Manganese ore magnetic separation equipment and dry beneficiation process

Abstract

The present application relates to the technical field of mineral processing, and more particularly to a manganese ore magnetic separation device and dry beneficiation process, wherein the magnetic separation device comprises a mounting frame, a first channel, a second channel, a distribution plate, a magnetic roller, a conveyor belt, a feeding mechanism and an auxiliary mechanism. The magnetic roller is composed of a roller shaft, an end cover and a plurality of magnetic rings, the magnetic rings comprising a magnetic gathering plate and a magnetic block and being tightly arranged by a screw rod. The feeding mechanism realizes uniform feeding through a vibration and suspension system. The auxiliary mechanism realizes the vibration and shunting of the ore sand through a guide strip. The beneficiation process comprises crushing, grinding, classification, roasting, magnetic separation and post-processing. The magnetic separation adopts a two-stage type of roughing and cleaning to improve the recovery rate. The present application has the advantages of high separation efficiency, high concentrate purity, low energy consumption, strong adaptability and the like, and is suitable for large-scale industrial production.

Description

Technical Field

[0001] This invention relates to the field of mineral processing technology, and in particular to a magnetic separation device for manganese ore and a dry mineral processing technology. Background Technology

[0002] Manganese ore, as an important raw material for steel smelting, new energy batteries, and chemical production, has always attracted much attention for its purification technology. Currently, the mainstream manganese ore purification process in the market is still mainly based on chemical methods, especially for the treatment of low-grade, weakly magnetic manganese ore, which often uses leaching or flotation with reagents such as oxalic acid and hydrofluoric acid. While these chemical methods can improve the grade of manganese powder to some extent, they have significant drawbacks: first, the high cost of reagents increases the overall beneficiation cost; second, the use of strong acids and other chemicals easily leads to wastewater and waste residue pollution, negatively impacting the environment; and third, in terms of finished product quality, the grade of the obtained manganese powder is still difficult to consistently meet the requirements of high-end applications, limiting its application in high-value-added fields.

[0003] To reduce reliance on chemical methods, the industry has gradually introduced physical beneficiation methods, among which magnetic separation technology has gained attention due to its reagent-free nature and low environmental impact. Dry roller magnetic separators, in particular, were once highly anticipated for achieving purely physical separation of manganese ore. However, traditional dry magnetic separation equipment has revealed numerous technical bottlenecks in practical applications. On the one hand, the magnetic field distribution generated by the magnetic rollers is uneven, and the magnetic field strength decreases significantly with increasing belt distance, resulting in insufficient capture capacity for fine-grained manganese ore. On the other hand, limited by the belt material and toughness, its linear velocity is usually difficult to exceed 2 meters per second, affecting processing efficiency. More importantly, if the separation effect of the upstream roller magnetic separator is unsatisfactory, a large amount of insufficiently separated ore sand will enter the subsequent high-gradient vertical ring magnetic separator, causing increased equipment load, decreased separation accuracy, and difficulty in producing qualified concentrate powder. Therefore, in previous processes, magnetic separation equipment was mostly used as a pre-selection or auxiliary means, unable to independently complete the entire purification process from raw ore to concentrate powder, ultimately still requiring chemical methods to improve grade. Summary of the Invention

[0004] To address the aforementioned technical problems, this invention provides a manganese ore magnetic separation device and a dry beneficiation process. By improving the magnetic roller structure of the roller separator and the structure and function of the magnetic separation device, it solves the industry's technical problem that traditional dry magnetic separators cannot independently complete the efficient purification of manganese ore due to weak magnetic fields and low belt speeds, and that they have long relied on chemical methods. Specifically, this is achieved through the following technical solutions.

[0005] First, this invention provides a manganese ore magnetic separation device, comprising:

[0006] Mounting frame, wherein the mounting frame is provided with mounting plates that form the side wall of the equipment;

[0007] The magnetic roller and the auxiliary roller are both rotatably mounted on the mounting frame. The magnetic roller includes a roller shaft, end caps fixed to both ends of the roller shaft, and a plurality of magnetic rings closely arranged along the axial direction of the roller shaft. Each magnetic ring consists of a magnetic plate and a plurality of axially magnetized magnetic blocks fixed to one side by fastening bolts.

[0008] A conveyor belt, which is tensioned and wound around the outer periphery of the magnetic roller and the auxiliary roller, is used for the cyclic transport of ore sand;

[0009] A drive motor is fixed on the mounting bracket and is connected to the magnetic roller drive mechanism;

[0010] A feeding mechanism, which is installed above the auxiliary roller, is used to uniformly feed material onto the conveyor belt;

[0011] An auxiliary mechanism, disposed above the magnetic roller, includes several guide strips whose lower surfaces are attached to the upper surface of the conveyor belt, and the gaps between adjacent guide strips are radially aligned with the magnetic focusing plate of the magnetic ring.

