Claims:We Claim:

1. A hydrocyclone (100) for separating particles of iron ore, the hydrocyclone (100) comprising:
a housing (1), defined with an inlet port (4) tangential to a longitudinal axis (9) of the housing (1) for feeding particles of the iron ore and an outlet port (5) distantly positioned from the inlet port (4); and
a vortex finder (6), coaxially extending in the housing (1) to separate the particles of the iron ore, the vortex finder (6) is defined with a helical rib (7) integrally formed on an outer surface of the vortex finder (6) to channelize the particles of the iron ore along the housing (1), wherein the inlet port (4) is defined tangentially relative to the vortex finder (6), to impart centrifugal force on the particles of the iron ore for channelizing along the helical rib (7);
wherein the helical rib (7) is configured to increase travel period of the particles of the iron ore about the vortex finder (6) and along the housing (1) such that, the particles of the iron ore are separated based on particle size.

2. The hydrocyclone (100) as claimed in claim 1, wherein the housing (1) comprises:
a cylindrical section (2) defined with the inlet port (4); and
a frustoconical section (3) extending from the cylindrical section (2), wherein an end of the frustoconical section (3) defines the outlet port (5).

3. The hydrocyclone (100) as claimed in claim 2, wherein the cylindrical section (2) is defined with an opening through which the vortex finder (6) coaxially extends in the housing (1).

4. The hydrocyclone (100) as claimed in claim 2, wherein the outlet port (5) of the housing (1) is configured to dispense the particles of the iron ore having a predefined particle size.

5. The hydrocyclone (100) as claimed in claim 1, wherein the inlet port (4) is tangentially defined in the cylindrical section (2) of the housing (1).

6. The hydrocyclone (100) as claimed in claim 1, wherein the vortex finder (6) is defined with an elongated conduit (8) and is configured to draw separated particles of the iron ore travelling along the helical rib (7) and proximal to the outer surface of the vortex finder (6).

7. The hydrocyclone (100) as claimed in claim 1, wherein the helical rib (7) extends on the outer surface of the vortex finder (6) at a defined helix angle, for channelizing and increasing travel path of the particles of the iron ore.

8. The hydrocyclone (100) as claimed in claim 1, wherein the particles of the iron ore travel along each helix of the helical rib (7) about the vortex finder (6) and along the length of the housing (1) such that travel period of the particle of the iron ore is increased.

9. The hydrocyclone (100) as claimed in claim 1, wherein the particles of the iron ore with the predefined particle size include larger particles travelling along the helical rib (7) and proximal to an inner surface of the housing (1).

Dated this 29th of March 2021
GOPINATH A S
IN/PA – 1852
OF K&S PARTNERS
AGENT OF THE APPLICANT(S)

, Description:FORM 2

THE PATENTS ACT 1970

[39 OF 1970]
&
THE PATENTS RULES, 2003

COMPLETE SPECIFICATION

[See section 10; rule 13]

TITLE: “A HYDROCYCLONE FOR SEPARATING PARTICLES OF IRON ORE”

Name and Address of the Applicant:
TATA STEEL LIMITED of Jamshedpur - 831001, Jharkhand, India.

Nationality: Indian

The following specification particularly describes the invention and the manner in which it is to be performed.

TECHNICAL FIELD
Present disclosure, in general, relates to metallurgy. Particularly, but not exclusively, the present disclosure relates to processing and separation of iron ore. Further, embodiments of the present disclosure disclose a hydrocyclone for separating particles of the iron ore.

BACKGROUND OF THE DISCLOSURE

Generally, to produce steel, iron ore with high percentage of iron constituents is required. The iron ore with high percentage of iron constituents have been depleting due to the prolonged mining to produce steel. With the depletion in quality of grade of the iron ore being available, further processing of such iron ores may be required to be carried out, to extract iron ore of sufficient quality for use in manufacturing steel. In general, for steel manufacturing, iron ore having at least 30 percent of iron composition may be considered as high-grade iron ore and may be used in processing for production of steel. Whereas the iron ore having iron composition below such minimum requirement may be classified as low-grade iron ore and may be discarded or be subjected to further refining processes to render the same capable of being employed in production of steel.

The low-grade iron ore includes high alumina content, which when fed to a blast furnace to produce the steel, may lead to increased slag production and increased energy consumption in the blast furnace. To process the low-grade iron ore and render the same being capable of use in production of steel, alumina particles in such low-grade iron ore may be required to be reduced. Further, the low-grade iron ore are easily available as the rejected low-grade iron ore during production of steel from iron ore with high percentage of iron constituents are stockpiled in industries which may be employed to produce steel.

