Process for separating mineral-metallurgical particles by action of combined physical phenomena, device, and use thereof

Abstract

The present invention relates to a process for separating fine-grained mineral-metallurgical particles by the combined action of magnetic, hydrodynamic, and mechanical physical phenomena, having distinct vectors that, collectively, promote the dispersion and separation of the particles of a slurry formed by said compounds. The slurry is subjected to the phenomena in a suitable tank for the time necessary for each material. The process does not replace conventional concentration methods, instead acting as an intermediate step prior to procedures such as Reichert spirals, flotation or hydrocyclones, improving their efficiency by increasing the separation of the particles. As it acts exclusively through physical phenomena, the process does not alter the composition of either the slurry or the water, allowing large-scale recovery and recycling thereof.

Description

"PROCESS OF INDIVIDUALIZING MINERAL-METALLURGICAL PARTICLES THROUGH THE ACTION OF COMBINED PHYSICAL PHENOMENA, DEVICE AND USE" Field of invention

[0001] The present invention applies to the industrial field of waste treatment and, in particular, to the area of ​​mineral and metallurgical waste treatment. Currently, the treatments available for these wastes are limited and often ineffective in terms of recovery efficiency and reduction of waste, resulting in low efficiency of recycling processes. Therefore, the constant search for new technical solutions to better treat and recover these wastes, in a cleaner, more effective and more efficient way, is justified.

[0002] The present invention proposes a new treatment method that uses a combination of physical active principles to improve the yield and efficiency of metal recovery from these wastes. The method is safe, effective, and presents no adverse collateral risks to the environment, since it operates with purely physical principles. The invention represents a significant innovation in the field of technological combination of physical phenomena and meets a critical need for more effective and accessible treatments for steelmaking waste, which is generated in ever-increasing quantities in the industrial sector. Fundamentals of the invention

[0003] Industrial waste is mostly treated by gravity separation processes after undergoing grinding or other release methods. This waste is subjected to processes that utilize density differences to recover the desired content. However, all of these processes leave levels of undesirable material in the concentrate and other materials. The objective in disposal is precisely because they fail to achieve adequate particle release; as a result, many particles with different properties remain bonded together, hindering recovery yield. Another inefficiency is the energy consumption of this process, since most of these processes are based on grinding. Another factor that reduces the efficiency of these methods is the fact that most of the treated waste generates concentrates that are used in low-yield agglomerates, where they could be used more efficiently in other recycling stages. An example of material to be treated is waste with magnetic properties and responses; in this case, waste with a significant metallic content of pure iron, from steelmaking, or mining waste that still has ore content and, in this case, magnetite, which allows for an effective response when subjected to high-intensity magnetic fields.These concentrates, after recovery, can be used as raw material in the processes that generated them.

[0004] Although various processes and technologies exist for recovering steelmaking waste (steelmaking sludge, rolling mill scale, mining tailings, etc.), the process proposed here offers an advantage because, by operating solely on physical rather than chemical principles, and by enabling the individualization of the component particles of the waste based on the magnetic response of its components, it utilizes the principle of differential inertial resistance between the components of these wastes, something that conventional processes cannot achieve. A high-intensity magnetic field, with adjustable frequency, is applied to a cylindrical tank, common in pulp treatment, with a water flow that is the reverse of the discharge process.

[0005] This field is adjusted by frequency and intensity, based on the properties of the material being treated. The counter-flow of water in the process The vector reverses in relation to the rotation vector of the pulp as well as the applied oscillating field. When exposed to the pulsed magnetic field, with adjusted frequency, the particles, both magnetic and non-magnetic, which are being dragged by the continuous flow of the pulp, caused by helical agitators, the magnetically susceptible particles undergo an orthogonal stress in relation to the tangential flow of the liquid, added to this is the drag of water on a third axis, and an efficiency of liberation and individualization of particles with different properties is achieved.

[0006] The drag process affects all particles according to their size; however, the response to this variation in movement is due to the differentiated density, since different densities create different masses for particles of the same size.

