- Research Article
- 10.1080/02726351.2026.2651123
Performance of spiral concentrator treating multi-component feeds – investigation of particle segregation
- May 11, 2026
- Particulate Science and Technology
- Prudhvinath Reddy Ankireddy + 2 more +2
Spiral flows exhibit complex fluid dynamics and interactions involving multiple phases and components in the process. Understanding the behavior of these phases within the spiral concentrator is crucial for achieving efficient separation. The investigation presents size-wise and mass-wise recovery of minerals at various feed concentrations and explains the factors affecting separation in the spiral concentrator. Considerable effort is devoted to understanding the separation processes, not only in chromite ores but also in artificial mixtures. An experimental bi-component (magnetite & silica) and multi-component (chromite ore) particle interaction study with different mineral compositions is conducted utilizing an industrial-scale spiral concentrator. The segregation pattern indicates that the heavier coarse component accumulates in the inner zone, whereas the lighter fine component occupies in the outer zone. The middle zone primarily consists of equal settling flux particles, i.e., heavier fine particles and lighter coarse particles. Misplacement of coarser and finer particles in non-designated zones of the spiral trough has been observed. By varying the feed proportions, a clear understanding is established in the increasing and decreasing trends of misplacement of lighter coarse particles to the concentrate and heavier fine particles to the tailings. The experiments with low-grade chromite ore are conducted to demonstrate the effectiveness of feed proportion in a practical application, highlighting the effects of hindered settling, mineral density, and liberation. The size-wise recoveries of bi-component and multi-component particles in the product streams are compared and analyzed to demonstrate the efficient separation of coarser and finer particles of the components. The bi-component system demonstrates clear separation, while multi-component systems exhibit more complex separation, resulting in increased middling recovery for all components due to the challenges associated with mineralogy, liberation, and specific gravities. The presence of additional components with varying densities creates complex particle interactions affecting recovery rates.
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