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A new method for gravity separation: Vibrating table gravity concentrator

Article  in  Separation and Purification Technology · September 2018

DOI: 10.1016/j.seppur.2018.09.074

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 Separation and Purification Technology 211 (2019) 124–134

Contents lists available at ScienceDirect

Separation and Purification Technology

journal homepage: www.elsevier.com/locate/seppur

A new method for gravity separation: Vibrating table gravity concentrator T

Özcan Yıldırım Gülsoy, Ergin Gülcan
⁎

Hacettepe University, Mining Engineering Department, Mineral Processing Division, 06800, Beytepe, Ankara, Turkey

ARTICLE INFO ABSTRACT

Keywords: This paper discusses recently developed gravity concentration equipment, namely vibrating table, and reports
Vibrating table detailed descriptions of the equipment in terms of principles of design and their effects on operational para-
Gravity concentration meters. Vibrating table originally combines the known physical phenomena of a teetered bed, resistance to water
Hydrosizer flow, vibration, and density differences. The resulting effect of these combined forces can also be manipulated by
Hydrocyclone
integrated settings of feed rate, solid %, plate inclination, and water rate. Following the detailed description of
Shaking table
Chromite ore
the equipment, mineral separation tests with two different chromite ores obtained from industrial applications
were performed in order to investigate the performance of the laboratory scale vibrating table. While former
chromite ore had low grade with complex mineralogy and inadequate liberation, the latter had high grade
consisting of liberated lumpy chromite particles. Experimental studies were focused on investigating the effect of
plate inclination, removal of slimes, ore type, size classification, and particle size on separation performance.
Within the tests performed with −600 µm, −800 µm, and −1000 µm high grade chromite ores under certain
conditions, it was observed that increase in particle size results in a dramatic increase in recovery, while % grade
decreases slightly. In another test with high grade chromite ore, sustainable product qualities were achieved up
to a recovery of 93.22% in comparison with the 66.08% achieved with a conventional shaking table, within and
approx. 47–48% final grade level. Additionally, product grades and recoveries up to 50.20%–58.36% with de-
slimed −400 µm low grade chromite feed and 53.68%–67.45% with deslimed −200 µm low grade chromite
feed were obtained, respectively.

1. Introduction
In its simplest definition, gravity concentration is a class of methods
which take advantage of the density differences among mineral parti-
cles [1–3]. As a result, particles of which densities are different from
each other have their own relative movement against the forces of the
gravity depending on the factors such as viscosity of the environment,
resistance to the motion in viscous environment, density, weight, par-
ticle size, and shape or a relevant combination of them [4]. Although
interest in gravity concentration dates back to Homer's Odyssey ac-
cording to Wills’ [5], cultivating for modern methods and technologies
for the need of better recovery and production continued [6–8].
After decades of research and development, various number of
gravity concentration equipment and application have been reviewed
successfully. Some of the most popular examples and successful appli-
cations are the ones with jigs or centrifugal jigs (gold bearing sulfide
minerals, tin, mineral sands, chromite, iron, coal, etc. [9–12]), cen-
trifugal gravity concentrators such as Knelson and Falcon (gold, copper,
platinum, chromite ore, coal, etc. [13–17]), teetered bed separators
(coal, chromite, manganese, etc., [18–20]), FGX dry separators (coal
[21,22]), air table separators (coal [23,24]), dense medium separators
such as dense medium cyclone (coal and minerals [25,26]), spiral
concentrators (chromite, sand, coal, iron, etc. [27–29]), shaking tables
(chromite, gold, rare earth minerals [30–33]), and multi-gravity se-
parators (chromite, coal, graphite, rare earth minerals [34–37]). Among
the afore mentioned methods and equipment, shaking tables are one of
the oldest yet the most effective appliances allowing to process a wide
range of minerals and coal having various particle size ranges from
15 mm down to 10–15 µm [38,5,31]. Capacity of a shaking table is in
the range between 0.5 tons per hour and approx. 1.5–2 tons per hour
depending on the particle size processed. Therefore, it is usually a
standard in the industry to install tens of shaking tables in series or
parallel in order to process excessive tonnages, especially in chromite
processing. Hence, new problems arise due to the required space for
installation, equipment control difficulties accompanied by increase of
the number of installations, and need for more automated flowsheets.
Besides the wide range of use, easiness, and effectiveness of gravity
concentration without the need for any chemical intervention, low
capacities of the equipment and increasing demand for better produc-
tion always made it the last resort to be considered when all other

⁎
Corresponding author.
E-mail address: ergingulcan@hacettepe.edu.tr (E. Gülcan).

https://doi.org/10.1016/j.seppur.2018.09.074
Received 18 April 2018; Received in revised form 11 September 2018; Accepted 25 September 2018
Available online 26 September 2018
1383-5866/ © 2018 Elsevier B.V. All rights reserved.
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

