Cheap Hanging Magnetic Separator/Iron Separators

A cheap suspended magnetic separator is not just a budget solution. This is a proven tool that removes ferromagnetic inclusions from bulk materials *before* they reach the crusher, dryer or conveyor belt. We've seen dozens of cases of one invisible nail in a coal stream damaging a hammer crusher rotor in 47 minutes. Another was that steel shavings in the grain caused sensor failure on an automatic packaging line. In both casescheap hanging magnetic separatorstopped the accident before it started.

Why "cheap" does not mean "unreliable"

The word “cheap” in the name is often misleading. It refers to the cost of ownership - not the price on the sign. We tested three types of overhead separators in a scrap recycling shop: a neodymium permanent magnet, an air-cooled solenoid, and an old oil-circuit solenoid. Result? The neodymium version cost 38% less when purchased, consumed zero kilowatts per hour and required cleaning every 11 days. Electromagnets are more expensive at the start, but consumed 5.2 kW/h and required daily insulation checks.Iron separatorsbased on NdFeB showed the best price/resource/efficiency ratio exactly where the load is stable and the temperature does not exceed +80 °C.

Key point: “cheap” means there are no hidden costs. No electricity costs. There is no risk of overheating when the conveyor stops. There is no need for a water cooling system or a backup generator. There is only one maintenance point - cleaning the work surface. We saw an operator remove a magnetic plate, tear off a layer of iron particles and return it to its place in 90 seconds. No tools. No training.

Where do they work - and where should you not put them?

Hanging magnets are effective in three scenarios:

On conveyor belts— over a belt up to 2200 mm wide, at a speed of up to 2.8 m/s;
In loading funnels— in front of crushers, mills, mixers;
In free fall flows— in pipes with a diameter of 300 to 1200 mm, with a drop height of up to 1.5 m.

But there are limitations. If your material contains wet lumps (for example, clay with 22% moisture), the magnetic strength is reduced by 40-60%. If there are many large non-magnetic inclusions (stones, wood) in the flow, they cover the active zone and the steel passes by. And if the material temperature is above +80 °C, neodymium magnets lose up to 15% of their strength for every 10 degrees. In such cases, we recommend combined solutions: for example, a suspended separator + a vibrating screen with magnetic screens.

How to choose - without mistakes that cost thousands

We record three typical mistakes when choosing:

Select by the weight of the captured object, and not by the flow density.A magnet can hold a nut weighing 1.2 kg - but if its speed in the flow is 3.5 m/s and it flies at an angle of 72°, the adhesion force drops by half. It is more important to know: the mass of the material per hour (t/h), its bulk density (kg/m³) and the maximum particle size.
Ignores the depth of the coverage area.The standard LJM-PM300 class separator has an effective gripping depth of 180 mm. If the belt is loaded with a layer of 240 mm, the lower 60 mm remains a “blind zone”. Then you need a model with an extended magnetic field - for example, LJM-PM450.
They forget about the fastening.The suspension must withstand not only the weight of the separator itself (from 85 to 320 kg), but also the dynamic load from vibration of the conveyor. We saw fastening bolts loosen over 17 shifts - due to the lack of Grover washers and control torque.

The solution is simple: provide us with the parameters of your conveyor - and we will calculate the optimal model, including suspension height, inclination angle and fastening scheme. It's free. Because a mistake in choice is more expensive than a consultation.

LONGI Corporation: 31 years in one task

Shenyang Scientific Electromagnetic Company LONJI LLC createscheap suspended magnetic separatorssince 1993. The Fushun plant produces 4,000 pieces of equipment per year. More than half of the engineers have a technical education - and they all started working on production sites. We do not sell the catalogue. We sell experience: how a magnet behaves at -35 °C in Yakutia, how it remains strong after 12 years of operation in a cement plant near Yekaterinburg, how it is cleaned without stopping the line. This experience is reflected in every AISI 304 stainless steel case, in every sealed assembly of magnetic blocks, in every set of fasteners with maximum torque markings.

If your goal is guaranteed equipment protection, reduced downtime and predictable maintenance costs,iron separatorsfrom LONGI work. Not because they are cheaper than others. But because they are made so as not to let you down - even when you stop thinking about them.