Gravity separation method using iron powder.

FIELD OF THE INVENTION

0001The present invention relates to a gravity separation method using iron powder for performing sink-­float separation of metals, ores and the like by using a specific gravity liquid in which iron powder is mixed and suspended.

DESCRIPTION OF THE PRIOR ART

0002In conventional methods of separating various raw materials by using a given specific gravity, the chemicals described below are generally used in laboratories. <tables id="tabl0001" num="0001"><table frame="all"><tgroup cols="4" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="39.37mm" /><colspec colnum="2" colname="col2" colwidth="39.37mm" /><colspec colnum="3" colname="col3" colwidth="39.37mm" /><colspec colnum="4" colname="col4" colwidth="39.37mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" align="center">Reagents</entry><entry namest="col2" nameend="col2" align="center">Molecular Formula</entry><entry namest="col3" nameend="col3" align="center">Maximum Specific Gravity</entry><entry namest="col4" nameend="col4" align="center">Viscosity (20°C)</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">Zinc chloride</entry><entry namest="col2" nameend="col2" align="left">ZnCl₂</entry><entry namest="col3" nameend="col3" align="char" char=".">1.95</entry><entry namest="col4" nameend="col4" /></row><row><entry namest="col1" nameend="col1" align="left">Carbon tetrachloride</entry><entry namest="col2" nameend="col2" align="left">CCl₄</entry><entry namest="col3" nameend="col3" align="char" char=".">1.60</entry><entry namest="col4" nameend="col4" align="char" char=".">0.98</entry></row><row><entry namest="col1" nameend="col1" align="left">Benzene</entry><entry namest="col2" nameend="col2" align="left">C₆H₆</entry><entry namest="col3" nameend="col3" align="char" char=".">0.88</entry><entry namest="col4" nameend="col4" align="char" char=".">0.65</entry></row><row><entry namest="col1" nameend="col1" align="left">Toluene</entry><entry namest="col2" nameend="col2" align="left">C₇H₈</entry><entry namest="col3" nameend="col3" align="char" char=".">0.88</entry><entry namest="col4" nameend="col4" align="char" char=".">0.59</entry></row><row><entry namest="col1" nameend="col1" align="left">Bromoform</entry><entry namest="col2" nameend="col2" align="left">CHBr₃</entry><entry namest="col3" nameend="col3" align="char" char=".">2.90</entry><entry namest="col4" nameend="col4" /></row><row><entry namest="col1" nameend="col1" align="left">Tetrabromoethane</entry><entry namest="col2" nameend="col2" align="left">C₂H₂Br₄</entry><entry namest="col3" nameend="col3" align="char" char=".">2.96</entry><entry namest="col4" nameend="col4" /></row><row><entry namest="col1" nameend="col1" align="left">Methyl iodide</entry><entry namest="col2" nameend="col2" align="left">CH₃I</entry><entry namest="col3" nameend="col3" align="char" char=".">2.29</entry><entry namest="col4" nameend="col4" align="char" char=".">0.50</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="left">Acetylene tetrabromide</entry><entry namest="col2" nameend="col2" align="left">(CHBr₂)₂</entry><entry namest="col3" nameend="col3" align="char" char=".">2.96</entry><entry namest="col4" nameend="col4" /></row></tbody></tgroup></table></tables>

0003However, all these chemicals are expensive, and some of them have high degrees of toxicity and are thus not usable by industry.

0004Gravity separation methods have been industrially used in which suspensions of fine particles of solid in water listed below which are relatively inexpensive, easily available and have substantially no toxicity are formed and these are adjusted to have a given specific gravity so as to be used in gravity separation, solid as ores being placed in these liquids used for sink-float separation therein. <tables id="tabl0002" num="0002"><table frame="all"><tgroup cols="2" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="78.75mm" /><colspec colnum="2" colname="col2" colwidth="78.75mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" align="center">Fine Solid Particle</entry><entry namest="col2" nameend="col2" align="center">True Specific Gravity</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">Barytes (BaSO₄)</entry><entry namest="col2" nameend="col2" align="char" char=".">about 4.6</entry></row><row><entry namest="col1" nameend="col1" align="left">Pyrite (FeSO₄)</entry><entry namest="col2" nameend="col2" align="char" char=".">about 4.6</entry></row><row><entry namest="col1" nameend="col1" align="left">Magnetite sand (Fe₃O₄)</entry><entry namest="col2" nameend="col2" align="char" char=".">about 4.7</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="left">Ferrosilicon (Fe + Si)</entry><entry namest="col2" nameend="col2" align="char" char=".">about 5.5</entry></row></tbody></tgroup></table></tables>

