Magnetic Slurry Separation with Moving Drum and Cake Segmentation
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Solution Overview
Problem
Conventional methods for dewatering magnetic material slurries, such as magnetite, are inefficient, leading to high losses and inability to achieve the desired transportable moisture limit of 5-8% solids, which is necessary for transportation and pelletization.
Innovation Solution
A method and apparatus using a moving surface with magnetic means to attract and separate magnetic material from a slurry, allowing for the formation of a magnetic material cake with adjustable liquid content, utilizing bladed means and air jets to achieve the desired moisture level, and reprocessing residual material to optimize liquid removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thickeners or filtration systems are used, then magnetic material can be separated from slurry, but the liquid content in the magnetic material cake cannot be reduced to the transportable moisture limit of 5-8%
Solution Approach 1:
The patent replaces conventional mechanical filtration systems with a magnetic field-based separation system. A rotating drum equipped with magnetic means attracts magnetic material from the slurry, allowing for more effective liquid removal and achieving the desired moisture limit of 5-8% in the magnetic material cake.
Solution Approach 2:
The patent changes the magnetic field intensity parameter by using high-intensity magnets on the rotating drum. This parameter change enables the system to achieve higher concentrations of magnetic material with lower liquid content, transforming the separation efficiency and enabling production of cake meeting transportable moisture limits.
2Quantity of substance
If high-intensity magnets are used in drum thickeners, then concentration of magnetic material increases to 85% solids w/w, but total loss of magnetic material occurs
Solution Approach 1:
The patent incorporates a feedback mechanism where the magnetic material cake is separated into inner and outer portions based on their liquid content. The inner portion with lower liquid content is collected as product, while the outer portion is returned to the feed slurry for reprocessing, creating a feedback loop that optimizes both concentration and material recovery.
Solution Approach 2:
The patent segments the magnetic material cake into distinct inner and outer portions based on their moisture content. This segmentation allows selective removal of the drier inner portion while returning the wetter outer portion for further processing, thereby reducing overall magnetic material loss while maintaining high concentration in the final product.
3Productivity
If traditional tank thickeners are used, then magnetic material can be settled from slurry, but the equipment requires large area and large support structure
Solution Approach 1:
The patent replaces the large-scale mechanical gravity settlement system with a compact magnetic field-based separation system. The rotating drum with magnetic means achieves efficient separation in a much smaller footprint, eliminating the need for large tank structures and extensive support frameworks.
Solution Approach 2:
The patent changes the separation mechanism from gravity-based to magnetic field-based, fundamentally altering how the system operates. This parameter change enables high-efficiency separation in a compact configuration, dramatically reducing the equipment area and support structure requirements compared to traditional tank thickeners.
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
The method effectively produces a magnetic material cake with a lower average liquid content than conventional methods, achieving the necessary transportable moisture limit and reducing silica content, thus enhancing transportability and market value.
Implementation Method 1
attracting at least a portion of the magnetic material of the slurry onto the the first moving surface by first magnetic means
Data Source
AI summary
A method and apparatus for separating magnetic material from a slurry is disclosed, the method including the steps of providing a first moving surface, depositing the slurry onto the first moving surface, attracting at least a portion of the magnetic material of the slurry onto the first moving surface by first magnetic means, arranging the first moving surface such that liquid from the slurry is removed due to the portion of the magnetic material being attracted to the moving surface by the first magnetic means to form a magnetic material cake, separating an inner portion of the magnetic material cake from an outer portion of the magnetic material cake, with respect to the first moving surface, such that the inner portion has a lower liquid content than the outer portion.