Dry-Type Attrition and Magnetic Separation for Saprolite Ore
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Solution Overview
Problem
The depletion of saprolite ore with high nickel content poses economic and environmental challenges in ferronickel smelting, as existing methods for nickel concentration are costly, environmentally unfriendly, and inefficient, particularly for saprolite ores with low nickel content and high moisture content.
Innovation Solution
A method involving crushing, dry-type attrition processing, dry-type classification, and dry-type specific gravity separation to enhance nickel content in saprolite ore, using a stirring-type dryer or autogeneous mill for simultaneous crushing and drying, and mixing the processed ore with high-nickel saprolite ore to reduce transportation and smelting costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If wet-type classification and specific gravity separation methods are used to concentrate nickel in saprolite ore, then nickel content can be increased, but processing cost increases extremely and environmental preservation becomes difficult
Solution Approach 1:
The patent replaces the wet-type mechanical classification system with a dry-type magnetic separation system. Instead of using water-based classification machines and thickening facilities, the invention uses magnetic fields to separate nickel-bearing particles from waste material, eliminating the need for complex wet processing equipment and reducing operational costs significantly
Solution Approach 2:
The patent employs air flow classification to replace water-based hydraulic classification. By using controlled air streams to separate particles based on size and density, the system achieves nickel concentration without requiring water management infrastructure, thickening facilities, or complex dehydration equipment
2Quantity of substance
If saprolite ore with high moisture content is transported to increase resource availability, then more ore can be processed, but transportation cost increases significantly
Solution Approach 1:
The patent performs preliminary dry-type magnetic separation and concentration at the mine site before transportation. By concentrating the nickel content in situ and removing moisture through dry processing, the ore requires less transportation capacity and energy, significantly reducing transportation costs while maximizing resource utilization
Solution Approach 2:
The patent extracts and removes moisture and waste material from the saprolite ore through dry-type processing methods before transportation. This extraction of unnecessary components reduces the overall mass that needs to be transported, thereby reducing transportation energy consumption and costs
3Loss of energy
If drying of ore at mine site is performed to reduce transportation cost, then transportation efficiency improves, but nickel amount loss and workability deterioration occur due to powder dust property
Solution Approach 1:
The patent replaces thermal drying with magnetic separation technology. Instead of heating the ore to remove moisture (which causes dust formation and nickel loss), the system uses magnetic fields to separate nickel-bearing particles from waste material in the moist state, maintaining particle integrity and preventing nickel loss while achieving concentration
Solution Approach 2:
The patent introduces magnetic field interaction as an intermediary mechanism to achieve separation without direct thermal contact. The magnetic field acts as a mediator that separates particles based on their magnetic properties rather than relying on moisture removal, thus avoiding the harmful effects of drying-induced dust formation
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 method effectively increases nickel content in saprolite ore to economically viable levels for ferronickel smelting, reducing transportation and smelting costs while minimizing environmental impact by eliminating the need for wet processing and tailing dams.
Implementation Method 1
a crushed ore obtained in the step of the above (1) is subjected to dry-type attrition processing of the surface layer part by attrition
Implementation Method 2
a ground ore obtained in the step of the above (2) is subjected to dry-type classification processing at a classification point to be selected from 0.5 to 2.0 mm
Implementation Method 3
an ore portion having a particle size over the classification point, obtained in the step of the above (3), is subjected to dry-type specific gravity separation processing
Data Source
AI summary
The method for nickel concentration processing, which is low cost, simple and convenient, as well as having low environmental load, which is capable of enhancing nickel content of a saprolite ore with low nickel content, which was not conventionally used effectively as a raw material of ferronickel smelting due to having low nickel content, to a level to be utilized economically as a raw material of ferronickel smelting.