Leading High Intensity Multilayer Magnetic Separator

The leading high intensity multilayer magnetic separator is not just a new model in the catalogue. This is a solution we have seen in use at three ore processing plants over the past 18 months: where traditional separators lost 0.8-1.2% of ferromagnetic particles down to 30 microns, this device consistently retained 99.94% of them at a feed rate of 120 t/h.

Why “multilayer” is not marketing, but the physics of separation

One layer of magnetic matrices creates a uniform field. Two already provide overlap of capture zones. But the leading high-intensity multilayer magnetic separator uses five independent levels, from coarse pre-collection of large inclusions to final purification of colloidal iron oxides. Each layer operates in its own tension zone - from 6,000 to 22,000 Oersted. We tested this on samples of quartz sand with an admixture of hematite: when passing through a three-layer system, the residual Fe₂O₃ content was 87 ppm; with five layers - 23 ppm. The difference is not in the numbers. It affects the service life of downstream filter equipment.

The key is not the number of layers, but their coordination. The design uses a dynamic magnetic flux compensation system: when the upper layer is saturated, the current in the lower one automatically increases. This prevents breakdown and maintains efficiency even when material moisture fluctuates from 4% to 16% - a condition often encountered at processing plants in Primorye and Kuzbass.

High intensity - but without overheating and downtime

Many customers ask: “How can 22,000 Oersted withstand without demagnetization?” The answer is in the cooling system. Not fans. Not a water jacket. And the combined circulation of oil and inert gas inside the magnetic circuit. The coil temperature does not exceed +58 °C even with 24-hour operation at 110% power. We observed this personally: measurements were carried out every 2 hours for three days at a bauxite processing site in the Sverdlovsk region. The drop in induction over the entire cycle is 0.37%.

This is critical for operators. We had a case: at one plant they replaced the old separator with a new model, but forgot to reconfigure the supply system. The material came with an increased concentration of clay particles. After 17 hours of operation in the “automatic shutdown when overload” mode, the device did not turn off. It went into low intensity mode (16,500 Oe), kept the output clean and sent a signal to the PLC - “feed correction required.” This resiliency is the result of 28 years of experience in electromagnetic system design.

What Really Changes Choice—and What Doesn’t

Some people think: “The main thing is the strength of the field.” But in practice we see the opposite. At two facilities in the Chelyabinsk region, separators with the same induction were installed - one with a flat matrix, the other with a wave-shaped matrix. Result: with the same air flow and material humidity, the second one showed 22% lower flow resistance and 14% lower energy consumption. Why? Because the shape of the matrix affects the distribution of field lines - and how particles “stick” rather than “clog.”

The industry's leading high-intensity multi-layer magnetic separator utilizes a modular hybrid alloy matrix with NdFeB outer layers for fast capture and SmCo inner layers for enhanced heat resistance. This is not a compromise. This is a calculation. We tested 17 layout options before making the final choice.

• Dimensions:2400 × 1800 × 2100 mm - fits into existing ramps without rebuilding the workshop
• Installation:requires only a flat concrete base and a three-phase power supply of 380 V ±5%
• Service:complete replacement of the matrix takes 38 minutes - regulated by the instructions, confirmed on 42 installations

Who is it for - and when should you start?

If your material contains ferromagnetic impurities as small as 5 microns, if the acceptable level of iron in the final product is below 50 ppm, if you pay for re-washing or extrusion waste - the leading multi-layer high intensity magnetic separator pays for itself in 11-14 months. We calculated this based on data from 19 clients: average savings are 1.8 million rubles per year per piece of equipment.

LONGI Corporation has been developing such solutions since 1993. Its engineers participated in the creation of GOST R ISO on testing methods for magnetic separators. The Fushun plant produces 4,000 units per year - not in bulk, but for specific technical specifications. Each model undergoes a 72-hour stress test before shipping.

Technical parameters, connection diagrams and test reports are available on the website ljmagnet.ru. There is also an interactive payback calculator for your raw material base and an equipment loading schedule for the next 90 days.