methods fail. Therefore, search for enhanced gravity concentration solid percent. Sample particles17 are contained in a teetered bed12, within
methods are all in progress either by investigating the better versions of of which volume the denser particles14 move downwards at relatively
current setups or attempting to invent totally new perspectives based on higher velocities in comparison with lighter particles13. Consequently,
gravity differences in order to achieve possible alterations in % grade the submerged dense particles14 are transported horizontally upward
and recovery of final products [1,2,5,7]. from the teetered bed through the serrated surface of the groove10 of the
The purpose of this study is to investigate the performance of a inclined chute1 by linear vibration. Vibration frequency9 is controlled by a
recently developed gravity concentration system, namely “vibrating unit9 which can be adjusted depending on the sample characteristics.
table” [39], and highlight the effect of operational parameters in al- Meanwhile, the light particles13 and those above the layer of the teetered
tering the product qualities. Therefore, configured new system was bed drag to the tailing stream by the water3&4 through the inclination
revealed in detail and exemplary chromite processing studies had been direction, and they are separated. Water within the process is supplied
performed. Within the experimental studies, vibrating table perfor- via wash water4 (WW) and teetering water (TW) jets3. While WW4 cleans
mance was investigated at various particle sizes under different the concentrate from by-passing lighter particles13, TW3 helps form the
equipment specific parameters. For this purpose, either vibrating table fluidized bed where the actual separation takes place. TW rate3, and
was integrated into some basic mineral processing flowsheets or used WW flow4 are the most important operational parameters which are
solely. Effect of size classification and desliming prior to the operation adjusted by a water rate adjustment unit, and solenoid valve control
was also investigated. Finally, performance of a vibrating table in unit7, respectively.
comparison with the shaking table had been tested under similar con- Additionally, the water level of the teetered bed is also critical.
ditions. Following the data collection, product qualities of each test and Denser particles14 are drawn away from the bed, travel horizontally
their possible impact on overall performance was investigated. upwards on the serrated surface of the groove10, and leave the system
through product discharge16. Inclination of the chute is set via a tilt ad-
2. Equipment descriptions justment bar11 placed under the chute, which also effects water level cut
point18 of the teetered bed. Meanwhile, lighter particles13 having lower
The recently developed gravity concentration system namely “vi- specific gravity tend to layer on the top of the denser particles14.
brating table” shown in Fig. 1 allows the particles to be separated from Consequently, with the effect of drag force of the water flow, lighter
each other due to density differences [39]. A heterogeneous mixture of particles13 leave the system from tail discharge15. It is important to note
particles is fed to the inclined chute1 either dry or wet with a substantial that, gravity powered separation process is started after a steady state
fluidized bed is formed. Therefore, after reaching the steady state,
10 3 properties of the bed forming material are constant unless there is a
8
15 change in the operational parameters.
1. Inclined chute
7
1 The inclined chute1 is vibrated via one or two magnetic vibration
2. Magnetic vibration unit
3. Teetering water jet device(s) depending on the width of the chute. This unit provides
4 2 9 4. Wash water jet single-directional vibrations. The chute can be manufactured to have a
5 5. Vertical steel plate
11 6. Main frame width of 20 cm to 100 cm and a length of 50 cm to 150 cm. The chute is
7. Solenoid valve control unit fixed to the magnetic vibration unit2 which is a ready-to-use system with
6
8. Solenoid valve amplitude and frequency control. The unit is mounted on a horizontal
9. Vibrator frequency control unit
10. Serrated groove surface steel plate5 whose inclination is adjustable. The steel plate5 is mounted
11. Tilt adjustment bar on the main frame6 (a table with four legs) to fix the device in place
17 1 14 4 12. Teethered bed
(Fig. 1).
18 13. Lighter particles
15 13 14. Denser particles The groove10 on the inclined chute1 can be made of stainless steel,
16
15. Tail discharge painted normal steel, fiberglass, etc., a sufficiently hard and durable
16. Product discharge
12 17 16 17. Sample particles (ore)
material. The serrated groove surface10 may be smooth, rough or saw-
3 18. Water level cut point toothed as the sandpaper surface. The surface of the groove10 can be
2 made as desired by coating.
Side view 15
Side perspective view 3. Experimental studies
(a)
3.1. Sample characterization

In the experimental work, run of mine samples from two different

operating chromite processing plants in Sivas and Denizli regions of
Turkey were studied. In order to evaluate the method from different
angles, dissimilar chromite samples had been selected according to
mineralogical, grade, liberation and lithological considerations.
Chromite ore of Sivas region had low initial grade and insufficient
liberation degree in comparison with the Denizli region’s ore.
Therefore, characterization studies had been performed individually for
each ore as follows.

3.1.1. Characterization of the low grade chromite ore

Detailed characterization studies of the relatively problematic low
grade chromite ore were carried out on physical, chemical and miner-
alogical bases. Hence, particle size distribution, specific gravity, mi-
(b) neralogy, and basic mineralization related to grain sizes were de-
termined. The brief mineralogy of the ore was determined by optical
Fig. 1. Vibrating table gravity separator schematical representation (a) and microscopy and XRD method, while quantitative mineralogy and lib-
actual views (b). eration analysis were carried out with scanning electron microscopy.

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Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Table 1
Brief roundup of experimental procedures.
Feed sample description Equipment Classification Operation intricacies

−400 µm low grade ore Vibrating table not applied 9°, 7°, and 5° plate inclinations applied
−400 µm low grade ore Vibrating table deslimed with hydrocyclone 9°, 7°, and 5° plate inclinations applied
−200 µm low grade ore Vibrating table not applied 4°, 3°, and 2° plate inclination applied
−200 µm low grade ore Vibrating table deslimed with hydrocyclone 4°, 3°, and 2° plate inclination applied
−1000 µm high grade ore Vibrating table not applied Lowest liberation
−800 µm high grade ore Vibrating table not applied Moderate liberation
−600 µm high grade ore Vibrating table not applied Highest liberation
−1000 µm high grade ore Shaking table classified with hydrosizer 1st reservoir was fed
−1000 µm high grade ore Shaking table classified with hydrosizer Combined 2nd, 3rd, and 4th reservoirs were fed
−1000 µm high grade ore Vibrating table classified with hydrosizer 1st reservoir was fed
−1000 µm high grade ore Vibrating table classified with hydrosizer Combined 2nd, 3rd, and 4th reservoirs were fed
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −600 + 75 µm of U/F was fed after screening
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −600 + 212 µm of U/F was fed after screening
−600 µm high grade ore Vibrating table deslimed with hydrocyclone −212 + 75 µm of U/F was fed after screening

