Lead electromagnetic separator

The leading electromagnetic separator is not just an equipment for removing ferromagnetic impurities. It is a precision tool that determines the purity of the final product, the life of crushers and the safety of conveyor belts. We have seen more than once how at a processing plant in the Kemerovo region, a stoppage of the conveyor due to a damaged crusher rotor caused downtime for 14 hours - the reason? Missed 850 gram piece of rebar that went past an outdated low induction separator with slow release time.

Why “leading” is not marketing, but a technical reality

The word “leading” in the context of an electromagnetic separator does not mean a sales leader, but a device that solves three problems simultaneously: removes weakly magnetic inclusions (up to 30 gauss), operates without overheating at +45°C, and maintains stable induction even with network voltage fluctuations of ±15%. In our testing of 12 models from different manufacturers, only two separators passed the 72-hour stress test with a constant load of 92% of nominal. One of them is the LJ-EMS-HD series from LONJI Corporation.

The key difference is the design of the magnetic system. Most competitors use air-cooled coils with 1010-grade steel cores. The LJ-EMS-HD has a sealed oil cooling system and a Hiperco 50 alloy core that provides induction up to 1.8 Tesla at an operating current of 12 A. This can capture particles as small as 0.1 mm, such as bolt chips or microscopic gear fragments.

We tested the effectiveness on samples of crushed granite stone from a quarry near Chelyabinsk. With an input iron concentration of 0.018 wt%, the standard separator left 0.0021% and the LJ-EMS-HD left 0.0003%. The difference is 7 times. For a cement plant, this means reducing the risk of “black spots” appearing in the finished product and eliminating the additional screening step.

What breaks most often - and how to avoid it

Customers often ask: “Why did the separator stop holding small nails after six months?” The answer is almost always the same: the installation type is chosen incorrectly. Suspended models (RCF) work well on belts up to 1200 mm wide and speeds up to 2.5 m/s. But if the speed exceeds 3 m/s - as on modern recycling lines - a built-in model (RCI) with an increased magnetic field depth and a forced discharge system is required.

Another common mistake is ignoring operating conditions. At one plant in the Irkutsk region, the separator failed every 4 months. Diagnostics showed that the air humidity in the workshop reached 88%, and the housing did not have IP66 protection. The solution is to replace it with the LJ-EMS-HD-IP66 modification with double-layer epoxy winding insulation and AISI 316 stainless steel. The service life has increased to 5 years without preventive maintenance.

Here are three mandatory parameters that need to be checked before purchasing:

• Operating ambient temperature - from −25°C to +55°C
• The time for complete magnetic field reset is no more than 0.8 seconds
• Guaranteed coil life - at least 100,000 on/off cycles

An economy that can be seen in numbers - not in advertising

The cost of the leading electromagnetic separator is 22–35% higher than the base model. But savings start from the first month. At the reinforced concrete plant in Tatarstan, after replacing the old separator with the LJ-EMS-HD-2000, downtime of crushing equipment decreased by 68%. Annual savings amounted to 2.4 million rubles - due to the prevention of breakdowns and reduction in repair costs.

Important: efficiency depends not only on the device itself, but also on proper integration. We recommend installing the separator no later than 1.5 meters before the entrance to the crusher and using automatic voltage control (a built-in stabilizer is available in the LJ-EMS-HD-Pro version). The connection diagram and calculation of the optimal installation location can be obtained on the websiteljmagnet.ru— 3D models are also available there for integration into design solutions.

Shenyang Longji Scientific Electromagnetic Co.,Ltd., founded in 1993, produces up to 4,000 units of equipment per year. More than 60% of the company’s engineers have higher technical education, and all separators are tested on a vibration platform and thermal cycling - from −40°C to +70°C for 200 cycles.

The future is adaptability, not power

The next generation of leading electromagnetic separators is already moving beyond the “strong magnet”. The new LJ-EMS-Smart models are equipped with load sensors on the tape, wear prediction algorithms and a Modbus TCP interface for integration into SCADA systems. They don't just remove iron - they tell you when it's time to clean the bin, how much impurity has passed through the shift, and how much efficiency has changed over the last 30 days.

When you choose a leading electromagnetic separator, you are investing not in iron and copper, but in process predictability. Because real reliability is when you know what will happen tomorrow.