0005However, although the upper limit of the specific gravity of a liquid which can be formed by this method depends upon the specific gravity of the fine solid particles serving as a medium and the ratio of water mixed therewith, any increase in the ratio of the fine particles mixed with the water causes the viscosity of the liquid to be increased. Thus, precise sink-float separation even of particles having sizes of 5 to 6 mm is difficult, and in practice the upper limit of the ratio of the fine particles mixed with the water is 40% by volume. Therefore, the upper limit for the specific gravity of a gravity liquid which can be formed by a medium of the type that generally used is 2.6 to 2.8 at most, and it is difficult to form a liquid having a specific gravity higher than this limit and yet having a low viscosity.

0006The treatment of scrap of automobiles and domestic appliances has recently become an important social problem, and the separation and recovery of the aluminium contained in this scrap has become a particularly important social demand.

0007Among these items of scrap, the engine blocks of automobiles contain portions made of aluminum alloy having a specific gravity reaching 3.15, while the true specific gravity of pure aluminium itself is 2.6. Thus, the specific gravity liquid formed by using a medium of the type generally used is unsatisfactory as a specific gravity liquid for use in sink-float separation of aluminium alloy, and such a specific gravity liquid cannot be easily formed.

SUMMARY OF THE INVENTION

0008The present invention has been achieved with a view to solving the above-described problem, and it is an object of the present invention to provide a gravity separation method which uses iron powder and which is capable of precise sink-float separation of aluminium alloy or the like using a specific gravity liquid having high specific gravity and yet low viscosity.

0009To achieve the above-described object, a gravity separation method using iron powder of the present invention is characterized by mixing and suspending the iron powder composed of fine particles having a size of 40 microns or less in water to form a specific gravity liquid with a specific gravity of at least 2.6 up to 3.5 depending upon the intended use, and by pouring the various raw materials to be treated such as metals, ores and the like into the specific gravity liquid formed so that the raw materials are subjected to sink-float separation.

0010In the aforementioned gravity separation method, iron powder which is produced by steel works and which is composed of fine particles having a size of 40 microns or less is mixed and suspended in water contained in a water bath for the purpose of separating and recovering aluminum or an alloy thereof from scrap derived from automobiles, domestic appliances or the like, or an ore, to form a specific gravity liquid with, for example, a specific gravity of about 2.6 to be used for recovering aluminium or a specific gravity liquid with a specific gravity of 3.15 or more and low viscosity to be used for recovering aluminium alloy. The scrap of automobiles etc. or ore is poured into the specific gravity liquid formed so that the aluminium alloy with a specific gravity of about 3.15 or other non-ferrous metals with specific gravities lower than this value can be separated and recovered as floated product.

0011As described above, in the present invention, the iron powder composed of fine particles having a size of 40 microns or less is used to form a specific gravity liquid with a specific gravity of 2.6 or more, depending upon the intended use, and various raw materials such as metals or ores are poured into the specific gravity liquid formed so as to subject these raw materials to sink-float separation. Therefore, it is possible to highly precisely separate aluminium or an alloy thereof which has a higher specific gravity from the shredded scrap of automobiles or domestic appliances, and to separate out substances which cannot be generally separated by conventional methods. In addition, since the use of iron powder in forming a specific gravity liquid with low viscosity enables separa­tion of particles having sizes down to about 3 mm which is smaller than which is feasible with conventional methods, the invention offers the remarkable effect that sink-float separation can be effected precisely.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