[0012] Preferably, the mounting frame is provided with a first channel for discharging waste and a second channel for discharging manganese ore sand on its lower side, and an inclined material distribution plate is provided between the first channel and the second channel;

[0013] The magnetic roller is positioned at the junction of the upper ends of the first channel and the second channel, with its axis located directly above the second channel.

[0014] Preferably, the conveyor belt has baffles perpendicular to its surface at both ends; the magnetic rings are fastened to the end caps by screws that pass through all the magnetic rings and nuts that are threaded into the screws.

[0015] Preferably, the magnetic block is made of cerium-free neodymium iron boron, and the magnetic plate is made of Q235 steel; the mounting holes on the magnetic block are chamfered at the ends, and the fastening bolts are countersunk bolts.

[0016] Preferably, the feeding mechanism includes a feeding bin fixed to the top of the mounting frame, a material tray located below the feeding bin, a first vibrator fixed to the side of the material tray away from the opening, and a suspension part connecting the feeding bin and the material tray;

[0017] The feed hopper has a cross-section that is wider at the top and narrower at the bottom, and a V-shaped plate is fixed to its inner bottom.

[0018] The opening side of the tray faces upward between the magnetic roller and the auxiliary roller.

[0019] Preferably, the suspension part includes a fixing hook fixed to the outside of the feed hopper, a connecting ring is suspended at the lower end of the fixing hook, an adjusting bolt is connected below the connecting ring, the adjusting bolt is threadedly connected to the connecting block to realize the adjustment of the suspension length, and a U-shaped ring is suspended at the lower end of the connecting block by a hook;

[0020] The end of the U-shaped ring is fixed with a suspension plate. The suspension plate is sleeved on the guide rod through a through hole in its middle and can slide along it. The guide rod is sleeved with a spring. The two ends of the spring are respectively connected to a fixing plate fixed to the top of the guide rod and the suspension plate. The bottom end of the guide rod is connected to the side of the material tray through a hanging ring.

[0021] Preferably, the auxiliary mechanism further includes a crossbeam connected to the mounting plate via a sliding part and a second vibrator fixed to the upper surface of the crossbeam, and the guide strips are evenly arranged via a connecting plate fixed to the lower surface of the crossbeam.

[0022] Preferably, the sliding part includes a sliding block fixed to the end of the crossbeam, a guide square tube fixed to the mounting plate, and a limiting pin;

[0023] The sliding block is slidably disposed inside the guide square tube, and the elongated hole on it cooperates with the limiting pin passing through the guide square tube to limit the reciprocating stroke of the crossbeam.

[0024] Preferably, the guide strip has a trapezoidal cross-section that is narrower at the top and wider at the bottom, and the end of it closest to the auxiliary roller is beveled.

[0025] Secondly, this invention provides a dry beneficiation process for manganese ore, which utilizes the aforementioned manganese ore magnetic separation equipment to complete the beneficiation process, specifically including the following steps:

[0026] Step 1: Crushing

[0027] After the raw manganese ore is initially crushed by a jaw crusher, it is then crushed by a cone crusher to a particle size of ≤10mm.

[0028] Step 2: Grinding

[0029] The crushed ore particles are ground to obtain ore sand with a particle size of -200 mesh accounting for 60% to 80%.

[0030] Step 3: Ore beneficiation

[0031] The mineral sands are classified into natural magnetic mineral sands and non-magnetic or weakly magnetic mineral sands according to their magnetic properties.

[0032] Step 4: Roasting

[0033] The non-magnetic or weakly magnetic mineral sand is roasted at 600-800℃ for 0.5-1 hour to obtain roasted mineral sand.

[0034] Step 5: Magnetic separation

[0035] The natural magnetic sand and the roasted sand are fed to the above-mentioned manganese ore magnetic separation equipment for roughing, and then the remaining sand after roughing is fed to a high gradient magnetic separator for fine selection to obtain manganese concentrate sand.

[0036] Step 6: Post-processing

[0037] The manganese concentrate is subjected to pulping, concentration, pressure filtration and drying to finally obtain manganese concentrate powder.

[0038] After adopting the above technical solution, the beneficial effects of the present invention are:

[0039] 1. By optimizing the magnetic roller structure, adopting a combination design of magnetic plates and magnetic blocks, and achieving a tight arrangement of magnetic rings through screw fastening, the uniformity and strength of the magnetic field are significantly enhanced, improving the adsorption efficiency of manganese ore particles, thereby improving the sorting accuracy and concentrate grade.

[0040] 2. The feeding mechanism adopts a suspended vibrating feeding system, combined with an adjustable suspension part and a spring buffer device, which realizes uniform and stable conveying of ore sand, effectively prevents accumulation and blockage, and ensures the continuity and stability of the sorting process.

