Electromagnetic Hydrocyclone for Magnetite Separation

During Coal Beneficiation

Natalie Keener, Shaun Valentine, Liam O’Sullivan,
Tim Tomko, Adam Kimmerle
Team Sponsor: Daniel Yanchak—Consol Energy

Problem Statement Background Work Performed

Sponsor: Consol Energy Coal Beneficiation: Separation of undesirable substances, such as Design:
Consol Energy is the leading diversified energy producer in dirt, rocks and inorganics from coal. Hydrocyclone
the Appalachian basin, producing both natural gas and high–
Overflow
BTU coal. 1. Mineral matter is liberated from coal via crushing
Design Problem: Improve Safety of Magnetite Recovery 2. Mineral matter is separated from coal by magnetite dense media
separation Inlet
Large magnetic drum separators, containing powerful rare
earth magnets, are the current mode of magnetite recovery. 3. Magnetite is recovered from water via the magnetic drum
However, rare earth magnets pose several safety concerns: separator (shown below)
1. Medical devices such as pace makers or insulin
pumps no longer function properly Hydrocyclones: Used to separate or classify particles in a slurry.
2. Physical dangers such as crushing or smashing of • Small magnetite particles cannot be
appendages separated by cyclonic forces alone
3. Routine maintenance becomes much more difficult • Additional forces must be added to
and taxing on the workers efficiently separate magnetite Underflow
particles in a hydrocyclone
4. Rare earth magnets are becoming increasingly
dangerous and difficult to acquire. • Magnetite particles should exit Electromagnet
through the underflow

Results Analysis and Future Work

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Testing: Baseline:

• A baseline test without the electromagnets was performed
to determine the separation efficiency:
• The mass of the solids in the respective flows and a
particle size distribution was determined through wet
sieving.
1. Maintaining a well mixed solution and the sample analysis
procedure are important in getting accurate results
• Add an impeller to the sump would increase mixing
• Develop a better way to measure the amount of magnetite in each
stream
Construction:
2. Without the magnets, the separation efficiency was already higher
than much of the literature (Our Number). (References) Integrated Design
Testing:

BASELINE (NO ELECTROMAGNET) 3. Visually, a better separation at higher currents, however, the system
--
RUN MASS (g) AVG (g) % OF TOTAL was unable to sustain such high currents without tripping the
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breaker.
 

+325 mesh
3   • Upgrade the control panel to run at a higher voltage and
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0
consequently, higher currents.
6 0    
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2
 

 
Due to time restraints and the extensive effort required to design and
OVERFLOW -325 x +400 mesh
3   construct the hydrocyclone system, the next group will be responsible
4 0
5 0
for fully testing and analyzing the capabilities of the magnets. The
6 0     parameters studied should include:
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2  

-400 mesh
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4
 
0.452
• Frequency • Pressure
5 0.256 • Current • % Solids
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1
0.690
 
   
• Magnet Pulsing • Magnet Positioning
2   Conditions
3  
+350 mesh
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5
6    
1    
Conclusions Acknowledgments
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3  
UNDERFLOW -350 x +400 mesh
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5
6
• Through the baseline testing, the efficiency of magnetite recovery of
   
1   the hydrocyclone was almost equal to the efficiency of the drum We would like to thank the following people
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rollers (~99.4%) used in Consol’s Rob Robinson plant. and their help and support with the project:
-400 mesh
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6
 
   
• Keeping the slurry well stirred is a major factor for the separation Dan Yanchak
process to get more accurate results. Consol Energy
Average total % solids in underflow: FLSmidth Krebs
• The magnets had a definite positive effect on the separation efficiency Electro-mec
Average total % solids in overflow: of the hydrocyclone West Virginia Electric
The Penn State Energy Institute
• A further increased magnetic field would increase the separation Our Group Advisor Dr. Andre Boehman
η = turd efficiency.