Magnetic separator has become an indispensable and important tool in recycling industries due to its efficient separation capability and wide range of applications. This article will give you a detailed introduction to the magnetic separators to help you learn about the functions and applications of magnetic separators more clearly.
Ⅰ. Understanding magnetic separators
First of all, let us understand the definition, function and classification of magnetic separator.
1. What is a magnetic separator?
Magnetic separator is a device that utilizes magnetic fields to separate magnetic substances from non-magnetic materials. This process is commonly used in mining, recycling, and food processing industries to extract valuable materials from the mixture.
2. Functions of magnetic separator?
Magnetic separator is a kind of equipment that uses magnetic difference to separate materials. It can play an important role in many fields, such as scrap recycling, mineral processing, and solid waste treatment. The basic functions of magnetic separator include:
⭐ Raw Material Pre-Treatment
- Magnetic separators are often used to remove ferrous impurities from raw materials and improve the efficiency and quality of further processing, they are always used as the pre process in many recycling lines.
⭐ Purification and Refining
- During the metal recovery and refining process, magnetic separators help separate high-purity metals, remove impurities and improve the quality of the product.
⭐ Resource Recycling
- Magnetic separators play a key role in scrap recycling. They can separate valuable metals from waste and achieve resource reuse.
3. Classification of magnetic separator
With the advancement of science and technology and the growing specialization of industrial demands, the design of magnetic separators has become more diverse to meet stringent requirements for material purity and recovery efficiency across various sectors. The most common types of magnetic separators include belt magnetic separators, drum magnetic separators and ring magnetic separators.
There are two main types of magnetic separators in BSGH Granulator: belt magnetic separator and drum magnetic separator.
⭐ Belt magnetic separator
Belt magnetic separators are mounted directly onto conveyor systems to provide continuous removal of iron from copper materials. They feature a fixed magnetic assembly positioned either above or below the conveyor, with a belt that moves over the magnetic field, efficiently extracting unwanted metal as materials pass through. As the conveyor belt moves, the magnetic field attracts iron and separates them from the copper.
We have two types of belt magnetic separators: one is belt magnetic separator another one is double layer magnetic separator:
For the double-layer magnetic separator:
- one dedicated to the D-series copper granulator machine and the other to the N series copper granulator machine. Double-layer magnetic separators are usually installed at the copper outlet to remove iron chips from copper granules and improve the purity of copper.
For belts magnetic separators are always installed on the conveyor belt.
| Item | N Series Magnetic Separator |
| Capacity | 300-800 KG/H |
| Power | 0.75 KW |
| Weight | 165 KG |
| Size | 2100*550*1550MM |
| Item | D Series Magnetic Separator |
| Capacity | 300-700 KG/H |
| Power | 0.75 KW |
| Weight | 195 KG |
| Size | 2100*550*1300MM |
⭐ Drum magnetic separator
Drum magnetic separators have a rotating drum with a magnetic element and a small conveyor belt. As the drum spins, it attracts and separates iron from wire pieces. Usually placed after the pre-shredder, this separator removes larger iron pieces from the cables, helping to reduce wear on the crusher blades.
| Item | High Strength Magnetic Separator |
| Capacity | 300-400 KG/H |
| Power | 0.5 KW |
| Weight | 145 KG |
| Size | 1200*850*840MM |
Ⅱ. Working principle
After learning about the basic information of magnetic separators, I will show you the working principle of magnetic separators.
The basic working principle of the magnetic separator is: when the material passes through the magnetic field of the magnetic separator, the magnetic material in it will be attracted by the magnetic field, while the non-magnetic material will move along its own motion trajectory due to the action of gravity and inertia, thereby achieving the purpose of sorting.
- Drum magnetic separators are typically installed before the crusher’s feeding port for pre-screening, always high-strength magnets. This is important because a high iron content in the wire can quickly wear down the crusher blades, reducing their lifespan and driving up production costs.
- The belt magnetic separator is generally placed above the conveyor belt, this is always a common magnet.
Ⅲ. Benefits of using a magnetic separator
Using magnetic separators in the recycling industry has the following benefits:
⭐ makes your raw material more valuable
Magnetic separators can separate all magnetic substances from recycled materials. This step allows recyclers to get high-purity recycled materials without impurities. For example, by adding a magnetic separator to your cable granulator, when recycling iron-containing waste cables, the machine will automatically separate iron blocks and copper granules, and you will eventually get copper with a purity of up to 100% without any impurities. Such copper is often more valuable and can be sold at a higher price.