0012An example of the present invention uses an iron powder, which is composed of carbon steel and which has the following physical properties, as the medium for forming a liquid having a high specific gravity and low viscosity: True specific gravity: 6.5 to 7.0 Particle size: <tables id="tabl0003" num="0003"><table frame="all"><tgroup cols="2" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="78.75mm" /><colspec colnum="2" colname="col2" colwidth="78.75mm" /><tbody valign="top"><row><entry namest="col1" nameend="col1" align="right">+100 mesh</entry><entry namest="col2" nameend="col2" align="right">10% or less</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="right">-325 mesh</entry><entry namest="col2" nameend="col2" align="right">80 to 90%</entry></row></tbody></tgroup></table></tables>

0013Surface property: The surfaces have films of iron oxide thereon so that no red rust occurs in water (for example, Fe₃O₄ film).

0014Magnetic property: The iron powder has strong magnetism so as to be suitable for recovering them in the water. <tables id="tabl0004" num="0004"><table frame="all"><tgroup cols="2" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="78.75mm" /><colspec colnum="2" colname="col2" colwidth="78.75mm" /><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">Content of non-magnetic substances</entry><entry namest="col2" nameend="col2" align="right">2% or less</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="left">Content of magnetic substances</entry><entry namest="col2" nameend="col2" align="right">98% or more</entry></row></tbody></tgroup></table></tables>

0015Settling property: The height of the clear water produced in 5 minutes is 10% or less of the height of a specific gravity liquid, and the settling speed of the iron powder in water is not so high.

0016A liquid with a high specific gravity of 2.6 or more is formed by using iron powder having such physical properties, depending upon the intended use. The formation of a liquid having a high specific gravity of 3.2 is discribed below. In this case, the ratio of the iron powder mixed with water is as follows: <tables id="tabl0005" num="0005"><table frame="all"><tgroup cols="3" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="52.50mm" /><colspec colnum="2" colname="col2" colwidth="52.50mm" /><colspec colnum="3" colname="col3" colwidth="52.50mm" /><thead valign="top"><row rowsep="1"><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">Weight (Kg)</entry><entry namest="col3" nameend="col3" align="center">Volume (m³)</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">Iron powder</entry><entry namest="col2" nameend="col2" align="right">2600</entry><entry namest="col3" nameend="col3" align="char" char=".">0.40</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="left">Water</entry><entry namest="col2" nameend="col2" align="right">600</entry><entry namest="col3" nameend="col3" align="char" char=".">0.60</entry></row><row><entry namest="col1" nameend="col1" align="left">Total</entry><entry namest="col2" nameend="col2" align="right">3200</entry><entry namest="col3" nameend="col3" align="char" char=".">1.00</entry></row><row><entry namest="col1" nameend="col3" align="justify">Concentration by volume = 40%</entry></row><row rowsep="1"><entry namest="col1" nameend="col3" align="justify">Concentration by weight = 83%</entry></row></tbody></tgroup></table></tables>

0017This specific gravity liquid has a concentration by volume of 40% and a sufficiently low viscosity, while a specific gravity as high as 3.2 can be obtained. Thus, the aluminium alloy contained in an engine block can be easily recovered by using a sink-float separation method. In addition, since the content of magnetic substances is as high as 98%, the iron powder can be recovered by means of a wet-type magnetic separator with substantially no loss if the product obtained by sink-float separation is washed with fresh water.

0018As described above, the iron powder liquid with high specific gravity has low viscosity and thus enables raw materials to rapidly settle or float and gravity separation can be achieved with little error occurring due to undesired movement of the materials.

