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Application Of Superconducting High Gradient

Magnetic Separation Technology On Silica
Extraction From Iron Ore Beneficiation Tailings

Changqiao Yang, Suqin Li, Changquan Zhang, Jiaxing Bai & Zijie Guo

To cite this article: Changqiao Yang, Suqin Li, Changquan Zhang, Jiaxing Bai & Zijie Guo
(2018) Application Of Superconducting High Gradient Magnetic Separation Technology On Silica
Extraction From Iron Ore Beneficiation Tailings, Mineral Processing and Extractive Metallurgy
Review, 39:1, 44-49, DOI: 10.1080/08827508.2017.1324439

To link to this article: https://doi.org/10.1080/08827508.2017.1324439

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May 2017.
Published online: 17 May 2017.

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MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW
2018, VOL. 39, NO. 1, 44–49
https://doi.org/10.1080/08827508.2017.1324439

Application Of Superconducting High Gradient Magnetic Separation Technology On

Silica Extraction From Iron Ore Beneficiation Tailings

Changqiao Yang, Suqin Li, Changquan Zhang, Jiaxing Bai, and Zijie Guo
School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing, China

ABSTRACT KEYWORDS
Comprehensive utilization of tailings resources not only solves environmental problems but also creates Iron ore beneficiation
huge economic benefits. In this paper, fine weakly magnetic particles were extracted from iron ore tailidddngs; magnetic flux
beneficiation tailings and silica (SiO2) was separated and purified using a superconducting high gradient density; pulp concentration;
magnetic separator. Based on plenty of contrast experiments, SiO2 content of the magnetic concentrate super conducting high
gradient magnetic
could be increased from 68.67% to 92.57% with the selected optimal parameter combination, i.e., a separation; slurry flow
magnetic flux density of 3.2 T, a pulp concentration of 40 g/L and a slurry flow velocity of 500 mL/min. velocity
The concentrate can be utilized as low-grade normal SiO2 sands for industrial use, or act as the raw
materials for preparing high-purity SiO2 product.

Introduction result, the valuable materials in these tailings cannot be ade-

China is currently in rapid progress of industrialization and
urbanization, which has consumed a lot of mineral resources.
During the mining process, the excessive development of
mineral resources and outdated exploration techniques has
resulted in a mass of tailings. Until 2013, the amount of
tailings had exceeded 8 billion tons in China. If these tailings
are not properly utilized or further processed, a series of
problems related to the environment and human health may
occur. For instance, tailings warehouses can occupy large
amounts of green space such as forest land and farm land,
trees, grass, and crops may be destroyed by these tailings so
that natural disasters such as landslide and debris flow may be
induced. In addition, tailings usually contain heavy metal
elements such as copper, lead, chromium, and so on, which
can cause serious pollution to the atmosphere, water and soil,
and thus endanger the whole ecological system. However,
since tailings are rich in valuable elements such as iron,
lead, zinc, silicon, and so on, they can be treated as a recover-
able industrial resource instead of a potential hazardous pol-
lution source if adequately u\\tilized. Some scholars used to
describe tailings as the misplaced reclaimable resources (Li
et al., 2010; da Silva et al., 2014). The potential value of
annually discharged tailings in China has gone beyond bil-
lions of U.S. dollars. The huge quantity of existing tailings and
ongoing production of new tailings have made the utilization
of these resources as an increasingly urgent topic. It is known
that tailings are generally used as filling materials for the
emptied underground space of mines, road pavement, con-
struction work, etc. However, up to now, most of tailings are
not reasonably used but directly stored in warehouse. As a
quately utilized, thus leading to a very low overall utilization
rate of tailings in China. To solve this issue, one effective way
is to improve the extraction and recovery technology of valu-
able materials in tailings resources. This technology not only
reduces the waste of tailings resources and relieves the burden
of environment protection, but also recycles the valuable
resources and alleviates the dependency of industries on ori-
ginal mineral resources to a certain extent.
Quartz sand is one of the most important nonmetallic
materials that are widely used in glass manufacturing, micro-
electronics, aerospace, biotechnology, new energy, and new
material fields (Lee et al., 2008; Guo and Li, 2011; Vadim
et al., 2015). With the rapid development of science and
technology, the demand for high-purity quartz sand of
various industries keeps an increasing trend, whereas natural
crystals, as the optimal raw material of high-purity silica
product, are becoming exhausted. Hence, it has become an
urgent task to find proper alternatives to natural crystals.
Magnetic separation is a vital beneficiation method com-
monly used in the separation and concentration processes of
magnetite such as chromite (Arol and Aydogan, 2004; Das
et al., 2010). The superconducting high gradient magnetic
separation (HGMS) technology was developed on the basis
of traditional magnetic separation technology of permanent
magnet. It is a simple, energy-efficient, inexpensive, nonse-
condary pollution, nondestructive and highly efficient tech-
nology for the separation and concentration of iron-bearing
minerals (Chen et al., 2013). The magnetic flux density of
superconducting magnet is several times higher than tradi-
tional permanent magnet, with a maximum value of 5.5 T.