[0007] Each particle, according to its density, due to the actions of the laws of fluid dynamic drag, has a resultant force that acts individually, shearing the bonds between particles of different sizes, densities, and masses. Magnetic attraction, however, is based on the ferromagnetism of metallic particles and the ferrimagnetism of mineral particles. This field creates an attraction and repulsion, given the oscillation of the field, only for particles with a magnetic response, causing a force orthogonal to the flow for these metallic particles, while non-metallic particles are inert to this variable field, experiencing drag according to the rotational flow. Thus, the resultant force is oscillating and cyclical, as the material is circulating at a controlled speed, while the magnetically responsive particles have the force vector caused by the pulsating magnetic field varying its angle relative to the drag velocity vector.

[0008] A second principle that aids in the efficiency of the process of individualizing particles with different properties consists of the mechanical principle that the magnetic field nucleating plate undergoes as a function of magnetostriction. This principle causes the plate to generate planar vibrations within the pulp volume, counteracting hydrodynamic and magnetic drag, resulting in a more efficient process of the forces that promote particle individualization.

[0009] This set of efforts causes a rupture in the bond between different particles, thus enabling the individualization of magnetic and non-magnetic particles of the residue present in the pulp. For this to operate properly, the frequency, magnetic field intensity, pulp density, and water reflux velocity are adjustable to each type of material that makes up the pulp. Furthermore, the rotation and angle of the propeller blades can be varied to allow for greater tangential speed, as well as greater upward drag of the treated residue particles. This gives the equipment a very broad scope in terms of the types of waste it can treat. Because it is a high-frequency magnetic field generator with a field concentrator core, specifically generated for each magnetic component of each residue, energy consumption is minimal.

[0010] After individualization is achieved, the material is directed to conventional gravity concentration processes, which are much more efficient. A single step achieves concentration levels that previously required several steps, and a more efficient release of particles with different properties is also achieved. The consumption of energy, water, and resources for concentration is drastically reduced. Since there is no chemical compromise of the pulp, the treatment of the secondary residue obtained from the gravity separation and concentration steps, after collection of the magnetic concentrate, is also possible. The goal is to allow for the recovery of almost all of the water, simply by draining the secondary residue as well as the concentrate. This is an important factor in the current situation.

[0011] Some steelmaking waste is rich in oxides in its non-metallic material, such as CaO, MgO, FeO, etc. When these are found in the secondary waste, it is directed to pools where carbon dioxide (from the company's own smoke, if applicable) is bubbled through to form carbonates, which precipitate during sedimentation, making the water reusable with a high degree of purity and, in turn, promoting carbon sequestration.

[0012] These formate carbonates can still be collected and used in soil amendment treatment. This promotes a high degree of recovery of this treated residue. Furthermore, secondary residues from the concentration of mining tailings, where the remaining iron ore content has been concentrated, are rich in silica, with considerable purity, since the fine colloidal sludge was removed in the washing process of the secondary residues.

[0013] This silica / quartz can be directed to direct recycling (fine construction sand) as well as, depending on its purity, to the production of metallic silicon. The concentrate, with a high magnetic content, is directed to use as scrap if it is of steelmaking origin, or for flotation and ore recovery processes if it is of mining origin. In the case of rolling mill scale, if it is oily scale, the process will promote the generation of an oil supernatant that will be recovered and separated from the water, that is, it will be removed from the equipment as overflow, preventing this oil from contaminating the recycled water, in separation processes by surfactant properties.

[0014] This oil can be separated and reused if it is still viable, or, in the worst case, used as fuel. The mill scale will undergo the same evaluation that applies to all concentrates and will be used according to its metallic content. Brief description of the drawings

[0015] Figure 1 shows the construction scheme of the particle individualization device. The electromagnetic transducers are installed in cavities so as not to interfere with pulp circulation. The pulp is hydrodynamically circulated by a set of vertically installed propellers (2), with adjustable speed and inclination. During the device's operation, the pulp is sucked through a duct at the bottom of the tank (3), recirculating it until it is ready to be discharged. The pulp movement pump (4) directs the sucked flow to a valve (5) that automatically or manually adjusts the flow diversion to the return channel (6) or to the discharge duct (7).

[0016] Figure 2 illustrates the three-dimensional scheme of the electromagnetic transducer device, highlighting the field generating coils (8), the magnetostrictive ferromagnetic front plate (9) and the ferromagnetic core that completes the magnetic circuit (10).

[0017] Figure 3 illustrates the schematic arrangement of the electromagnetic transducers (1) within the device in perspective and plan view. On the face of each transducer are the magnetostrictive ferromagnetic faces (11) and on the back of these is the ferromagnetic core (12) which completes the transducer circuit.