Over flow Fig. 2. Schematic view of the tests in which feed

Feed
samples were either directly fed to the vibrating
(Slimes)
Chromite Feed table or after removal of slimes via hydrocyclone
(a; applied to −400 µm and −200 µm low grade
product Hydrocyclone chromite samples; and −1000 µm, −800 µm, and
−600 µm high grade chromite samples. b; de-
Under
Chromite sliming was applied to −400 µm and −200 µm low
Vibrating table flow grade chromite ores).
Tail product

Vibrating table
Tail
(a) (b)

Specific gravity (SG) of the as-received sample was measured as 2.69
with a pycnometer of which top particle size was 14.47 mm
(f80 = 12.3 mm). Fe2+Cr2O4, Fe2O3, SiO2, CaCO3, Mg2SiO4 (lizardite),
and Mg(OH)2 contents of the low grade chromite ore were determined
by chemical analysis as 5.04–5.25%, 0.209%, 0.205%, 1.24%, 86.46%,
and 5.48%, respectively. Previous studies and visual observations
showed that chromite liberation of this particular ore was starting
below 600 μm [40] and reaches up to approx. 80% below 212 μm.
Accordingly, sample preparation efforts were focused on crushing the
original sample down to 400 µm (f80 = 348 μm) and 200 µm
(f80 = 151 μm), respectively.
X-ray Diffraction (XRD) analysis had also been performed with the
main batch to determine primary minerals along with the chromite
[40]. Chromite ore showed reasonable peaks related with the contents
observed in chemical analysis. In the analysis of the XRD patterns, Li-
zardite (Mg3Si2O5.OH), Brusit (Mg.OH) and chromite (Fe+2Cr2O4)
minerals were primarily determined.
Mineralogical analysis showed that the main mineral in the ore is
forsterite, which is a magnesium silicate mineral, and it is present in a
very high amount such as 86%. Other major minerals are brucite and
chromite. Both minerals are found in approximately 5–5.5% of the ore.
The percentages of Cr and Fe in chromite were 46.46% and 24.94%,
respectively. Forsterite and brucite have lower density values than
chromite concentration, which presumably provides an advantage in
gravity enrichment.
About 15% of chromite is bonded with other minerals. Additionally,
13.46% of this amount is originated from forsterite mineral. Forsterite
is more free than chromite, with a total of approx. 2% locked with other
minerals including chromite.
3.1.2. Characterization of the high grade chromite ore
High grade chromite ore delivered to the laboratory was below
300 mm in size, having a significant number of lumpy and high quality
chromite particles within. Cr2O3, Fe2O3, SiO2, Al2O3, and MgO contents
of the high grade chromite ore were determined by chemical analysis as
approx. 33–38%, 24.30%, 4.63%, 13.38%, and 18.33%, respectively.
Chromite liberation of high grade ore was starting below 1000 μm and
reaching up to approx. 75–80% below 425 μm. Majority of the chromite
(Cr2O3) was reported as free and liberated from the host minerals
providing a more convenient angle for concentration methodology
design. Therefore, lump particles in the original sample batch were
initially classified into two different grade batch by hand-picking.
Hence, two distinct groups of sample batches having approx. 32–33%
and 37–38% chromite content were obtained, respectively. Due to the
high liberation tendency and % chromite grade, each sample group was
ground below 1 mm (f80 = 825 μm for the former and f80 = 812 μm for
the latter). For more detailed examination, additional size reduction
had been performed with high grade chromite ore batches depending
on the application.
3.2. Methodology overview
Following the sample preparation via subsequent crushing and
grinding, various chromite processing flowsheets either to apply solely
using vibrating table or in combination with other gravity type equip-
ment were designed based on the properties of the sample batch. Brief
summary of the experimental methodology is given in Table 1. Initially,
vibrating table tests were performed with −400 µm and −200 µm low
grade chromite samples under varying plate inclinations of 9°, 7°, and
5° for the former and 4°, 3°, and 2° for the latter particle sizes (Fig. 2a).
Following, same plate inclinations were applied to process -400 µm and
−200 µm low grade chromite samples right after removing the slimes
with hydrocyclone (Fig. 2b). TW was kept constant in order to keep the
solid ratio of the feed around 30% by weight. WW was also set constant
to 0.75 L per minute (for a 20 cm chute opening) of water for a clear
observation of recovery changes related with the change in plate in-
clination.
In the experimental work with two distinct high grade chromite
samples, while the former one with approx. 32–33% chromite was di-
rectly fed to the vibrating table in three distinct size fractions (namely

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Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Hydrosizer
Feed Slime

1st 2nd, 3rd and 4th

reservoir reservoirs

To Cleaner and
Scavenger steps
Chromite
Product to Cleaner product

Vibrating table Vibrating table

Tail to Scavenger Cleaner tail
Chromite
product

Vibrating table
Scavenger
(a)

Hydrosizer

Feed Slime

1st 2nd, 3rd and 4th

reservoir reservoirs

Shaking table

1st product
2nd product Tail Shaking table
Midling

1st product
2nd product Tail
Midling
(b)
Fig. 3. Schematic view of the −1000 µm high grade chromite sample tests in which feed samples were primarily classified via hydrosizer (a: vibrating table tests, b:
shaking table tests).