[0041] 3. The auxiliary mechanism, through the coordinated action of the guide bar and the vibration device, diverts and guides the ore sand on the conveyor belt, bringing the manganese-containing ore sand closer to the magnetic field area, thereby enhancing the sorting effect and reducing the loss of useful minerals.

[0042] 4. The mineral processing technology classifies ores according to their magnetic differences and performs targeted roasting and conversion on weakly magnetic ores, which enhances the adaptability of the process and the resource utilization rate, and improves the overall recovery rate.

[0043] 5. A two-stage magnetic separation process combining roughing and cleaning is adopted, along with a high-gradient magnetic separator, to effectively capture fine and weakly magnetic particles, ensuring full recovery of manganese ore. At the same time, multi-stage dehydration and drying processes reduce the product moisture content, meeting industrial standard requirements. Attached Figure Description

[0044] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0045] Figure 1 A 3D view of a manganese ore magnetic separation equipment;

[0046] Figure 2 for Figure 1 Front view after removing part of the mounting plate;

[0047] Figure 3 for Figure 2 A front sectional view of the middle part;

[0048] Figure 4 A three-dimensional view of the suspension section;

[0049] Figure 5 This is a front view of the magnetic roller;

[0050] Figure 6 for Figure 5 Partial disassembly 3D diagram;

[0051] Figure 7 This is a 3D diagram of the magnetic block;

[0052] Figure 8 This is a schematic diagram showing the magnetization direction of some of the magnetic blocks;

[0053] Figure 9 This is a schematic diagram of the auxiliary mechanism;

[0054] Figure 10 This is a structural disassembly diagram of the sliding part.

[0055] Explanation of reference numerals in the attached figures:

[0056] 101-Mounting frame, 102-Mounting plate, 103-First channel, 104-Second channel, 105-Distribution plate, 106-Drive motor, 107-Auxiliary roller, 108-Conveyor belt, 109-Baffle, 110-Magnetic roller, 111-Roller shaft, 112-Bearing, 113-End cap, 114-Magnetic plate, 115-Magnetic block, 116-Fasting bolt, 117-Screw, 118-Nut;

[0057] 200-Feeding mechanism, 201-Feeding bin, 202-Material tray, 203-First vibrator, 204-V-shaped plate, 210-Suspension part, 211-Fixing hook, 212-Connecting ring, 213-Adjusting bolt, 214-Connecting block, 215-Hook, 216-U-shaped ring, 217-Suspension plate, 218-Through hole, 219-Guide rod, 220-Fixing plate, 221-Spring, 222-Hanging ring;

[0058] 300-Auxiliary mechanism, 301-Crossbeam, 302-Second vibrator, 303-Connecting plate, 304-Guide strip, 310-Sliding part, 311-Sliding block, 312-Elongated hole, 313-Guide square tube, 314-Limit pin. Detailed Implementation

[0059] The features and exemplary embodiments of various aspects of the present invention will now be described in detail. To make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are only configured to explain the present invention and are not configured to limit the present invention. For those skilled in the art, the present invention can be practiced without some of these specific details. The following description of the embodiments is merely intended to provide a better understanding of the present invention by illustrating examples of the invention.

[0060] The directional terms used in the following description refer to the directions shown in the figures and are not intended to limit the specific structure of the invention. It should also be noted that, unless otherwise explicitly specified and limited, the terms "installation" and "connection" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0061] An embodiment of the present invention provides a manganese ore magnetic separation device, see [link to relevant documentation]. Figures 1-10 The manganese ore magnetic separation equipment includes a mounting frame 101, which is used to build the external frame of the equipment. Several mounting plates 102 are installed on the mounting frame 101 to form the side wall of the equipment. The various components of the equipment are installed inside the side wall to jointly complete the magnetic separation process of manganese ore.

[0062] The manganese ore magnetic separation equipment also includes a first channel 103 and a second channel 104 installed on the lower side of the mounting frame 101. The first channel 103 is used to output the waste material after magnetic separation, that is, to output the remaining ore sand after magnetic separation of manganese ore. The second channel 104 is used to output the manganese ore sand after magnetic separation. An inclined material distribution plate 105 is installed between the first channel 103 and the second channel 104. The material distribution plate 105 is parallel to the side wall of the first channel 103 and extends outward from the first channel 103 to better prevent ore sand without manganese content from entering the interior of the second channel 104, thereby improving the purity of the manganese ore sand after magnetic separation.

[0063] An auxiliary roller 107 is installed directly above the second channel 104. The auxiliary roller 107 is rotatably mounted on the mounting frame 101. The outer surface of the auxiliary roller 107 and the outer surface of the magnetic roller 110 are together tensioned and wound with a conveyor belt 108. The conveyor belt 108 is used to realize the rolling transmission of the magnetic roller 110 and the auxiliary roller 107, and at the same time, it is used for the circulation conveying of ore. Each end of the conveyor belt 108 is equipped with a baffle 109 perpendicular to the conveyor belt 108 to prevent ore from falling outward from the side of the surface of the conveyor belt 108.

