Rotating Turntable Magnetic Separator for Iron Oxide Recovery
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Solution Overview
Problem
Current mineral processing systems are ineffective or too expensive to efficiently recover iron oxides from natural occurrences or tailings, which are economically and environmentally significant due to the industrial revolution's increased demand for commodities.
Innovation Solution
A high-intensity magnetic separation device and system that uses a rotor with a circular channel and permanent magnet members to separate magnetic particles from non-magnetic particles in a slurry, creating distinct magnetic and non-magnetic zones to effectively isolate and recover iron oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional mineral processing systems are used to recover iron oxides from natural occurrences or tailings, then the processing can be performed with standard equipment, but the systems are ineffective or prohibitively expensive to build and operate
Solution Approach 1:
The rotor is segmented into multiple channels, each containing matrix material for magnetic separation. This segmentation allows the system to process slurry through multiple parallel pathways, increasing overall recovery efficiency while keeping each individual channel relatively simple and cost-effective to manufacture
Solution Approach 2:
The system changes the magnetic field parameters by using permanent magnet members that generate high-intensity magnetic fields in specific zones. This parameter change enables effective separation of weakly magnetic or para-magnetic iron oxide particles that conventional systems cannot recover, improving productivity without requiring expensive electromagnet systems
2Manufacturing precision
If high-intensity magnetic fields are applied to separate weakly magnetic particles, then separation effectiveness improves, but energy consumption and system complexity increase
Solution Approach 1:
The rotor rotates periodically, bringing different channel sections through magnetic zones and non-magnetic zones in sequence. This periodic action allows particles to be subjected to high-intensity magnetic fields only when needed (in magnetic zones), reducing overall energy consumption compared to continuous high-intensity field application, while maintaining effective separation of weakly magnetic particles
Solution Approach 2:
Permanent magnet members are used to generate magnetic fields without requiring external power input during operation. The permanent magnets self-generate the necessary magnetic fields, eliminating continuous energy consumption for field generation while maintaining high separation effectiveness for weakly magnetic particles
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 system efficiently separates magnetic and non-magnetic particles, enabling the recovery of iron oxides from previously unrecoverable sources, reducing costs and environmental impact by utilizing a cost-effective and efficient method for processing iron-containing slurries.
Implementation Method 1
the permanent magnet members effective to apply magnetic fields across a plurality of portions of the path where the channel is straddled by the permanent magnet members
Data Source
AI summary
There are provided devices, systems and processes to treat slurries that include magnetic and nonmagnetic particles suspended in water in such a fashion as to separate certain valuable elements and/or minerals from less valuable minerals or elements. A high intensity magnetic separator includes at least one large rotatable turntable that defines at least one circular channel therethrough in which a matrix material is positioned. The turntable is configured to rotate in a generally horizontal plane about a generally vertical virtual axis, causing the at least one circular channel to rotate through a plurality of intermittent magnetic and nonmagnetic zones generated by a plurality of permanent magnet members. A treatment slurry is directed into the channel or channels in one or more of the magnetic zones as the turntable rotates. A tailings fraction passes through the channel or channels in a generally downward direction in the magnetic zones and is collected in tailings launders. Magnetic particles are attracted to the matrix material in the magnetic zones and remain in the channel until it passes into an adjacent nonmagnetic zone, where the magnetic particles are washed form the channel into concentrate launders.