material.
B = µ0 H ( 1+ S)
• The magnetising force which induces the lines of force
through a material is called the Field Intensity (H) = B = µ0 µ H
ampere /metre 1 + S = µ Relative permeability (dimentionless)
(1 ampere /metre = 4π x 10 – 7 Tesla)

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• The Intensity of Magnetisation (M) (ampere /metre) of a • For paramagnetic materials, S is a small positive
constant
material relates to the magnetisation induced in the
• For diamagnetic materials, S is a negative constant
material, and :
For Hematite, S = 0.01
For Quartz, S = - 0.001
B = µ 0 (H + M ) • The magnetic susceptibility of a ferromagnetic material
is dependent on the magnetic field , decreasing with
µ 0 = Permeabili ty of free space field strength as it is saturated.
• At an applied field of 1 Tesla, S = 0.35
( = 4π x 10 -7 T m /A)
• In vacuum M =0 • Iron cores or frames used in high intensity magnetic
separators, iron saturates at 2 – 2.5 T, so the use of very
In air, M is very very low , therefore M is neglected large currents (≈ hundreds of amperes) is necessary.
B = µ0 H means B=H
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• Converging field is produced by providing a V-shaped pole


above a flat pole. Upper pole concentrates the magnetic flux
The capacity of a magnet to lift a mineral is dependent into a small area giving high intensity. The lower flat pole has
1. The value of field intensity, H the same total magnetic flux distributed over a larger area.

2. Field gradient • There is a steep field gradient across the gap.

Field Gradient = The rate at which the field intensity


increases towards the magnet surface = dH / dl
• F : Force on the particle
(or lifting force )
H : Field intensity dH
Fα H⋅
dL

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MAGNETIC SEPARATORS
Magnetic field intensity can be varied by :
Low intensity
1. Varying the current (especially in
electromagnetic separators)
• Magnetic separators 2. By changing the interpole distance (in permanent
magnets)
High intensity
• In commercial magnetic separators (continuous –
and process), the separation is carried out on a
Dry Separators moving stream of particles passing (through or
into) the magnetic field.

Wet Separators
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• When a ferromagnetic particle is introduced into


• Requirement : a magnetic field, the lines of force concentrates
Steep field gradient in a high – intensity field (converge to the particle) and the particle
behaves as magnet.

Methods to produce steep field gradient are:


• Magnetic flocculation or agglomeration of the
particles can occur if they are small.
1. By using a pole which is constructed of alternate
magnetic and non-magnetic laminations • It is a serious problem especially with dry
2. By producing a converging field separating machines (they can entrain gangue
particles, reducing the efficiency).

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• Low intensity wet magnetic separation (LIWMS) is


widely used for purifying (regeneration) the
• Flocculation is minimised by passing the material magnetic medium in the HMS Process.
through consecutive magnetic fields (successive
reversal of the polarity). Crockett Separator : LIWMS

• For collection of magnetic and non-magnetic • An endless belt is dipped into the trough into which
fractions, most separators are designed so that the pulp is fed.
the magnetics are attracted to the pole pieces,
but come into contact with the conveying device • The magnetic particles are picked up (lifted) by a
(not directly the pole-piece). bank of magnet and then carried to the concentrate
discharge (water spray wash the concentrate)
• The magnets have alternating polarity so that
• The non-magnetics fall freely into a bin. entrained gangue particles released.

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TYPE OF MAGNETIC SEPARATOR

Can be classified into :

1. a) Low intensity
b) High intensity
2. i) Dry feed
ii) Wet feed

Taken from Wills 3rd edition

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DRUM SEPARATORS (LIWMS)


