In-Plant Testing of High-Efficiency Hydraulic Separators
The mineral processing industry has commonly utilized hydraulic separators throughout history for classification and gravity concentration of various minerals. More commonly referred to as hindered-bed or fluidized-bed separators, these units make use of differential particle settling rates to segregate particles according to shape, size, and/or density. As with any equipment, there are inefficiencies associated with its operation, which prompted an industry driven research program to further evaluate two novel high-efficiency hindered bed separators. These units, which are commercially called the CrossFlow separator and HydroFloat separator, have the potential to improve performance (separation efficiency and throughput) and reduce operating costs (power consumption, water and reagent usage). This report describes the results of Phase I activities (laboratory and pilot-scale tests) conducted with the CrossFlow and HydroFloat separators at several locations in the minerals and coal industries. Details of the testing programs (equipment setup, shakedown testing and detailed testing) associated with four coal plants and two phosphate plants are summarized in this work. In most of these applications, the high-efficiency units proved to provide a higher quality product at reduced costs when compared against the performance of conventional separators. Based on promising results obtained from Phase I, full-scale prototypes will be purchased by several mining companies for use in Phase II of this project. Two of the prototype units, which will be constructed by Eriez Manufacturing, are expected to be installed by a major U.S. phosphate producer and a large eastern U.S. coal company. Negotiations are also underway to purchase and install additional prototype units by a mineral sands producer and a second phosphate producer. The data obtained from the full-scale evaluations will be used to further promote commercialization and industrial applications of these innovative technologies.
- Research Organization:
- Virginia Polytech Inst/St Univ
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC26-03NT41789
- OSTI ID:
- 907886
- Country of Publication:
- United States
- Language:
- English
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