Hydrocyclone

Hydrocyclones have been used for mineral processing for more than 100 years.
Nowadays hydrocyclones are extensively used in the industry to remove or classify
particles, and to separate particles by density or size.
Hydraulic residence times for hydrocyclones are about 1 to 2 second, compared to
several minutes for traditional gravity separators .

The fluid flows into hydrocyclone and develops an outer vortex and a reversed inner
vortex, where particles move in the underflow and in the overflow direction,
respectively. In such vortex systems centrifugal fields as strong as 2000-3000 g are
created. Therefore an air core forms due to high centrifugal forces and an open
overflow. The air core in hydrocyclone will arise turbulence fluctuation and decrease
separation efficiency.
Hydrocyclone
Hydrocyclone

Inlet diameter = Square root of 0.015-0.02 πDc2

=
Square root of 0.05 DC2

Vortex diameter = 0.35 -0.4 Dc

Apex Diameter = >0.15 Dc

Cone Angle = 10-150 for small diameter cyclone

= 15-200 for ;arge diameter column
 Hydrocyclone
❖ The inlet cross sectional area is roughly 70% of the cross sectional area of the
feed chamber.
❖ Rectangular sections of the inlet is probably better than other sections.
❖ Increased inlet area permits increased input and therefore imparts increased
tangential velocity to the slurry inside the cyclone.
❖ Larger diameter cyclones are more suitable for coarse size
❖ Longer cylindrical sections tend to yield high underflow recoveries.
❖ Shorter cylindrical sections yield coarse separations
❖ Smaller cone angles are suitable for finer separations.
❖ Larger cone angles are suitable for producing sharper and coarser separations.
❖ Apex diameter should have the flexibility so that it may be adjusted and be just
larger than that at which roping occurs.
❖ If the pressure drop is greater than 70 kPa the ratio (Do/Du) should be less than
3.5-4.0.
 Hydrocyclone
The hydrocyclone is a classifier with no moving parts and its operation
depends on the following points;

❖ The characteristics of the feed material like size and size

distribution, pulp density and pulp viscosity, inlet pressure and
solid concentration

❖ The geometry of the cyclone like inlet shape and inlet area,
cyclone diameter, length of cyclone, length of cylindrical
section, vortex diameter, apex diameter, inlet diameter and cone
angle
 Hydrocyclone
Efficiency of sepration in Hydrocyclone

By convention the efficiency of operation and separation of hydrocyclones

are determined by the sharpness of separation and the d 50 value.

To determine the efficiency of separation of a sample of known size

distribution, pulp density and flow rate, a hydrocyclone of known
geometry, including the inlet, overflow and underflow diameters, is
operated in closed circuit until a steady state is reached.

Simultaneous samples of the feed, overflow and underflow streams are

collected dried and analysed for size distribution. The calculations
involved to determine the efficiency can be taken up by the following
example.

1. Feed rate = 55.0% solids at 206.5 t/h

2. Overflow rate = 19.6% solid at 29.4 t/h
3. Underflow rate = 78.2% solids at 177.1 t/h
Hydrocyclone
Hydrocyclone
 Hydrocyclone

The distribution of water in the different streams may be determined as:

Water in feed = 100-55.0=45.0%

Water in overflow = 100-19.6 = 80.4%
Water in underflow = 100-78.2=21.8%

Hence:
mass of water in feed = 206.5 x (45/55)= 169.0t/h
mass water in overflow = 29.4 x(80.4/19.6)= 120.6 t/h
mass water in underflow = 177.1 x(21.8/78.2) =49.4 t/h
 Hydrocyclone

❖ The curve shows that the cyclone cut size, separation size or d50 is 135 microns.

❖ It has been seen that the curve does not pass through the origin.

❖ It has been understood that a fraction of the slurry is bypassing the cyclone and
not being classified.

❖ Thus if 5% of the feed slurry bypassed the unit then only 95% of the slurry would
be subjected to the classification process.

