In the mining industry, the separation of fine iron ore particles (<0.045 mm) has always been a technical challenge. These particles, due to their large surface area and high surface energy, tend to form aggregates, often resulting in low magnetic capture efficiency and significant fluctuations in concentrate grade for traditional magnetic separation equipment. The breakthrough design of high-intensity magnetic separators, through innovative magnetic field configurations and medium optimization, has successfully increased the recovery rate of micro-fine iron ore particles to over 92% (industry average is 85%), becoming a core piece of equipment for quality improvement and efficiency enhancement in modern concentrators.
1. Strong Magnetic Field Magnetic Separators: Advanced Precision Capture Technology
(1) High Gradient Magnetic Separator (HGMS)
Technical Parameters: Maximum 3T background magnetic field + 1000 T/m gradient value
Core Advantages: Uses steel wool matrix to create a 200-500 μm magnetic capture space
Application Scenarios: Processing -30 μm micro-fine hematite ore, increasing concentrate grade by 3-5 percentage points
(2) SLon Vertical Ring Pulsating High Gradient Magnetic Separator
Dual Breakthrough Design:
Vertical Ring: Enables high-speed continuous operation of the medium (3-5 m/s)
Pulsating Mechanism: Frequencies of 50-300 cycles per minute to break magnetic aggregation
Production Data: In a certain iron ore plant, the recovery rate of -0.038 mm particles increased from 78% to 89%
2.Permanent Magnetic Separators: Economical and Efficient Classic Choice
Wet Permanent Magnetic Drum Separators (CTB Series)
Magnetic System Configuration: Neodymium iron boron permanent magnet assembly, surface magnetic induction of 0.8-1.4 T
Energy-Saving Performance: Reduces electricity consumption by 60-70% compared to electromagnetic types, lowering annual operating costs by over $12,000 per unit
Maintenance Points: Recommend checking the oxidation of magnetic blocks every 2,000 hours
3.Superconducting Magnetic Separators: Industrial Practice of Future Technology
Cryogen-Free Superconducting High Gradient Magnetic Separator
Technological Breakthroughs:
Zero Liquid Helium Consumption: Closed-loop cooling system maintains a continuous 5T magnetic field
Energy Consumption Comparison: Energy consumption is only one-third of traditional equipment for the same processing capacity
Economic Analysis: Although the initial investment is 30% higher, the total cost of ownership (TCO) decreases by 22% over five years
4.Dry Magnetic Separators: Innovative Solution for Water-Scarce Areas
Dry Strong Magnetic Separators (CRS Series)
Wind Selection System: Four-stage cyclone separation + pulse dust removal, dust emission<10 mg/m³
Typical Case Study: In Australia's Pilbara mining area, the moisture content of tailings was reduced to below 8%
1.Ore Characteristics Analysis
Magnetic susceptibility measurement (FeO/TFe)
Inclusion grain size analysis (MLA detection)
Mineral liberation degree (>85% is ideal)
2.Process Adaptability
Matching coarse and fine selection stages
Interconnected control with flotation and re-selection equipment
3.Economic Evaluation Model
Return on Investment (ROI) calculation: [(equipment cost) / (annual efficiency gain - operating cost)]
Typical Case Study: A 2 million ton concentrator using SLon magnetic separators reduced the ROI period to 16 months
4.Intelligentization Requirements
Online mineral analysis instrument interfaces (e.g., MLA system)
Automatic adjustment module for magnetic induction intensity
5.Environmental Compliance
Water consumption indicators (for wet equipment)
Noise control (<85 dB(A))
1.Project Background
Processing capacity: 5 million tons/year, original ore Fe grade 32%, -0.038 mm particles account for 45%
2.Technical Scheme
3.Economic Benefits
Annual increased revenue: $18.7 million (concentrate premium + recovery rate increase)
Energy-saving benefits: Electricity consumption per ton reduced by 2.3 kWh
Environmental benefits: Wastewater reuse rate increased to 92%
Our engineering team provides full lifecycle services:
Laboratory Verification: Provides 50 kg-level ore separation experiments
3D Simulation: Optimizes equipment layout using EDEM software
Intelligent Operation and Maintenance: Predictive maintenance based on vibration spectrum analysis
Process Training: Specialized courses on magnetic system adjustment and medium replacement
