High gradient magnetic separation (HGMS) achieves effective separation to fine weakly magnetic minerals using numerous small magnetic wires in matrix, and its separation performance is inherently dependent on the capture characteristics of the wires. In this work, the selective capture of magnetic wire to particles in high gradient magnetic field was theoretically described and simulated using COMSOL Multiphysics. It was found that the capture trajectories of a small amount of particles under the ideal condition was significantly different from those of a large amount of particles under the actual condition, and non-magnetic particles would be much more easily entrained into magnetic deposits captured onto the wire surface under the actual condition than those under the ideal condition. These theoretical and simulated results were basically validated with the experimental magnetic capture to an ilmenite ore, and the wires in slow feed mode have achieved much higher capture selectivity than those in the fast feed mode. For instance, at the magnetic induction of 0.8 T, the TiO₂ grade of magnetic deposits captured by 3 mm diameter wire in the slow feed model reached 36.78%, which is higher than 28.32% in the fast feed model. The selective capture difference between the fast and slow feed models increased with increase in the magnetic induction and with decrease in the pulsating frequency. This investigation contributes to improve HGMS performance in concentrating fine weakly magnetic ores.

China is rich in titanium resources, which accounts for more than 35% of the world. But, until today, the industrial TiO₂ recovery for ilmenite ore is slightly higher than 30% in the current pulsating high-gradient magnetic separation-flotation process (HGMS) so that a large amount of ilmenite value were lost in tailings. A centrifugal HGMS (CHGMS) method was introduced and a novel HGMS-flotation process combining the method was investigated to achieve an enhanced separation for Panzhihua ilmenite tailings in China. The results of this investigation indicate that this new process achieved a superior separation performance to the current one and produced a qualified ilmenite concentrate assaying 46.62% TiO₂ at a significantly enhanced recovery reaching 40.42%. In the new process, the CHGMS separator concentrated ilmenites at high selectivity and produced a high-grade ilmenite concentrate fed to flotation cleaning process, which significantly benefited the enhanced separation for the ilmenite tailings. It was concluded that this new HGMS-flotation process is prospective in improving the separation performance for ilmenite from tailings.

China is rich in magnetite mineral resources, but they are generally characterized by low grade, fine dissemination size, and a high content of harmful impurities. Wet low-intensity magnetic separation (WLIMS) is an important method for processing fine-grained magnetite. However, during the separation process, fine magnetite particles are prone to magnetic agglomeration, which makes it difficult for conventional WLIMS separators to achieve high-selectivity separation. To address this issue, a novel WLIMS separator based on a rotating magnetic system was developed in this investigation, and its separation characteristics were systematically investigated through a combined approach comprising CFD–DEM–FEM multiphysics coupling simulations and experimental validation. Simulation results indicate that the rotating magnetic system significantly reduces the chain length and the structural stability of magnetic agglomerates just as magnetite particles enter the magnetic field region. Furthermore, under the rotating action of the magnetic system, the magnetic chains only enclose a portion of the intergrowth minerals, while gangue minerals remain unattached, which positively contributes to improved separation selectivity. Both laboratory-scale experimental results and industrial production data indicate that, compared to the conventional WLIMS separator, the rotating magnetic system WLIMS separator achieves significantly superior separation performance. For a magnetite ore with a grade of 57.68%, the rotating magnetic system WLIMS separator achieved an optimal concentrate grade of 65.43% (with a recovery of 94.78%), whereas the conventional WLIMS separator attained only 60.32% at a similar recovery rate. This investigation provides an important basis for the large-scale industrial application of rotating magnetic system WLIMS separators and the efficient development and utilization of fine-grained magnetite resources.