[0018] Figure 4 shows top views of the force fields acting on the devices. The alternating forces of the generated magnetic fields (13), the hydrodynamic drag forces generated by the rotation of the pulp (14) and the forces mechanical effects resulting from the magnetostrictive pulsation of the faces of each transducer (15).

[0019] Figure 5 shows how the device (16) can be installed before traditional concentration processes (17) and a simple decantation system (18) that allows cleaning, recovery and recycling of the water used. Description of the Invention

[0020] The process consists of subjecting a pre-dimensioned pulp to a particle individualization device that operates on three associated principles of electromagnetic, hydrodynamic, and mechanical forces applied to a pulp previously prepared based on concentration, degree of aggregation, density, particle size, and composition. This mixed system of various combined efforts of magnetic force, hydrodynamic force, and mechanical oscillation acts for as long as necessary to achieve the best and most effective individualization of the particles of different solid phases that make up this pulp.

[0021] Once the composition of intensities to be imposed on this pulp has been determined, it is subjected to these combined phenomena for the time and intensity necessary to achieve the best efficiency / energy ratio. The pulp is subjected to this process until it is properly and efficiently processed. This pulp is recirculated in the processing tank until it is adequately treated; then, a valve redirects the flow sent by the pump to the conventional concentration processes suitable for each type of pulp. The process operates based on three principles: a magnetic field that oscillates between the two faces of the magnetic generators so that the material is subjected to these forces during the hydrodynamic path along which it is dragged.

[0022] The response to these magnetic forces is related to the ferromagnetic and / or ferrimagnetic characteristics of the metallic components to be individualized. These magnetic forces act on a quarter of the cylindrical volume of the tank. The magnetic circuit is such that the interfaces between the poles compose it, with the particles exposed to the field being responsible for forming the core between the poles. The hydrodynamic drag forces act with different resultants depending on the different densities and sizes of the particles that make up the pulp, resulting in variable stresses on each particle individually, even in relation to those that are aggregated together.

[0023] Thus, even when forming a single object, initially two different phases will end up undergoing shear stresses of different intensities, resulting in a shear stress that tends to promote separation and individualization.

[0024] Finally, the magnetostrictive mechanical responses of the front faces of the magnetic cores promote, orthogonally to each other, mechanical drag waves within the pulp volume, resulting in variations in stress that corroborate the rupture of the bonds of particles of different phases and, thus, increasing the efficiency of the equipment in the process of individualizing the particles that will compose the pulp. The intensity of the current that feeds the field and, in this case, the intensity of the magnetic field itself, as well as its operating frequency, the rotation speed of the pulp, and finally, the frequency of the mechanical oscillation of the magnetostrictive plate, are variables adjustable to each type of composite pulp based on its fundamental characteristics and empirical results for each material.

[0025] After this individualization, the particles with different properties are sent to conventional gravity concentration processes and / or Magnetic. The pulp is then separated into concentrate and reject. These components then undergo conventional dewatering processes. The water, after cleaning the contaminating particles, once recovered, as it has not suffered any type of chemical compromise, can be recirculated and reused for the composition and treatment of new pulp.

[0026] The magnetic forces acting on materials can be interpreted mathematically according to the expression below: where: p is the magnetic permeability of the particle; N: number of turns of the magnetic core coil; A: cross-sectional area of ​​the core face; IM: effective current flowing through the coil; f: frequency of oscillation of the magnetic field.

[0027] Hydrodynamic forces can be represented by the expression: where: q: viscosity of the liquid medium; Rp: radius of the entrained particle; co: rotation of the hydrodynamic flow; q: radial distance where the particle is located.

[0028] The mechanical forces generated by the magnetostrictive response of the core face can be represented by the expression: Where: P: power of the magnetic equipment; r p : particle radius; THE N : cross-sectional area of ​​the magnetostrictive core; VH: speed of sound in the fluid; IM: oscillation frequency of the magnetostrictive plate.

[0029] The vector sum of these forces makes up the total force that will act individually on each particle immersed in the pulp:

[0030] The resultant of these forces acts as a vector over time, promoting a dynamic action of varying stresses in each individual particle, thus causing its detachment from the others and its individualization within the pulp.

