Enrichment

Enrichment


Washing


Separation


Flotation


Leaching


After liberation of all individual minerals in a rock or an ore feed, either by grinding or by natural size
reduction (beach sands a.o.) they can be separated individually.

Depending on their behaviour, different technologies are applied.

Separation by gravity

If there is a certain difference in density between two minerals or rock fractions they can be separated
by using this difference. Separation by gravity covers two different methods.
Separation in water (Gravity concentration)
Separation in a heavy medium (Dense Media Separation, DMS)
Separation in Water
Equipment Particle size range Typical applications
Coal Jigs 40 200 mm (1.6 - 8) Coal
Mineral Jigs 75 m - 6 mm (31/2 mesh) Gold, Chromite, Galena
Spirals 75 m - 1.0 mm light, (16 mesh) Coal, Beach sands, Iron
75 m - 0.5 mm heavy, (32 mesh) Cassiterit
Shaking tables 50 m - 2 mm (9 mesh) Tin, Copper, Gold, Lead, Zinc, Tungsten

Separation by Jigs

The jig operation consists of two actions. One is the effect of hindered settling meaning that a
heavier particle will settle faster than a light particle. The other one is the separation process in
an upward flow of water which will separate the particles by their density. These two actions are
combined in a Jig by slurry pulses generated mechanically or by air.

Separation by Spiral Concentrators

A spiral concentrator uses gravity to separate particles of different densities. It should not be confused
with a Spiral Classifier which usually separates particles of different size.

A Spiral concentrator consists of one or more helical profiled troughs supported on a central column.
As slurry travels down the spiral high and low density particles are stratified and separated with
adjustable splitters at the end of the spiral.

Separation by Shaking Tables

A cross stream of water transports material over the table to riffles running perpendicular to the
direction of feed. Particles build up behind each riffle and stratification occurs with heavier particles
sinking to the bottom. The light particles are carried over each riffle to the tailings zone. The shaking
action of the tables carries the heavy particles along the back of each riffle to the concentrate
discharge.

Separation in Dense Media

Gravity separation utilises the settling rate of different particles in water to make a separation. Particle
size, shape and density all affect the efficiency of the separation. Dense Media Separation (DMS) takes
place in fluid media with a density between that of the light and heavy fractions that are to be
separated. The separation is dependent upon density only.

Dense Media Separators

Drum Separator
Mainly mineral applications
Particle size range 6-200 mm (1/4 8)
Simple and robust
Low medium input
Max. media density =3.5

DMS applications
Coal Tin
Diamonds Manganese
Iron Ore Phosphate
Chromite Scrap metals
Fluorspar

In many cases Dense Media Separation is used for Pre- concentration e.g. rejecting waste material
prior to further processing (typical between crushing and grinding).

Magnetic Separation

By creating an environment comprimising a magnetic force (Fm), a gravitional force (Fg) and a drag
force (Fd) magnetic particles can be separated from nonmagnetic particles by magnetic separation.

Magnetic attraction force (Fm)

Fm = V x X x H x grad H
V = particle volume (determined by process)
X = magnetic susceptibility (see table below)
H = magnetic field (created by the magnet system design) in mT (milliTesla) or kGauss (kiloGauss) 1
kGauss = 100 mT = 0.1 T grade H = Magnetic field gradient (created by the magnet system design)
in mT/m

Magnetic field and magnetic gradient are equally important factors for creating the magnet attraction
force.

Competing forces

Gravitational force (Fg) determined by particle size and particle density.
Hydraulic force (Fd) for wet magnetic separators, determined by particle diameter, shape, liquid
viscosity and velocity (see wet LIMS and wet HGMS
below.)
Centrifugal force (Fc) for rotating dry magnetic separators, determined by particle size, density and
drum speed. (see dry LIMS below.)
Air drag force (Fa) for dry magnetic separators, determined by particle size, density and air velocity.
(see dry HGMS below).