CONTACT Suqin Li lisuqin@metall.ustb.edu.cn School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing
100083, China.
© 2017 Taylor & Francis Group, LLC

A higher magnetic flux density normally can bring higher
separation efficiency (Mishima et al., 2007), so that this super-
conducting HGMS technology is recommended for capturing
fine weakly magnetic particles. For instance, it can be
deployed for wastewater purification to remove heavy metal
ions from the wastewater produced by steel industry. The first
application of superconducting HGMS in mineral processing
field was to improve the whiteness of kaolin clay by eliminat-
ing iron impurities, which achieved good test indices
(Zhu et al., 2013). However, to the best of our knowledge,
the superconducting HGMS technology has rarely been used
for the separation and purification of solid particles, especially
in tailings processing.
In order to solve the above problems, many researchers
have explored the comprehensive utilization of tailings. Dwari
et al. (2013) employed a wet low-intensity magnetic separator
to collect iron resources from iron ore beneficiation tailings.
They obtained a magnetic separation concentrate with 67%
iron of 200 μm in particle size and achieved a recovery rate of
90%. Chen et al. (2015) carried out beneficiation experiments
on hematite with an average particle size of 75 μm to inves-
tigate the use of HGMS technology, and the results proved
that magnetic flux density was the most significant factor
affecting the performance of this technology. Li et al. (2009)
analyzed the effects of high gradient magnetic field on the
distribution of silicon, and confirmed that a high gradient
magnetic field was capable of separating dissolved silicon
and main silicon-containing materials from gangue.
This paper investigated the removal of fine weakly mag-
netic particles from tailings using the superconducting HGMS
technology. Besides the detailed characterization of the
tailings, single factor experiments were conducted to analyze
the influences of various parameters, such as magnetic flux
density, pulp concentration, and slurry flow velocity on the
separation performance, and meanwhile to provide some
experimental evidences and theoretical basis for application
of separation technologies in industrial practices.
Materials and methods
Tailings samples
The tailings samples were provided by Chengde located in
Hebei Province of China. A total of 100 kg samples were
collected from different zones of the lagoon, with an average
particle size of 250 μm.
In the laboratory, these samples were grinded into 45 μm
size particles. Afterwards, their chemical constituents and
mineralogical characteristics were analyzed using a series of
detection methods, i.e., chemical analysis (CA), X-ray fluor-
escence (XRF), and X-ray diffraction (XRD) with Cu-Kα
radiation between 10°and 80° (2θ), and a set of instruments
including a scanning electron microscope combined with
Table 1. Component analysis of tailings samples by XRF (%).
Constituent SiO2 Al2O3 MgO Fe2O3
Content 68.67 9.84 5.66 5.48
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 45
an energy-dispersive X-ray spectroscope (SEM/EDS) and a
reflective microscope. The XRF analysis results of the tail-
ings samples are presented in Table 1. It is found that the
samples have high Si, Al, Mg, and Fe contents. Since Si is
the targeted valuable element of this study, those elements
other than Si need to be cleared. The phase analysis results
of the tailings are presented in Figure 1, Figure 2 and
Table 2, as can be seen quartz is the main phase and
gangue minerals include pyroxene, feldspar, and magnetite.
Experimental system
The magnetic separation experiments were performed using a
superconducting high gradient magnetic separator designed
by the Institute of High Energy Physics (IHEP) of Chinese
Academy of Sciences (CAS). The experimental schematic
diagram of the separator is shown in Figure 3. It is composed
of two superconducting magnets and a high gradient reactor.
The two superconducting magnets are used to generate a high
intensity magnetic field, while the high gradient reactor is
filled with steel wools which can raise the gradient of the
magnetic field and increase the magnetic force acting on
magnetic particles.
The prepared slurry was fed into the high gradient reactor
via the inlet. Magnetic particles were captured by the mag-
netic matrix (steel wools) and nonmagnetic particles (silica)
were to be exported with the slurry through the outlet. In
order to study the influence of various parameters of super-
conducting HGMS technology on silica extraction and pur-
ification of tailings, several single factor tests focusing on
magnetic flux density, pulp concentration and slurry flow
velocity were conducted, respectively.
Based on the analysis of earlier experimental data, the
following technological parameters were selected for the mag-
netic separation experiments: magnetic flux density from 2.5
to 4.0 T, pulp concentration from 30 to 100 g/L, slurry flow
velocity from 500 to 2500 mL/min and a fix filling rate of steel
wools at 20%. The magnetic concentrate was dried in a drying
oven at 105 °C, and then their chemical constituents were
examined. Separation efficiency was evaluated using the SiO2
content in magnetic concentrate. A higher SiO2 content in
concentrate means a higher magnetic separation efficiency.
Results and discussion
Influence of magnetic flux density on separation
efficiency
Magnetic flux density is an influential parameter to separation
efficiency. In the experiments, different magnetic flux densi-
ties from 2.5 to 4.0 T were attempted with a pulp concentra-
tion of 30 g/L and a slurry flow velocity of 500 mL/min. The
test results are exhibited in Figure 4. It can be seen from
CaO K2O Na2O P2O5 TiO2 Cr2O3 MnO
4.69 2.52 1.95 0.53 0.20 0.14 0.12
46 C. YANG ET AL.