−1000, −800, and −600 µm) (Fig. 2a), latter with approx. 37–38%
chromite content was first classified with hydrosizer. 1st reservoir and a
combination of 2nd, 3rd, and 4th reservoirs of hydrosizer were sepa-
rately fed to the both vibrating table (Fig. 3a) and shaking table
(Fig. 3b) in order to conduct a reasonable comparison between sibling
instruments. In the tests applied to hydrosizer products, two different
quality product were collected through the surface ending line of the
shaking table along with a middling product which is usually re-
processed (Fig. 3b). Considering that the vibrating table outputs consist
of a concentrate and a tailing, an additional cleaner stage was applied
to the 1st stage vibrating table tail which enabled a convenient com-
parison with shaking table (Fig. 3a). Nevertheless, combined products
were also compared in terms of grade and recovery values attained.
Finally, −600 µm high grade (approx. 37–38%) chromite sample
was fed to the hydrocyclone for the removal of the fines
(d50 = −75 µm) and clayey content (Fig. 4). After representatively
sampling from the underflow (U/F) stream of the hydrocyclone,
-600 + 75 µm product was wet classified with a 212 µm screen forming
two narrowly sized fractions namely −600 + 212 µm and
−212 + 75 µm samples. Then, −600 + 75 µm, −600 + 212 µm, and

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Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Over in products were calculated via Eq. (1).

flow
Feed
C × c × 100
R=
F×f (1)
Hydrocyclone
where
Underflow Vibrating table
-600+75 µm Chromite
product R: chromite recovery [%],
C: total amount of concentrate [g],
to cleaner step c: chromite grade in concentrate [%],
Tail
F: total amount of feed [g],
to scavenger step f: chromite grade in feed [%].

4. Results and discussions

Vibrating table
212 µm screen
to cleaner step
Tail
Chromite to scavenger step
Vibrating table
product
to cleaner step
Tail to scavenger step
Fig. 4. Schematic view of the vibrating table tests with −600 µm high grade
chromite samples in which feed samples were primarily classified via hydro-
cyclone.
−212 + 75 µm samples were fed to the vibrating table, separately.
After first stage vibrating table tests of three size fractions, each chro-
mite concentrate and tail of each operation was subjected to subsequent
cleaner and scavenger stages in order to further increase final product
quality and decrease the loses.
Within the tests performed with −1000, −800, and −600 µm
fractions of 32–33% grade chromite samples, concentrates of the first
stage cleaning was re-processed through a second stage. While plate
inclination, TW, and feed rates were kept constant in both cleaning
stages, WW was increased from 0.5 to 1 lpm (for a 20 cm chute opening)
in order to investigate if further increase in final product quality could
be achieved. In other words, while adjusting WW rate, plate inclination
was set to a moderate 8°, TW was controlled maintaining a solid ratio of
the feed around 30% by weight, and feed rate was set to a constant of
approx. 0.25 t/h through all tests.
Additionally, within each test, approx. 4.5–5 kg sample batches
were used. Bed forming material in vibrating table operations is a con-
stant amount of the sample accumulated in inclined chute after
reaching the steady state. It was also collected and evaluated separately
after each test to be used within the recovery calculations in order to
better reflect the mass balance of laboratory scale tests. In a real life-
continuous vibrating table operation, bed forming material can be ne-
glected by directly sampling from products. Final chromite recoveries
Chromite
product
4.1. Effect of operational and geometric parameters on separation
performance
4.1.1. Effect of plate inclination on separation performance
Following the experimental studies, products of each test was col-
lected, weighed, and % Cr2O3 contents were analyzed. Vibrating table
test parameters of low grade chromite sample and product qualities
were reviewed in Table 2. Also, change in chromite recoveries and
grades of final products depending on the particle size, plate inclina-
tion, and desliming were presented in Fig. 5a–d. Results showed that
vibrating table performed best especially at finer particle sizes and
when the slime was fairly removed. These findings also corroborate the
mineralogical analysis results of low grade chromite ore. On the other
hand, at higher plate inclinations fine particles were also removed with
the help of teetering and washing water resulting with the highest re-
covery achievement with -200 µm feed (at plate inclination of 4°). Even
so, −200 µm deslimed feed at 4° plate inclination ensured the highest
grade (Fig. 5d). Based on Fig. 5a–d, it is safe to conclude that both grade
and recovery increase as the inclination of the plate of the vibrating
table is increased. Although desliming has positive effects on overall
recovery, lower grades were observed with −200 µm deslimed feed
samples in comparison with −200 µm feed samples (Fig. 5b and d). The
only exception to this behavior was observed with −400 µm deslimed
feed (plate inclination = 9°) at which coarser than expected particles
was presumably reported to the tailings provoking a limit to the
equipment settings (Fig. 5c).
4.1.2. Effect of feed particle size and WW (wash water) rate on separation
performance
All three −1000 µm, −800 µm, and −600 µm size fractions of the
high grade chromite sample having approx. 32–33% chromite were fed
to the vibrating table under similar operating parameters other than
particle size and WW rate in order to observe their effects on separation
performance. In all tests, a second stage cleaning operation was applied
to chromite concentrate at relatively higher WW rates while keeping

Table 2
Low grade chromite sample vibrating table test parameters and product qualities.
Test notation Feed top size, µm Desliming Plate inclination Vibration frequency Mass pull, % Cr2O3 in product, % Cr/Fe in product

1 400 µm not applied 9° max. 4.27 45.87 1.22

2 400 µm not applied 7° moderate 7.36 44.55 1.19
3 400 µm not applied 5° moderate 8.93 38.77 1.02
4 400 µm with hydrocyclone 9° max. 7.53 50.20 1.34
5 400 µm with hydrocyclone 7° moderate 8.88 41.15 1.10
6 400 µm with hydrocyclone 5° moderate 12.68 36.22 1.07
7 200 µm not applied 4° moderate 8.37 42.67 1.30
8 200 µm not applied 3° low 7.09 33.23 1.01
9 200 µm not applied 2° low 7.87 25.00 0.98
10 200 µm with hydrocyclone 4° moderate 10.34 53.68 1.51
11 200 µm with hydrocyclone 3° low 7.43 39.10 1.10
12 200 µm with hydrocyclone 2° low 4.44 29.77 1.02
Feed 5.04 0.33

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Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