⭐ Reduce Costs
With rising labor costs, manually separating magnetic materials from recycled materials is both time-consuming and expensive. A magnetic separator can replace manual labor to separate magnetic materials, realize automated production, and save a lot of labor costs. In addition, the magnetic separator is efficient and accurate, which can minimize material loss during the process and reduce operating costs.
⭐ Strong adaptability
The magnetic separator can be customized and adjusted according to different needs to meet the needs of different types of material processing. This adaptability enables the magnetic separator to be applied to various recycling scenarios, whether it is metal recycling, wood industry, mining, building materials, etc.
⭐ Increase profits
Magnetic separators can achieve higher recovery rates, reduce labor and operating costs, simplify operating procedures, improve efficiency, increase material purity, and reduce material loss rate. The ultimate goal of these benefits is to help recyclers achieve higher profits. Using magnetic separators can enable recyclers to achieve the same profit at a lower cost, and achieve higher profits at the same cost, thereby maximizing their benefits.
Ⅳ. Application of magnetic separator
In addition to the recycling industry, magnetic separators are also used in the following industries:
1. Mining Industry
In the mining industry, magnetic separators are mainly used for ore dressing. It can effectively separate non-ferrous metals and ferrous metals in minerals. Magnetic separators are widely used in iron ore, copper ore, gold ore and other mining fields, and have achieved good separation effects and economic benefits.
2. Metallurgical Industry
In the metallurgical industry, magnetic separators can separate magnetic materials from non-magnetic materials and are used for waste recycling and forging in steel mills, metallurgical plants, and ferroalloy plants, etc. This can improve production efficiency, reduce costs, and achieve environmental protection.
3. Chemical Industry
In the chemical industry, magnetic separators can be used to separate metal ions such as iron, nickel, and cobalt from various chemical substances to reduce the impact of these metals on production. They are mainly used for process control in the production of acids, dyes, additives, pesticides, etc.
4. wood processing industry
Magnetic separators can also be used in the wood processing industry, especially before the production of finished products such as furniture and wooden doors, the iron impurities that may exist in the wood will affect the quality and appearance of the finished products. Through the treatment of magnetic separators, not only can the iron impurities in the wood be effectively removed, but also the mechanical iron that may be mixed in during the processing can be removed, thereby improving the quality and purity of the wood.
Ⅴ. Maintenance of magnetic separator
Magnetic separator is an indispensable equipment in the production process, and daily maintenance is essential. The following points and maintenance methods can ensure the normal operation of the magnetic separator and improve production efficiency:
1. Daily maintenance methods of magnetic separator
- Clean the iron and other impurities of the magnetic separator regularly to avoid affecting the magnetic separation effect.
- Check the magnetic force of the magnetic separator regularly. If the magnetic force is insufficient or ineffective, it needs to be replaced in time.
- Check the circuit and motor of the magnetic separator regularly to ensure that the circuit connection is firm and the motor is running normally.
- Lubricate the bearings of the magnetic separator regularly to reduce friction loss and noise.
2. Common troubleshooting of magnetic separator
- The magnetic separator cannot start normally: First check whether the power supply is normal and whether the wiring is loose; secondly check whether the fuse is blown, if it is blown, it needs to be replaced in time; finally check whether the switch is normal, if there is a problem, it needs to be repaired or replaced.
- The magnetic field of the magnetic separator is weak: Check whether the magnets in the magnetic separator have fallen off or the magnetic force has weakened. Repair or replace them in time.
- The magnetic separator has poor sorting effect: First check whether the feed is uniform, if not, it needs to be adjusted; secondly, check whether the magnetic field strength of the magnetic separator meets the requirements, if not, it needs to be adjusted.
- The magnetic separator is too noisy: Check whether the mechanical transmission parts of the magnetic separator, such as belts and chains, are damaged or loose and need to be repaired or replaced; at the same time, check whether the supporting facilities of the magnetic separator are firm. If not, they need to be reinforced.
Ⅴ. Conclusion
In summary, magnetic separators have an irreplaceable position and role in industrial production. With the continuous advancement of technology and the continuous expansion of application areas, magnetic separators will continue to be optimized and upgraded to meet a wider range of production needs and market changes, and make greater contributions to industrial production and economic development.
