Technical Information

Magnetic drum separator technical and maintenance

information from IMS Magnetic Mining
INTRODUCTION
This page has been compiled by International Magnetic Solutions (IMS) to give
operations personnel a greater understanding of the functions magnets have in drum
separators. Having an understanding will assist in the correct care and maintenance
of separators. Figure 1.1 shows a typical set-up for a concurrent unit.

The magnet assemblies are fixed to a central shaft allowing the stainless steel outer
skin to rotate freely around them as pictured below (click on either photo for a larger
view). A common arrangement for the magnet assemblies is shown in figure 1.2

In this case each individual bank of magnets is arranged in brick formation and
enclosed in a stainless steel skin to form a single magnet assembly. The picture on the
left shows the magnet assembly with the skin partially removed. When these
individual magnet assemblies are fitted together they form a sub-assembly as shown
in figure 1.2.

Basics of Magnetic Separation

The translational magnetic forces on magnetisable particles is of the form:
F = V k grad(B )
2

(1)

2
Where the volume susceptibility is k and the particle volume V. Formula (1) holds for
weakly magnetic particles but is also valid with some restrictions (demagnetisation
factor, saturation) for more or less strongly magnetic particles.
To obtain high forces, the factor grad (B ) or |B| has to be optimised in the separation
volume. This volume ranges from drum radius to the bottom of the trough.
What we need is high flux density and high gradient. But if we aim at a high gradient
at the drum surface, then the flux density will decrease rapidly in radial direction. To
obtain high forces at the outer region of the working volume, we have to carefully
adjust the gradient depending on the specific application (grain size, throughput rate,
gap width, etc). Once attracted to the drum surface, particles must remain there while
being transported to the magnetic discharge. Therefore field gradients parallel to this
path (ie variations of the magnetic field which are identical to transverse forces)
should be minimised. Such transverse forces hold particles in the regions of relatively
higher fields and give rise to clogging and losses of magnetic particles.
On the other hand, many pole changes on the path along the drum surface are
advantageous. Strongly magnetic particles rotate with changing polarity, and nonmagnetic particles which might be captured by the clogging of some magnetic
particles can be freed. This leads to cleaner products and better selectivity.
0

We now can state what we think to be best:

High flux density at the drum surface

High field gradient according to the requirements of the specific application
Many pole changes
Minimum variations of the absolute field value on the drum surface

The basic principles

Magnetic separation is used for the concentration of minerals and for the removal of
suspended magnetisable particles in a fluid. As a method it depends on the behaviour
of different minerals under the influence of magnetic force. Broadly minerals can be
classified into three groups whether they are attracted to, repelled by, or unaffected
by a magnet.
Paramagnetic minerals are attracted in the direction in which the field intensity
increases. In almost all cases this results in attraction aligned with magnetic
flux urging particles towards a magnetic surface. They can be concentrated in high
intensity magnetic separation.
Ferromagnetic minerals are generally included in this classification since they are
attracted in the same way. Ferromagnetics can be strongly magnetised by a low
external field.
Diamagnetic minerals are repelled in the direction of decreasing field intensity. The
forces involved are small and diamagnetic substances are not concentrated
magnetically except by bench scale equipment.
The capacity of a magnet to lift a mineral is not only dependant on the field intensity
but on the field gradient ie the rate at which the field intensity increases towards the
magnet surface. Paramagnetic minerals have higher permeabilities than the
surrounding fluid; water or air and therefore concentrate the lines of force of an
external magnetic field. Thus the higher the magnetic susceptibility is the higher the
density in the particle and the greater its attraction up the field gradient towards
increasing magnetic strength. Diamagnetism results from induction in a substance of
magnetic moment opposite in direction to the external field.
All magnetic separators are designed to provide a magnetic field gradient, either in
the gap between the poles of amagnetic circuit or in the air space near the magnetised
surface such as that of a permanent magnet. An effect of the field gradient is to
induce stronger magnetism in one pole than the other pole. The particle then
experiences a translational force that urges it in the direction of increasing field

