MAGNETIC SEPARATOR
The present invention relates to a magnetic separator and more particularly to a matrix for such a magnetic separator.
Magnetic separators are known which comprise a cylindrical canister containing at least one matrix of magnetic or magnetisable material, and an electromagnet coil or permanent magnet arrangement for subjecting the matrix to a magnetic field axially of the canister.' The matrix comprises a body of e.g. ferromagnetic material, which may generally be in the form of, for example, wire wool, metal mesh, expanded metal, metal balls or metal rods. The magnetic field is generally uniform but, within the matrix, the matrix material causes localised disturbances of the magnetic field and hence localised regions of high field gradient. In use, a suspension or slurry is passed through the matrix, from one end of the canister to the other. The localised regions of high magnetic field gradient provide for the capture of particles of magnetic material from the suspension or slurry.
It has become common to use such magnetic separators for the removal of mineral particles, particularly particles of iron- or titanium-based minerals, from clay minerals such as kaolin. Magnetic separators have indeed been in industrial use, for this purpose, for some thirty years. For the matrices of such separators, ferromagnetic stainless steel wool is universally used, following extensive testing carried out by the industry and research organisations . It has been believed that the effectiveness of the steel wool is due to the fibres having edges of very small radius along their lengths. It has been believed that the increased field gradient provided by these sharp edges give the steel wool matrix enhanced performance.
Proposals have also been made to use, for the matrix, a stack of sheets of wire mesh or woven wire cloth. In line with a general approach to provide a maximum capture area for
particles, such proposals have involved the use of a mesh or cloth formed from a relatively large-diameter wire and/or with its array of apertures providing an open area forming a relatively small proportion of the area of the sheet. We have now found, surprisingly, that improved performance is obtained using, for the separator matrix, sheets of wire mesh or woven wire cloth formed of relatively small-diameter wire and with its apertures forming a relatively large open area. In accordance with the present invention, there is provided a magnetic separator which comprises a tubular canister, at least one matrix disposed within the canister for the through-flow of a suspension or slurry, and means for providing a magnetic field through the matrix, the matrix comprising a spaced stack of sheets of wire mesh or woven wire cloth formed substantially of wire 110 microns or less in diameter, the apertures in each said sheet forming an open area of at least 55% of the area of the sheet.
The wire diameter and size of the apertures are optimally selected in accordance with the material to be passed through the separator. Thus, the larger the coarsest particles in the slurry, the larger the apertures in the matrix sheet should be: however, the optimum wire diameter depends on the size of the magnetic-material particles; the smaller these particles, the smaller the optimum wire diameter.
Preferably the gap between adjacent wires of each sheet of mesh or woven cloth is at least 100 microns. More preferably, the gap between the adjacent wires is in the range 250 to 300 microns.
A separation gap is provided between the adjacent sheets of wire mesh or woven wire cloth, or at least between major areas of them. Preferably this separation gap is at least 100 microns (and more preferably 300 to 400 microns) . The gap may be formed by a spacer which comprises a sheet
formed with an array of apertures which are large compared with the apertures in the wire mesh or woven wire cloth sheets: for example, the apertures in the spacer sheet may be of the order of 5000 microns across. The spacer sheet may comprise a sheet of expanded metal, or it may comprise a mesh or cloth formed from wires of relatively large diameter (e.g. at least 150 microns) with relatively large inter-wire gaps (e.g. at least 2000 microns) .
The matrix may comprise a stack of expanded metal sheets, in place of the sheets of wire mesh or woven wire cloth. Thus, also in accordance with the present invention, there is provided a magnetic separator which comprises a tubular canister, at least one matrix disposed within the canister for the through-flow of a suspension or slurry, and means for providing a magnetic field through the matrix, the matrix comprising a stack of expanded metal sheets, the apertures in each sheet forming an open area of at least 55% of the area of the sheet and the elongate metal webs between adjacent apertures being 110 microns or less in width. In an another embodiment, the matrix may comprise mesh or woven cloth sheets, in which at least alternating sheets incorporate a larger-diameter wire at intervals, so that the adjacent sheets may be laid directly in contact with each other, the larger-diameter wires of the adjacent sheets providing the required spacing between the major areas of the two sheets. Preferably the larger-diameter wires run in one direction only in each sheet, adjacent sheets being laid so that the larger-diameter wires of one sheet extend at an angle, e.g. orthogonally or diagonally, relative to the corresponding wires in the adjacent sheet.
In a further embodiment, the matrix may comprise sheets of wire mesh or woven wire cloth which are corrugated, pleated or formed with alternating folds, then laid one-upon-another with the corrugations or folds of adjacent sheets at an angle to each other. Such sheets may alternate with flat sheets.
In general, the sheets (or at least alternate sheets) may be locally deformed at intervals to provide the required separation gap between adjacent sheets.
