Optimization of the Matrix in a Transverse-Field High-Gradient Magnetic Separator for an Improved Ilmenite Separation

Transverse-field high-gradient magnetic separators (HGMSs) are an important complement to longitudinal-field HGMSs in mineral processing due to their several advantages. However, the processing capacity of the transverse-field HGMS is smaller than that of the longitudinal-field HGMS. Consequently, research on the optimization of the matrix box for improving the processing capacity is essential. This work investigates the optimization of the matrix box for the SSS® HGMS to enhance the ilmenite separation efficiency and processing capacity. The results show that the matrix’s influence on separation performance is primarily influenced by the diameter of the rod matrix, the filling ratio, the depth of the matrix in the direction of slurry flow, and the ore unloading efficiency. Ilmenite pre-concentration tests are carried out using a test sample ore from Panzhihua, China. Pilot-scale validation research is carried out. The test results indicate that the depth of the matrix box should not be considerably thick, as an excessive number of layers increases the capture zone, but simultaneously reduces the unloading efficiency. The depth of the matrix box should neither be considerably thick nor particularly thin, as this would result in low processing capacity. Meanwhile, the segmented multi-layer matrix box should be used to balance the capturing and unloading performance. Finally, an optimal double-layer matrix ring is applied to the industrial transverse-field HGMS, and its inner and outer rings are equipped with matrix boxes with ϕ3 mm and ϕ2 mm rods, respectively, which improves its pre-concentrate efficiency and processing capacity. The concentrate indexes of the transverse-field HGMS is achieved with a TiO2 grade of 18.01% and a recovery of 87.28%, which is better than the separation indexes of the longitudinal-field HGMS.