Channel for Quality! Magnetic Separator Serial No.MSMO2013.08.09
Contents 1. An Overview 2 2 Wet Low Intensity and Medium Intensity Magnetic Separator 2 3. Wet High Intensity Magnetic Separator 2 4. Dry Low Intensity and Medium Intensity Magnetic Separator 3 5. Electromagnetic Separator 3 6. Permanent Magnetic Separator 3 7. Lifting Magnet 4 8. Eddy Separator 4 9. LGS Wet High Intensity Magnetic Separator 4 10. Cylinder Screen 8 11. Wet Drum Magnetic Separator 12 12. Dry Drum Magnetic Separator 22 13. LTC Demagnetizer 31 14. LJK Electromagnetic Separator 33 15. Industry Served 35 16. Typical Application in Iron Mining 36 17. Facility 37 1
1. An Overview Magnetic separator is a kind of device in which a strong magnetic field is employed to remove magnetic materials from sand or a concentrate, or to selectively remove or separate their constituent minerals. Magnetic separators are commonly used in conjunction with high tension separators to process the heavy mineral concentrates obtained from beach sands, monazite placers, tin placers, etc. The extensive range of our products use the principle of magnetic force extending to a full range of industrial magnetic equipment that separate, concentrate or lift materials used in mining, recycling, coal handling, etc. 2. Wet Low Intensity and Medium Intensity WHIMS is used for concentration of weak magnetic mineral like hematite or purification of non-ferrous mineral like kaolin, quartz. Variable magnetic intensity is up to 22,000Gs. The unique design of magnetic system and water cooling system delivers grade and recovery improvement and minimize maintenance. WHIMS sizes or models range from laboratory research, pilot to large machines for industrial application. Ring diameter is from 600mm and up to 3000mm with a handling capacity of up to 400t/h 3. Wet High Intensity Magnetic Separator WHIMS is used for concentration of weak magnetic mineral like hematite or purification of non-ferrous mineral like kaolin, quartz. Variable magnetic intensity is up to 22,000Gs. The unique design of magnetic system and water cooling system delivers grade and recovery improvement and minimize maintenance. WHIMS sizes or models range from laboratory research, pilot to large machines for industrial application. Ring diameter is from 600mm and up to 3000mm with a handling capacity of up to 400t/h. 2
4. Dry Low Intensity and Medium Intensity Magnetic Separator Our LCG series magnetic separator is applied for dry separation in the primary stage of concentrator or working site with limited availability of water. Material or Feeding particle size is 0-12mm. The magnetic system can be ferrite or rare earth depending on magnetic intensity required. Magnetic intensity ranges from 600GS to 7000GS, magnetic drum diameter in 800mm or 1000mm in different length. 5. Electromagnetic Separator RCD Series electromagnetic magnetic separator is available in both manual and self-cleaning, and classified into air-cooled, fan-cooled and oil cooled to fit for different working conditions. The RCD Series electromagnets are used for continuous removal of tramp iron weighing 0.1-35kg buried in material on belt conveyor to protect costly equipment or expensive belt conveyor systems. Magnetic intensity ranges from 500Gs to 1600GS at rated suspension height adapted to variable belt width from 600mm to 2400mm. 6. Permanent Magnetic Separator RCY Series permanent magnetic separator is available in both manual and self-cleaning, used for continuous removal of tramp iron weighing 0.1-35kg buried in material on belt conveyor to protect valuable plant or machinery equipment and costly conveyor belts. Magnetic intensity ranges from 500GS to 1 500GS at rated suspension height adapted to variable belt width from 500mm to 2000mm. The Magnetic system of RCY Series magnetic separator is high grade quality Ferrite or Rare Earth material and demagnetization is less than 5% within 8 years. 3
7. Lifting Magnet There is a full range of lifting magnets for handling of steel plates, coils, bundles, and scrape steel in steel plants shipyards, and foundries. It can be applied with a single unit or in group to handle large sized steel plates or bundles 8. Eddy Separator Eddy Current Separator (ECS) employs a conductive or repelling force between the magnetic field generated inside a unique rotor to throw or separate the non-ferrous metal out from other materials such as plastic, paper or other non-metallic material in the waste stream. The ECS has a wide application in recycling industry like aluminum recovery from crushed automobiles, refrigerators, scrape aluminum, etc. It is available in concentric and eccentric, and with feeding width ranges from 500mm to 2000mm. 9. LGS Wet High Intensity Magnetic Separator 9.1 Application RCY Series permanent magnetic separator is available in both manual and self-cleaning, used for continuous removal of tramp iron weighing 0.1-35kg buried in material on belt conveyor to protect valuable plant or machinery equipment and costly conveyor belts. Magnetic intensity ranges from 500GS to 1 500GS at rated suspension height adapted to variable belt width from 500mm to 2000mm. The Magnetic system of RCY Series magnetic separator is high grade quality Ferrite or Rare Earth material and demagnetization is less than 5% within 8 years. 4
