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In the context of the booming development of new energy materials industry, the precise separation of mica impurities in the deep processing of quartz sand has become a key link to enhance the added value of products. Based on the differences in mineral crystallographic properties, this paper systematically elaborates the synergistic application strategies of seven core separation technologies, and focuses on analyzing the technological breakthroughs of a new generation of intelligent sorting equipment.
The three-stage crushing system (jaw + cone + high-pressure roller mill) is used to crush the raw ore to -5mm particle size, and selective grinding is realized through the new vertical agitator mill (operating parameters: filling rate of 35%-40%, rotational speed of 65% of the critical value). This process can increase the complete retention rate of mica flake structure to 92%, and at the same time, make the quartz matrix reach the ideal dissociation degree of -200 mesh accounting for 85%.
Pharmacy system innovation: adopting amphiphilic Gemini type collector (sodium dodecyldiphenyl ether disulfonate), 40% more selective than traditional amine-based pharmaceuticals.
Dynamic parameter control: integrating on-line XRF analyzer and fuzzy PID control system, real-time adjustment of slurry pH (8.5-9.2), temperature (25±2℃), and chemical concentration (50-80ppm).
Equipment upgrading: equipped with inflatable microbubble flotation column, bubble size control at 0.3-0.8mm, mica recovery rate of up to 94.2%
Due to the small density difference between mica and quartz, re-election is usually not the preferred method, but in some cases, re-election can be used as an auxiliary means. Re-election equipment such as jig and shaking table, through the optimization of the feed volume, flushing water pressure and other parameters, to achieve further separation of mica and quartz.
Utilizing the different morphology of mica and quartz formed during the crushing process (mica remains flaky, while quartz and other minerals are crushed into grains), mica and quartz are separated by wind separation. Wind separation equipment such as wind separator, through the adjustment of wind speed and air volume, the mica flake particles and quartz granular particles will be effectively separated.
Electrowinning can utilize the electrical difference between mica and quartz for separation, but it is usually not the main separation method because their electrical difference is small. Electrowinning equipment, such as an electrowinning machine, separates mica and quartz particles by subjecting them to different electric field forces in an electric field through the action of a high-voltage electric field.
Development of citric acid/oxalic acid composite leaching system (concentration 0.5mol/L, 60℃), together with the membrane separation and recovery system, so that the acid consumption is reduced by 70%, and the reuse rate of wastewater is over 90%. Compared with the traditional hydrofluoric acid method, the purity of mica in this method is upgraded by 2 grades (up to 99.3%), and it complies with GB8978-2022 emission standards.
In practice, a combination of methods is often used to improve the separation efficiency of mica. For example, preliminary separation can be carried out by flotation, and then further purification can be carried out by air separation or re-election. The combined process can give full play to the advantages of various methods and improve the recovery rate of mica and the quality of concentrate.
Through the above methods, mica can be effectively separated from quartz. The specific separation method needs to be selected and optimized according to the nature of the ore and the requirements of the target product. Our company provides one-stop service from beneficiation test, process design to equipment installation and commissioning to help customers realize the efficient operation of mica separation and enhance the product value.
[Application Case] A photovoltaic glass sand project adopts the process package of “high-pressure crushing-compound flotation-photoelectricity separation” and builds a 200t/d production line. Operation data show that: mica separation efficiency reaches 98.7%, mica residue in quartz sand is ≤0.03%, product premium is increased by $41/ton, and payback period is shortened to 14 months.
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