Leading high intensity wet magnetic separator for ferromagnetic materials

The leading high intensity wet magnetic separator for ferromagnetic materials is more than just a technical specification. This solution, which results in 3-7% higher concentrate yields when processing low iron content ores, reduces the loss of valuable particles in the tailings and operates reliably even with fluctuations in pulp moisture content of up to ±12%. We tested this at three plants: in the Kursk magnetic anomaly, in the Urals and in Transbaikalia - the results coincided.

Why “high intensity” is not marketing, but a measurable parameter

Many customers confuse “strong magnetic field” with “effective separation”. In fact, the key indicator is not the maximum induction in the gap (for example, 1.8 T), but its gradient and stability in the working area under load. LONGI Corporation's leading high-intensity wet magnetic separator for ferromagnetic materials produces a gradient of up to 450 T/m at a winding current density of 12 A/mm² - without overheating, without field drift for 16 hours of continuous operation. We measured: the induction deviation does not exceed ±0.8% per shift. This is achieved due to a three-layer cooling system: an internal circuit with a thermostabilized coolant, a sealed aluminum alloy housing and an external air blower with temperature sensors in each module.

The critical feature is the drum design. Standard solutions use coated steel. LONGI has a combined system: a base made of AISI 316L stainless steel, on top there is a layer of magnetically conductive alloy with controlled permeability, and on top there is a ceramic coating with an adhesion coefficient of 9.2 MPa. When tested on ore with an abrasiveness of 0.45 g/kWh, wear was 0.13 mm in 6 months - 2.4 times lower than that of analogues.

What breaks separators in practice - and how this is taken into account

Some people believe that if the field is strong, then the separation will be of high quality. However, we encountered the opposite - at two enterprises, separators produced 82% iron recovery, although the declared efficiency was 94%. The reason was not magnets, but hydrodynamics: turbulence in the supply of pulp caused a “slippage” of particles measuring 35–55 microns. The solution is not to increase the field, but to redesign the distributor. The LONGI model uses an adjustable tray with six degrees of freedom, a tilt angle from 12° to 28° and a water micro-dosing system. It compensates for changes in pulp density in the range of 28-38% by weight - without stopping the equipment.

Another common failure scenario is the ingress of large inclusions. Standard grilles only block >10mm. This separator has three-stage protection: a primary grid (12 mm), a secondary magnetic barrier with automatic release of ferroimpurities and the third stage - a built-in ultrasonic load control sensor. It responds to changes in acoustic impedance within 180 ms and blocks the flow if it detects an inclusion >8mm.

• Working capacity - from 15 to 220 m³/h (depending on modification)
• Maximum feed particle size: 3 mm (subject to prior classification)
• The iron content in the concentrate is up to 68.2% Fe with the original ore being 28–32% Fe
• Electricity consumption - 14.3 kWh/t of concentrate (at 35% solids)
• The service life of the main components is at least 12 years, subject to maintenance regulations

How to choose a specific modification - without overpayment and redundancy

We do not recommend choosing by “power” or “induction”. The decisive factor is the mineralogical composition of the ore and the distribution of particles by class. For example, quartzites with magnetite-ilmenite admixture require a different configuration of the magnetic system than hematite ores with clay inclusions. On the websiteljmagnet.ruA free preliminary calculation form is available: just upload sample analysis data (granulometry, magnetic susceptibility, SiO₂/Al₂O₃ content), and the system will offer three options - basic, optimized and energy saving - indicating the expected recovery and permissible deviation.

The installation technical conditions are simple: pulp lifting height is up to 1.2 m, inlet pressure is 0.12–0.25 MPa, ambient temperature is from −25 °C to +45 °C. No foundation required: installation can be done on a flat concrete area with a slope of no more than 0.3%. Average commissioning time is 38 hours.

The leading high-intensity wet magnetic separator for ferromagnetic materials from LONGI Corporation is not equipment, but a technological unit that is built into the existing enrichment circuit without reworking flotation shops or rebuilding pumping stations. Its advantage appears not in the first days, but after 4–6 months of operation: stable performance, reduced downtime, predictable wear. That is why more than 60% of our customers return for the second and third units - for other sections of the plant.