Cheap High Intensity Wet Magnetic Separator for Ferromagnetic Materials

A low-cost, high-intensity wet magnetic separator for ferromagnetic materials is not a marketing slogan, but a real technical possibility. We saw how at processing plants in the Urals and Kuzbass they replaced outdated drum separators with modern models with an adjustable field gradient - and obtained +12–18% magnetite recovery while reducing water consumption by 23%. The key question is: how to achieve this without overpaying for a “premium brand”? The answer lies in the balance of three parameters: design simplicity, magnetic field stability and adaptation to real operating conditions.

Why "cheap" does not mean "short-lived"

Many customers mistakenly believe that low price = weak magnets or thin case walls. In practice it’s different. In 2022, we conducted comparative tests of three models with a working field from 1.2 to 1.8 Tesla. The cheapest of them (model LJM-WIMS-1200) showed a minimal drop in induction - only 0.4% over 72 hours of continuous operation at a temperature of 45°C. The reason is not in expensive neodymium blocks, but in a competent heat-dissipating design: aluminum radiators are integrated into the frame, and not welded on top. This eliminates local overheating of magnetic circuits. We don’t skimp on magnets—we optimize their cooling and mounting systems.

Another myth: “low cost = no service.” But at the LONJI plant in Fushun, 60% of engineers have experience working at Russian mining and processing plants. They know that in Siberia, protection against condensation in electrical panels is important, and in the Krasnodar Territory, resistance to chlorides in circulating water is important. Therefore, the basic package includes: IP55 for the power cabinet, AISI 316 stainless steel for all wet areas, pre-calibration of the field by points - at no extra charge.

Where exactly are costs reduced - and why is it safe?

The price is determined not at the warehouse, but at the design stage. Here are three points where LONGI consciously simplifies the solution - without losing efficiency:

• Unified power module.Instead of an individual rectifier for each separator, there is a single 3x380 V / 200 A unit with digital current stabilization. It serves up to four cars at the same time. Savings - 37% on electrical equipment.
• Elimination of complex gap adjustment systems.Instead of hydraulic drives, there is a mechanical scale with fixation through locking screws. The gap is set once during commissioning and remains stable for 18 months. Experience shows: 92% of clients do not change it during operation.
• Localized assembly of units.The body, frame, and pulp supply system are manufactured in Russia according to LONGI's drawings. This reduces logistics, speeds up replacement of parts and provides a clear price without currency fluctuations.

What to check before buying - 4 prerequisites

"Cheap High Intensity Wet Magnetic Separator for Ferromagnetic Materials" only works if the conditions are met. We recorded 78% of failures - not because of the equipment itself, but because of ignoring these points:

1. Pulp particle size.When maintaining a fraction<0.045 mm >35% requires preliminary classification. Otherwise, the separation zone becomes clogged. The solution is to install a hydrocyclone in front of the separator, rather than increasing the magnet power.
2. Iron content in water.At Fe²⁺ > 12 mg/l, sediment forms on the surface of magnetic plates. Preliminary aeration or filtration through quartz sand is required.
3. Inlet pressure.Minimum - 0.18 MPa. At lower pressures, the uniform distribution of the pulp across the width of the drum is disrupted. Check the pressure gauge - not against the pump data sheet, but directly on the supply flange.
4. Ambient temperature.When operating below −10°C, modifications are required: heating the oil in the gearbox, antifreeze in the electromagnet cooling system.

How to choose a specific model - without overpayment

There are 11 models of wet separators in the LONGI catalogue. For most Russian tasks, three are enough:

• LJM-WIMS-800— for pulp with a productivity of up to 45 m³/h and a magnetite content of 12–25%. Used on small enrichment lines and in laboratories.
• LJM-WIMS-1200— “workhorse”: 80–110 m³/h, field up to 1.65 Tesla, separation zone depth 120 mm. Suitable for 70% of mining and processing plants in Central Russia.
• LJM-WIMS-1500- for large factories with a high content of paramagnetic impurities. Additionally, there is a system for automatically blowing magnetic surfaces with compressed air.

Technical maps are available on the ljmagnet.ru website indicating actual energy consumption, weight, dimensions and recommendations for the foundation. There are no “conventional units” - only numbers verified at partner factories.

A low-cost, high-intensity wet magnetic separator for ferromagnetic materials is not a compromise, but the result of an engineering choice. A choice based on thousands of hours of real-world use, not theoretical calculations. It gives stable results where other systems lose 5-7% yield every two months. The key is not to look for the cheapest model, but to find one that takes into account your pulp, your water and your shutdown schedule. This is exactly how LONGI engineers have been working - since 1993.