Separator types

Wet LIMS = Low Intensity Magnetic Separator
Wet separation of ferromagnetic particles
Magnetic field in separation zone * = 1-3 kGauss
* approx. 50 mm (2 inches) from drum surface

Wet HGMS = High Gradient Magnetic Separators
Wet separation of paramagnetic particles
Magnetic field in separation zone* = 2-20 kGauss
* on matrix surface

Dry LIMS = Low Intensity Magnetic Separators
Dry separation of ferromagnetic particles
Magnetic field gradient in* separation zone = 1-3 kGauss
* approx. 50 mm (2 inches) from drum surface

Dry HGMS = High Gradient Magnetic Separators
Dry separation of paramagnetic particles
Magnetic field in separation zone* = 2-20 kGauss
* on matrix surface

Wet LIMS - Concurrent (CC)

Short pickup zone
Coarse particle tolerant up to 6 mm
- 0.2 inch (up to 20 mm - 0.8 inch
with special tank)
High capacities for low grade feeds
Dia 1200 mm (48")
Length 600, 1200, 1800, 2400,
3000 and 3600 mm.
Length 24", 48", 72", 96",120" and 144"
CC is normally used as primary separation (cobber), "working horse" for large
capacities and coarse feeds, mainly in iron ore industry.

Wet LIMS - Countercurrent (CTC)

Long pickup zone = improved recovery
Many pole passages = improved grade
Self adjusting level control
Coarse particle intolerant max 0.8 mm, due to sedimentation risk.
Dia 1200 mm (48")
Length 600, 1200, 1800, 2400, 3000 and 3600 mm.
Length 24", 48", 72", 96", 120" and 144"
CTC used as: Rougher and finisher for multistage concentration of magnetic iron ore.

Wet LIMS - Counter Rotation (CR)

Very long pickup zone
Good separation with high
recoveries
For both low and high grade feeds
Unsensitive for sedimentation,
particles up to 3 mm can be separated
Self adjusting level control
Dia 1200 mm (48")
Length 600, 1200, 1800, 2400, 3000
and 3600 mm
Length 24", 48", 72", 96", 120" and 144"
CR used as: same as CTC above when sedimentation is at risk, mainly in the iron ore industry.

Wet LIMS - Dense Media Recovery (DM)

Very long pickup zone
For extremely high recoveries of
very fine particles
HG (high gradient) version
available for high recovery
from very dilute pulps
Dia 1200 mm (48")
Length 600, 1200,
1800, 2400, 3000 and 3600 mm.
Length 24", 48", 72", 96", 120"and 144"

Wet LIMS - Feed densities

Con-current (CC) 35-45 percent solids by weight
Counter-current (CTC) 25-40 percent solids by weight
Counter-rotation (CR) 25-40 percent solids by weight
Dense-Media (DM) 25-300 grams per liter
Dense-Media (DMHG) 5-100 grams per liter

Wet LIMS Sizing

For sizing, use dry solids feed rate normally at high solids content (>25% solids by weight) and
volumetric feed rate at low solids content (<25% solids by weight) ex: Magnetite rougher, coarse
particles 20% minus 200 mesh, capacity 500 t/h. (555 stph)
Sizing: select concurrent separator.
Capacity (see table above) is say 140 t/h (155 stph) and m drum (dia 1200 mm, 48") 500/140 gives
3,6 m (144") drum length. Max length
is 3m (120").

2 x drum length 1800 mm (72") gives 504 t/h (556 stph). Select:2 x WS 1218 CC.

Note: There are magnetite deposits where the ore is various stages of transformation (e.g.
martitisation). These ores will exhibit different magnetic properties
and must be tested before separation equipment can be correctly sized.