Typically, the alumina particles present in the low-grade iron ore consists of minute dimensions and have a smaller size compared to the required iron ore which generally is coarser and have larger dimensions than the alumina particles. Conventionally, a hydrocyclone is employed to filter the iron ore particles. However, as the size of the low-grade iron ore is small, the alumina particles mixed with the iron ore particles do not separate and the iron ore collected after passing through the hydrocyclone is unfit for producing steel.

The present disclosure is directed to overcome one or more limitations stated above or any other limitations associated with the conventional mechanisms.

SUMMARY OF THE DISCLOSURE

One or more shortcomings of the prior art are overcome by a device as claimed and additional advantages are provided through the device as claimed in the present disclosure. Additional features and advantages are realized through the techniques of the present disclosure. Other embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed disclosure.

In one non-limiting embodiment of the present disclosure a hydrocyclone for separating particles of iron ore is disclosed. The hydrocyclone includes a housing that is defined with an inlet port tangential to a longitudinal axis of the housing. The inlet port is configured to feed particles of the iron ore. Further an outlet port is distantly positioned from the inlet port. A vortex finder coaxially extends in the housing to separate the particles of the iron ore. The vortex finder is defined with a helical rib integrally formed on an outer surface of the vortex finder to channelize the particles of the iron ore along the housing. The inlet port is defined tangentially relative to the vortex finder, to impart centrifugal force on the particles of the iron ore for channelizing along the helical rib. Furthermore, the helical rib is configured to increase travel period of the particles of the iron ore about the vortex finder and along the housing such that, the particles of the iron ore are separated based on particle size.

In an embodiment, the housing includes a cylindrical section defined with the inlet port and a frustoconical section extending from the cylindrical section, where an end of the frustoconical section defines the outlet port.

In an embodiment, the cylindrical section is defined with an opening through which the vortex finder coaxially extends in the housing.

In an embodiment, the outlet port of the housing is configured to dispense the particles of the iron ore having a predefined particle size.

In an embodiment, the inlet port is tangentially defined in the cylindrical section of the housing.

In an embodiment, the vortex finder is defined with an elongated conduit and is configured to draw separated particles of the iron ore travelling along the helical rib and proximal to the outer surface of the vortex finder.

In an embodiment, the helical rib extends on the outer surface of the vortex finder at a defined helix angle, for channelizing and increasing travel path of the particles of the iron ore.

In an embodiment, the particles of the iron ore travel along each helix of the helical rib about the vortex finder and along the length of the housing such that travel period of the particle of the iron ore is increased.

In an embodiment, the particles of the iron ore with the predefined particle size include larger particles travelling along the helical rib and proximal to an inner surface of the housing.

The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The novel features and characteristic of the disclosure are set forth in the appended claims. The disclosure itself, however, as well as a preferred mode of use, further objectives, and advantages thereof, will best be understood by reference to the following detailed description of an illustrative embodiments when read in conjunction with the accompanying figures. One or more embodiments are now described, by way of example only, with reference to the accompanying figures wherein like reference numerals represent like elements and in which:

Figure 1 illustrates a schematic view of a hydrocyclone for separating particles of iron ore, in accordance with an embodiment of the present disclosure.

Figure 2 illustrates a schematic view of a helical rib formed on an outer surface of a vortex finder, in accordance with an embodiment of the present disclosure.

The figures depict embodiments of the disclosure for purposes of illustration only. One skilled in the art will readily recognize from the following description that alternative embodiments of the system and method illustrated herein may be employed without departing from the principles of the disclosure described herein.

DETAILED DESCRIPTION

The foregoing has broadly outlined the features and technical advantages of the present disclosure in order that the detailed description of the disclosure that follows may be better understood. Additional features and advantages of the disclosure will be described hereinafter which form the subject of the claims of the disclosure. It should be appreciated by those skilled in the art that, the conception and specific embodiments disclosed may be readily utilized as a basis for modifying other devices, mechanisms, systems, assemblies, methods, and processes for carrying out the same purposes of the present disclosure. It should also be realized by those skilled in the art that, such equivalent constructions do not depart from the scope of the disclosure as set forth in the appended claims. The novel features which are believed to be characteristics of the disclosure, to its system, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present disclosure.