[0031] Magnetic pulse cores have a ferromagnetic plate on the outside to enable the formation of a magnetic circuit where the pulp, composed of particles, is located between the inner faces of these cores and acts as part of this circuit, thus being exposed to the oscillating magnetic field. The power of the fields applied to the cores is related solely and exclusively to the operating time for each pulp and the viable cost / benefit ratio for each material to be treated. Factors such as solid density, pulp density, solids content in the pulp, particle size, etc., should define the equipment design data according to the characteristics of each material treated. Examples of embodiments of the invention

[0032] The proposed process aims to give individuality to the particles that make up mineral-metallurgical composite pulps so that they can be more efficiently separated and concentrated in processes. Conventional. That is, the process proposed here does not replace conventional concentration processes; it acts as an intermediate step aimed at improving the yield of these processes. Any process that separates and concentrates targeted particles while discarding those that make up the tailings can have the presented process acting beforehand to improve its yield, whether it be gravity, magnetic, and / or flotation concentration processes. The operational proposal that comprises this process is to act before these conventional steps, creating a better yield for them.

[0033] This process was tested on a low-grade ore pulp that underwent flotation. This pulp was subjected to a rougher stage with and without the process, and the results obtained are shown in the following tables. Table 1 - Composition of Flotation Feed. Table 2 - Composition of Concentrate and Tailings after the Rougher stage of Flotation WITHOUT using the process, with mass balance. Table 3 - Composition of Concentrate and Tailings after the Rougher stage of Flotation WITH the use of the process, with mass balance.

[0034] These tables show how the process influenced a single flotation step, giving the same result in this first step as those obtained in several subsequent flotation steps.

Claims

CLAIMS 1- PROCESS OF INDIVIDUALIZING MINERALS AND METALLURGICAL PARTICLES THROUGH COMBINED PHYSICAL PHENOMENA, characterized by using the combined action of distinct physical phenomena of electromagnetism, hydrodynamics, and mechanical waves to promote the individualization of mineral-metallurgical particles that make up a pulp subjected to the process. This individualization acts in an intermediate stage, prior to the conventional concentration processes of these particles. Once individualized, the particles are concentrated more easily by the underlying conventional processes. 2- PROCESS, according to claim 1, characterized by the magnetic field causing oscillations between the two faces of the magnetic generators. 3- PROCESS, according to claims 1 and 2, characterized by the input material having ferromagnetic and / or ferrimagnetic and / or paramagnetic characteristics and / or materials with a response to magnetic field induction. 4- PROCESS, according to claim 1, characterized by the magnetic pulse cores having a ferromagnetic plate on the outside so that it is feasible to form a magnetic circuit where the pulp, composed of particles, is located between the inner faces of these cores and acts as part of this circuit, thus being exposed to the oscillating magnetic field. 5- PROCESS, according to claim 1, characterized by the magnetostrictive mechanical forces of the front faces of the cores. Magnetic elements, aligned orthogonally to each other, promote mechanical drag waves within the pulp volume. 6- DEVICE FOR INDIVIDUALIZING MINERAL-METALLURGICAL PARTICLES BY ACTION OF COMBINED PHYSICAL PHENOMENA, characterized by the electromagnetic transducers being installed in cavities in such a way as not to impair the circulation of the pulp, which is hydrodynamically circulated by a set of propellers (2) installed vertically, with adjustable speed and inclination, during the operation process of the device the pulp is sucked through a duct at the bottom of the tank (3) recirculating it until it is ready to be discharged, the pulp movement pump (4) directs the sucked flow to a valve (5) that automatically or manually adjusts the diversion of the flow to the return channel (6) or to the discharge duct (7). 7- DEVICE, according to claim 6, characterized by the electromagnetic transducer having field generating coils (8), with the magnetostrictive ferromagnetic front plate (9) and the ferromagnetic core that completes the magnetic circuit (10). 8- DEVICE, according to claims 6 and 7, characterized in that the interior of the electromagnetic transducers (1) has on the face of each transducer the magnetostrictive ferromagnetic faces (11) and on the back of these the ferromagnetic core (12) which completes the circuit of the transducers. 9- USE OF THE DEVICE FOR INDIVIDUALIZING MINERALS AND METALLURGICAL PARTICLES BY ACTION OF COMBINED PHYSICAL PHENOMENA, as defined in claims 6 to 8, characterized in that the device (16) can be installed before traditional concentration processes (17) and a simple settling system (18) that allows cleaning, recovery and recycling of used water.

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