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Recently, a two-stage dynamic dense medium separator, called Tri-Flo, has become more applicable for treating difficult-to-wash coals. In this study, a 70-mm diameter transparent Tri-Flo separator was manufactured using prototyping and the effects of geometrical and operating parameters were investigated. Central composite design (CCD) was used in the experimental phase. The effects of internal tubes diameter, the installation slope, and the internal flow rate on the Tri-Flo performance were analyzed. CFD simulation was also used for better understanding of the flow pattern and interpretation of the experimental results. The results indicated that the air core diameter in both stages of the separator increases with all three variables. It was also found that medium recovery to float product in rougher and cleaner stages increases with unit inclination and internal tubes diameter, while it decreases with medium flow rate. The decrease in the air core size with increasing the feed tube diameter was an outstanding finding in both experiments and simulations. On average, a 16% decrease in the air core diameter was obtained when the feed tube diameter was increased from 23 mm to 26 mm. The results of the CFD simulation showed that there is a meaningful compatibility between the experimental observations and mathematical simulations.

Toward a better understanding of a Tri-Flo separator using prototyping, central composite design (CCD) and CFD simulation