[0064] The magnetic roller 110 is located at the junction of the upper ends of the first channel 103 and the second channel 104, and the axis of the magnetic roller 110 is located directly above the second channel 104. The magnetic roller 110 is driven and connected to the output end of the drive motor 106 through a transmission mechanism. The drive motor 106 is fixedly installed on the lower side of the mounting bracket 101.

[0065] As a feasible application scenario, the above-mentioned transmission mechanism includes a first pulley, a second pulley, and a transmission belt. The first pulley is coaxially fixed to one end of the magnetic roller 110, and the second pulley is coaxially fixed to the output end of the drive motor 106. The first pulley and the second pulley are tensioned and wound together by the transmission belt to realize the drive transmission between the first pulley and the second pulley.

[0066] See Figure 5 , Figure 6 , Figure 7 The magnetic roller 110 includes a roller shaft 111. Both ends of the roller shaft 111 are rotatably mounted on the mounting frame 101 via bearings 112. Both sides of the roller shaft 111 are coaxially fixedly mounted with end caps 113. Between the two end caps 113, a number of magnetic rings are tightly mounted along the axial direction of the roller shaft 111. The magnetic rings include a magnetic plate 114 and a number of magnetic blocks 115 arranged in a ring on one side of the magnetic plate 114. The magnetic blocks 115 have mounting holes arranged along their axial direction. The magnetic blocks 115 are fixedly mounted on the magnetic plate 114 by fastening bolts 116 arranged in the mounting holes.

[0067] Several magnetic rings are sequentially attached and fastened to the end cover 113 by a screw 117 that passes through all the magnetic rings and a nut 118 that is threaded to the screw 117.

[0068] With the installation of screw 117 and nut 118, several magnetic rings can rotate synchronously with end cover 113, thereby driving conveyor belt 108 and auxiliary roller 107 to rotate.

[0069] The conveyor belt 108 carries a portion of the ore sand for circulation. When the ore sand flows to the side near the magnetic roller 110, the manganese-containing ore sand in the manganese ore is adsorbed onto the outer surface of the conveyor belt 108 by its annularly distributed magnetic field, and thus continues to flow with the rotation of the conveyor belt 108. When the manganese-containing ore sand flows to a position where it is no longer affected by the magnetic field of the magnetic roller 110, that is, when it moves to the top of the second channel 104, it falls into the second channel 104 under the action of gravity. Meanwhile, the ore sand that does not contain manganese metal flows to the side of the magnetic roller 110 as the conveyor belt 108 rotates. Because it is not attracted by the magnetic field of the magnetic roller 110, it flows into the first channel 103 under the action of inertia. The separation of ore sand is achieved in the above manner.

[0070] Among them, the magnetic block 115 is magnetized along its axial direction, and the magnetic poles of the magnetic block 115 are in accordance with Figure 8The magnetic poles of the two adjacent magnetic blocks 115 are the same, and the magnetic poles of the two adjacent magnetic blocks 115 are symmetrically distributed about the magnetic plate 114 between the two magnetic blocks 115.

[0071] As a feasible application scenario, the magnetic block 115 is made of cerium-free neodymium iron boron, and the magnetic plate 114 is made of carbon steel, preferably Q235.

[0072] The above-mentioned distribution structure of the magnetic block 115 and the magnetic focusing plate 114, combined with their materials, enables the magnetic focusing plates 114 to fully realize the function of concentrating magnetic field lines. The magnetic focusing plate 114 gathers the magnetic field lines of the same magnetic pole distributed on its two end faces and distributes them along the radial direction of the magnetic focusing plate 114, thereby greatly enhancing the magnetic field line density at the outer circumferential surface of the magnetic focusing plate 114, so that it has a stronger magnetic field strength under the same conditions.

[0073] As a feasible application scenario, the mounting hole on the magnetic block 115 is chamfered at the end, and the fastening bolt 116 is a countersunk bolt. With this structure, when the fastening bolt 116 fastens the magnetic block 115 to the side of the magnetic plate 114, it can ensure that the end face of the magnetic block 115 is flush, which makes it easy to fit tightly with the adjacent magnetic ring.

[0074] See Figure 2 , Figure 3 , Figure 4 The manganese ore magnetic separation equipment also includes a feeding mechanism 200 installed directly above the auxiliary roller 107. The feeding mechanism 200 includes a feed bin 201, a material tray 202, a first vibrator 203, and a V-shaped plate 204. The feed bin 201 is fixedly installed on the top of the mounting frame 101 and is used to transport the ore to the upper surface of the material tray 202. The cross-section of the feed bin 201 is wider at the top and narrower at the bottom, which facilitates the collection of the ore inside the feed bin 201 and orderly conveying it into the material tray 202.