❖ Hence the d50 calculated by the above method has to be corrected as d50c.

where di = mean size of screen interval i

miU, mjF = mass in size interval i in the underflow and feed respectively
w = fraction of feed water in the underflow
Hydrocyclone
Hydrocyclone
Hydrocyclone
 Hydrocyclone
The water split between the feed and the underflow will depend on the diameter of
the apex (Du) and the vortex finder (Do). Lynch observed that the water split bears a
linear relationship with the apex diameter. For all particle sizes data, Lynch derived
the equation:
 Hydrocyclone
The corrected efficiency curve derived after correcting for the water split is
specific for the specific slurry and cyclone geometry. To apply the method in a
wider context, such as different flow rates, slurry percent solids, diameters of
vortex finder and apex, Lynch and Rao normalised the curve by dividing each
particle size, d, by d5oc- Plotting d/d50c against the fraction to underflow they
obtained a series of curves which described the performance of a hydrocyclone
independent of operating conditions and hydrocyclone size. The advantage of
plotting in this manner is that the results can be translated to any larger
size cyclone.
 Hydrocyclone
Effect of cyclone variables on operation

A: Cyclone Geometry

❖d50C will increase with increasing vortex finder diameter

❖d50C will increase with decreasing spigot diameter,
❖d50C will increase with increasing inlet diameter,
❖d50C will decrease with increasing length.

B: Slurry characteristics

❖Finer the feed size the smaller the d50C value,

❖Increased feed rate decreases the d50C value,
❖Increased SG of the feed solids decreases the d50C value.
 Hydrocyclone
Hydrocyclone Model

The model developed by Lynch and Rao was obtained as a product of individual
(quantitative) relationships of each variable with the d50.
 Hydrocyclone
JKTech Model
 Hydrocyclone
Hydrocyclone Capacity

According to Dahlstrom, the capacity is also proportional to the square of

the cyclone diameter and is given by the relation:
 Gravity Separation
Gravity separation is based on the following physical characteristics;

➢ Size
➢ Shape
➢ Density

Not all mineral combinations are amenable to this type of concentration technique.
To determine the suitability of gravity separation processes to a particular ore type,
a concentration criterion is commonly used. A concentration criterion (CC) can be
defined as
Gravity Separation
 Gravity Separation
Concentration criterion guide for gravity separation

Particle shape can be taken into account by including a shape factor defined as the
ratio of shape settling factors for the heavy and light minerals. The shape settling
factor is the ratio of the terminal velocity of two particles of the same density, same
size but different shape.
 Gravity Separation
Sp. Gravity of different Minerals

Metals Ore Minerals Chemical Formula Sp.Gr

Aluminium Diaspore AlO(OH) 3.2-3.5
Gibbsite Al(OH)3 2.3-2.4
Boechmite AlOOH 3.0-3.1
Corundum Al2O3 3.9-4.1
Iron Hematite Fe2O3 5.1-5.2
Magnetite Fe3O4 5.0-5.2
Goethite Fe2O3-H2O 4.0-4.4
Limonite Hyd- ferric oxides 3.6-4.0
Siderite FeCO3 3.7-3.9
Pyrrhotite 4.6
FeS
Pyrite 4.9-5.2
FeS2
Magnesium Dolomite MgCa(CO)3)2 2.8-2.9
Magnesite MgCO3 3.0-3.2
Silicon Quartz SiO2 2.6

Calcium Calcite CaCO3 2.7

Clay Kaolinite Al2Si2O5(OH)4 2.6
Illite (K,H3O)(Al,Mg,Fe)2(Si,Al)4O10[(OH)2, 2.6
(H2O)]
 Gravity Separation
Mechanism---------

• Stratification- The various mineral constituents are

stratified by being subjecting to an intermittent
fluidization in a vertical plane. Jig, action/ shaking
table behind riffles
 Gravity Separation
Mechanism------
• Flowing Film- The various constituents are separated
by the relative movement through a stratification
which is flowing down in a inclined plane under
gravity. This is one of the oldest mechanism. Sluices,
Cones and even spirals

• .
 Gravity Separation

Mechanism----

• Horizontal Shear- The various constituents are

stratified by superimposing on the flowing film on a
horizontal shear force which may be continuous or
discontinuous, Shaking table, cross belt separator,
centrifugal separator.

