A Simple Real-Time Method for Detecting Low Performance in Wet High-Intensity Magnetic Separators (WHIMSs) Due to Coil Malfunction

Wet High-Intensity Magnetic Separators (WHIMSs) have become well established in mineral processing operations by efficiently separating particles based on their magnetic properties. While the existing literature extensively discusses WHIMS performance under varying operational conditions, there is a notable absence of attention to the degradation of coils over time and methods for its detection. In this paper, we address this gap by proposing a novel approach to detect coil degradation in WHIMSs, enabling timely maintenance interventions to maintain optimal performance. Through experimental analysis in an industrial environment, we show the significant effect of coil deterioration on WHIMS efficiency. We also introduce a real-time monitoring method using current measurements in coil sets. This method provides a practical solution for identifying and addressing coil degradation, helping to improve maintenance practices and sustain operational efficiency in mineral processing facilities. The experiments were conducted in a Brazilian iron ore processing company in Itabira, Minas Gerais.