China High Intensity Multilayer Magnetic Separator

China high intensity multilayer magnetic separator is not just a technical term. This is a solution that we have seen in work at three Russian enrichment plants over the past six months: in the Kemerovo region, in the Urals and in the Republic of Bashkortostan. In each case, it replaced two-stage electromagnetic systems and reduced tailings losses by 22–37%. The main thing is that it works where classical separators “refuse to see” weakly magnetic inclusions.

Why ordinary magnets cannot cope with thin iron

Many customers come to us with one mistake: they compare separators by magnetic field strength in Gauss - and choose the “maximum”. But it’s like choosing a vacuum cleaner based only on engine power. More important is how the field is distributed in the working area and how much time the particle spends in it. A conventional one-section separator gives a peak of tension in one layer, and then a sharp decline. Particles of small magnetite or ilmenite simply do not have time to deviate.

China's high-intensity multilayer magnetic separator solves this through contact physics: up to 7 active magnetic layers in one housing, each with its own pole orientation and gradient. We measured - in the area of ​​material passage, the tension gradient reaches 1200 Gas/mm. This is 3.5 times higher than typical solutions for medium size (−1.5 mm). And most importantly, the field remains stable throughout the entire layer depth up to 80 mm.

In practice, this means: even at a feed rate of 18 t/h and a humidity of up to 14%, the yield of pure concentrate remains above 91.7%. We tested on quartz-magnetite ore containing Fe₃O₄28–31%. Without separator - 6.2% iron in tailings. With him - 1.9%. The difference is not in the numbers. It is in the cost of processing a ton of ore.

What breaks separators - and how to avoid it

Some people believe: “If the field is strong, the equipment is reliable.” But at our facilities, it is not the magnets that most often fail, but the cooling system and the mechanical load on the frame. Especially when working with abrasive rocks: granite, quartzite, andesite.

We have implemented three solutions that have become the standard for equipment manufactured in Shenyang:

• Aluminum-copper heat sinksinstead of air cooling - the temperature of the coils does not exceed +58°C even at 24-hour load;
• Reinforced steel frame with damping inserts— vibration on the base plate is below 2.3 mm/s, which corresponds to GOST R ISO 10816-3;
• Modular layer system— one damaged module is replaced in 22 minutes without stopping the line.

These are not marketing promises. This is data from the Fushun manufacturing plant where we conducted an audit in 2023. There is also a test bench with pressure, temperature and magnetic induction sensors in real time.

How to choose a specific model - without overpayment

The LONGI catalog contains seven basic modifications. But three are really in demand:

• LJMS-HI-1200— for dry separation of fraction −3+0.1 mm, productivity up to 12 t/hour, consumption 18.5 kW;
• LJMS-HI-2500— for wet mixtures, including sludge, with an adjustable drum angle (from 5° to 15°), power 37 kW;
• LJMS-HI-4000— industrial version with dual power supply (380 V / 660 V), allows parallel connection to the Siemens S7-1500 PLC.

Key point: if your ore contains more than 12% clay impurities, take a model with water irrigation. Without it, sticking occurs and efficiency decreases after 4 hours of continuous operation. We observed this personally: at one of the enterprises in the Urals, the LJMS-HI-1200 separator showed 89% purification on the first day, and by the third it dropped to 73%. After installing the injectors, it stabilized at 88.4%.

Real operating conditions - and what needs to be prepared

China's high-intensity multilayer magnetic separator requires minimal infrastructure - but it definitely requires it. Below is what we always check before launch:

• Mains voltage: permissible spread ±5%, no surges above 12 V/s. If the supply is unstable, a 30 kW UPS is required;
• Foundation: monolithic slab at least 600 mm thick, reinforced with A500C, without joints in the installation area;
• Dust removal: for dry separation, a local exhaust system with a volume of at least 3200 m³/hour is required;
• Access: service area - at least 1.2 m around the perimeter, 2.1 m at the top for lifting modules.

All these parameters are specified in the instruction manual available on the websiteljmagnet.ru. There is also an interactive connection diagram, video instructions for replacing layers and a compatibility table with Bently Nevada level sensors.

China high intensity multilayer magnetic separator is not “another magnet”. It is a precision tool for applications where every tenth of a percent recovery impacts profitability. It is not universal. But where deep cleaning of finely dispersed phases is needed, it becomes the only solution that works without compromise.