TITLE: RECOVERY OF OIL AND IRON FROM

COLD ROLLING MILL SLUDGE

Team Name: Phoenix

By Shantanu Hazra
 Background Theory:
AIM: To separate iron It is a well-established fact that froth floatation is being used for a very
from oily cold rolling long time to separate metals from their metallic ores.
Another important aspect for separation of magnetic metals is by using
mill using froth magnetic separation on conveyor belts.

floatation under the

influence of high
magnetic field.

Source:Researchgate.net Source:Vedantu.com
Proposed Idea:
 In the beginning the fluidity of the sludge is determined
if it is not enough fluid more oil is mixed with it.

 Now the mixture is put in a froth floatation vessel with an electromagnetic

impeller.

 The impeller must be so selected that it has highest surface area so that
maximum amount of iron particles get attached to it
 The impeller should be removable so that after every run it can be removed from
froth floatation chamber and demagnetized in a different vessel to collect the iron
particles sticking to it

 Now the froth floatation chamber is filled by water to some extent and the froth is
slowly added with constant high-speed stirring of the impeller

 The base of the tank is also expected to have a detachable magnetic plate just above
the original tank base so that the heavier iron particles settle at the bottom
 Now once the impeller gets saturated with iron particles it should be taken
out and demagnetized to collect the iron particles

 The oil can now be skimmed off and collected in a different vessel ready
to be reused

 And after certain time the magnetic base plate can be lifted and
demagnetized to collect the heavier magnetic particles
Apparatus required:
1. A froth floatation vessel
2. A suitable impeller with high surface area
3. A device to create strong electromagnetic field

Raw Materials:
1. Cold rolling mill sludge
2. Water
3. More oil if required depending on viscosity of the given sludge oil
4. Surfactants or depressants if required
Challenges:
1. The specific gravity of the sludge depending on its source and iron contents will determine if the sludge
will settle above the water surface or below .Based on that we need to decide the type of froth floatation
technique we need .

2. Viscosity of the given sludge will largely determine the success of the process

3. The size of the iron particles will largely determine if they can be attracted by the magnetic field of
impeller even if it touches them.

4. Cost effectivity as to how much iron and oil are recovered vs the amount of energy used for the process.

5. Impeller needs to be selected appropriately keeping in mind the corrosion factor

6. Pollution and health Hazard associated with the process

Disclaimer: This is completely a self made idea and self made
presentation except for two pictures whose source have been
mentioned.