LOW INTENSITY MAGNETIC SEPARATION
• Used for concentrating finely ground iron ore, and for
• Dry Low Intensity Magnetic Separator = Cobbing process cleaning the medium in HMS circuit.
• Cobbing is concentration of coarse particles which are • They consists essentially a rotating non- magnetic
strongly magnetic. Cobbing can be carried out in drum drum containing 3 to 6 stationary magnets of
separator. alternating polarity.
• Magnetic particles are lifted by the magnets and
• Below 0.5 cm particles size range, dry separation tends to pinned to the drum and are conveyed out of the field,
be replaced by wet methods, which produce much less leaving the gangue in the tailing compartment.
dust loss, and usually a cleaner product. • Water is introduced into the machine to keep the pulp
in suspension.
• Field intensity up to 0.7 T

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Counter- current separator


Concurrent type :
rotation of drum and feed flow are
in the same direction. Produces
clean magnetic concentrate,
especially in HMS circuit.
• Drum Separator Relatively for coarse material.

Counter current type :


Tailings flow in the
opposite direction to the
rotation
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Cross – Belt Separator

• Counter current separator is used in roughing operations and • Used to concentrate moderately magnetic ores.
magnetic material losses are held to a minimum. Relatively for
fine material < 250 µm. • It consists of two or more horseshoe
electromagnets, arranged one above the other. The
• Drum separators are widely used to treat taconite ores, cross – belts prevent the magnetic particles from
containing 40 – 50 % Fe as magnetite, or sometimes hematite adhering to the pole.
which needs fine grinding.
• The poles of the upper magnets are wedge shaped
while the lower poles are flat

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HIGH INTENSITY MAGNETIC SEPARATORS

• High intensity fields of 2T are used to


extract very weakly paramagnetic minerals.

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Disc Separator (Boxmag Rapid Ltd)


Induced roll separators [high intensity]
• It permits a much smaller air gap than the belt separator
and a greater degree of selectivity.
• To treat beach sands, tin ores, wolframite, glass
sands and phoshate rock.
• It consists of a series of discs, incorporating concentrating
grooves, revolving above a conveyor belt, magnetised by
induction from a powerful stationary electromagnets • Field strengths of up to 2.2 T are attainable in the
situated below the belt. gap between the feed pole and roll.

• Each disc permits to extract and separate 2-products of • The gap between the feed pole rotor is adjustable
different permeability. and is usually decreased from pole to pole to take off
successively more weakly magnetic products.
• Progressive intensification of the magnetic field is obtained
by vertical adjustment of the discs (gap)
• The flux is ≈ 0.8 – 1.5 T (which is strong enough to pick up
many paramagnetic minerals).
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Permroll
• Jones HIWMS : The most well known separator to
• Permroll is a roll separator which uses powerful treat fine hematite ores.
permanent magnets.
• The magnet yokes are welded to strong main frame,
• The magnetic field is generated without an air gap, and with the electromagnetic coils enclosed in air cooled
the separator is able to handle highly magnetic as well as cases.
weakly paramagnetic. • The actual separation takes place in the plate boxes
which are on the periphery of one or two rotors
• In Permroll, the belt passes over the magnetic roll, attached to the central roller shaft.
preventing direct roll -particle contact. • The feed slurry flows into plate boxes which are
grooved.
• Dry HIMS is limited to ores containing little siz material < • Feed points are at the leading edges of the magnetic
75 µm. The efficiency of separation on fine material is field.
severely reduced by the effects of air currents, particle – • Each rotor has two symmetrically disposed points.
particle adhesion, and particle – rotor adhesion.
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• Continuous HIWMS : Reduces the minimum particle • Any entrained non-magnetics are washed out by low
size for efficient separation. Expensive drying pressure water.
operations can be eliminated. • When the plate boxes reach a point midway between
the two magnetic poles, where the magnetic field is
• Gill Separator : Designed on the principle of the essentially zero, the magnetic particles are washed out
induced roll machines. The laminated grooved rotor with high pressure water spray.
rotates about a vertical axis at the centre of a set of
electromagnetic pole pieces. • Field intensities of over 2T can be produced in these
• The feed slurry flows down along the grooves machines.
between the pole piece and the rotor. • For 1.5 T field, electrical power consumption in the
• It generates a maximum field of < 1.4 T coils of 16 kW / pole.
• Previously used in Australia and Malaysia for • 4 tons of water is used per tonne of solids (90 % of
separating highly magnetic ilmenite. water is recycled ).
• It does not treat weakly magnetic hematite ores
effectively.
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• Disadvantages :
• Very high capital cost (cost of flotation equipment
to concentrate weakly magnetic ore is ≈ 20 % of a
Jones separator)
• Total cost depends on terms for capital
depreciation.
• Over 10 years, HIMS may be the most attractive
process.
• Example : One of the largest applications is in
Brazil.120 tph of - 150 µm specular
hematite ore.

