Dense Media Separation Using Coarse Magnetic Particles
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Dense Media Separation (DMS) systems face significant media losses due to the use of fine magnetic particles, which adhere to solids, are susceptible to corrosion, and difficult to recover, leading to high operating costs and inefficient separation.
Innovation Solution
Increasing the coarseness of magnetic particles in the DMS system by determining the optimal particle size based on vessel dimensions, magnetic field application, and feed pressure, allowing for larger media particles to be used while maintaining separation efficiency, and reducing media viscosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If fine magnetic particles are used in DMS, then media stability is improved, but media losses increase due to adhesion, corrosion, and difficult recovery
Solution Approach 1:
The patent changes the particle size parameter from fine to coarse (greater than 44 micrometres, preferably greater than 63 micrometres) while maintaining media stability through the application of a magnetic field during separation, thereby reducing media losses due to adhesion, corrosion, and recovery difficulties
Solution Approach 2:
The patent replaces the purely mechanical hydrodynamic separation system with a magnetic field-assisted separation system, where a magnetic field is applied during the separation process to maintain media stability and enable easier recovery of coarser magnetic particles
2Quantity of substance
If fine magnetic particles are used in DMS, then media density is maintained, but separation efficiency decreases due to high viscosity
Solution Approach 1:
The patent changes the particle size parameter to coarse particles (greater than 44 micrometres) which reduces media viscosity and improves separation efficiency, while maintaining adequate media density through the use of high-density magnetic materials and optimization of particle size distribution
3Loss of substance
If coarse magnetic particles are used in DMS, then media losses are reduced, but separation precision deteriorates
Solution Approach 1:
The patent optimizes the particle size parameter to a specific coarse range (greater than 44 micrometres, preferably greater than 63 micrometres) and applies a magnetic field during separation to maintain separation precision while achieving reduced media losses
Solution Approach 2:
The patent employs a magnetic field during the separation process that provides feedback control on particle behavior, allowing coarse particles to be retained effectively while maintaining precise separation of the solids based on density differences
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces media losses by up to 90%, increases separation efficiency, and allows for the use of less expensive magnetite instead of ferrosilicon, improving media stability and recovery, and enhancing separation quality.
Implementation Method 1
applying, during operation of said separation vessel, a magnetic field to said combined solids and suspension in said separation vessel
Implementation Method 2
locating the combined solids and suspension in a separation vessel such that rotation is imparted to the combined solids and suspension around a space bounded by an outer wall of the vessel to impart a centrifugal force on the solids
Data Source
Figure 1~4
Figure 5~6
Figure 7~8
AI summary
A method of separating solids, the method comprising: •adding said solids to a suspension of particulate material comprising magnetic, or magnetized, particles in a liquid, •locating the combined solids and suspension in a separation vessel such that rotation is imparted to the combined solids and suspension around a space bounded by an outer wall of the vessel to impart a centrifugal force on the solids; and •applying, during operation of said separation vessel, a magnetic field to said combined solids and suspension in said separation vessel to impart a magnetic biasing force on the particles of said particulate material in an inwards direction away from the outer wall of the vessel at least in a lower region of the vessel, •wherein said particulate material has a coarseness (particle size) that is determined by at least one of the size of said separation vessel, the particulate material shape and type, the solids particle size and type, the feed pressure of the combined solids and suspension, and a desired specific gravity of said suspension, and wherein said method further comprises: •causing said particulate material to be relatively coarser (larger) than a nominal coarseness that is determined by at least one of the size of said separation vessel, the particulate material shape and type, the solids particle size and type, the feed pressure of the combined solids and suspension, and a desired specific gravity of said suspension in the absence of said magnetic field.