Automatic electromagnetic slurry iron separator
● Purpose
For production processes involving a slurry stage, it is recommended to use a slurry electromagnetic separator. Since the slurry state allows for better dispersion, performing magnetic separation at the slurry stage can yield more effective results.
● Working principle
1. When the electromagnetic coil is energized, it forms a magnetic circuit with the carbon steel casing, generating a strong magnetic field within the chamber. The magnetic conductive medium placed in the hollow cavity concentrates and amplifies the magnetic field, creating a high-intensity and high-gradient separation zone.
2. When the slurry passes through the magnetic concentration medium from bottom to top, non-magnetic materials flow smoothly and exit through the material outlet, while magnetic substances are adsorbed onto the magnetic concentration medium.
3. The material pipeline is equipped with a motorized ball valve. Through PLC automatic control, the magnetic field is periodically interrupted, and the pipeline switches to the impurity discharge position. Flushing water and compressed air are introduced to wash the magnetic substances off the magnetic concentration medium, discharging them through the iron removal outlet, thereby separating magnetic impurities and obtaining high-purity material.
4. The coil is cooled by circulating insulated transformer oil, while the oil is further cooled through heat exchange with circulating water, ensuring stable operation of the system.
5. The system employs an HMI (Human-Machine Interface) for operation and PLC-based fully automatic control, enabling automatic iron removal, automatic slag discharge, automatic alarm functions, and unmanned automatic operation with status monitoring.
● Process flow
● Improvements and innovations
1. The magnetic field control adopts a constant current method. The PLC automatically adjusts the voltage to ensure a stable magnetic field, avoiding fluctuations caused by temperature variations that occur with constant voltage control methods.
2. The elevated tank design incorporates more layers of magnetic media. Under the same filtration conditions, it can adsorb more magnetic impurities, achieving 20–25% higher efficiency compared to similar models on the market. The increased height of the separation zone improves the capture probability of magnetic impurities in the material by 5–10%.
3. The unique internal oil circulation design of the cooling system, combined with a generously sized cooler, ensures reliable operation even in environments with suboptimal cooling water temperatures. This prevents localized overheating and damage to the electromagnetic coil. With proper oil-water circulation and regular maintenance, the coil’s service life can exceed 10 years.
4. An industry-exclusive oil filter design effectively removes trace impurities from the oil, ensuring smooth oil flow and extending the oil's service life by more than double.
5. The electromagnetic coil insulation uses DuPont NOMEX® insulation paper, which withstands temperatures up to 200°C. High-temperature, oil-resistant, and 1100V-rated heat shrink tubing is used at connection points, enhancing insulation, reducing tape usage, and minimizing the risk of contaminating the oil circuit.
6. Equipped with a dedicated lifting arm for media removal, frontline workers can clean and maintain the media more conveniently and quickly. Compared to similar equipment, our product reduces routine maintenance labor costs by 50–70% and improves efficiency by over 30%.
7. The electrical control cabinet features a Human-Machine Interface (HMI) touchscreen for easy operation. The display provides real-time monitoring of equipment status, and detailed alarm prompts ensure immediate feedback on faults to operators. Different access levels for the touchscreen facilitate management control over operator permissions. The system also includes data export functionality and reserves an Ethernet communication interface for integration with DCS systems.
8. The material flow path can be coated with corrosion-resistant and wear-resistant materials such as PTFE, ETFE, or nano-ceramics, reducing the risk of magnetic contamination.
● Selection criteria
Electromagnetic filters are standardized based on the magnetic field intensity (background field intensity) within the cavity of the electromagnetic coil after removal of the magnetic medium and the processing capacity of the equipment. The background field intensity refers to the magnetic field strength inside the cavity after the magnetic conductive medium is removed. The magnetic conductive medium can concentrate the background magnetic field to form a high-gradient magnetic field. For example, a background field intensity of 5,000 Gauss can result in a working field intensity of 20,000 Gauss.