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Application of Wet HIMS


In some magnetic materials, saturation is the state reached when an increase in applied external magnetic (H) cannot
increase the magnetization of the material further, so the total magnetic flux density B levels off. It is a characteristic
1. Recovery of hematite. particularly of ferromagnetic materials, such as Fe, Ni and Co and their alloys.

2. Magnetic impurity from cassiterite concentrate.


3. Removal of fine magnetic impurities from asbestos. • As iron saturates at ≈ 2 – 2.5 T, conventional iron circuits
are of little value for generating field above 2 T.
4. Removal of fine magnetic impurities from scheelite
concentrates.
5. Purification of talc • Such fields can only be generated by the use of high H field
(Magnetic field intensity), produced in solenoids , but the
6. Recovery of wolframite and non-sulphide Mo – energy consumption is extremely high, and there are
bearing minerals from flotation tailings problems in cooling the solenoid.
7. Treatment of heavy mineral beach sands.
8. Recovery of Au and Uranium from cyanidation
residue (Fe coating)

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High Gradient Magnetic Separator (HGMS) Alternatives to increase magnetic field


• Used to separate very feebly (weakly) magnetic
particles. • In HGMS, the magnetic force is incrased by increasing
the value of the magnetic field gradient.
• Therefore, high magnetic forces must be generated
• Uniform field of a solenoid is used instead of using one
by increasing the magnetic field strength large convergent field.
• Ferromagnetic properties of are are utlized to • The core or working volume, is filled with a matrix of
generate a high induced field (B) for this purpose secondary poles (wire wool ). (wire wool is filling only
• In the conventional HIMS , the working field occurs about 10 % of the working volume ).
in air gaps in the magnetic circuit. • Each secondary pole, can produce a maximum field
strength of 2T, but more importantly, each pole
• The volume of iron required is many times greater produces in its immediate vicinity, high field gradient
than the gap volume where separation takes place of up to 14 T/mm.
which is a disadvantage.
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• Thus HIMS using conventional iron circuits


tend to be very massive and heavy in relation
to their capacity.
• A large separator may contain over 200 t of
iron to carry the flux, therefore, capital and
installation cost are extremely high

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• Example : Eriez Magnetics (superconducting HGMS)


• The matrix is held in a canister into which the process kaolinite clay in U.S.
slurry is fed. The particles are captured. • This machine use only 0.007 kW in producing 5 T; the
ancient equipment require 20 kW.
• Conventional 2 T HGMS needs about 250 kW.
• Periodically, the magnetic field can be removed
and the matrix flushed with water to remove the
captured material.

• Disadvantage: An increase in field gradient


necessarily reduces the working gap between
secondary poles. Therefore, the matrix separators
are best suited to very fine particles treatment.

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HIGH TENSION SEPARATORS


(Electrostatic Separation)

• High tension separation utilises the difference in electrical


• e.g., They are used mainly in the kaolin industry, for conductivity between the various minerals in the feed.
removing micron sized particles which contain iron.
Limitations :
• In USA and in UK (Cornwall) separator with 2 m 1. Its greatest use is in separating some of the minerals
diameter basket which contains ferromagnetic found in heavy sands from beach or stream placers
matrix, are in commercial use. (alluvial deposits)
• Field : 2 T, capacity 10 – 80 tph. (for clay purification). 2. The feed must be perfectly dry.
• Future use may be for desulphurization of coals. 3. The capacity is very small for finely divided material. ( For
most efficient operation, the feed should be in a layer;
one particle deep; the through put is severely restricts if
the particles are small, i.e., below 75 µm).
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SUPERCONDUCTING SEPARATORS

• Special alloys which do not present any resistance to


electric current are used at extremely low
temperature. e.g., Niobium – tantalum at 4.2 K (the
temperature of liquid He)
• Once a current commences to flow through a coil,
which was made of superconducting material, it will
continue to flow without being connected to a power
source, the coil will become a permanent magnet.
• Superconducting magnets can produce magnetic fields
up to 15 T.