0019When non-ferrous metal pieces obtained from shredded automobile scrap were subjected to gravity separation using the liquid with a high specific gravity of 3.2 having the above-described physical properties, the results obtained were as follows: <tables id="tabl0006" num="0006"><table frame="all"><tgroup cols="3" colsep="1" rowsep="0"><colspec colnum="1" colname="col1" colwidth="52.50mm" /><colspec colnum="2" colname="col2" colwidth="52.50mm" /><colspec colnum="3" colname="col3" colwidth="52.50mm" /><thead valign="top"><row><entry namest="col1" nameend="col1" /><entry namest="col2" nameend="col2" align="center">Example</entry><entry namest="col3" nameend="col3" align="center">Conventional Example</entry></row></thead><tbody valign="top"><row><entry namest="col1" nameend="col1" align="left">Float yield of recovered aluminium</entry><entry namest="col2" nameend="col2" align="right">40%</entry><entry namest="col3" nameend="col3" align="right">40%</entry></row><row><entry namest="col1" nameend="col1" align="left">Sink yield of non-ferrous metal alloy exclusive of aluminium</entry><entry namest="col2" nameend="col2" align="right">60%</entry><entry namest="col3" nameend="col3" align="right">60%</entry></row><row><entry namest="col1" nameend="col1" align="left">Aluminium recovery efficiency</entry><entry namest="col2" nameend="col2" align="right">98%</entry><entry namest="col3" nameend="col3" align="right">95%</entry></row><row rowsep="1"><entry namest="col1" nameend="col1" align="left">Contents of impurities in recovered aluminium</entry><entry namest="col2" nameend="col2" align="right">2.0% or less</entry><entry namest="col3" nameend="col3" align="right">5% or more</entry></row></tbody></tgroup></table></tables>

0020The precision of this separation is extremely high compared with conventional separation methods using other media and liquids with high specific gravities. The above-­described aluminium recovery efficiency and contents of impurities in the recovered aluminium are much better than the above-described values for the Conventional Example which cannot be easily obtained by conventional methods. The value of recovered aluminium depends to a significant extent upon the amount of impurities contained therein, i.e., the purity of aluminium. The example of the present invention shows a reduction in the amount of impurities to a value one half or less that obtainable with conventional methods.

0021In addition, in the sink-float separation of the above-mentioned example using the high-specific gravity liquid composed of iron powder, the specific gravity liquid has low viscosity and thus enables gravity separation of fine particles and separation of particles having a size down to 3 mm with high precision. In contrast, the high-specific gravity liquid obtained from a medium (the above-described fine solid particles) which is generally used has high viscosity and thus makes precise sink-float separation even of particles having a size of 5 to 6 mm difficult.

0022Therefore, the separation method using the high-­specific gravity liquid obtained from the above-described medium can be applied to almost all sink-float separators such as rotary drum-type, vertical wheel-type and screw sweeping-type separators regardless of the classes thereof. Although this example concerns a liquid with a specific gravity of 3.2, the use of iron powder having a true specific gravity of up to 7.0 is feasible and liquids having specific gravities within the range of 2.6 to 3.5 can be formed by changing the ratio of iron powder mixed in. Aluminium alloys as well as certain types of ore can be subjected to sink-float separation using a high-specific gravity liquid having a specific gravity of 3.5.

0023It is also effective to add fine particles (slime) of some clay minerals for the purpose of maintaining the stability of the above-described specific gravity liquid of iron powder.

0024Since there is no industrial example in which various raw materials are subjected to sink-float separation using the above-described specific gravity liquid obtained by using iron powder as a medium, this invention will allow the development of a new industrial field in which iron powder is used as a new heavy media material.

0025As described above, in the present invention, a liquid having a specific gravity of 2.6 or more is formed by using iron powder composed of fine particles having a size of 40 microns or less, depending upon the intended use, and various raw materials such as metals or ores are poured into the specific gravity liquid so as to be subject­ed to sink-float separation. Therefore, aluminium or an alloy thereof having a high specific gravity can be separated and concentrated with high precision from shredded automobile scrap or scrap derived from domestic appliances, and substances which cannot be separated by conventional methods can thus be separated. In addition, since the specific gravity liquid using iron powder has low viscosity, the present invention enables separation and concentration of fine particles having a size down to about 3 mm, which is smaller than what can be separated by conventional methods, and offers the excellent effect that precise sink-float separation is possible.