• However a combination of two or more mechanism is

generally required for any gravity concentration
techniques
 Gravity Separation
Effective Range of Application of
Gravity Separation Units
 Gravity Separation
Size range Applicability of Commercial
Gravity Separation Equipment
Type Machines Operating Range Water requirements Capacity
(mm)
Stratification Jig-Conventional 0.10-100 High Medium
Jig-Circular 0.05-100 High High
Jig-Centrifugal 0.02-2.0 High Medium
Flowing Film Sluice Box 0.15-10.0 High Medium
Reichart Cone 0.05-1.5 Low High
Pinched sluice 0.05-1.5 Low Medium
Strake 0.15-2.0 High Low
Spiral 0.03-2.0 Medium Medium
Shaking Shaking Table 0.02-2.0 Medium Medium
Orbital 0.01-0.07 High Low
Crossbelt 0.01-0.03 High Low
Centrifugal Spinning Bowls 0.01-1.7 Very High High
Hindered settler Density separator 0.07-0.60 Medium High
Air Dry Pneumatic Jig 0.15-25 None Medium
Air Table 0.25-6 None Low
 Gravity Separation
Gravity Separators

• Conventional Jigs
• Centrifugal Jigs
• Spirals concentrator
• Mozley Gravity Separator (MGS)
• Falcon Concentrator
• Shaking Tables
• Knelson Concentrator
• Allflux
• Floatex
• Hydrocyclone
• Kelsey Jig
 Free settling Hindered settling
When the motion of the
When the particle is at particle is obstructed by
sufficient distance from other particle due to their
the boundaries of the presence near by , the
container and from other process is called hindered
particles, so that its fall settling
is not affected by them
 Free Settling
❖ It refers to the sinking of particles in a volume of fluid which is large with
respect to the total volume of particles.
❖ Hence, particle crowding is negligible.
❖ It predominates when the percent of solids in weight is less than 15%.
❖ The particle is acted upon by three forces

➢ Gravitational force acting downward

➢ Buoyancy force acting upward
➢ Drag force acting upward.

❖ Consider a spherical particle of diameter d and density ρs falling under

gravity in a fluid of density ρf under free settling condition.
 Gravity Separation
The equation of motion of the particle is

dx/dt = mg - m’g - D

m=Mass of particle
m’=Mass of displaced fluid
x=Particle velocity
g= Acceleration due to gravity
When the terminal velocity is reached , dx/dt=0.
Hence D= (m-m’)g
Therefore D=π/6gd³(ρs-ρf)

Strokes assumed the drag force on a spherical particle to be entirely due to

viscous resistance and deduced the expression
D = 3πdμν, where μ is the fluid viscosity and ν is the terminal velocity.

So, 3πdημ = π/6gd³ (ρs-μf) and

νT = gd²(Ds-Df)/18η
This equation is know as Stokes law.
 Gravity Separation

Stokes' equation is said to apply to conditions where the particle Reynolds

number is less than 1 and Newton's equation applies for Reynolds numbers
> 1000.
 Gravity Separation
For particles of quartz in water, this represents an upper size limit of around 110
um for Stokes' Law and a lower limit of around 3.5 mm for Newton's Law. Thus for
particles of quartz between 110 microns and 3.5 mm neither equation accurately
describes the settling rate of objects and this size range represents a major size
range of interest in gravity separation. A number of researchers have developed
empirical correlations to fill this size gap. Dietrich derived a using dimensionless
parameters, W and D , and incorporating shape and angularity factors:
 Gravity Separation
Problem:

Determine the settling rates for spherical particles of quartz settling in water for
particles of size 38 micron to 16 mm. The density of quartz and water are 2650
and 1000 kg/m3 respectively and the viscosity of water is 0.001 Pa s. Drag
coefficient is 0.44.
 Gravity Separation
The separation by gravity is based on the difference in settling rates or terminal
velocities of particles of different density and size. The forces acting on a particle
settling in a fluid under free settling conditions are gravity, buoyancy in the fluid and
drag.