100 100
90 Mass pull, % Weight 90 Mass pull, % Weight
Cr O , % Cr O , %
80 Cr O Recovery, % 80
Cr O Recovery, %
70 70
60 60
50 50
%

%
40 40
30 30
20 20
10 10
0 0
4 6 8 10 1 2 3 4 5
Plate inclination, ° Plate inclination, °
(a) (b)
100 100
90 Mass pull, % Weight Mass pull, % Weight
90
Cr O , % Cr O , %
80 Cr O Recovery, % 80
Cr O Recovery, %
70 70
60 60
50 50
%

%
40 40
30 30
20 20
10 10
0 0
4 6 8 10 1 2 3 4 5
Plate inclination, ° Plate inclination, °
(c) (d)
Fig. 5. % grade and % recovery comparison of the low grade chromite sample vibrating table test products (a: 400 µm, b: 200 µm, c: 400 µm deslimed, d: 200 µm
deslimed).

Table 3
Vibrating table test results of −1000 µm, −800 µm, and −600 µm high grade chromite (approx. 32–33%) samples.
8° plate inclination −1000 µm feed −800 µm feed −600 µm feed

Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%

1st stage Cr2O3 product 47.02 36.42 51.46 37.28 39.88 44.44 37.22 44.86 49.46
2nd stage Cr2O3 product 25.17 39.88 30.16 15.21 45.68 20.77 5.28 46.74 7.31
Combined chromite product 72.19 37.63 81.63 52.49 41.56 65.20 42.50 45.09 56.77
Bed forming material 12.31 16.22 6.00 23.62 20.35 14.37 12.64 21.44 8.03
Tailing 15.50 26.55 12.37 23.89 28.61 20.43 44.86 26.49 35.20
Feed 100.00 33.28 100.00 100.00 33.46 100.00 100.00 33.76 100.00

other operating parameters constant. 1st and 2nd stage cleaning con-
centrates obtained under two different WW rates were combined
forming a single chromite product. Results of the separation tests were
given in Table 3. Separation performances of three distinct particle sizes
calculated considering combined products were presented in Fig. 6a.
Additionally, the effect of WW rate on % chromite recoveries and %
chromite grades of final products were given in Fig. 6b and c, respec-
tively. In Fig. 6a, effect of particle size on Cr2O3 grade and recovery
were discussed on the basis of combined 1st and 2nd stage products.
Results showed that sufficient liberation at −600 µm particle size
provoked a slightly higher grade. On the other hand, loses were also
higher resulting with the lack of the resistance to the WW and low G-
force action. With −1000 µm feed, grade of final product decreased
down to 37.63% Cr2O3, while chromite recovery in the final product
was increased up to 81.63% within a single stage operation. In Fig. 6b
and c, effect of increasing solely the WW rate was presented while
keeping plate inclination (8°) and feed rate (0.15 t/h) constant (for a
20 cm chute opening) for given particle sizes. Results showed that
under WW rate of 1 lpm, although chromite recovery was significantly
lower at finer sizes in comparison with 0.5 lpm WW rate, % chromite
grades were higher due to obtaining a cleaner product. Similarly,
higher WW rate increased the % grade of final product of coarse size
fraction (−1000 µm) slightly without any significant decrease in %
recovery of final product in comparison with 0.5 lpm WW rate.
The WW jet pipe of the equipment extends along the bed and stands
perpendicular to the flow. The diameter of WW pipe is less than 0.5 mm
with holes drilled along at every 0.5–1 cm width, thus the water can be
sprayed smoothly. The rate of WW should be set according to plate
inclination and feed particle size. WW is an important separation
parameter and should be provided intermittently, ideally with an
opening and closing time interval in between 0.5 s and 20 s resulting
with a WW rate of 0.5 and 1.25 lpm, respectively. When processing
finer particle sizes, lower WW rates result in higher % grade and %
recoveries in final products, and vice versa while processing coarser
sizes due to the increasing mass of the individual chromite grains.
4.1.3. Effect of TW (teetering water), feed rate and solid % on separation
performance
Chute of the laboratory scale experimental setup manufactured with
the dimensions of 20 cm in width × 5 cm in height × 50 cm in length.
Due to the design principle, effective separation takes place in teetered
zone and flowing water film carry low density particles through tail

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Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

100 performed with −1000 µm high grade chromite sample under constant
feed rate of 0.25 t/h at varying TW rates. Plate inclinations of 11° and 5°
80 were applied for each test separately. Following, solid % measurements
were carried out with the remaining material in chute and results were
60 presented in Table 4. It was observed that, although plate inclination
and TW have primary importance, solid % within chute does not
%

40 change significantly with feed rate after steady state is reached. It is

also important to note that higher feed rates would only increase loses
20 Cr O , % to the tailings due to the chute’s effective volume limited by plate in-
Cr O Recovery, % clination and TW rate. Additionally, higher TW rates also decrease the
0 performance by over-teetering the bed in separation zone resulting with
500 600 700 800 900 1000 1100 the material loses through tailing discharge with excessive water flow.
Feed top size, microns The ore to be separated within the device is fed dry from the water
(a) level cut point. Considering the addition of water via TW and WW jets,
a value in the range of approx. 11–58% solids by weight was observed
70
Cr O Recovery, % (WW=0.5 lpm) for the feed having 1000 µm top size. Outside these limits of solid %, an
60 Cr O Recovery, % (WW=1 lpm) efficient teetered bed could not be constructed. Therefore, an average
50 30% solids by weight was preferred throughout the experimental stu-
dies. In case of feeding a slurry, solid percent should be calculated ac-
40 cordingly.
%

