Higher quality products, all at lower costs. These objectives, typically contradictory in the minerals processing arena, are, in the case of rare-earth magnetic separation, in fact most complementary.
Since 1982, when the first commercial unit was commissioned in South Africa, the use of rare-earth magnetic separators has become convention in many of the worlds modern industrial minerals operations. They typically process, amongst many others, mineral sands, glass sands, garnets, refractories, and ultra-high purity materials.
As is common with many new technologies, initial installations of rare-earth magnets were introduced at the end of the circuit, as a ‘patch’ to clean-up or improve inefficient technologies. Their use included tailings retreatment operations from electromagnets and new applications where standard electromagnets simply could not cope. Over the past two decades, however, rare-earth magnetic separators have been recognized as the superior solution, in many cases replacing the bulk of induced roll magnetic separators due to their greater separation efficiencies and lower power consumption. Thousands of separators are now used in the industry. Rare-earth rolls and drums are available in a variety of different designs, and with magnetic forces far exceeding prior art separators.
There are two main suites of rare-earth magnetic separators – rare-earth rolls and rare-earth drums. Process widths are usually 1m to 1.5m, with 2-4 magnetic stages.
In a rare-earth roll, material is fed evenly on its separator belt and is transported over a uniquely designed magnetic roll. As the feed material moves through the magnetic field, all magnetic particles are attracted to the roll. Depending on the magnetic susceptibility of the particle, it either:
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