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Properties:
Corona effect
• Lifting effect:
The attraction of particles carrying one kind of charge
toward an electrode of the opposite charge.

• Pinning effect:
Non-conducting mineral particles, having received a
surface charge from the electrode, retain this charge
and are pinned to the oppositely charged separator
surface by + / - attraction.

• Corona effect

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• Electro – static Rotor Type Separator (Acquiring


surface charge by conductance)

• There are 2 basic types of electostatic separator


:
1. Electro – static Separators (old)
Acquiring surface
Plate charge by
Rotor type Plate type conductance.
Screen
2. Electro – dynamic Separators (recent)

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• Corona Effect :
• There is a large single producing an electric field
An electrode assembly, comprising a brass tube in (there is no ionizing electrode).
front of which is supported a length of fine wire, • Particles are placed on the grounded rotor in the
is supplied with DC current up to 50 kV (create
very dense high voltage discharge and thin wire presence of electric field. Particles develops a
tends to discharge it, when ionization occurs, the surface charge by induction, they are polarized.
minerals receive a spray of electricity and gain • Conductors have the same potential as the
charge). The voltage is so that ionization of air
takes place. This can be seen as visible corona grounded rotor, they are attracted toward the
discharge electrode.
• Non- conductors fall by their gravity.

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Electro–static Plate Type Separator


(used to clean small amount of NC from a
predominantly conducting feed)
• For cleaning of small quantity of conductors
from large amount of non-conductors.
• (fine particles are affected by the weak forces).

(use for remove small amount of conductors from


mainly NC)

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Tube Electrode : Create
Ahmad non-discharging field. Ahmad

Electro-dynamic Electrostatic Separator


(Ion bombardment)
• The feed particles slide down a ground plate into the
divergent electric field induced by the large curved
electrode.

• The particles are charged by induction; the conductor


particles acquiring a charge opposite to the electrode.

• Thus, the conductor particles are attracted towards the


electrode the non conductors continue down the plate
or through the screen.

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Electro – static Screen Type Separator • The feed is carried by the grounded rotor into the field of
a charged ionizing electrode.
• The feed particles accept a charge by ion bombardment.
• The conductor particles lose their charge to the
grounded rotor and thrown from the rotor surface by
centrifugal force, and they come under the influence of
nonionizing electrode and are attracted further from the
rotor.

• As the rotor carries the non-conductor particles on its


surface, their charge is slowly lost (or they retain the
charge) and thus held to the surface (pinned).

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Typical Beach Sand Treatment [pg. 361]

• NC is negatively charged, rotor surface is


positively charged, NC is pinned to the oppositely
charged surface by + / - attraction.

• Difference in wire and tube electrode:


Fine wire tends to discharge readily; whereas the
large tube tends to have a short , dense, non-
discharging field.

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Behaviour of Mineras in High Tension Separators


Minerals pinned to rotor Minerals thrown from rotor
(Non conductor = Insulator) (Conductors)
Apatite Cassiterite
Barite Chromite
Calcite Diamond
Corundum Fluorspar
Garnet Galena
Monozite Gold
Quartz Hematite
Zirkon Limonite
Scheelite Pyrite
Gypsum Sphalerite
Wolframite
Rutile
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Typical Beach Sand Minerals

Magnetics Non – Magnetics

Magnetite (T) Rutile (T)

Ilmenite (T) Zirkon (P)

Garnet (P) Quartz (P)

Monazite (P)

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