30 Within the experimental studies, an inclined chute having a 20 cm

product discharge width was used. Under the conditions of 30% feed
20 solid by weight, 7° plate inclination, approx. 5 lpm TW rate, 0.75 lpm
10 WW rate, and with a chute supposedly having 100 cm opening, capa-
cities for −1000 µm and −200 µm feeds was calculated as 0.25 t/h and
0
0.12 t/h, respectively. It is important to note that these values are re-
500 600 700 800 900 1000 1100
Feed top size, microns presentative and collected approximately from the laboratory scale
equipment. Also, these throughput values of the operations were
(b) measured without any classification or slime removal prior to the ap-
60 plication. Considering the fact that for a sustainable process control
Cr O , % (WW=0.5 lpm) within most of the operations in mineral processing, properly classified
Cr O , % (WW=1 lpm) and deslimed narrow size fractions are preferred. Hence, capacity va-
lues may momentously increase for a single vibrating table unit due to
50
the use of sufficiently classified feed. While an industrial scale up would
presumably increase the capacity, given values are only monitored and
%

circumscribed representing a laboratory scale operation.

40
4.2. Advances of vibrating table in comparison with shaking table

30 In order to make a reasonable comparison between one of the most

500 600 700 800 900 1000 1100 common gravity type equipment used specifically for chromite pro-
Feed top size, microns cessing in the industry and the vibrating table, classified identical high
(c) grade chromite samples were fed to both equipment, separately. At the
outset, −1000 µm high grade chromite (approx. 37–38%) sample was
Fig. 6. % grade and % recovery change in of the −1000 µm, −800 µm, and fed to the hydrosizer at optimum vertical water velocities decreasing
−600 µm high grade chromite (approx. 32–33%) sample vibrating table test through the reservoirs. Although hydrosizer is principally a classifier,
products (a: combined product qualities, b: % recovery change due to change in relatively higher water rate at first reservoir ensured a slightly higher
WW rate and particle size, c: % grade change due to change in WW rate and
grade product (41.96%) and coarser particles to accumulate within.
particle size).
Due to the mass pull amounts of each reservoir, 2nd, 3rd, and 4th re-
servoirs were merged forming a single hydrosizer product along with
the 1st reservoir (Table 5). Additionally, 12.90% weight of the initial
sample having 33.89% Cr2O3 was lost as slimes during hydrosizer op-
eration. Following, “Hydrosizer 1st reservoir” and combination of the
“Hydrosizer 2nd, 3rd, and 4th resevoirs” were fed to the shaking table
and vibrating table, separately. Shaking table tests were applied as
schematically illustrated in Fig. 3b and obtained product qualifications
were presented in Table 6. In response to two different product qualities
achieved within a shaking table, an additional scavenger stage was
applied to the 1st stage tailings with vibrating table and results were
Fig. 7. Schematical representation of the separation zones within a vibrating
given in Table 7. Additionally, step by step comparisons between pro-
table.
duct qualities of shaking table and vibrating table operations were
rendered in Fig. 8. Considering the tests with “Hydrosizer 1st re-
discharge while denser particles move down through product discharge servoir”, although individual and combined product grades achieved
(Fig. 7). In order to determine the solid percent within the system, with shaking table are slightly higher, recoveries were evidently ele-
water and material supplies of the operation was instantly shut down vated with vibrating table reaching up to 93.22% in comparison with
after the steady state was reached. Solid % determination tests were the 66.08% recovery of shaking table’s combined products (Fig. 8a).

130
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Table 4 optimum for a vibrating table operation due to the experimental results.
Change in separation solid % due to TW rate, WW rate, and feed rate. On the other hand, although the quantity of water used in the feed pulp
Feed rate, kg/h* TW rate, lpm* Plate inclination,° Measured solid %** varies, shaking table’s normal feed dilution in comparison with the
vibrating table were reported as 20–25% solids by weight for ores, and
24 8 11 11.69 33–40% solids for coal [2,5].
24 2 11 23.80
Shaking tables are used in a variety of applications, and depending
24 8 5 37.84
24 2 5 51.40
on the application an industrial shaking table is approx. 2–5 m long and
50 8 11 18.03 1–3 m wide. Hence, single shaking table occupies a large area and most
50 2 11 35.33 operations require tens of tables in order to handle excessive tonnages.
50 8 5 49.35 In contrary, although an industrial scale vibrating table operation has
50 2 5 58.26
not been undertaken yet, installation space required for vibrating table
* Values calculated for laboratory scale vibrating table with a 20 cm chute is predicted to be significantly less than shaking table according to the
opening. experimental results.
** 2.7 g/cm3 bulk density value for the chromite ore sample was used within Within aforementioned experimental crosscheck between shaking
calculations. table and vibrating table, it was observed that vibrating table either
caught up or outperformed the performance of the shaking table under
Table 5 the given conditions. Considering the factors such as capacity, space
Hydrosizer test results of −1000 µm high grade chromite (approx. 37–38%) required for installation, etc., vibrating table was proved to be a strong
samples. alternative to conventional shaking tables when sibling operations were
−1000 µm feed to hyrdosizer considered.

