Spiral concentrators are gravity and centrifugal force-based devices designed for mineral concentration. During processing operations, dynamic variations in the slurry’s liquid film thickness can induce hydrodynamic instability, generating roll waves on the free surface that compromise particle separation efficiency. To ensure operational stability and efficacy, this study establishes a theoretical shallow-water flow model for slurry dynamics in spiral concentrators based on hydraulic principles. Through L27(313) orthogonal experiments and real-time ultrasonic film thickness monitoring, the influence of key parameters on roll wave evolution is quantified. Results indicate that roll waves follow an “instability-development-dissipation” sequence. The pitch-to-diameter ratio (P/D) exerts a highly significant effect on roll wave intensity, while particle properties (density and size) exhibit moderate significance. In contrast, feed flow rate and solid concentration show negligible impacts. Roll waves amplify fluid turbulence, triggering stochastic migration of particles (especially low-density grains), which increases the standard deviation of zonal recovery rates (ZRR) and degrades separation precision. This work provides critical insights into particle behavior under roll wave conditions and offers a theoretical foundation for optimizing spiral concentrator design and process control.
Wang et al. (Mon,) studied this question.
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