The terms “comprises”, “comprising”, or any other variations thereof, are intended to cover a non-exclusive inclusions, such that a mechanism, an assembly, or a device that comprises a list of components or steps does not include only those components or steps but may include other components or steps not expressly listed or inherent to such setup or device or method. In other words, one or more elements in a system or apparatus proceeded by “comprises… a” does not, without more constraints, preclude the existence of other elements or additional elements in the system or apparatus.

In accordance with various embodiments of the present disclosure, a hydrocyclone for separating particles of iron ore is disclosed. The hydrocyclone includes a housing that is defined with an inlet port tangential to a longitudinal axis of the housing. The inlet port is configured to feed particles of the iron ore. Further an outlet port is distantly positioned from the inlet port. A vortex finder coaxially extends in the housing to separate the particles of the iron ore. The vortex finder is defined with a helical rib integrally formed on an outer surface of the vortex finder to channelize the particles of the iron ore along the housing. The inlet port is defined tangentially relative to the vortex finder, to impart centrifugal force on the particles of the iron ore for channelizing along the helical rib. Furthermore, the helical rib is configured to increase travel period of the particles of the iron ore about the vortex finder and along the housing such that, the particles of the iron ore are separated based on particle size. The increase in travel period due to the helical rib may lead to separation of particles having minute dimensions.

Reference will now be made to the exemplary embodiments of the disclosure, as illustrated in the accompanying drawings. Wherever possible, same numerals will be used to refer to the same or like parts. The following paragraphs describe the present disclosure with reference to Figures 1 and 2.

A hydrocyclone (100) may be employed to classify, separate and/or sort particles from a feed based on a centrifugal force of the particles. The centrifugal force may be high for dense (where separation by density is required) and coarse (where separation by size is required) particles, and low for light and fine particles. The hydrocyclone (100) is configured to create a vortex through which a mixture injected into the hydrocyclone (100) is configured to flow, where the dense and coarse particles undergo centrifugal acceleration which causes the dense and coarse particles to move away from the central core of the vortex. Further, the light and fine particles having lesser weight and lesser dimensions compared to the dense and coarse particles in the vortex move towards the central core of the vortex. The light and fine particles collected at the central core of the vortex are discarded out of the hydrocyclone (100) and the dense and the coarse particles may be collected.

The hydrocyclone (100) may be employed in an iron ore washing plant for processing iron ore, where processing may be carried out by subjecting the particles of iron ore in fluids to classify the particles of the iron ore. The particles of the iron ore having particle size less than 0.15mm may be introduced into the hydrocyclone (100) for classification of the particles of the iron ore based on particle size.

Figure 1 is an exemplary embodiment which illustrates the hydrocyclone (100) for separating particles of iron ore. The hydrocyclone (100) includes a housing (1) defined with a cylindrical section (2) and a frustoconical section (3) extending from the cylindrical section (2). An end of the frustoconical section (3) with larger diameter may be connected to the cylindrical section (2). Further, the housing (1) may be defined with an inlet port (4), which is tangential to a longitudinal axis (9) of the housing (1). The inlet port (4) may be defined in the cylindrical section (2) of the housing (1) and may be disposed tangential to the cylindrical section (2) of the housing (1) to feed particles of the iron ore. Further, an outlet port (5) may be defined in the housing (1) which may be distantly positioned from the inlet port (4). In an exemplary embodiment, the outlet port (5) may be defined at an end of the frustoconical section (3) with a smaller diameter. The outlet port (5) may be configured to dispense the particles of the iron ore having a predefined particle size. The predefined particle size may be based on the percentage of iron composition associated with size of the particles of the iron ore.

Further, the hydrocyclone (100) may include a vortex finder (6). The vortex finder (6) may coaxially extend in the housing (1) and a portion of the vortex finder (6) may be circumscribed by cylindrical section (2) of the housing (1) to separate the particles of the iron ore. In an exemplary embodiment, the vortex finder (6) may be adapted to extend through an opening defined in the cylindrical section (2) of the housing (1). The vortex finder (6) may be defined with as an elongated conduit (8) which may be configured to draw separated particles of the iron ore which are less than the predefined particle size travelling in the housing (1). The vortex finder (6) may be configured to draw the separated particles of the iron ore which are less than the predefined particle size as a low-pressure region may be created along the longitudinal axis (9) of the housing (1) due to the vortex created in the housing upon tangentially feeding the particles of the iron ore. The particles drawn by the low-pressure region may be channelized out of the housing (1) through the vortex finder (6).

