MMPB-738G

Ferrous
Wheel
TM

…Only from Eriez.

High Gradient Magnetic Separator

Wet High Gradient

Magnetic Separators
utilizing high strength
permanent magnets and
flux-converging matrix.
Continuous operation
for the concentration
of magnetic ores or
the cleaning of
non-magnetic ores.

Features
• High strength
permanent magnetic field
• High capacity
® • Continuous operation Patented in U.S. & Mexico
• Low operating and maintenance costs Others pending and applied for.
• Inversion of matrix prevents plugging
due to oversize particles
 ®

In the design of a magnetic separator, the magnetic field expanded metal, steel balls, and steel wool have been used.
intensity and the magnetic field gradient are the only two first When placed in a magnetic field, the function of the matrix
order variables that affect separation response. The intensity of is threefold. The matrix 1) amplifies the magnetic field, 2)
the magnetic field refers to the number of lines of flux passing converges the lines of flux to produce localized regions of
through a unit area. Lines of flux are measured in gauss extremely high magnetic field gradient, and 3) provides
(1 line/cm2). collection sites for the magnetic particles.
The magnetic field gradient refers to the rate of change or Separator Design and Operation
the convergence of the magnetic field strength. Figure 1
A conceptual illustration of the Ferrous Wheel™ Separator is
illustrates two different magnetic field configurations. Case
shown in Figure 2. The separating ring is vertical and rotates
A has a very uniform pattern of flux lines without gradation.
clockwise. The separating ring consists of two discs with the
The magnetic field intensity is essentially equal at any point
matrix situated in pockets between them. The depth of the
in the field. A magnetic particle entering this field will be
matrix is typically 5-inches (125 mm). The separating ring
attracted to the lines of flux and remain stationary without
is open in the middle to allow the removal of the separated
attraction to either pole piece. Case B illustrates a converging
products. Magnets are mounted on each side of the separating
pattern of flux lines displaying a high gradient.
ring and generate a magnetic field through the matrix.

A B Two magnetic stations, each with approximate 60 degree

magnetic arcs, are used on the separating ring. When
concentrating a magnetic ore, the feed enters the matrix in
the magnetic field located near the top of the separating ring.
In this “rougher” stage, the feed enters from the outside of
the separating ring and flows inward toward the center. The
non-magnetic particles pass through the matrix and are
Fm collected in the center of the separating ring and channeled
out of the system. The magnetic particles are collected and
held in the magnetized matrix.
Feed Rinse Water
dH dH
=0 >0
dX dX

Figure 1. Magnetic Flux and Gradient Patterns.

t
gne
Ma
As these lines pass through a smaller area, there is a
significant increase in the magnetic field intensity.
A magnetic particle entering this field configuration will
not only be attracted to the lines of flux but will also migrate
to the region of highest flux density, which occurs at the Non-Mags I
Mags
tip of the bottom pole piece. In simplified terms, the magnetic
field intensity holds the particle while the magnetic field
gradient moves the particle. This illustrates the methodology Rinse Water
for magnetic separation.
The magnetic attractive force acting on a particle is
proportional to the product of the magnetic field intensity et
a gn
and the magnetic field gradient. To maximize the magnetic M
force acting on a particle, the product of the magnetic field
intensity and magnetic field gradient must be optimized.
It has been demonstrated in magnetic separation technology
Non-Mags II
that the most effective method of maximizing the magnetic Final Mags II
field gradient is with the use of a matrix. The matrix typically
Figure 2. Ferrous Wheel Magnetic Separator. Magnetic
resembles a metal mesh and such materials as screen cloth,
Upgrading in a Rougher/Cleaner Configuration.

©2001 ERIEZ MAGNETICS ALL RIGHTS RESERVED

2
 ®

As the matrix rotates out of the magnetic field, these particles

are rinsed out of the matrix and collected in the center of the
separating ring. The magnetic fraction is then channeled to a
“cleaner” separation stage located at the bottom of the
separation ring. In the cleaner stage, the feed enters from
the inside of the separating ring and flows outward. Again
the non-magnetic particles pass through the matrix and are
channeled out of the system. The magnetic particles are
magnetically collected and rinsed out of the matrix representing
the final magnetic product.
When cleaning a non-magnetic ore, the initial rougher
magnetic separation stage is used to remove most of the magnetic
contaminants. The non-magnetic product is then repassed through
a secondary “cleaner” separation stage to further remove any
residual magnetic contaminants.
There are several unique features about the Ferrous Wheel
Separator. The magnetic field is generated with permanent
magnets. Conventional barium ferrite magnets are used to Each of these 15 ring model Ferrous Wheel Separators can
produce magnetic fields up to 1500 gauss, while high energy process up to 22 tons per hour of iron ore, using only five
kilowatts for operation.
rare earth magnets are used to produce magnetic fields up
to 4000 gauss in the open matrix gap.
The evolution of permanent magnets has provided a cost
effective alternative to electromagnets for the generation of
high intensity magnetic fields. Specifically, in recent years,
the strength of permanent magnets has increased several-fold
with neodymium-boron-iron rare earth magnets now providing
an energy product of 45 million gauss-oersted. Figure 3
shows the evolution the strength of permanent magnets.
The development of these earth magnets has led to the design
of magnetic circuits possessing a magnetic attractive force
an order of magnitude greater than that of conventional
permanent magnetic circuits.