800 1 1. quartz (SiO2) the same time, the contents of P, Ti, Cr, and Mn all dropped
2. pyroxene ((Ca,Mg,Fe,Al)2(Si,Al)2O6)
to 0.10% or below. Since the particles containing these ele-
ments were adhered to or associated with magnetic particles,
3. feldspar (KAlSi3O8)
600 they were then captured by the steel wools together with the
Intensity (Counts)

4. magnetite (Fe3O4) magnetic particles and could be removed effectively. In the-

400

13 24
2
200 23
3 4 13

10 20 30 40 50 60 70 80 90
Theta (°)

Figure 1. X-ray diffraction pattern of the tailings samples.

Figure 3. Schematic diagram of superconducting HGMS.

94

92
SiO2 Content (%)

90

88

86
Figure 2. Reflective microscope image of tailings samples 1. pyrite, 2. magnetite,
3. quartz, 4. feldspar, 5. pyroxene.
84
2.6 2.8 3.0 3.2 3.4 3.6 3.8
Figure 4 that magnetic flux density has an appreciable effect
Magnetic flux density (T)
on separation efficiency. The SiO2 content of magnetic con-
centrate firstly increases with the increase of magnetic flux Figure 4. The influence of magnetic flux density on separation efficiency.
density and reaches the maximum value of 92.89% at a mag-
netic flux density of 3.2 T, and then sharply drops with its
further increase. ory, weakly magnetic pyroxene and ferromagnetic magnetite
XRF detection was performed on the concentrate obtained particles should be completely captured by the steel wools.
from magnetic separation process at the magnetic flux density The superconducting HGMS is physical separation method
of 3.2 T. According to the results, the content of SiO2 was based on the difference in magnetic properties of different ore
found to be 92.89%; the contents of Mg, Ca, Al, and Fe minerals (Li et al., 2012). In the magnetic field, particles are
dropped to 0.52%, 1.42%, 2.91%, and 0.84%, respectively; at under a three-way competition: magnetic force, gravitational,

