Leading High Intensity Wet Magnetic Separator

The leading high intensity wet magnetic separator is not just a ferromagnetic impurity removal equipment. This is a precision tool that solves three critical problems at the same time: it protects expensive crushing and grinding equipment from accidents, ensures the stability of the technological process in real time and guarantees that the final product meets the requirements of GOST and TU for purity. We've installed such systems at 17 concentrators over the past five years - and in every case, the operators' first reaction was the same: "Why didn't we install this sooner?"

Why “high intensity” is not a marketing term, but a technical necessity

Conventional wet separators with an induction of up to 0.8 Tesla often pass weakly magnetic particles - for example, hematite inclusions measuring 15-40 microns or oxidized shavings from pipelines. The leading high intensity wet magnetic separator creates a field of up to1.8 Tesla in the working area, while maintaining a uniform distribution of lines of force over the entire cross-section of the flow. The key difference is not only in the power of the electromagnet, but also in the geometry of the matrix: a special set of ferromagnetic pins with sharp edges forms local gradients of up to 800 T/m. They are the ones who “catch” particles that freely pass through standard installations.

In practice, this means: when processing quartz sands with an iron content of 0.12% wt. the yield of purified product with Fe₂O₃ ≤ 0.015% is achieved without recirculation. In one of the projects in the Murmansk region, replacing an old separator with a high-intensity model made it possible to reduce crusher downtime by 37% by eliminating the entry of metal inclusions into the crushing chamber.

What breaks separators - and how to avoid it

We recorded three typical causes of failures in the first 6 months of operation:

• Coil overheatingwith insufficient cooling water flow (less than 3.5 m³/h at 40 °C at the inlet);
• Hammering the matrixwhen feeding a suspension with a hardness above 7 on the Mohs scale without preliminary classification;
• Hull corrosionat pH below 4.2 in high chloride environments.

The solution is not in strengthening components, but in a systematic approach. The leading high-intensity wet magnetic separator has: automatic winding temperature control with forced current reduction when exceeding 75 °C; removable matrix with an inclination angle of 12° for self-cleaning when reversing the flow; body made of steel 1.4571 (02Х17Н14М2) with double fluoroplastic coating of internal channels. The implementation of these solutions reduced the number of service engineer visits by 64% compared to analogues.

How to choose - and what to check before ordering

Don't go by the "maximum performance" claims. Actual throughput depends on three parameters that need to be negotiated together:

1. Concentration of the solid phase in the suspension (optimum - 25–35% by weight);
2. Average particle size (for D₅₀ > 250 µm, preliminary hydrocyclone classification is required);
3. Dynamic viscosity at 20 °C (if above 18 mPa s, a heating section in front of the separator is required).

We always require clients to sample the suspension with a volume of at least 5 liters. In the LONGI laboratory we carry out test runs with samples of matrices of different densities and geometries. Only after this we calculate the optimal mode: excitation current, flow speed, reverse frequency. This approach avoids over-equipping - for example, installing a 200 kW installation where 90 kW with the correct settings is sufficient.

LONGIE Corporation: engineering, not assembly

Shenyang Longji Scientific Electromagnetic Co., Ltd. has been operating since 1993. The Fushun plant has more than just assembly lines - it has its own testing center with simulated pressures up to 1.6 MPa and a temperature range from −25 to +85 °C. More than 60% of employees have a higher technical education, and each sales engineer completes 280 hours of on-site training. Every year the company produces more than 4,000 units of equipment - and each model undergoes a three-level test: at the stand, in the laboratory and under real operating conditions at partner enterprises.

The leading high intensity wet magnetic separator is the result of 12 years of research in the fields of magnetic gradients and slurry hydrodynamics. Its effectiveness is confirmed by ISO 9001 and TR CU 010/2011 certificates. And most importantly, he works where others are silent: in the quarries of the Kola Peninsula, at construction materials factories in Siberia, in processing complexes in Central Russia. Detailed technical data, connection diagrams and integration recommendations are available on the website https://www.ljmagnet.ru.