In an embodiment, the hydrocyclone (100) may be configured to separate the particles of the iron ore based on a centrifugal force induced during feeding of the particles of the iron ore tangentially into the housing (1), that causes particles of the iron ore to move in a circular path in the housing (1). Further, an air core may be created at the center of the housing (1) due to the due to the vortex created by the particles of the iron ore entering the housing (1) through the inlet port (4). The air core may be configured to extend into the vortex finder (6). The centrifugal force enables the particles of the iron ore with the predefined particle size to travel along the inner surface of the housing (1) and enables the particles of the iron ore having size less than the predefined particle size to travel along the outer surface of the vortex finder (6). Suction forces may be created by the air core to draw the iron ore having size less than the predefined particle size travelling proximal to the vortex finder (6) into the vortex finder (6) and dispose out of the hydrocyclone (100). Further, the particles of the iron ore having the predefined particle size remaining in the housing (1) may be collected at the outlet port (5) of the housing (1).

Referring to Figure 2, the vortex finder (6) may be defined with a helical rib (7). The helical rib (7) may be integrally formed on an outer surface of the vortex finder (6). The helical rib (7) formed on the vortex finder (6) may be configured to channelize the particles of the iron ore along each helix of the helical rib (7) in the housing (1). Further, the helical rib (7) may be configured to increase travel period of the particles of the iron ore about the vortex finder (6) and along the housing (1) as the particles of the iron ore are channelized along each helix of the helical rib (7) such that, the particles of the iron ore are separated based on particle size. Furthermore, the vortex finder (6) may be disposed such that the inlet port (4) may be defined tangentially relative to the vortex finder (6) to impart centrifugal force on the particles of the iron ore entering the housing (1) and channelizes the flow of the particles of the iron ore along the helical rib (7).

Further, the helical rib (7) may extend on the outer surface of the vortex finder (6) at a defined helix angle for channelizing and increasing the travel path of the particles of the iron ore. The helical rib (7) may be defined in a direction of flow of the particles of the iron ore entering the housing (1) from the inlet port (4) which prevents turbulence from forming in the cylindrical section (2) of the housing (1). Each helix of the helical rib (7) may be defined in the direction of flow of the particles of the iron ore, where such helix of the helical rib (7) may guide the particles of the iron ore along the helix and length of the housing (1). In an embodiment, the particles of the iron ore travel along each helix of the helical rib (7) about the vortex finder (6) and along the length of the housing (1) such that, travel period of the particle of the iron ore is increased to prevent early removal i.e., before the separation of the particles of the iron ore from the housing (1) through the vortex finder (6). The increased travel period and the centrifugal force enables the particles of the iron ore with the predefined particle size which include larger particle to travel along the helical rib (7) and proximal to an inner surface of the housing (1). The particles of the iron ore having particle size lesser than the predefined particle size travel along the helical rib (7) and proximal to the vortex finder (6) in the housing (1). Furthermore, the vortex finder (6) may be configured to draw the separated particles of the iron ore having particle size lesser than the predefined particle size travelling along the helical rib (7) and proximal to the outer surface of the vortex finder (6) and dispense the particles having particle size lesser than the predefined particles size out of the housing (1). The increase in the travel period due to the helical rib (7) increases residence time of the particles of the iron ore in the housing (1) which in-turn improves a separation efficiency of the hydrocyclone (100).

In an embodiment, the particles collected at the outlet port (5) of the hydrocyclone (100) may be classified as the desired particles of the iron ore having the predefined particle size and the particles of the iron ore collected from the vortex finder (6) having the particle size less than the predefined particle size may be classified as inferior quality and may be considered as slimes.

In an embodiment, the particles of the iron ore fed into the hydrocyclone (100) may contain particles having high percentage of iron composition. The particles having high percentage of iron composition are classified as the particles having the predefined particle size. Further, the particles of the iron ore may include other impurities such as but not limited to alumina and other particles which reduces the grade of the particles of the iron ore. Alumina may have dimensions lesser than predefined particle size, for example, particle size equal to or less than 150microns. The particles of the iron ore when fed into the hydrocyclone (100) attain centrifugal force due to the tangential inlet port (4) and are channelized along the helical rib (7). Further, the particles having high percentage of iron composition are channelized proximal to the inner surface of the housing (1) due to the heavy weight. Furthermore, the alumina having dimensions lesser than predefined particle size and less weight may be channelized with the particles having predefined particle size. Due to the increased travel period of the particles of the iron along each helix of the helical rib (7). The alumina is separated from the particles having predefined particle size and channelizes along each helix of the helical rib (7) proximal to the vortex finder (6) due to less weight compared to the particles having high percentage of iron composition. The alumina proximal to the vortex finder (6) may be drawn into the vortex finder and discarded from the hydrocyclone (100). In contrast the particles having predefined particle size having high percentage of iron composition that is channelized proximal to the inner surface of the housing (1) may be collected at the outlet port (5) for producing a required metal.