Channel for Quality! 9.2 Features Vertical ring provides jam-free operation Improved concentrate grade and recovery Adjustable magnetic intensity 0-22,000Gs for beneficiation of minerals with different magnetic susceptibilities Low consumption of electrical power and cooling water Compact structure Low maintenance 9.3 Work Principle Matrix on ring induces high intensity magnetic field up to 22,000gs on its surface when it rotate in magnetic area. The high intensity magnetic field suits it for concentration of weak magnetic mineral and purification of non-magnetic material. Pulp is introduced into separation zone. When magnetic particles run through highly induced matrix, they are attracted on matrix surface, and then run out of separation zone with the ring. The high intensity magnetic field disappeared immediately after leaving separation zone. Most of the attracted magnetic particles fall into concentrate tray, and low pressure water rinse spray is directed onto the ring on top to discharge remanence on the ring. Non-Magnetic particles run through matrix with water and discharged through tailings outlet. During the separation, the pulsation unit drives rubber drumhead, making pulp level move up and down. Movement of pulp rinses particles attracted on surface of matrix, and keeps particles loose in pulp, offering thorough separation. Therefore, it delivers higher recovery with desirable concentrate grade, and prevents jam in matrix. Magnetic Field Inducted By High Permeability Matrix Distribution Of Background Field Coil and Separate Water Cooling System 3D Simulation Of Magnetic Field 5
1. Flushing water 2. Matrix box 3. Rotation ring 4. Upper magnetic pole 5. Excitation coil 6. lower magnetic pole 7. Small tailings bucket 8. Big tailings bucket 9. Pulsator 10. Rubber drumhead 6
Channel for Quality! 9.4 Technical Parameter ( ) 7
10. Cylinder Screen 10.1 Application Cylinder screen sure used where the particle sizing of material being fed to the equipment is critical, eg WHIMS. 10.2 Features Automatic classification of minerals Low failure rate Easy operation and maintenance No impact, less vibration, low noise and long service life Easy replacement of screen mesh 10.3 Technical Parameter Φ Φ Φ Φ Φ 8
Channel for Quality! 10.4 Working Principle 9
10.5 Mineral 10
Channel for Quality! 10.6 Recommended Flowsheet 11
11. Wet Drum Magnetic Separator 11.1. Summary Brief Introduction Wet drum magnetic separator ranges from 650GS to 7000GS in magnetic intensity. It is suitable for concentration of ferromagnetic mineral like magnetite and heavy media recovery. We launched the worldwide largest wet drum separator. This kind of separator with1500mm diameter and 5000mm width whose capacity can reach to 400 t/h in 2011. Add-on Enhancement Demagnetizer breaks magnetic coagulation between magnetized particles after magnetic separation. It works to improve screening and beneficiation efficiency. Separation Tank We provide three types of tanks for different separation stages of beneficiation plant Concurrent Tank Counter Rotation Tank Counter Current Tank 12
Variables that affect separation of wet drum magnetic Magnetic intensity and magnetic gradient Shape and structure of separation tank Position of magnetic element Gap between separation tank and magnetic drum Beneficiation result of counter current wet drum separator is well recognized. Our improvements based on years of research and abundant knowledge in mining delivers excellent performance Breakthrough Magnetic element with multi-pole and large wrap angle Separation tank with hydro dynamically efficient curve Easy adjustment to position of magnetic element and working gap Quality abrasion-proof layer provides effective protection to separation tank Spray nozzle discharges concentrate efficiently New Design Concept 13
Magnet System Design Customized Service We operate our own laboratory within our manufacturing center, which is a state-of-the-art magnetic separation engineering facility. This laboratory undertakes professional sample testing and reporting for a wide range of mineral and some of recycling industries. Quality Magnet Magnet with high coercive force is applied for the magnet system to deliver stable magnetic performance, and ensures demagnetization less than 5% in 8 years. High Gradient Magnetic Field Magnetic gradient affects the magnetic force much as showed at right. The engineer has employed special design to create higher gradient to improve recovery. Multi-Pole Magnet System Multi-pole magnet system structure design helps improve the concentrate grade by increasing turn-over of magnetic particles on drum surface, which enables magnetic particles be attracted out of magnetic balls, and get rid of non-magnetic thoroughly. 14
High-Performance Magnetic System Multi-pole with small gap offers thorough separation. Large wrap angle, long pickup area. High gradient magnetic field. Magnetic system with the above improvement raises concentrate grade and recovery rate efficiently. Efficient Separation Tank We have employed a hydro dynamically efficient curve for the tank arc to prevent large particle blockage in primary pass. The tank is fabricated from stainless steel with special wear resistant measurement in impact area. Modular Design Tank can be adjusted up and down, forward and back to get suited separation result according to practical conditions Spray Nozzle Spray nozzle discharges concentrate attracted on magnetic drum effectively with less water consumption. It is an our exclusive design. 15
