Dynamic behavior and separation prediction of magnetic ore bulks in dry medium-intensity magnetic separator

Dry medium-intensity magnetic separator (DMIMS) plays a vital role in enhancing the separation of low-grade raw magnetite ore. A good understanding of the dynamic separation process of DMIMS would further boost its economic competitiveness in minerals processing and engineering. Herein, this study analyzed the basic structure and simulated the dynamic separation process of DMIMS in detail using CT4050 magnetic separator as an example. Forces (e.g., magnetic force, magnetic particle-particle attraction and gravity) acting on magnetic ore bulks in multi-physical fields have been systematically investigated to deepen the understanding for the dynamic behavior of magnetic ore bulks based on elaborate experiments and dynamic simulation using the finite element method (FEM). Results show that the realistic movement trajectory of isolated magnetic ore bulks can be well predicated using dynamics simulation. Force analysis demonstrates that the size significantly affects the forces acting on magnetic ore bulks. The magnetic permeability of bulks not only determines their movement trajectory just as the speed of conveyor belt does, but also is vital in improving the separation efficiency. Whereas, the shape, size and rotation angle of bulks demonstrate negligible influence on their movement trajectory and separation efficiency. This study could provide theoretical insights for optimizing the magnetic separation process and designing high-performance DMIMS.