Dry LIMS Drum Separator (DS)

Alternating polarity with different pole pitches giving good recovery and grade
Variation of drum speed 1-8 m/s (3 - 26 ft/s) gives metallurgical flexibility
Not sensitive to particle size 0.01 - 20 mm (150 mesh - 3/4")
Dia 916 mm (36"), 1200 mm (48")
Length 300 (dia 916 only), 600, 1200, 1500*, 1800, 2400 and 3000 mm.
Length 12" (dia 36" only), 24", 36", 48", 60"*, 72", 96", and 120"
For high speed (+5 m/s) separation maximum length is 1500 mm (60")
DS can be used for separation of all types of dry ferromagnetic separation processes:
Iron and steel slag treatment
Reduced pyrite ash separation
Calcined ilmenite production
Iron metal powder production
Magnetite or supergrade magnetite production

* Max lenght - hight speed plastic drum

Dry LIMS Belt Separator (BSA)

For coarse particles minus 200 mm
Alternating polarity with different pole pitches giving good selectivity
Rubber belt for protection of separator drum and even distribution of the feed
Variable speed for optimal separation
Diameter 1200 mm (48")
Length 600, 900, 1200, 1500, 1800 and 2400 mm.
Length 24", 36", 48", 60", 72", 96"

Dry LIMS - Belt Separator (BSS)

Extremely strong separation force for - 300 mm lump sizes
Disc type magnets with no particle rotation giving lower selectivity
Rubber belt protection
Variable speed
Dia 1200 mm (48")
Length 600, 1200, 1800 and 2400 mm.
Length 24", 48", 72", 96"

BSA and BSS mainly used for separation of coarse ferromagnetic ores and slags.

Dry LIMS - Particle size in feed

DS 0-20 mm (0 - 3/4") Selectivity drops under 30 microns
BSA 5-200 mm (3/16" - 8") Selectivity drops under 5 mm (3/16")
BSS 5-300 mm (3/16" - 12") Selectivity drops under 5 mm (3/16")

Wet HGMS Matrix Design

By disturbing the electromagnetic field by introducing a ferromagnetic material with sharp edges high
magnetic field gradients are created at all disturbing
points.

These disturbing elements (filaments) are spaced apart to allow pulp flow around them.

Facts about filaments:
Made of ferromagnetic material in format expanded metal (x) or steel wool (w)
Filament thickness is related to the particle size
Spacing can be approx. 10 times the filament thickness
The matrix can contain filaments of various thickness, "sandwich matrix"

Wet HGMS Separator Types

Cyclic Separators: For applications with low magnetic content in the feed (< 4% weight)
Continuous Separators: For applications with higher magnetic content in the feed (Carousels): (> 4%
by weight)

Wet Cyclic HGMS

Robust and simple design (few moving parts)
Magnetic field from 3-20 kGauss
Canister dia. up to 305 cm (120")
High magnetic fields and field gradients giving a good "polishing" of contaminated products

Wet Cyclic HGMS Sizes and Nomenclature

Sizes referring to:
Outer diameter of canister (cm): 10, 22, 38, 56, 76, 107, 152, 214 and 305 (4", 9", 15", 22", 30",
42", 60", 84" and 120")
Magnetic field: 3, 5, 10, 15 and 20 kGauss
Height of matrix (mm): 15, 30 and 50 cm (6", 12", 20")

Nomenclature
HGMS 107-30-20 = Cyclic separator with canister (or matrix)
diameter 107 cm, matrix height 30 cm and magnetic field of 20 kGauss.

Our laboratory unit is Model 10-15-20 (dia 10 cm, matrix height 15 cm and magnetic field of 20
kGauss)

Wet Cyclic HGMS Process System

Compact system design
Fail-safe protection (thermal)
Customer built power supply
Completely automatic process control

Wet Cyclic HGMS Applications

Kaolin Beneficiation (brightening)
Fe2O3 reduction in glass sand, feldspar, barite
Cu-reduction in Mo Cu concentrates
De-ashing and desulphurisation of coal
Phosphates upgrading

Wet Carousel HGMS Applications

1.Concentration of paramagnetic oxide minerals such as:
chromite
hematite
ilmenite
manganite
volframite
2. Rare earth minerals
3. Industrial minerals (reduction of paramagnetic contaminations)
4. Coal (desulphurisation and de-ashing)
5. Separation of base metal minerals such as:
Cu-Mo
Cu-Pb
Zn-Pb