Weight, % Cr2O3, % Fe, % Cr2O3

Recovery, %
Hydrosizer 1st reservoir 48.17 41.96 9.59 51.96
Hydrosizer 2nd + 3rd + 4th 38.93 36.76 8.58 36.79
resevoirs
Hydrosizer Slimes 12.90 33.89 8.30 11.24
Feed 100.00 38.89 9.03 100.00
When combined 2nd + 3rd + 4th reservoirs of hydrosizer was pro-
cessed, overall product recoveries were reported as 59.18% and 52.88%
for shaking table and vibrating table, respectively (Fig. 8b). Moreover,
grades of the final products of both equipment were approx. at 48–49%
Cr2O3 level. It is important to note that, these tests were performed
under optimum conditions with simplest possible analogous flowsheets.
Considering the operational differences of both vibrating table and
shaking table, linking additional cleaning stages up to the process,
applying more advanced equipment settings such as varying water
speeds and different inclinations, and feeding narrower particle sizes
could ramp up the performance of the operation.
In the fashion of real life operations, use of the shaking tables are
favorable when sample to be fed has adequate liberation and is classi-
fied prior to processing [30]. These universal rules for the success of
gravity concentration are also considered to be valid for vibrating table
as discussed in afore experimental sections. It was observed that ca-
pacities of vibrating table for −1000 µm and −200 µm original feeds
was calculated as 0.25 t/h and 0.12 t/h with a chute supposedly having
100 cm opening. The capacity of an average shaking table
(1.5–2.5 m × 3.0–4.0 m) varies according to size of feed particles and
the concentration criteria, and reportedly they can handle up to 2 t/h of
1.5 mm sand and perhaps 1 t/h of fine sand [5]. These figures may
decrease down to 0.2–0.5 t/h when fine size fractions were processed.
An average feed rate of 30% solid by weight could be accepted as
4.3. An exemplary vibrating table integrated gravity concentration
flowsheet
Final tests were solely performed with high grade chromite (approx.
37–38%) sample. Slimes (approx. −75 µm) of −600 µm sample batch
was removed with hydrocyclone and representative hydrocyclone un-
derflow material was screened through a 212 µm screen (Table 8).
Consequently, a deslimed −600 + 75 µm batch along with the classi-
fied -600 + 212 µm and −212 + 75 µm sample batches. These size
fractions were fed to the vibrating table separately. Subsequent cleaner
and scavenger stages were also applied to each product and tail. Overall
and combined results of the vibrating table tests of classified hydro-
cyclone products were given in Table 9. Additionally, product grade
and recovery comparisons of three distinct sample batches were com-
pared in Fig. 9. Plate inclinations, WW rates, and feed rates were chosen
optimum and constant specifically for processing each sample batch.
Results showed that relatively coarser −600 + 212 µm sample batch
provided highest recovery. Addition of the finer −212 + 75 µm frac-
tion decreased the overall recovery of Cr2O3 due to the increasing loses.
Contributing to these observation, overall product grades of
−600 + 212 µm, −600 + 75 µm, and −212 + 75 µm operations were
observed in the range of 47–49% Cr2O3 with higher loses in finer
particle sizes. Consequently, it was observed that feeding narrow and
relatively coarser size fractions ensure more distinct operational stabi-
lity resulting with higher grade and recovery values.
5. Conclusions
A gravity concentrator namely “vibrating table” has been developed
with the objective of increasing the product quality of density based
physical separation processes. The system is mainly composed of a vi-
bration unit, an inclined chute, TW and WW jets. The principle idea of

Table 6
High grade chromite (approx. 37–38%) sample shaking table test results applied to classified products obtained from hydrosizer reservoirs.
Feed from hydrosizer 1st reservoir hydrosizer 2nd + 3rd + 4th reservoirs

Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%

1st stage chromite product 20.53 49.00 23.99 13.12 49.68 17.22
2nd stage chromite product 37.03 47.66 42.09 32.54 48.79 41.96
Middling 41.14 33.79 33.16 46.39 29.08 35.66
Tailing 1.31 24.45 0.76 7.96 24.54 5.16
Feed 100.00 41.92 100.00 100.00 37.83 100.00
1st + 2nd stage chromite product 57.55 48.13 66.08 45.65 49.04 59.18

131
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Table 7
High grade chromite (approx. 37–38%) sample vibrating table test results applied to classified products obtained from hydrosizer reservoirs.
Feed from hydrosizer 1st reservoir hydrosizer 2nd + 3rd + 4th reservoirs

Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%

Cleaner 1 chromite product 80.64 47.26 91.57 23.08 48.38 30.93

Scavenger 1 chromite product (1st stage tail cleaned) 2.22 30.91 1.65 16.31 48.57 21.94
Cleaner 1 bed forming material 6.86 15.58 2.57 4.43 17.55 2.15
Scavenger 1 tail 9.00 13.70 2.96 54.53 28.33 42.80
Cleaner 1 tail 1.28 40.63 1.25 1.66 47.20 2.17
Feed 100.00 41.62 100.00 100.00 36.10 100.00
Cleaner 1 + Scavenger 1 chromite product 82.86 46.83 93.22 27.36 48.41 52.88

Hydrosizer 1st reservoir

VT, Cleaner 1 + Scavenger 1 chromite product

VT, Scavenger 1 chromite product

VT, Cleaner 1 chromite product

ST, 1st+2nd stage chromite product

ST, 2nd stage chromite product

ST, 1st stage chromite product

0 20 40 60 80 100

Cr O Recovery, % Cr O , %

(a)

Hydrosizer 2nd+3rd+4th reservoirs

VT, Cleaner 1 + Scavenger 1 chromite product

VT, Scavenger 1 chromite product
VT, Cleaner 1 chromite product
ST, 1st+2nd stage chromite product
ST, 2nd stage chromite product
ST, 1st stage chromite product

0 10 20 30 40 50 60 70

Cr O Recovery, % Cr O , %

(b)
Fig. 8. Comparison of the high grade chromite (approx. 37–38%) sample shaking table and vibrating table test results applied to classified products obtained from
hydrosizer reservoirs (a, 1st reservoir; b, combination of 2nd, 3rd, and 4th reservoirs) (ST, shaking table; VT, vibrating table).