CTS Concurrent Wet Drum Separator Application Short pickup area, high capacity, feeding size 0-12mm, is suitable for rougher separation of coarse materialeg, sea sand or river sand. Features Magnet system is well protected from peeling off or damage. Concurrent tank design delivers large handling capacity and jam-free operation. Sludge discharge on both ends of tank allows easy cleaning. Structure 16
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CBT Counter Current Wet Drum Separator Application Long pickup area, multi-pole with small gap, feeding size 0-3mm, is used for cleaner and finisher stages. Features Quality magnet provides stable performance. Shaft is well protected from magnet system for safe running. Sludge discharge on both ends of tank allows easy cleaning. Structure 18
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CTN Counter Rotation Wet Drum Separator Application For automatic, continuous concentration of ferrous and weakly magnetic ores. The feeding material size 0-3mm. Features Quality magnet provides stable performance. Shaft is well protected from magnet system for safe running. Sludge discharge on both ends of tank allows easy cleaning. Structure 20
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12. Dry Drum Magnetic Separator 12.1 Summary Brief Introduction Our dry drum magnetic separator is applied for iron ore with lower moisture in dry area. like Chile, Mongolia, Mexico, northwest of China, etc. The application of dry drum magnetic separator lowers beneficiation plant s reliance on water and is environmental friendly. The magnetic element can be ferrite or rare earth depending on magnetic intensity required. Magnetic intensity ranges from 600GS to 7000GS. Magnetic drum diameter in 800mm or 1000mm in different width Add-on Enhancement We provide vibrating feeder. We defined reasonable structure by simulating feeding in computer, so to distribute materials evenly into magnetic separator, improving utilization of magnetic element and separation efficiency Features No water consumption Quality magnetic material guarantees long term stable performance Reasonable design of magnetic element ensures ferrous material in tailings is lower than 1% High gradient, mufti-pole design, big wrap angle Quality wear resistant layer like rubber or ceramic delivers long service life with low maintenance Safe, easy control via control panel to achieve optimal separation 22
12.2 LCG Dry Drum Magnetic Separator Application LCG series dry drum magnetic separator is applied in rougher or primary stages to reduce the amount of material to grinding or to improve the feed grade of ore, feeding size 0-12mm, Fe grade 5%-20%. Features Excellent separation performance The magnet system design improves concentrate grade with low ferrous loss to tailings. Large capacity Capacity is 1.5 times that of similar equipment. Ceramic protection layer providing improved wear resistance. Wide application range Assists to control grade of concentrate and tailings, suitable for pre-concentration of 0-12mm dry particles. Structure 23
12.3 NEW Design Concept Magnet System Design Customized Service We operates our own laboratory within our manufacturing center, which is a state-of-the-art magnetic separation engineering facility. This laboratory undertakes professional sample testing and reporting for a wide range of mineral and some of recycling industries Quality Magnet Magnet with high coercive force is applied for the magnet system tc deliver stable magnetic performance, and ensures demagnetization less than 5% in 8 years. High Gradient Magnetic Field Magnetic gradient affects the magnetic force much as showed at right. The engineer has employed special design to create higher gradient to improve recovery. Multi-pole Magnet System Multi-pole magnet system structure design helps improve the concentrate grade by increasing turn-overs of magnetic particles on drum surface, which enables magnetic particles be attracted out of magnetic balls, and get rid of non-magnetics thoroughly. Movement of magnetic particle 24
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Structure Advanced Manufacture Technique N40H magnet is of high coercive force and remanence, and with chromium plating protection. Demagnetization shall be less than 5% in 8 years. Assembly of magnet system: magnet are fixed on yoke plate with stainless steel bolt, and wrapped with stainless steel plate to prevent magnet from peeling off. Measurements like sealant on machining surface, stainless steel flange, 4mm thick drum shell with sealing ring, etc, are applied to protect drum from dust, water and moisture and ensuring long term stable operation. Drum surface is protected with wear resistant ceramic plate,which features as: Hard and wear resistant Hardness of ceramic plate is up to HRA92, which is 100 times than that of manganese steel, and 20 times that of high chromium cast iron Non-magnetic property Ceramic plate is not of any magnetic property, which makes it irreplaceable of wear resistant metal High separation efficiency Good property of ceramic plate helps to improve separation efficiency and grade of product. Safe and reliable Ceramic plates are pasted with high intensity non-magnetic glue. Shear strength between drum shell and ceramic plate is more than 30MPa with strong toughness, which suited it for changes of temperature and vibration.n 26