We have found that the above-defined separator has a substantially improved performance, owing to the use of sheets of wire mesh or woven wire cloth which are formed of relatively small-diameter wire and with its apertures forming a relatively large-size open area (or to the use of equivalent sheets of expanded metal) . Accordingly, the suspension or slurry may be passed through the separator at a greater flow-rate, therefore increasing the throughput of the separator, for a given quality of end-product.
Further in accordance with the present invention, there is provided a matrix for a magnetic separator, the matrix comprising a stack of sheets of wire mesh or woven wire cloth formed substantially of wire of 110 microns or less in diameter and with the apertures in each sheet forming an open area of at least 55% of the area of the sheet, or a stack of expanded metal sheets, the apertures in each sheet forming an open area of at least 55% of the area of the sheet and the elongate metal webs between adjacent apertures being 110 microns or less in width.
Preferably the wire or expanded metal of the matrix sheets comprises ferromagnetic stainless steel or other ferromagnetic material.
Embodiments of the present invention will now be described by way of examples only and with reference to the accompanying drawings, in which:
FIGURE 1 is a schematic longitudinal section through a magnetic separator in accordance with the present invention;
FIGURE 2 is an enlarged plan view of a portion of a sheet of woven wire cloth used in the matrix of the magnetic separator;
FIGURE 3 is an enlarged sectional view through a portion of the matrix of the magnetic separator;
FIGURE 4 is a corresponding section through a portion of a second embodiment of matrix in accordance with the present invention;
FIGURE 5 is a view of two sheets of wire mesh or woven wire cloth of a third embodiment of matrix in accordance with the present invention.
Referring to Figure 1 of the drawings, there is shown a magnetic separator which comprises a cylindrical canister C for the through-flow of a suspension or slurry from which e.g. ferromagnetic particles are to be trapped. A matrix M is disposed within the canister for the suspension to pass through. An electromagnet (not shown) encircles the canister C, or a permanent magnet assembly is provided, to produce a magnetic field which passes through the matrix M generally parallel to the axis of the canister.
The matrix comprises a stack of sheets of wire mesh or woven wire cloth, indicated at S in Figure 1. Referring to Figure 2, the steel wire, from which the cloth is woven, has a diameter d and there is a gap w between adjacent wires. In accordance with the present invention, the wire diameter is less than 110 microns and the array of apertures A provide an open area of greater than 55% of the total area of each sheet (w2>55% of (w+d)2) .
Referring to Figure 3, adjacent sheets S of the wire mesh or woven wire cloth are spaced apart by a spacing sheet G. The gap g between adjacent woven wire sheets S is at least 150 microns. The spacing sheet G is formed with an array of apertures which are large (typically 2000 microns or more across) compared with the apertures in the woven wire sheets. The spacing sheet G may comprise a sheet of expanded metal: instead, the spacing sheet G may comprise a cloth woven from wires of relatively large diameter and with relatively large gaps between them (e.g. wire of at least 150 microns diameter with inter-wire gaps of at least 2000 microns) . In a modification of the above-described embodiment,
the matrix sheets S may comprise sheets of expanded metal, the apertures in which form an open area of greater than 55% of the total area of the sheet, and the webs Of metal between adjacent apertures are 110 microns or less in width. The metal sheet (prior to expansion) is preferably 110 microns or less in thickness. The overall thickness of the expanded metal sheet may be such that the sheets may be in direct contact with each other, without intervening spacers.
In the embodiment of Figure 4, the matrix comprises a stack of sheets of wire mesh or woven wire cloth laid one-on- another, in direct contact and without spacing sheets between them. However, each sheet S includes a larger-diameter wire W at intervals: the larger-diameter wires run in one direction only (either the warp or weft direction) and adjacent sheets S are laid so that the larger-diameter wires of one extend orthogonally or diagonally to the larger-diameter wires of the adjacent sheet. The larger-diameter wires thus provide the desired spacing between the intervening major areas of the sheets. In the embodiment of Figure 5, the matrix comprises a stack of sheets S of wire mesh or woven wire cloth laid one- upon-another, in direct contact and without spacing sheets between them. However, each sheet is corrugated (or alternately folded along parallel lines) and oriented so that its corrugation (or fold lines) run orthogonally to the corrugations of its adjacent sheets. The arrangement obviates the need for spacing elements to be provided between adjacent sheets and so increases the amount of "active" matrix material which can be accommodated within the canister. Also, the matrix exhibits a degree of resilience, and may be placed under slight compression, with the effect of expanding the matrix transversely to urge it against the side wall of the canister: the risk is thereby minimised of the slurry bypassing the matrix by flowing between the matrix and the side wall of the canister.
In each of the above-described embodiments, the matrix may comprise a number of units, each unit comprising a plurality of sheets S (and their intervening spacers, where provided) bonded or otherwise connected together. This arrangement facilitates removal of the matrix components for cleaning and replacement.
It will be appreciated that, in the magnetic separator which has been described, the matrix is of straightforward construction. However, as explained above, the separator is found to have a substantially improved performance: in particular, the suspension or slurry can be pumped through the separator at a substantially higher flow-rate, therefore substantially increasing the throughput of the separator, for a given quality of end-product.