Dividing above equation by the solid mass gives

 Gravity Separation
The drag force increases with increasing particle velocity and eventually
balances the other forces acting on the particle to yield a constant falling
velocity, the terminal velocity. The drag force is given by:
 Gravity Separation

Settling curves for separation of pyrite Settling curves for separation of gold
(sg= 5.0) from arsenopyrite (6.1) using (sg=18) from arsenopyrite using the
the Dietrich correlation. The Dietrich correlation. The concentration
concentration criterion is 1.275. criterion is 3.33
 Gravity Separation
Sorting
Column
Classificationconsists essentially
of a sorting column in which the
fluid is rising at a uniform rate.
Particles introduced in to the
sorting column are either sink or
float according to whether their
terminal velocities (vt) are
greater or smaller than the
upward velocity (V) of fluid. The
sorting column separates feed
into two products - an over flow
and under flow.
Gravity Separation
 Gravity Separation
Fluidisation is the operation by which solid particles are transformed into a
fluid like state through suspension in a gas or liquid.

• Fixed bed
• Expanded bed
Particle Bed Wall
• Incipiently fluidised bed ( bed at minimum fluidisation)
s
• Homogeneously fluidised bed (smooth)
• Heterogeneously fluidised bed ( bubbling)
Distributor
• Slugging
• Turbulent fluidising bed
• Lean phase fluidised bed- Pneumatic conveying
Flow of
fluid
 Gravity Separation

Various types of fluidisation

 Gravity Separation

Typical pressure drop & bed height vs superficial velocity plot of

fluidised bed
 Gravity Separation
Fluidized beds display a
number of liquid-like
properties:

• Lighter objects float on top

of the bed.

• The surface stays

horizontal even in tilted
beds.

• The solids can flow

through an opening in the
vessel just like a liquid.

• Levels between two similar

fluidized beds equalize their
static pressure heads. Liquid like properties of fluidised beds

• The beds have a “static”

pressure head due to
gravity.
 Gravity Separation
Characteristics of Particulate solids
Particle size: Surface volume diameter- Diameter of a sphere
of the same surface area to volume ratio as the actual particle

Particle density : Weight of single particle per unit volume

Particle shape factor : (Sphericity)
Particle Regime: Geldart’s Groups A,B,C & D

Fluidisation characteristics
Minimum fluidisation velocity

Terminal settling velocity

 Gravity Separation
Geldart’s classification of
powder ( particle regime)

Group A

• Aeratable, small mean particle size, low

density<1.4 g/cm3 solids fluidised easily

Group B

• Coarser particles than group A particles (40

μm<dp<500 μm) and more dense 1.4 – 4 g/cm3

• Form bubbles as soon as the gas velocity

exceeds minimum fluidisation.

Group C
• particles are cohesive and very fine.
• difficult to fluidise and tend to rise as a slug of
solids
• Form channels in large beds with no
fluidization
Group D
•Large & dense particles.
• Form bubbles which coalesce rapidly and grow
large
• Spout from the top of the bed easily.
The force balance across the fluidised bed at
minimum fluidisation
Pressure loss across the bed of particles is equal to the
effective weight of particles per unit area of the bed

Accorging to Ergun equation the pressure difference

across the bed is

From these two we get

Particle fluidisation is controlled by voidage, density of

the particle & fluid, viscosity of fluid, fluid velocity and
size of the particle.
 Gravity Separation
Parameters that control fluidisation separation