intensity. Simple means for producing a field gradient are a V-shaped pole above a
flat pole. Alternate magnetic and non-magnetic laminations also produce field
gradients. By placing ferromagnetic elements in a magnetic field to serve as
secondary poles, a number of separate regions in which field gradients effective for
separation can be provided. The shape and orientation of the ferromagnetic elements
determine their degree of magnetisation and the field intensity gradient adjacent to
their surfaces. For continuous machines the speed at which material passes through
machines is also important.Flocculation of particles is also often avoided by passing
material through consecutive magnetic fields, usually arranged with successive
reversal of the polarity. This causes the particle to turn through 180 with the reversal
releasing entrained particles. The main disadvantage of this is flux leakage from pole
to pole thus reducing the effective field intensity.
There are several different separation techniques encompassed under the umbrella of
magnetic separation including:

dry low intensity magnetic separators

wet low intensity magnetic separators
high intensity magnetic separators
wet high intensity high gradient magnetic separators
superconducting magnetic separators

Dry low intensity magnetic separation

Low intensity magnetic separation is well established technology and some of the
basic techniques are reviewed here.
Low intensity drum separators date from the turn of the century and are still the most
common form. Typically the rotating drum contains from three up to ten magnets of
alternate polarity. These are arranged radially on the shaft covering approximately
180 of the drum. Initially the magnets were electromagnets but now have all been
replaced in designs by permanent magnets using, for example, strontium-ferrite
magnets.
The drum cover is non-magnetic, and the drum rotates about the hub at typically 40
rpm. Material is fed onto the top of the drum and separated as shown in the
accompanying diagram. The alternating polarity aids the rotation of magnetic
particles and the release of non-magnetics.
Typical uses for this type of separator includes upgrading of blast furnace slag, iron
ore, and sponge iron and commercial separators are available over a wide range of
sizes. Drum diameters vary from 300 to 1500mm and drum lengths from 300 to

4000mm. The performance of a drum dry low intensity magnetic separator can be
predicted by the use of four parameters magnetic field at the drum surface, angular
spacing between the magnets, drum radius and the revolution rate. By correct
adjustment a fairly high degree of control is offered over the concentrated grade. The
typical radial magnetic induction values for current drum separators are of the order
of 0.1 0.15 Tesla (1000 1500 Gauss) at the drum surface.
Dry low intensity magnetic separation is mainly applied to strongly magnetic coarse
sands, typically 5 8mm material economic feed rates of 150 tph per metre of length
can be obtained.
In other forms dry low intensity magnetic separators are often used as pulleys
installed over the end of conveyor belts which draw the tramp iron from the material
and carry it to the underside of the conveyor to be discharged. Over band separators
and suspension magnets are installed over conveyor belts to remove tramp iron.
Suspension magnets are used to extract iron form the material being transported and
are used on conveyor widths up to 2200mm with an operating gap up to 850mm.

Wet low intensity magnetic separators

This is today by far the most widely used type of magnetic separation. But it can only
be used for strongly magnetic minerals, so its primary use is for magnetite and
ferrosilicon recovery in dense media circuits. Other applications include iron ore
concentration and removal of highly magnetic material prior to high intensity wet
magnetic separation. Other low intensity wet magnetic separations take the form of
matrices through which the product percolates, such as clayslip in order to remove
any ferrous contaminants.
Several industrial mineral processes use dense media recovery as a preconcentrating
stage including fluorspar, barytes, petalite and diamonds. The economic recovery of
the medium is an important integral part of the process.
Typical wet drum separators are available in diameters from 600 to 1200mm and in
lengths of up to 3000mm.
There are three basic designs of wet low intensity magnetic separation concurrent,
countercurrent and counter rotation.
Concurrent