[0075] Several V-shaped plates 204 are also fixedly installed on the bottom inner side of the feed hopper 201 to simply disperse and guide the ore inside the feed hopper 201, so as to avoid large-volume block structures in the ore from affecting the feeding.

[0076] The side of the material tray 202 is bent upward, and its opening side is located directly above the middle of the magnetic roller 110 and the auxiliary roller 107. A first vibrator 203 is fixedly installed on the side of the material tray 202 away from the opening, which is used to drive the vibration of the material tray 202, thereby achieving uniform distribution of ore sand in the material tray 202.

[0077] The material tray 202 is suspended directly below the feed hopper 201 by at least four sets of suspension parts 210. Each suspension part 210 includes a fixing hook 211. The first end of the fixing hook 211 is fixedly installed on the outside of the feed hopper 201, and the second end of the fixing hook 211 is suspended by a connecting ring 212. The bottom of the connecting ring 212 is fixed to the first end of the adjusting bolt 213. The adjusting bolt 213 is threadedly connected to the first end of the connecting block 214. The connecting ring 212 is screwed onto the first end of the connecting block 214 by the adjusting bolt 213. The distance between the connecting ring 212 and the connecting block 214 can be adjusted by using different environments, so that the length of the entire suspension part 210 can be adjusted appropriately, which facilitates the adjustment of the tilt angle of the material tray 202.

[0078] The second end of the connecting block 214 is threadedly connected to the hook 215. A U-shaped ring 216 is suspended on the hook 215. The U-shaped ring 216 is an inverted U-shaped structure, with its middle part suspended on the hook 215 and its end fixed to the suspension plate 217.

[0079] A through hole 218 is provided in the middle of the suspension plate 217. A guide rod 219 is provided in the through hole 218 and slides along it. The top end of the guide rod 219 is fixed coaxially with the fixing plate 220. The fixing plate 220 is fixed with the first end of the spring 221. The second end of the spring 221 is fixed with the suspension plate 217. The spring 221 is sleeved on the outside of the guide rod 219. A ring is fixed at the bottom end of the guide rod 219. The ring is fastened to the lifting ring 222. The lifting ring 222 is fixedly installed on the side of the material tray 202.

[0080] The present invention suspends the material tray 202 directly below the feeding bin 201 through the suspension part 210. Through the threaded connection between the adjusting bolt 213 and the connecting block 214 in the suspension part 210, the overall length of the suspension part 210 is adjustable. The length of several suspension parts 210 can be adjusted within a certain range to maintain the posture of the material tray 202 and meet the requirements of feeding speed and feeding uniformity.

[0081] The suspension connection method using hooks 215 and U-shaped rings 216 facilitates assembly and disassembly, improves structural flexibility, and makes equipment maintenance and upkeep easier.

[0082] The suspension plate 217 and the material tray 202 are connected by a fixing plate 220, a spring 221 and a lifting ring 222. The elasticity of the spring 221 combined with the vibration of the first vibrator 203 effectively amplifies the vibration amplitude of the material tray 202, which is conducive to more uniform and efficient feeding of the material tray 202.

[0083] See Figure 3 , Figure 9 , Figure 10The manganese ore magnetic separation equipment also includes an auxiliary mechanism 300, which is installed directly above the magnetic roller 110. The auxiliary mechanism 300 includes a crossbeam 301, a second vibrator 302, a connecting plate 303, a guide bar 304, and a sliding part 310. The crossbeam 301 is mounted on the mounting plate 102 through the sliding parts 310 at both ends. The sliding parts 310 allow the crossbeam 301 to reciprocate within a certain range along its length. Several second vibrators 302 are fixedly installed on the upper surface of the crossbeam 301 to provide power for the reciprocating motion of the crossbeam 301 along its length.

[0084] A number of connecting plates 303 are uniformly fixed on the lower surface of the crossbeam 301 along its length. Guide strips 304 are fixed to the bottom of each connecting plate 303. The cross-sectional shape of the guide strips 304 is a trapezoidal structure that is narrow at the top and wide at the bottom. The lower surface of the guide strips 304 is in contact with the outer surface of the conveyor belt 108. The gap between two adjacent guide strips 304 is aligned radially with the magnetic plate 114.

[0085] The guide bar 304 is beveled at one end near the auxiliary roller 107 to facilitate the diversion and guidance of the ore carried on the conveyor belt 108, so that the ore flows backward along the gap between the guide bars 304 under the guiding action of several guide bars 304.