Fluid velocity
Critical fluid velocity is that velocity at which the heaviest particle is in equilibrium and
the drag on it equals the combined force of gravity and buoyancy.
Voidage in fluidised system
• Effect of size ratio: With decreasing size ratio voidage in the binary particulate system
decreases.
• Effect of volume fraction: Voidage in binary system is highest for equal volume fraction
of coarse and fine particle.
Particle density
Degree of particle segregation increases with increase of reduced bulk density
differences.
Particle Size
Bed expansion decreases with increase in particle size.
 Gravity Separation
Fluidisation separation

Dry fluidisation separation Wet fluidisation separation

Air Classifiers Jig

Air dense medium fluidised Hydraulic Classifier (Hydrosizer)

bed separator Allflux
Air Jig Floatex density separator
Hydrofloat
 Gravity Separation

Particle segregation during fluidisation & defluidsation

 Gravity Separation
Air Pulsed Jig
Feed
• Air-pulsed jig with minimum energy consumption
• jigging stroke control by rotary or poppet valves Light
particle
• Capacity 5 -700 tph
• Size range 150 mm to 1 mm

•Separation of minerals in jigging machines is based

on the fact that particles will stratify in pulsating
water.
•The upward and downward currents fluidize and Heavy
compact the grains into relatively homogenous particle
layers.
•Low density pieces stratify on the surface, while
specifically heavy grains settle to the lower level of
the bed.
•The pulsation of the water may be achieved nearly
wear-free and the stroke-motion (frequency,
amplitude and shape) can be adjusted within wide
parameters during operation.
•The operating parameters of jigging machines can be
adjusted and optimized according to feed
characteristics during operation.
 Gravity Separation
Dry air pulsed jig Feed

•Mostly used for coal & recycled

material
Exhaust
•Capacity 20-100 TPH air

•Large feed size range 50 to 1 mm

•Air pulsating jig is a total dry density
separation unit. No need of water for Pulsed air
separation flow

Constant
air flow

Heavy
particle
Light
particle
 Gravity Separation
Air Dense Medium Fluidised Bed Separator
Archimedes’ principle :
Light & heavy particles separate from each other due to Fsd
differences in densities with respect to fluidised bed.
Light particles floats
Fg Fb
Heavy particle sinks

Fg

Where,

Gravity

Drag force of gas exerted on particle

Fluid flow
= Buoyancy force exerted on particle
Drag force of air dense medium exerted on particle
 Gravity Separation

Schematic diagram of Air Dense Medium Fluidised bed Separator

 Gravity Separation

Photo of IMMT-Bhubaneswar Air Dense Medium Fluidisation Separator

 Gravity Separation
Hindered bed separator is a vessel in which feed settles against an evenly
distributed upward flow of water or other fluidising medium

•A down comer is used to feed the material to the

feed zone

•The feed encounter either free or hindered settling

conditions, depending on the concentration of
particles.

•The settling particles form a fluidised bed above

the fluidisation water injection point .

•Material is then segregated based on terminal ,

hindered settling velocities.

•Slower settling material reports to the top of the

bed ie. low density and fine material reports to the
over flow.

•Faster settling particle descend to the bottom of

the teeter zone ie. Coarse and high density material
report to the underflow Conventional hindered
settled separator
 Gravity Separation
Feed

Allflux hydrosizer

•The Allflux® separator uses fluidized bed

technology for classifying, separating,
thickening and desliming of slurry.

•The two-step process permits the

handling of slurries without pre-thickening.
Fine sand
•The coarse and heavy particles are
separated in the coarse section. Water
Light particle
•The discharge of coarse material out of
the central hopper is automatically
controlled by an analog system utilizing a Coarse sand
density probe and a pinch valve.