12.4 LCT Magnetic Drum Application LCT series dry drum magnetic separator serves as a primary stage separation by being the head pulley of conveyor belt. Removing waste stone in the primary stage, reducing the amount for crushing. Feeding size is up to 300mm. Features Quality rare earth magnet provides stable performance with less than 5% demagnetization over 8 years. Magnet system is well protected Installation dimension suits DT75, DTI I standard belt conveyor for easy installation. Outer bearing offers convenient maintenance. Half magnet system structure prevents ferrous material from entering inside of belt conveyor for safe operation. Able to act as conveyor belt drive drum for belts up to 100m long. Structure Working Principle Schematic Drawing 27
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12.5 LCGX High Frequency Dry Drum Magnetic Separator Application LCGX series dry drum magnetic separator is newly launched equipment with special design to improve concentrate grade in cleaner separation of dry processing line, especially project sites with limited source of water. Feeding size is 0-12mm. Structure 29
Typical Dry Processing Line 30
13 LTC Demagnetizer Application Demagnetizers are used to break-up "magnetic balling" or clumping in multi-stage magnetic separations. It generates a continuous constant magnetic field and will break up 'clumps' efficiency and increase concentrate grade. Features It uses a single coil to induce a core magnetic field with a constant peak value and offers low power consumption and good demagnetization. We apply high wear resistant material in abrasive areas. Unique circuit design presents rectangular sine-wave of voltage and continuous angular current wave. The magnetic field generated by the coil decreases along an arc and alternates at high frequency to magnetize pulp in the opposite direction repeatedly, reducing magnetic force gradually to zero. The magnetic circuit adopts imported IGBT module as the switch element to guarantee safe current alternation, and in turn, to assure continuous oscillation of the magnetic field to provide the continuous demagnetization required. IGBT is integrated within the IPM module and the drive module is designed to prevent over-current, short circuiting, voltage deficiency and over-heating. 31
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14 LJK Electromagnetic Application LJK series magnetic separator separates magnetic material and tramp iron by using a unique arrangement of magnetic fields with little or no magnetic ore being removed to protect downstream crushing equipment. Features The entire system can operate automatically; no operator required. Magnetic separator starts on receiving signal from metal detector. Special magnetic system design differentiates tramp iron from Ferrous material, and return attracted ferrous material back to belt conveyor. Real time monitoring from metal detector ensures removal of tramp iron from conveyor. System installed parallel to belt conveyor, saving space and offering ease of operation and maintenance. The system includes: LJK electromagnetic separator, GLA-LK control panel, UT metal detector, non-magnetic platform (optional), and non-magnetic idler (optional). 33
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15. Industry Served We have provided service to over 5,000 worldwide customers from a range of industries such as concentrator plants, coal washing plants, recycling facilities, shipyards, thermal power stations, pharmaceutical and food industries, etc. Our products have been applied widely across China and exported to overseas market, including: Brazil, Australia, America, India, Indonesia, Canada, Japan, etc. 15.1 Mining Industry We provide a full range of magnetic equipment applied in different stages in beneficiation plant of magnetic, weak magnetic and non-ferrous minerals. Our magnetic separators are applied in most large and middle-scaled beneficiation plant in China and exported to Brazil, India, Australia, America, etc. 15.2 Recycling Industry Recycling system usually consists of cross belt magnetic separator, magnetic drum, vibrating feeder and eddy current separator. Cross belt magnetic separator and magnetic drum serves to remove any coarse and fine ferrous material contaminated in material before feeding to Eddy Current Separator. Eddy current separator (ECS) separates non-ferrous metal from non-metallic material. 15.3 Bulk Handling Permanent and electro-magnetic separator serves to remove contaminated iron object for protection of downstream equipment or improve purification of products, such as coal handling, food and pharmaceuticals industry, etc. 15.4 Steel Plant Lifting magnet is applied in steel plant shipyard to lift and transport all kinds of material, steel sheet, bars, turnings, bundles, scrap, etc. Lifting magnet can work separately or in group. 35
16 Typical Application in Iron Mining 36
17 Facility 37