Lead Wet Belt Magnetic Separator

The leading wet belt magnetic separator is not just a ferromagnetic impurity removal equipment. It's a precision tool that does three things at once: protects crushing and grinding units from damage, guarantees final product purity 99.7% of the time, and reduces maintenance downtime by 40-60%. We observed this directly - at a processing plant in the Kemerovo region, where, after replacing an outdated drum separator with a modernLeading Wet Belt Magnetic Separator, emergency shutdowns of crushers fell from 12 to 2 per month.

Why belt works where drums fail

Drum separators are good at removing large particles - nuts, bolts, scraps of fittings. But they are almost helpless in the face of thin iron oxides, rusty dust and small fragments of worn parts. In a suspension with a hardness of 35–45% by weight, such impurities behave like colloids: they hang in the flow, do not settle, and do not cling to the rotating surface. A belt separator solves the problem differently: a magnetic system creates a field up to 180 mm deep, and a moving belt continuously “pulls” particles out of the stream and carries them to the discharge zone. In real tests, at a flow rate of 800 m³/h and a Fe₃O₄ content of up to 0.8 g/l, the cleaning efficiency was 99.2% - provided that the belt speed and field gradient were correctly selected.

Key parameters that cannot be ignored:

• Belt speed: 0.1 to 0.6 m/s (optimally 0.25–0.35 m/s for most mineral suspensions)
• Induction on the surface of the tape: ≥ 12,000 Gauss (not less than 1.2 Tesla) in the working area
• Belt angle: 12–18° - critical for self-cleaning and preventing re-entry of impurities
• Belt material: wear-resistant polyurethane with reinforcing steel mesh (lifetime - at least 18 months with 24-hour operation)

Where are the most common mistakes made when choosing - and how to avoid it

Some customers believe: “the higher the induction, the better.” This is a dangerous misconception. A field above 15,000 Gas sharply increases the magnetization of non-magnetic particles (for example, hematite or pyrite), causing their aggregation and the formation of “magnetic lumps” that clog the tape and disrupt the hydrodynamics of the flow. We recorded such cases at two enterprises in the Sverdlovsk region: after 72 hours of operation, the belt was covered with a dense layer of sludge, and throughput dropped by 35%.

The right approach is balance. The induction must be sufficient to capture the target impurities (Fe, FeO, Fe₂O₃), but below the magnetization threshold of the main product. For quartz sands - 11,500–12,500 Gas. For clay suspensions - 10,000–11,000 Gas. For ores with a high paramagnetic content - up to 13,500 Gas, but with mandatory correction of the inclination angle and belt speed.

What is needed for installation - and how long will it take to get started?

The driving wet belt magnetic separator does not require a foundation. It is mounted directly on the production line - between the pump and the hydrocyclone or in front of the mill feeder. Basic conditions:

• Access to a DC power source 220 V / 50 Hz (power supply - from 1.2 to 3.5 kW depending on size)
• Free space 1.2 × 0.8 × 1.0 m for maintenance and discharge of impurities
• The presence of a channel or container for collecting waste sludge (volume - from 15 to 60 l/hour)

Launch takes from 4 to 8 hours. The first 30 minutes are to check the tightness of the connections and adjust the belt speed. Next is an idle start, then a gradual introduction of the suspension. After 2 hours, a control analysis of the output flow is carried out: three samples are taken at intervals of 15 minutes, and the magnetic susceptibility is determined on a laboratory separator of the MSL-2 type. A deviation of more than ±5% from the set value requires adjustment of the angle of inclination or the current in the winding.

LONGI Corporation: experience that is measured not in years, but in thousands of installed units

Shenyang Longji Scientific Electromagnetic Co., Ltd. has been designing and manufacturing wet belt separators since 1993. Over 31 years, the company has produced more than 4,000 such units. They are distinguished not only by stable induction - it remains within ±1.5% throughout the entire service life - but also by thoughtful engineering: a belt with self-adjusting tension, an automatic wear compensation system, a modular design for quickly replacing components without dismantling the housing.

Technical data sheets, connection drawings and video guides for setting up are available on the ljmagnet.ru website. But the main thing is real data: the average service life of the main components is 12 years, the percentage of failures due to the fault of the manufacturer over the last 5 years is 0.8%, the average repair time is 2.4 hours. These are not catalog numbers. This is what we saw on site - in workshops, on sites, in operation logs.

The leading wet belt magnetic separator is a solution that starts with flow understanding and ends with predictable, measurable, repeatable cleaning. Not ideal. But reliable. Tested - not in a laboratory, but in conditions where every minute of downtime costs tens of thousands of rubles.