[0086] The sliding part 310 includes a sliding block 311, an elongated hole 312, a guide square tube 313, and a limiting pin 314. The end of the crossbeam 301 is fixedly connected to the sliding block 311. Several elongated holes 312 are vertically opened on the sliding block 311. The cross-sectional shape of the elongated holes 312 is racetrack-shaped. The long axis of the cross-section is parallel to the length direction of the crossbeam 301. The sliding block 311 is slidably disposed in the guide square tube 313. The guide square tube 313 is fixed to the mounting plate 102. Several limiting pins 314 are vertically installed on the guide square tube 313. The cross-sectional shape of the limiting pins 314 is circular. The limiting pins 314 are disposed inside the elongated holes 312.

[0087] In the above structure of the present invention, the cooperation between the guide square tube 313 and the sliding block 311 ensures that the crossbeam 301 can only move along its length direction, and the cooperation between the limiting pin 314 and the elongated hole 312 limits the movement stroke of the crossbeam 301, so that the crossbeam 301 can only slide back and forth within a certain range.

[0088] During the process of the crossbeam 301 being driven to slide back and forth by several second vibrators 302, the crossbeam 301 drives the guide bar 304 to move synchronously within a certain range through several connecting plates 303. During the movement of the guide bar 304, the ore sand located on the upper surface of the conveyor belt 108 is diverted and guided, so that the ore sand flows backward along the gap between the guide bars 304 under the guidance of the guide bar 304.

[0089] Since the gap between adjacent guide bars 304 is radially aligned with the magnetic plate 114, and due to the magnetic effect of the magnetic plate 114, the magnetic adsorption effect on the manganese-containing ore is stronger when the ore flows backward through the gap between the guide bars 304.

[0090] Furthermore, the reciprocating motion of several guide strips 304 helps prepare for further separation of the ore on the upper surface of the conveyor belt 108. This is because when the ore flows backward through the gaps in the guide strips 304, the ore containing manganese metal is more likely to adhere to the outer surface of the conveyor belt 108 under magnetic adsorption. The reciprocating motion of the guide strips 304 forces the ore in the gaps to shift to a certain extent. Therefore, under the action of the guide strips 304, the ore containing manganese metal tends to move closer to the outer surface of the conveyor belt 108 each time it shifts, while the ore without manganese metal tends to move away from the outer surface of the conveyor belt 108 each time it shifts. Thus, after the guide strips 304 touch the ore multiple times, the part of the ore containing manganese metal will definitely be closer to the outer surface of the conveyor belt 108. At this time, by adjusting the specific position of the material distribution plate 105, the ore can be classified, avoiding the loss of manganese-containing ore while ensuring the purity of manganese ore, making the classification of ore more accurate.

[0091] Embodiments of the present invention also provide a dry beneficiation process for manganese ore, specifically including the following steps:

[0092] Step 1: Crushing

[0093] The raw manganese ore is initially crushed by a jaw crusher until the ore particle size is ≤50mm. Then, it is further crushed by a cone crusher to obtain ore particles with a particle size of ≤10mm for later use.

[0094] Crushing is a pretreatment stage in mineral processing. It uses mechanical force to cause brittle fracture of the ore, with the aim of breaking large pieces of raw ore into smaller particles, providing suitable feed size for subsequent grinding and mineral processing. The crushing step can effectively improve the efficiency of subsequent grinding processes and reduce overall energy consumption, while keeping the ore particle size uniform and reducing unnecessary wear on equipment.

[0095] Step 2: Grinding

[0096] The ore particles obtained in step 1 are finely ground using a ball mill or rod mill to obtain ore sand for later use.

[0097] In this step, the grinding fineness is controlled according to the ore dispersive particle size, and the fineness of the final ore sand is controlled at 60% to 80% of -200 mesh. The purpose is to ensure that the manganese minerals are fully liberated from the gangue, while avoiding over-grinding that would lead to mud formation and affect the magnetic separation efficiency.

[0098] The grinding process ensures efficient dissociation of manganese minerals from gangue, thereby significantly improving the accuracy of subsequent magnetic separation. By precisely controlling the fineness, the problem of increased slime caused by over-grinding is effectively avoided. This not only reduces the risk of clogging in the magnetic separation equipment but also reduces manganese loss. At the same time, it optimizes energy consumption, achieving a good balance between grinding costs and beneficiation results.

[0099] Step 3: Ore beneficiation

[0100] The mineral sands obtained in step 2 are classified according to the type of manganese ore into natural magnetic mineral sands and non-magnetic or weakly magnetic mineral sands.

[0101] Manganese ore can be classified into naturally magnetic ores and non-magnetic or weakly magnetic ores based on differences in magnetic properties. Magnetic ores, such as manganese oxide ore, contain iron-manganese nodules or lattice defects and have natural magnetism. Non-magnetic or weakly magnetic ores, such as manganese carbonate ore, do not contain iron oxides or have very low iron oxide content, resulting in them being non-magnetic or weakly magnetic. This part of the ore powder needs to be roasted to make it magnetic before further magnetic separation.