This type of drum separator is almost exclusively used for the treatment of
particles of 5mm and below. The ore is carried forward by the drum since it
flows in the same direction as the drum rotation. It then passes through a gap
where it is compressed and dewatered before leaving the separator. Magnetic
material is picked up by the drum and the non-magnetics are discharged at the
bottom of the tank. This method is widely used in heavy media recovery
systems since it offers a magnetic concentrate from relatively coarse material
with high throughput rates.
Counter rotation
In the counter rotation design of wet low intensity magnetic separation the
feed flows in the opposite direction to the drum rotation. This type is often
used in roughing operations where occasional surges in feed must be
accommodated without a minimum loss of magnetic material and where a
high quality concentrate is of secondary importance. This is because the
tailings flow along the entire magnetic arc of the drum. The feed size for a
counter rotation drum separator is nominally less than 1mm for optimum
results.
Counter current
The term counter current is derived from the fact that the tailings flow counter
to the rotation of the drum when leaving the tank. Sometimes known as the
Steffenson Tank the separator is often used for the separation of finely ground
particles of approximately 100 and less in size. Coarser ores cause settling
problems. The feed is introduced near the bottom of the drum and the
magnetic particles are picked up by the drum and agitated by wash water jets.
The tailings discharge through an overflow at the opposite end of the tank,
which also acts as a pulp level control. The counter current design ensures a
high recovery of magnetic material and a high quality concentrate.

What does IMS test?

Our current standard testing procedure is based on the assumption that the current
manufactured drum separators have optimised the field strength and gradients in
their equipment designs. As this is controlled by the geometry of the design the
relationship between field strength and gradient is fixed. So simply by measuring

changes in field strength it is obvious that the effective gradients are also changing in
a similar way.
It is also obvious that the fields and gradients experienced by the flow
of magnetite change with the density ofmagnetite in the flow but again the total field
effect on the magnetite is directly related to the fields measured on a clean drum.
Hence IMSs test reports give you comparative information on the magnets in your
drum by:

Comparing the magnetic characteristics of other drums of the one type in

service and
Identifying changes in your drums magnetic characteristics between

successive tests.
The test results tell the story in two ways:

Is your drum as strong as it should be?

Is your drums performance deteriorating?

If the drum strength is significantly low or is deteriorating then we look for the cause.

CARE OF DRUMS
Owing to a minimal gap between the outer stainless steel skin and the magnet
assemblies any dings in the outer skin can cause damage to the magnets within.
Some of the major causes of dings in the drums skin are:

bolts, washers etc. entering the system during operation

incorrect lifting of the drums when replacing or installing
pressure applied to the skin during storage

These pictures show how a magnet can be worn away when rubbing on a damaged
skin, and the resulting wear on the magnets (click on either image for a larger view).

PROBLEMS THAT MAY AFFECT THE EFFICIENT OPERATION OF YOUR

SEPARATOR
Magnetite leaking internally is a problem that will reduce efficiency. Internal leaking
means the magnetite is able to enter the inside of the drum through the shaft seal,
damaged outer skin or via the seal between the end cap and outer skin.

This photo shows a large build-up

of magnetite on the drum.Magnetite laying on the magnet assembly short circuits and
absorbs the magnetic flux, resulting in less magnetic influence on the outside of the
skin.

The incorrect installation of magnets within the individual assemblies will also reduce
the drums efficiency. As previously shown the magnets are stacked in brick
formation. It is vitally important that the magnets should be facing the same
direction.

The diagram above shows this (correct arrangement on left). If some are stacked in
reverse as shown on the right then their effectiveness will be greatly reduced.
Excessive heat directed onto magnetic material will decrease its magnetic properties.
Heat from an oxy torch being used when the drums are being refurbished will
decrease the magnetic properties of the magnets in the drums.
For further maintenance information and details on correct settings for your drum
separators consult your manufactures handbook.

CONCLUSION
In conclusion it is of great importance that care and maintenance of your drum
separators be of a high standard. Any defect will influence your magnetite recovery.