Table 2. Mass percentages (determined by EDS) of the particles shown in Figure 2. (%).
O Si Ca Mg Fe Al K Na Ti S Mineral type
1 47.59 52.43 pyrite
2 11.29 85.26 3.45 magnetite
3 40.64 59.36 quartz
4 38.63 40.05 2.25 1.96 10.47 1.96 4.11 feldspar
5 35.33 20.24 14.02 7.11 16.03 5.36 1.08 0.85 pyroxene

or inertial force, attractive or repulsive interparticle force
(Katharina et al., 2012). The magnetic force can promote the
separation of small magnetisable particles from nonmagnetic
particles. The element type and content of particles determine
the magnetic susceptibility of particles (Nishijima, 2008). That
is, for the same particle size, a higher content of magnetic
elements leads to a greater magnetic force in the magnetic
field. The magnetic susceptibility of particles is the most
significant factor that influences the magnetic efficiency
(Takeshi et al., 2001). The magnetic force (FM) of particles
in the magnetic field is calculated by the following equation:
χ dB
FM ¼ V B (1)
μ0 dx
Where χ is the magnetic susceptibility of particles, μ0 is the
permeability in vacuum, V is the particle volume, B is the
magnetic flux density, and dB/dx is the magnetic flux density
gradient.
In the magnetic field, a high magnetic gradient was gener-
ated by the steel wools. Thus, the ferromagnetic, paramagnetic
or diamagnetic particles in tailings samples could be easily
captured by the steel wools. Then, the particles can be well
separated by the high gradient magnetic field.
The experimental results revealed that the SiO2 content
increased with the increase of magnetic flux density before 3.2 T,
and then dropped with its further increase. The possible reasons
are summarized as follows.
The magnetic susceptibility of particles generally varies
with the magnetic flux density. Within a certain range, the
magnetic susceptibility increases as the magnetic flux density
increases. After the magnetic flux density goes beyond a
threshold value, the magnetic susceptibility drops with its
further increase, so that the magnetic force of particles also
begins to decrease. In the above experiments, the threshold
value was 3.2 T, after which the separation performance was
degraded. With the increase of magnetic flux density, the steel
wools gradually achieved magnetic saturation, and the mag-
netic strength on the surface of the steel wools no longer
increased with the increase of magnetic flux density. Further
increase of magnetic flux density after the saturation point
would not contribute much to the improvement of magnetic
separation efficiency, but caused the magnetic flocculation of
steel wools. Meanwhile, the area of steel wools capturing
magnetic particles decreased rapidly with the further increase
of magnetic flux density above the threshold value. These all
resulted in the decrease of separation efficiency.
Influence of slurry flow velocity on separation efficiency
Based on the above test results, the optimum magnetic flux
density was determined to be 3.2 T, and thus the magnetic flux
density was fixed at the optimal value in the subsequent experi-
ments. The effects of slurry flow velocity (ranging from 500 to
2500 mL/min) on separation efficiency were investigated with a
magnetic flux density of 3.2 T and a pulp concentration of 30 g/L.
The results are shown in Figure 5. It is found that the SiO2 content
firstly decreases sharply with the increase of slurry flow velocity
until it reaches 1500 mL/min, and then it increases slowly with the
MINERAL PROCESSING AND EXTRACTIVE METALLURGY REVIEW 47
94
92
SiO2 Content (%)
90
88
86
84
500 1000 1500 2000 2500
Slurry flow velocity (mL/min)
Figure 5. The influence of slurry flow velocity on separation efficiency.
further increase of slurry flow velocity. Hence, the optimal value
for slurry flow velocity was selected as 500 mL/min.
The particles in the slurry were under not just the stress
of magnetic force, but a combined stress including fluid
force, gravity, buoyancy, etc. The separation effect mainly
depends on the magnetic force and fluid force. The fluid
force (FD) of particles can be calculated by the following
equation (Subrata, 2012):
FD ¼ 6πηrp ðνf  νp Þ (2)
Where η is the rate of viscosity, rp is the radius of particle, vf is
the slurry flow velocity, and vp is the particle velocity.
The magnetic particles can only be separated from non-
magnetic particles when the condition FM >FD is satisfied.
Hence, the control of fluid force is deterministic to the mag-
netic separation effect (Ebner et al., 1997). However, the
influence of the slurry flow velocity on FD is obvious. The
slurry flow velocity through the steel wool layer determined
the shear force acting on the particles, and also the grade of
concentrate. In the high gradient magnetic separation process,
a greater flow velocity could lead to a lower magnetic separa-
tion efficiency. The increased slurry flow velocity could
strengthen the hydrodynamic viscous resistance, which
might result in the increase of FD and the decrease of resultant
force acting on the magnetic particles. As a result, those
weakly magnetic impurities failing to be captured by the
steel wools would mix into concentrate. Accordingly, the
SiO2 content in concentrate decreased, and the magnetic
separation performance was degraded.
Influence of pulp concentration on separation efficiency
To investigate the effects of pulp concentration on separation
efficiency, the pulp concentration was changed from 30 to 100
g/L, with other parameters keeping constant, i.e. a magnetic
flux density of 3.2 T and a slurry flow velocity of 500 mL/min.
As Figure 6 shows, the SiO2 content of magnetic concentrate
does not change much at pulp concentration between 30 and
40 g/L. Hence, the optimal value for pulp concentration is
48 C. YANG ET AL.