[0102] This sorting step enables the separate processing of different magnetic ores, greatly enhancing the flexibility of the process flow.

[0103] This step provides a dedicated path for roasting pretreatment of non-magnetic or weakly magnetic ores, thereby maximizing resource utilization and reducing the handling of ineffective materials during direct magnetic separation, saving energy and time costs.

[0104] Step 4: Roasting

[0105] The non-magnetic or weakly magnetic mineral sand from step 3 is transferred to a rotary kiln or fluidized bed roasting furnace and roasted at 600–800°C for 0.5–1 hour, then cooled to form roasted mineral sand for later use.

[0106] In this step, MnCO3 is converted into Mn2O3, Mn3O4 and CO2 gas at 600-800℃. Since Mn2O3 has weak magnetism and Mn3O4 has strong magnetism, it is convenient to carry out magnetic separation in subsequent processes.

[0107] The roasting process described above successfully transforms ores that were originally not magnetically separable into materials that can be effectively captured by magnetic separation equipment, greatly expanding the range of ores that can be processed. It is especially suitable for low-grade manganese carbonate ores. This step significantly improves the overall recovery rate of manganese, and because the reaction conditions are mature and controllable, the entire process is easy to implement stably on an industrial scale.

[0108] Step 5: Magnetic separation

[0109] The magnetic ore sand from step 3 and the roasted ore sand from step 4 are transported to the above-mentioned magnetic separation equipment to complete the roughing process. The tailings after the roughing process are transported to a high-gradient magnetic separator for further magnetic separation to recover the residual weakly magnetic manganese ore sand and obtain manganese concentrate ore sand.

[0110] When using the aforementioned magnetic separation equipment for roughing, the magnetic separation speed is fast and the magnetic separation efficiency is high, which can basically extract the magnetic manganese-containing ore sand from the ore sand. The remaining small amount of weakly magnetic manganese-containing ore sand is further refined by a high-gradient magnetic separator to avoid the loss of manganese-containing ore sand.

[0111] The above steps employ a two-stage magnetic separation process of roughing and cleaning, which greatly improves the recovery rate of manganese ore and effectively reduces the loss of valuable metals. The application of high-gradient magnetic separators is particularly beneficial for capturing fine, weakly magnetic particles, thereby improving the final grade of manganese concentrate. The entire magnetic separation process is continuous and efficient, making it very suitable for large-scale industrial production.

[0112] Step 6: Post-processing

[0113] The manganese concentrate obtained in step 5 is mixed with water to prepare a slurry. After being processed by a thickener, it is then filtered and dried to finally obtain manganese concentrate powder.

[0114] The thickener initially concentrates the slurry to 50%–60%, and the vacuum filter or plate and frame filter press is used for dewatering during the filtration process to reduce the overall moisture content to below 10%. Finally, the slurry is further dried to below 5% by a hot air dryer or roller dryer to meet the industrial standards for manganese concentrate.

[0115] The above steps, through a multi-stage dehydration and drying combination, significantly reduce the moisture content of the product. This not only reduces transportation costs but also prevents the product from clumping or oxidizing during storage, ultimately resulting in a dry, stable manganese concentrate product that meets industrial standards and satisfies the stringent requirements of downstream applications such as metallurgy and chemicals.

[0116] This process design features low energy consumption and high efficiency, ensuring both the quality and economy of the final product.

[0117] The embodiments described above are not exhaustive, nor do they limit the invention to any specific embodiments. Clearly, many modifications and variations can be made based on the above description. These embodiments are selected and specifically described in this specification to better explain the principles and practical applications of the invention, thereby enabling those skilled in the art to effectively utilize the invention and its modifications. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the invention should be included within the scope of protection of the invention.

Claims

1. A magnetic separation device for manganese ore, characterized in that, include: Mounting bracket (101), on which mounting plate (102) forming the side wall of the equipment is provided. The magnetic roller (110) and the auxiliary roller (107) are both rotatably mounted on the mounting frame (101). The magnetic roller (110) includes a roller shaft (111), end caps (113) fixed to both ends of the roller shaft, and a plurality of magnetic rings closely arranged along the roller shaft axis. Each magnetic ring consists of a magnetic plate (114) and a plurality of axially magnetized magnetic blocks (115) fixed to one side by fastening bolts (116). A conveyor belt (108), which is tensioned and wound around the outer periphery of the magnetic roller (110) and the auxiliary roller (107), is used for circulating transport of ore sand; A drive motor (106) is fixed on the mounting bracket (101) and is driven to the magnetic roller (110) through a transmission mechanism; A feeding mechanism (200) is installed above the auxiliary roller (107) for uniformly feeding material onto the conveyor belt (108); An auxiliary mechanism (300) is disposed above the magnetic roller (110) and includes a plurality of guide strips (304) whose lower surfaces are in contact with the upper surface of the conveyor belt (108), and the gaps between adjacent guide strips (304) are radially aligned with the magnetic plate (114) of the magnetic ring. The auxiliary mechanism (300) also includes a crossbeam (301) connected to the mounting plate (102) via a sliding part (310) and a second vibrator (302) fixed to the upper surface of the crossbeam (301). The guide strips (304) are evenly arranged via connecting plates (303) fixed to the lower surface of the crossbeam (301). The sliding part (310) includes a sliding block (311) fixed to the end of the crossbeam (301), a guide square tube (313) fixed to the mounting plate (102), and a limiting pin (314). The sliding block (311) is slidably disposed inside the guide square tube (313), and the elongated hole (312) opened on it cooperates with the limiting pin (314) passing through the guide square tube (313) to limit the reciprocating stroke of the crossbeam (301).

