DMC Workshop 18/8/10

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

Total iron Ferrous/total iron ratio Titanium +30um -30um+10um -10um

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/low head screen

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

Hurdles and cross dams

Only effective for flat particle shapes Major factor in magnetite recovery

Particle size distribution

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

With coal With magnetite concentrate Manual or automatic addition

Magnetite Concentrate Addition

Direct from separators Metered via control valve Screen carry-over Medium bleed

Correct Medium Circuit Losses

Medium Bleeds

Problems with large bleed off

Loose finest magnetite fraction Lower density concentrate Removal of stabilising clays

Problems with small bleed off

Recirculating load of fine coal & reject Reduced medium/coal ratio Increased viscosity (clay buildup)

Circuit Design

Wing tanks or draft tubes Correct medium density measurement

Air entrainment Magnetite settling

Wear factors and critical alignments Cross-bleeding Floor cleanup systems