A Combined RSM-FEM Analysis of Electric Field Distribution in a Novel Design of an Inclined-Plane Electrostatic Separator

The electrostatic separation effectively sorts mixed granular insulators using electrical and mechanical forces. For optimal process performance, particles require a high electric field (E-field) to enhance separation. The present study was aimed at analyzing the E-field distribution within a novel design of an inclined-plane electrostatic separator, which features four flat electrodes and two side openings adjacent to the plane to prevent particle rebound. Simulation experiments were designed to optimize key operating factors, specifically, the width of the horizontal electrodes and both the width and inclination angle of the vertical electrodes using Finite Element Method (FEM) in COMSOL Multiphysics, alongside Response Surface Methodology (RSM) and Central Composite Design (CCD) in JMP statistical software. Maximum, average, and center E-field values were evaluated as performance responses. The quadratic models identified optimal parameters: a horizontal electrode width of 3 cm; vertical electrode width of 1 cm; inclined at 90°, yielding a maximum desirability of 94%. The width of the horizontal electrodes was found to be the most significant factor, contributing over 80% to E-field strength. The correlation between simulated data and model predictions was strong (R² > 0.99), with prediction errors not exceeding 5.83%. Comparative analysis revealed that our model enhanced E-field parameters by approximately 65% compared to conventional designs.