selected as 40 g/L. The SiO2 content was 92.57% at the pulp

92 concentration of 40 g/L. Afterwards, the SiO2 content
decreased with the further increase of pulp concentration.
Figure 7 shows the SEM images of the magnetic concentrate
88
SiO2 Content (%)

at different pulp concentrations. When the pulp concentration

is relatively low (ranging from 30 to 40 g/L), as seen from
Figures 7(a) and (b), the surface of the particles are relatively
84
smooth and the amount of fine particles is least. Then, the
amount of fine particles gradually increases with the increase
80 of pulp concentration (Figures 7c–f).
The adsorption capacity of steel wools at the saturation
point determined the feed quantity. The increased pulp con-
76 centration was equivalent to the increase of feed quantity per
unit time. When the adsorption capacity of steel wools
20 40 60 80 100 reached saturation, they could not capture magnetic particles
Pulp concentration (g/L) any longer. Large amounts of weakly magnetic particles thus
failed to be captured, which reduced the SiO2 content in
Figure 6. The influence of pulp concentration on separation efficiency. magnetic concentrate.
The distance between particles varied with the pulp con-
centration. A higher pulp concentration could shorten the
between 30 and 40 g/L. From the perspective of improving distance between particles and increase their interaction. In
adsorption capacity, the optimal pulp concentration was addition, a higher pulp concentration also increased the pulp

Figure 7. The microscopic pictures of magnetic concentrate at different pulp concentrations: (a) 30 g/L, (b) 40 g/L, (c) 50 g/L, (d) 60 g/L, (e) 70 g/L, and (f) 100 g/L.

Table 3. Component analysis of concentrate by XRF (%).
Constituent SiO2 Al2O3 MgO Fe2O3 CaO
Content 92.57 2.41 0.50 0.82 1.39
viscosity and the load on the steel wools, which intensified the
nonselective magnetic flocculation phenomenon (Oka et al.,
2009). As a result, the separation effect became worse.
Comprehensive condition experiment
Under the optimal parameters, i.e., a magnetic flux density of
3.2 T, a slurry flow velocity of 500 mL/min, and a pulp concentra-
tion of 40 g/L, the SiO2 content was boosted from 68.67% to
92.57% after once superconducting HGMS test. Chemical analysis
results are shown in Table 3. It can be seen that the impurity
elements mainly include Al, K, Ca, etc. These impurities should be
feldspar and another kind of calcium-iron-bearing silicate.
Nevertheless, this kind of impurity had a low content, so that
XRD detection did not find them. How to determine its phase
composition and how to separate the feldspar will be our future
work. Another work is to improve the yield, since the average yield
of concentrate is only 41.78% in the current test.
Conclusions
The superconducting HGMS technology was proved to be an
effective way for the separation and purification of SiO2 from
iron ore beneficiation tailings. The paramagnetic minerals such
as pyroxene and magnetite could be removed and SiO2 could
be separated effectively from these weakly magnetic particles.
Three main factors influencing the separation efficiency were
analyzed. With the increase of magnetic flux density, the SiO2
content firstly increased and then decreased when magnetic flux
density was beyond 3.2 T, so that the optimal value for magnetic
flux density was 3.2 T. With the increase of slurry flow velocity or
pulp concentration, the SiO2 content showed a decreasing trend.
Under the optimal technological parameters, i.e., a magnetic flux
density of 3.2 T, a slurry flow velocity of 500 mL/min and a pulp
concentration of 40 g/L, the SiO2 content of concentrate was
boosted from 68.67% to 92.57%. This concentrate can meet the
technical requirements of primary glass manufacturing compa-
nies and foundries. Also, it can be used as the raw materials for
producing high purity silica product.
Acknowledgments
The authors wish to thank Zhu Zian from Institute of High Energy
Physics, Chinese Academy of Sciences for his technical assistance.
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