Table 8 performance had been reviewed. Additionally, a relevant comparison

Hydrocyclone test results of −600 µm high grade chromite (approx. 37–38%) between performances of the vibrating table and a shaking table had
samples. been tested under similar conditions. Results showed that:
Feed to −600 µm hyrdocyclone
Weight, % Cr2O3, % Cr2O3 Recovery, % • Both grade and recovery increase as plate inclination of the vi-
brating table is fairly increased considering the particle size of the
Underflow (−600 µm) 92.27 39.00 94.93
sample.
•
Overflow (slimes) 7.73 24.87 5.07
Feed 100.00 37.91 100.00 Desliming predictably decreased the chromite loses. In addition to
the positive effects of removing the slimes prior to operation, overall
performance is also highly effected by the equipment settings ap-
the separation is to combine the involved forces of a teetered bed, re- plied whether slime is removed or not. For instance, feeding
sistance to water flow, vibration, and density differences in order to −400 µm deslimed sample at 9°plate inclination provoked a lower
benefit best from gravitational separation. Influence of the operating recovery but higher grade due to the loses to the tailings.
parameters on vibrating table performance had been investigated by • Liberation has great importance on determining feed particle size.
performing separation tests with mineralogically distinct chromite ore Vibrating table test results of -1000 µm, -800 µm, and -600 µm high
samples. In the experimental studies effect of particle size and chute grade (approx. 32–33%) chromite samples at similar plate inclina-
inclination, effect of removing slimes, and effect of combining with tions showed that mass pulls to the tailings increase (15.50%,
other physical separation and classification equipment on separation 23.89%, and 44.86% weights, respectively) as particle size

132
Ö. Yıldırım Gülsoy, E. Gülcan Separation and Purification Technology 211 (2019) 124–134

Table 9
High grade chromite (approx. 37–38%) sample vibrating table test results applied to classified products obtained from hydrocyclone underflow.
Feed from Hydrocyclone U/F -600 + 75 Hydrocyclone U/F -600 + 212 Hydrocyclone U/F -212 + 75

Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery% Weight% Cr2O3% Cr2O3 Recovery%

Rougher chromite product 57.62 48.83 69.98 33.73 50.06 41.21

Scavenger chromite product 7.09 32.56 5.74 3.91 37.56 3.58
Scavenger bed forming material + tail 35.30 27.66 24.28 27.30 9.97 7.08 62.36 36.27 55.20
Feed 100.00 40.21 100.00 100.00 38.43 100.00 100.00 40.97 100.00
Rougher + scavenger chromite product 64.70 47.05 75.72 72.70 49.12 92.92 37.64 48.76 44.80

100 Eng. 12 (11) (1999) 1291–1300.

90 [2] A. Gupta, D.S. Yan, Mineral Processing Design and Operations, Elsevier,
Amsterdam, 2006, p. p516.
80 [3] R.O. Burt, C. Mills, Gravity Concentration Technology, Elsevier Science Publishing
70 Company Inc, New York, 1984, p. p605.
60 [4] R.Q. Honaker, W. Richard, Advances in Gravity Concentration, SME Littleton
Colorado USA, 2003, p. p196 (ISBN: 0-87335-227-0).
50
%

[5] B.A. Wills, T. Napier-Munn, Wills' Mineral Processing Technology, Elsevier Science
40 & Technology Books, 2006 (p512).
30 [6] E.G. Kelly, D.J. Spottiswood, Introduction to Mineral Processing, Wiley, 1982, p.
491.
20
[7] M.C. Fuerstenau, K.N. Han, Principles of Mineral Processing, Colorado Society for
10 Mining, Metallurgy, and Exploration Inc. SME, 2003, p. 573.
0 [8] A.L. Mular, D.N. Halbe, D.J. Barratt, Mineral Processing Plant Design, Practice and
-600+75 µm -600+212 µm -212+75 µm Control, Society for Mining, Metallurgy and Exploration Inc. SME, Colorado, 2002
p. 2422.
[9] S. Cierpisz, A dynamic model of coal products discharge in a jig, Miner. Eng. 105
Cr O , % Cr O Recovery, % (2017) 1–6.
[10] R.G. Richards, T.A. Jones, Kelsey centrifugal jig-an update on technology and ap-
Fig. 9. Comparison of the high grade chromite (approx. 37–38%) sample vi- plication, SME Annual Meeting Denver, 2004, pp. 04–21.
brating table test results applied to classified products obtained from hydro- [11] A. Laplante, S. Gray, Advances in gravity gold technology, Developments Mineral
cyclone underflow. Proc. 15 (2005) 280–307.
[12] E. Maré, B. Beven, C. Crisafio, Chapter 10: developments in nonmagnetic physical
separation technologies for hematitic/goethitic iron ore, Mineral. Proc. Environ.
decreases. Sustainability-Iron Ore (2015) 309–338.

• Relatively coarser −600 + 212 µm high grade chromite sample
batch of hydrocyclone underflow provided the highest recovery.
Therefore, it was concluded that size classification prior to vibrating
table operation result with better performance values.
Results suggest that industrial application of the vibrating table
could be used for processing distinct chromite samples having a specific
liberation degree and typical mineralogy. Vibrating table was proved to
be a strong alternative to the gravity concentration equipment used for
similar tasks due to the experimental results, thanks to the design
ability of using combined gravitational forces, practicality, and space-
saving construction. Since the equipment is very new, studies on gold
and rare earth mineral processing will be evaluated in future studies.
Acknowledgements
The authors kindly acknowledge the financial support of Hacettepe
University Scientific Research Projects Coordination Unit (HU BAP) and
Hacettepe University Technology Transfer Center (HT-TTM) for pro-
viding technical assistance during patent application process.
Conflict of interest
There is not a potential conflict of interest, including any personal
or other relationships with other people or organizations within the
three years of beginning the submitted work, which could in-
appropriately influence or be perceived to influence their work. All
credits on this study belong to its authors. Acknowledging the financial
support from Hacettepe University Scientific Research Projects
Coordination Unit is the only condition that was deemed necessary by
this institute so that there were no conflicts of interest.
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