60

Advanced RE ERIUM
50 5000

Present RE

ERIUM
40 4000

ERIUM
Early RE 3000
30 ERIUM
ERIUM 45 2000
Original RE

ERIUM
20 1000
35% 5, 6, & 7 9 Mish-Metal RE
Early 5
Cobalt 5DG
1% Steel
6% 2, 3, & 4 5
Carbon Tungsten
10 Steel ALN 1 ERIUM 25
Lodestone Steel
M2 BC
5 8
12 3 Ferrite
0
1860 1880 1900 1920 1940 1960 1980 2000 2020
Eriez Engrg Doc 9918583

Multiple 15 ring Ferrous Wheel units recovering iron minerals

Figure 3. Evolution of Permanent Magnets from tailings.

3
 As a point of reference, upgrading magnetite ore requires The magnetic particles are rinsed from the matrix from the
magnetic fields of less than 300 gauss. The collection of para- outside of the separating ring in the rougher stage, and from
magnetic hematite, ilmenite, or chromite typically the inside of the separating ring in the cleaner stage. This
requires magnetic fields of 1500 - 2500 gauss. prevents buildup of oversize particles and physically entrapped
There are several types of continuous feed wet particles that is common on all carousel separators.
high-intensity magnetic separators. Essentially all other
separators use electromagnets to generate the magnetic field Capacity
and have the separating ring in a horizontal “carousel” The feed capacity is related to the diameter and width of the
configuration. Although the magnetic field strengths available separating ring. The ring diameter is an engineered option with
from permanent magnets may not be as high as those 96-inches (2440 mm) as standard. A magnetic field of 1000
produced by electromagnets, there are several major gauss can be generated in a 5-inch (125 mm) wide separating
advantages with using permanent magnets to generate the ring capable of treating up to 10 tph feed. A magnetic field of
magnetic field. Initially, the capital cost is significantly 3000 gauss can be generated in a 2 1/2-inch (65 mm) wide
reduced compared to separators using electromagnets. separating ring capable of treating up to 5 tph feed.
Permanent magnets eliminate the need for a magnetic coil, Several separating rings are combined to provide the
an extremely heavy steel circuit to carry the flux, a direct necessary production capacity feed rates. The permanent
current rectifier and heat exchangers and pumps for cooling magnets are placed between each ring to generate the magnetic
the magnetic coil. Operating costs are greatly reduced when field. The feed distributor consists of a box that runs the length
using permanent magnets. The only utility required is the of the separator. Each separating ring has a single feed nozzle
power to drive the separating rings. Approximately .5 HP attached to the distributor box to accept new feed.
per ring is required. The separating rings are typically driven
at 2-3 rpm. Further, with a lighter and more compact separator,
installation costs and maintenance costs are greatly reduced.
Pumping costs are minimized; feed flows through the Ferrous
Wheel Separator by gravity flow, and the separated products
are also channeled out of the system by gravity flow.
Several rinse stations can be employed to control both grade
and recovery. Although a rinse is usually not used in the
magnetic field while magnetic collection takes place, one
may however be employed for grade control. In such a
configuration, the rinse further expels entrapped non-magnetic
particles or even locked particles.

Typical Applications
Magnetic Concentration Magnetic Cleaning
• Magnetite • Ilmenite • Mica Group • Talc
• Hematite • Chromite • Alumina • Kaolin
• Zircon • Rutile
• Calcium Carbonate
96-inch diameter, 5-inch wide separating rings containing
• Silica Sand / Quartzite flux-converging matrix. In this machine, each ring can treat
• Feldspar Group up to 10 tph feed.

Dimensions and specifications are subject to change without notice.

Eriez and Eriez Magnetics are registered trademarks of Eriez Manufacturing Co., Erie, PA ©2001 ERIEZ MAGNETICS ALL RIGHTS RESERVED

World Authority in Advanced Technology for Magnetic, Vibratory and Metal Detection Applications
HEADQUARTERS: 2200 ASBURY ROAD, P.O. BOX 10608, ERIE, PA 16514-0608 U.S.A.
Telephone 814/835-6000 • 800/345-4946 • Fax 814/838-4960 • International Fax 814/833-3348
®
Web Site: http://www.eriez.com e-mail: [email protected]
MANUFACTURING FACILITIES IN: AUSTRALIA • BRAZIL • CANADA • INDIA • JAPAN • MEXICO • SOUTH AFRICA • UNITED KINGDOM • UNITED STATES

201-5.5M-SP-SP ERIEZ MANUFACTURING CO. PRINTED IN USA