In an embodiment, the hydrocyclone (100) may be capable of treating slurry having 10% solids by weight. In an embodiment, the hydrocyclone (100) with the helical rib (7) may reduce 28-33% of alumina at the outlet. Further, the hydrocyclone (100) may be configured to recover at least 59% of iron content from low-grade iron ores.

In an embodiment, the vortex finder (6) may be defined with a cylindrical profile having a wall thickness of at least 7mm.

In an embodiment, the diameter of the vortex finder (6) may be at least 25mm and the outlet port (5) diameter may be at least 15mm based on the size of the particles of the iron ore channelized into the housing (1) at the inlet port (4).

In an embodiment, the width of the helical rib (7) may be at least 5mm.

In an embodiment, the dimensions of the helical rib (7) for example, pitch, height, width, length, angle number of helix and any other parameter may be varied to increase or decrease a separation efficiency of the hydrocyclone (100). Further, dimensions of the helical rib (7) may be varied based on the size of the particles of the iron ore and velocity at which such particles of the iron ore may be fed into the hydrocyclone (100).

In an embodiment, the helical rib (7) may be formed over a full length of the vortex finder (6). Further, the helical rib (7) may be formed on at least a portion on the outer surface of the vortex finder (6).

In an embodiment, the vortex finder (6) may be defined with a connecting portion protruding from the outer surface of the vortex finder (6) which is configured to secure the vortex finder (6) with the housing (1).

In an embodiment, the helical rib (7) may be removably fixed on the outer surface of the vortex finder (6). Further, the vortex finder (6) may be configured to selectively accommodate helical ribs (7) configured to be removably fixed on the outer surface of the vortex finder (6) having different dimensions based on the size of the particles of the iron ore fed into the housing (1).

In an embodiment, the helical rib (7) may be disposed between the vortex finder (6) and the inner surface of the housing (1) to channelize the particles of the iron ore. Further, the helical rib (7) may be disposed on the inner surface of the housing (1) to channelize the particles of the iron ore.

In an embodiment, a conduit may be structured to extend from the inlet port (4) to receive the particles of the iron ore.

In an embodiment, the helical rib (7) improves rejection efficiency of small and lighter particles in the hydrocyclone (100).

In an embodiment, the helical rib (7) in the hydrocyclone (100) enables beneficiation of low-grade iron ore having size less than 150 microns.

In an embodiment, majority of alumina in the iron ore may be drawn out of the housing (1) through the vortex finder (6) due to the increased residence time. Further, the grade of the iron ore in finer sizes is improved by removal of alumina for steel production through blast furnace.

In an embodiment, the helical rib (7) minimizes turbulence generation in the housing (1).

Equivalents:
With respect to the use of substantially any plural and/or singular terms herein, those having skill in the art can translate from the plural to the singular and/or from the singular to the plural as is appropriate to the context and/or application. The various singular/plural permutations may be expressly set forth herein for sake of clarity.
It will be understood by those within the art that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as “open” terms (e.g., the term “including” should be interpreted as “including but not limited to,” the term “having” should be interpreted as “having at least,” the term “includes” should be interpreted as “includes but is not limited to,” etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases “at least one” and “one or more” to introduce claim recitations. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles “a” or “an” limits any particular claim containing such introduced claim recitation to inventions containing only one such recitation, even when the same claim includes the introductory phrases “one or more” or “at least one” and indefinite articles such as “a” or “an” (e.g., “a” and/or “an” should typically be interpreted to mean “at least one” or “one or more”); the same holds true for the use of definite articles used to introduce claim recitations. In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of “two recitations,” without other modifiers, typically means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). In those instances where a convention analogous to “at least one of A, B, or C, etc.” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and/or A, B, and C together, etc.). It will be further understood by those within the art that virtually any disjunctive word and/or phrase presenting two or more alternative terms, whether in the description, claims, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”
In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.
While various aspects and embodiments have been disclosed herein, other aspects and embodiments will be apparent to those skilled in the art. The various aspects and embodiments disclosed herein are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

Referral Numerals:

Reference Number Description
100 Hydrocyclone
1 Housing
2 Cylindrical section
3 Frustoconical section
4 Inlet port
5 Outlet port
6 Vortex finder
7 Helical rib
8 Elongated conduit
9 Longitudinal axis of housing