•Fine material and low-density particles

Particle size range : Up to 4 mm
overflow the coarse separation section.
Capacity : up to 2000 cum/hr
Gravity Separation
 Gravity Separation
Floatex Density Separator

•The FDS consists of a

vertical square tank followed
by a conical bottom.
•Feed slurry with feed water
is introduced through a
centralised feedwell.
•Teeter Water is introduced
through a bank of perforated
tubes.
•A pressure sensor is
mounted at the bottom of
the square tank.
•An under flow pinch valve
is automatically operated
• Very accurate cut size from 1 mm to .075 mm
using a PID controller
• 0.2 m3 to 24 m3 size range
•Segregated particles are separated by the
action of upward force resulting from the
rising teeter water.
•The separation can be described by the
relative velocity of each particle with
respect to the velocity of water, which is
called the slip velocity.
•Particles having a slip velocity equal to
the rising velocity of water have equal
chances of settling or being transported
upward by water.
•Particles settle with different settling
velocities depending on their size and
density leading to segregation.
•If the slip velocity of a particle is greater
than the rising water velocity, the particle
settles downwards and reports to the
underflow, otherwise it is carried away to
the overflow

Large scale use of Floatex for sand segregation

 Gravity Separation
HydroFloat Separator

Misplacement effect is more in

Conventional hydrosizers
Hydrofloat separator operates much
like a traditional hindered bed
separator with feed settling against
upward current of fluidisation water.
The teeter bed is continuously
aerated by injecting compressed air
and a small amount of frothing agent
into the fluidisation water.

Coarse particle recovery in Hydro Float Separator

 Gravity Separation

Multi Spigot Hydrosizer

The Multi Spigot Hydrosizer is a

well-known classifier that has been
operating successfully for many
years on a wide range of minerals.
It is primarily used for separating
minerals of different specific
gravities and classifying by size.
 Gravity Separation
Stratification in a bed of particles results from the repeated pulsation of a current of
fluid up through the bed. The particles in the bed are expanded so that when
pulsation ceases, the particles are allowed to consolidate under the influence of
gravity. Fig. illustrates the expansion and contraction of the bed with the heavier,
larger particles falling under hindered settling conditions.

Fig. Expansion and contraction of a bed of particles due to jigging action

Gravity Separation
 Gravity Separation

Speed of flow through bed during jig cycle

1. Harz Jig
2. Mineral Jig
3. Kelsey Centrifugal Jig
4. Batac Jig
5. APIC Jig
6. All Mineral Jig
Gravity Separation

Harz jig
Baum jig

Mineral jig Batuc jig

 Gravity Separation
A particle settling in a viscous fluid. As a particle just starts to move from rest, the
particle velocity is small and hence the drag force acting on the particle, FD, is
negligible since the drag force increases with particle velocity relative to the fluid.
Thus:

That is, the initial acceleration of the particles depend only on the specific gravity of
the solid and fluid and is independent of the particle size.

Once the particles reach an appreciable velocity the fluid drag force becomes
significant and it opposes the particle's further acceleration to the extent that
eventually the particle acceleration drops to zero and a constant terminal velocity is
reached which will dependent on the particle diameter as well as density. If the
duration of the particle movement under gravity is kept short by having a high cycle
frequency then the total distance travelled by the particles will be governed more by
the difference in the initial acceleration between particles due to their density
difference rather than by their terminal velocities which is also influenced by the
particle size.
 Gravity Separation
However, for coarser particles, longer strokes with decreased speed is found to give
better stratification and hence it may be preferable to split the feed into closely sized
fractions and have a jig optimised for each size fraction.

The parameters that will effect hindered settling during jigging are particle size,
density and shape, the fluid density and viscosity, the percent solids and the
separator characteristics.

Parameters which determine the cycle frequency include the feed rate, feed size and
density and the jig design. A jig pulsation is a case of simple harmonic motion. The
period of pulsation can be given by the basic formula for simple harmonic motion
based on a compound pendulum;
Gravity Separation
 Gravity Separation
Length of the pulsation stroke
 Gravity Separation
Problem
 Gravity Separation

In jigging, it is desirable to have a high system density while the bed is fluidised.
Lovell and Luckie compared the settling velocities of two particles, to illustrate
the effect of relative density with increasing medium density. For two particles of
coal having densities of 1650 and 1550 kg/m3 in air (density 1.239 kg/m3), the
concentration criterion (ratio of relative densities) is calculated as:
 Gravity Separation
In water it becomes;