2. The manganese ore magnetic separation equipment according to claim 1, characterized in that, The mounting frame (101) is provided with a first channel (103) for discharging waste and a second channel (104) for discharging manganese ore sand on its lower side. An inclined material distribution plate (105) is provided between the first channel (103) and the second channel (104). The magnetic roller (110) is arranged at the junction of the upper end of the first channel (103) and the second channel (104), and its axis is located directly above the second channel (104).

3. The manganese ore magnetic separation equipment according to claim 1, characterized in that, The conveyor belt (108) has baffles (109) perpendicular to its surface at both ends; the magnetic rings are fastened to the end cap (113) by screws (117) that pass through all the magnetic rings and nuts (118) that are threaded to the screws (117).

4. The manganese ore magnetic separation equipment according to claim 1, characterized in that, The magnetic block (115) is made of cerium-free neodymium iron boron, and the magnetic plate (114) is made of Q235 steel; the mounting holes on the magnetic block (115) are chamfered at the ends, and the fastening bolts (116) are countersunk bolts.

5. The manganese ore magnetic separation equipment according to claim 1, characterized in that, The feeding mechanism (200) includes a feeding bin (201) fixed to the top of the mounting frame (101), a material tray (202) located below the feeding bin (201), a first vibrator (203) fixed to the side of the material tray (202) away from the opening, and a suspension part (210) connecting the feeding bin (201) and the material tray (202). The feed hopper (201) has a cross-section that is wider at the top and narrower at the bottom, and a V-shaped plate (204) is fixed to its inner bottom. The opening side of the tray (202) faces upward between the magnetic roller (110) and the auxiliary roller (107).

6. The manganese ore magnetic separation equipment according to claim 5, characterized in that, The suspension part (210) includes a fixing hook (211) fixed to the outside of the feed hopper (201). A connecting ring (212) is suspended at the lower end of the fixing hook (211). An adjusting bolt (213) is connected below the connecting ring (212). The adjusting bolt (213) is threadedly connected to the connecting block (214) to realize the adjustment of the suspension length. A U-shaped ring (216) is suspended at the lower end of the connecting block (214) through a hook (215). The end of the U-shaped ring (216) is fixed with a suspension plate (217). The suspension plate (217) is sleeved on the guide rod (219) through a through hole (218) in its middle and can slide along it. The guide rod (219) is sleeved with a spring (221). The two ends of the spring (221) are respectively connected to the fixing plate (220) fixed to the top of the guide rod (219) and the suspension plate (217). The bottom end of the guide rod (219) is connected to the side of the tray (202) through a hanging ring (222).

7. The manganese ore magnetic separation equipment according to claim 1, characterized in that, The guide bar (304) has a trapezoidal cross-section that is narrower at the top and wider at the bottom, and its end near the auxiliary roller (107) is beveled.

8. A dry beneficiation process for manganese ore, characterized in that... The mineral processing using the manganese ore magnetic separation equipment according to any one of claims 1 to 7 specifically includes the following steps: Step 1: Crushing After the raw manganese ore is initially crushed by a jaw crusher, it is then crushed by a cone crusher to a particle size of ≤10mm. Step 2: Grinding The crushed ore particles are ground to obtain ore sand with a particle size of -200 mesh accounting for 60% to 80%. Step 3: Ore beneficiation The mineral sands are classified into natural magnetic mineral sands and non-magnetic or weakly magnetic mineral sands according to their magnetic properties. Step 4: Roasting The non-magnetic or weakly magnetic mineral sand is roasted at 600-800℃ for 0.5-1 hour to obtain roasted mineral sand. Step 5: Magnetic separation The natural magnetic sand and the roasted sand are fed into the manganese ore magnetic separation equipment as described in any one of claims 1 to 7 for roughing, and then the remaining sand after roughing is fed into a high gradient magnetic separator for fine selection to obtain manganese concentrate sand. Step 6: Post-processing The manganese concentrate is subjected to pulping, concentration, pressure filtration and drying to finally obtain manganese concentrate powder.

Images