Leading suspended magnetic separator/iron separators

The leading suspended magnetic separator is not just “another magnet above the belt”. This is the intersection of three demands that we hear every day from processing plant engineers, feed mill technologists and cement line operators:reliability during 24/7 operation, stable cleaning without loss of performance, ease of maintenance in conditions of dust, vibration and temperature changes.

We have been developing and implementing iron separators since 1993. During this time, more than 200 configurations of suspended separators were tested in real conditions: at coal unloading platforms in Kuzbass, in recycling lines near Yekaterinburg, in food terminals in the Far East. One conclusion was repeated repeatedly:the most powerful magnet is useless if it does not hold ferromagnetic inclusions at belt speeds above 2.5 m/s or at material layer thicknesses above 300 mm. That's why LONGI's leading suspended magnetic separator is built around three principles - not just marketing numbers.

Grip depth, not just surface strength

Technical data sheets often indicate “induction at the pole” - up to 12,000 Gauss. But this value is measured under ideal laboratory conditions, on a clean steel plate, in direct contact. In the real flow of material, something else is important:induction at a depth of 150–250 mm from the working surface. We measure it on a stand simulating a bulk flow: crushed granite, wet sand, a mixture of grain and small metal debris. For models of the LJ-HPM series, this value is 2800–3400 Gas - 1.8 times higher than typical solutions of the same weight. Why? Because we use not just “powerful” neodymium blocks, butthree-level magnetic field focusing system: The inner poles form the base field, the intermediate shunts direct it inward, and the outer ferromagnetic frame prevents scattering. The result is a clear “magnetic shadow” under the tape, rather than a blurry field around the edges.

Working with a real load - not with a calculated one

Many customers are faced with a situation: the separator passed acceptance at idle speed, but after two weeks of operation it began to leak bolts and washers. The reason is almost always the same:underestimation of dynamic load. When the conveyor is started abruptly, when the loading window is clogged, or when a large stone hits, an impact load of up to 8–10 kN occurs. Standard fasteners and sheet steel housings are deformed. We do things differently: the frame of the leading suspended magnetic separator is made of cast iron SCh20 with reinforced support sockets; brackets are made of high-strength steel 40X with heat treatment; suspension system - with damping bushings made of Shore A 95 polyurethane. In 2023, we tested at the dynamic load stand in Fushun: 12,000 cycles of impacts with an amplitude of 6 kN - not a single displacement of the fastening, not a single microcrack in the body.

Maintenance without stopping production

“How often should I clean?” - the most common question at the selection stage. The answer depends not on the type of magnet, but onremoval system designs. Most iron separators have manual cleaning: turn off the power, go down the stairs, open the lid, remove the magnetized particles. That's 20-35 minutes of downtime. LONGI's leading suspended magnetic separator offers two solutions: automatic cleaning with pneumatic drive (for lines with high metal content) and semi-automatic cleaning with a mechanical lever (for medium loads). Both options allow you to remove ferromagnetic inclusionswithout stopping the conveyor and without access to height. The operator presses a button - the mechanism moves the protective plate, and the metal falls into the hopper below. Cleaning takes 45 seconds. We implemented such a system at a feed mill in the Belgorod region: we reduced downtime by 7 hours per month, and the number of emergency stops due to metal jamming fell by 92%.

The leading suspended magnetic separator is not a compromise between strength and practicality. This is an engineering solution that has grown out of thousands of hours of on-site work. It works where other magnets lose efficiency: at high speeds, with variable layer thicknesses, with stringent requirements for uninterrupted operation. LONGI iron separators are not an additive to the line. They become its invisible guarantor of product purity. Detailed technical specifications, connection diagrams and recommendations for choosing a model can be found on the company’s website.