Taggart gives an estimate of the power consumption of a jig as:

 Gravity Separation
Spiral Concentrator
A cross section of a spiral concentrator can be divided into various regions,
with each region describing the effect it has on the slurry traveling through it.
Outer most regions (1) will have mostly water, with fine particles, trapped by
the high velocity of the moving water.
 Gravity Separation
Spiral Concentrator

Moving inward towards the center of the spiral, the next region (2) would
consist of a very small area where the maximum water velocity exists, and
prevents any separation to occur.
 Gravity Separation
Spiral Concentrator

Region 3 is a very active region where the velocity begins to slow down and
most of the separation occurs, as more dense particles settle to the bottom and
the water velocity keeps the light density particles in the stream near the
surface, where they eventually wind up in the outer regions (2 and 1).
 Gravity Separation
Spiral Concentrator

The next region 4 is actually where two regions overlap (region 3 and 5), and
is a very narrow region (like region 2).
 Gravity Separation
Spiral Concentrator

Next to the last region (region 5) is where the heavy density concentrates
collect.
 Gravity Separation
Spiral Concentrator

The remaining low density particles in this region find their way to the
top of the slurry surface and are carried off by the fast flowing water to
the perimeter of the spiral, with the bulk of the water and the low density
solids.
 Gravity Separation
Spiral Concentrator

❖ Extensive use in beach sands minerals

❖ Feed pulp between 15-45% solids
❖ Size range of 3 mm to 75 micron
❖ Separation due to combined effect of
centrifugal force, the differential settling
rates of the particles and the effect interstitial
tricking through the flowing particle bed.
❖ The capacity of spiral ranges from 1 to 3
ton/hr
❖ Spiral length is usually five or more turns for
roughing duty and
❖ three turns in some cleaning units.
❖ Modern spirals are constructed from fiber
glass and plastic with rubber lining
 Gravity Separation
Wilfley Table

Washwat
Field er
Lunder
Concentr
ate
Inclined
deck

Riffl
es

Tailing
s
Slow forward
motion
Gravity Separation
Wilfley Table
 Gravity Separation
Wilfley Table

❖ Particles of different density and size that are dropped into the flowing film will
reach the slope surface at different points because of the difference in settling
rate.

❖ Particles that take longer to settle such as the fine light particles will be carried
further down the slope than particles that are faster settling.

❖ For equal settling particles such as large light particles and small heavy particles,
these will contact the slope surface at the same position.

❖ If the particle shape is flat then it will have less tendency to roll and will
complicate the separation.
 Gravity Separation

The Important Factors Flowing Film Concentration

❖ Slope of the deck

❖ Thickness of the fluid film
❖ Viscosity of the fluid
❖ Coefficient of friction between various particles
❖ Sp. gravity of the particles
❖ The shape of the particle
❖ Roughness of the deck
❖ wash water
❖ Feed pulp density
❖ Amplitude and
❖ Feed rate
 Gravity Separation
Heavy Media Separation
If the density of the medium lies between the densities of the two minerals, then
separation becomes much simpler since the lighter mineral will float in the fluid
medium and the heavy mineral will sink. Hence separations of this kind are
referred to as sink-float separation.

The medium used for the separation depends on the specific gravity of the
minerals and may be made up of dissolved salts such as calcium chloride in water,
where densities around 1350 kg/m3 may be produced or zinc chloride up to 1800
kg/m3. This medium density is low but has been used for the separation of coal.
Heavy organic liquids have been proposed for industrial use but for reasons of
toxicity and cost these are restricted to small scale laboratory use and even here
they are becoming less utilised because of the toxic or carcinogenic nature of the
organics.
 Gravity Separation

Any substance used for media must have the following characteristics:

1.Hardness: It must not easily break down or abrade into a slime under working
conditions.
2. Chemical Stability: It must not be chemically corrosive or liable to react with the
ore minerals undergoing treatment.
3. Slow settlement at reasonable viscosity: It must form a fairly stable pulp without
having to be ground very fine, otherwise the medium will be too viscous.
4.Specific gravity: It must have high enough specific gravity to give the required
bath density at low % solids, again to minimise the viscosity.
5.Regeneration: The dense media must be easy to clean for recycling.
6.Price and availability: The solid should be readily available and cheap. Losses of
up to 0.5 kg/t could lead to high operating costs.
Gravity Separation
 Gravity Separation

Problems

How much 10% FeSi needs to be added to 1L of water to make a heavy liquid
of S.G. 2.8? What is the maximum media S.G. that can be used with this solid?
Density of FeSi = 7000 kg/m3 Density of water = 1000 kg/m3
Assuming 35% solid volume achieve the permissible viscosity.
Gravity Separation
Knelson Concentrator

• A Knelson Concentrator utilise the principles of a

centrifuge to enhance the gravitational force
experienced by feed particles to effect separation
based on particle density.
• The key components of the unit are a cone shaped
"concentrate" bowl, rotated at high speed by an
electric motor and a pressurized water jacket
encompassing the bowl.
• Feed material, is fed toward the centre of the
bowl. The feed slurry due to its rotation, is thrust
outward. During operation the lighter material
flows upward over the grooves and heavy mineral
particles (usually of economic value) become
trapped within them.
• Pressurized water is injected through a series of
tangential water inlet's along the perimeter of
each groove to maintain a fluidized bed of
particles in which heavy mineral particles can be
efficiently concentrated.
• The Knelson concentrator typically operates as a
batch process, with lighter gangue material being
continuously discharged via overflow and a heavy
mineral concentrate periodically removed by
flushing the bowl with water.
 Gravity Separation
Falcon Concentrator
• This machine is basically a
combination of a sluice and a
continuously operating centrifuge.
Capable of operating at a high speed
of rotation and hence ‘‘g’’ force,
• it enables fine particles of different
SG to be separated.
• The shape of the spinning bowl is
such that as the feed slurry moves up
the bowl the heavier particles react
more than the lighter particles to the
forces acting upon them.
• This results in migration of the
heavier particles within the slurry
stream to the surface in contact with
the bowl, while the lighter particles
tend to move to the top of the slurry
with the water.
• Separation then takes place by
removal of the lower (higher SG)
portion of the slurry through a
collection lip/slot, the flow through
which is regulated by a number of
orifices which open and close in a
controlled manner, removing the
concentrate from the main stream,
which discharges to tails
 Gravity Separation
Kelsey Centrifugal Jig
❖ The Kelsey Centrifugal Jig (KCJ) offers enhanced
gravity separation by applying centrifugal force
to conventional jigging principles. KCJ
efficiently separate fine minerals and/or
minerals with small differences in specific
gravity.
❖
❖ The KCJ was first installed commercially at the
Renison Bell tin mine in Australia in 1992.
❖
❖ Now mineral sands, tin, tantalum, gold and
nickel operations. Other areas of application
include tungsten, chromite and base metals.
 Gravity Separation

Mozley Multi-Gravity Separator (MGS)

 Gravity Separation

Mozley Multi-Gravity Separator (MGS)

• It is essentially an enhanced gravity separation

device using the flowing film and shaking
table principle.
• The MGS is designed for fine and ultra fine
mineral separation.
• It can be looked upon as essentially wrapping
the horizontal concentrating surface of a
conventional shaking table into a cylindrical
drum and rotating it.
• A force of many times greater than normal
gravity is exerted on the particles in the
flowing film thus greatly increasing the fine
particle separation process.
• An additional shaking action adds shear to the
particles increasing the separation process.
• These actions enable the MGS to recover
particles down to 1 micron in diameter with at
least 1.0 S.G. difference.
• The capacities are up to 30 t/h for mineral
separation and 50 t/h for coal.