Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
Introducing the S99 Magnetic Separator, a marvel of engineering crafted from high-strength magnetic materials. Renowned for its robust magnetism, exceptional magnetic separation prowess, and smooth operational consistency, this device sets a new standard in reliability. Designed specifically for the sand casting industry, it excels at extracting iron impurities from old sand. Its strategic installation, cross-aligned with the sand conveying belt, ensures that the powerful magnetic adsorption methodically separates impurities, all while the belt facilitates seamless conveying and meticulous separation.
S99 High-Intensity Magnetic Separator: the revolutionary solution for excelling in iron impurity extraction from casting sand.
In the sand casting arena, the efficiency of iron impurity removal within the old sand regeneration system is pivotal. It not only influences the reuse rate of molding sand but also the surface quality of the finished castings. Enter the S99 High-Intensity Magnetic Separator, the undeniably crucial component of the foundry's sand treatment system. Its stellar magnetic separation capabilities and advanced design position it as a key player in the workshop. This article dives deep into how this equipment empowers industries to achieve superior sand resource regeneration and elevate casting quality, through an exploration of magnetic principles, process adaptability, economic benefits, and smart operation and maintenance.
1. Technical Principles and Core Design Breakthroughs
Harnessing the physical attributes of ferromagnetic impurities in old sand—such as iron beans, flash, and core bones—the S99 Magnetic Separator achieves remarkable separation by leveraging gradient magnetic field design combined with dynamic adsorption technology:
NdFeB Permanent Magnet Matrix:
Utilizing N52-grade sintered NdFeB magnetic material (remanence ≥1.45T, coercive force ≥1120kA/m), the magnetic roller's surface magnetic induction intensity reaches an astounding 18000 Gauss. This force is five times stronger than traditional ferrite magnetic separators, enabling the capture of micron-level iron particles (≥50μm) with unprecedented precision.
With magnetic poles artfully staggered at a 45° angle, a gradient magnetic field (≥0.5T/m) is created, ensuring iron impurities are captured in a three-dimensional matrix from the sand flow, achieving a separation efficiency exceeding 99.5%.
Intelligent Dynamic Separation System:
The magnetic roller and conveyor belt are meticulously positioned at a 75° cross-angle, with adjustable sand flow speeds ranging from 0.8 to 2.5 m/s. This setup ensures iron impurities are efficiently separated from the sand flow through the combined forces of centrifugal and magnetic actions, allowing for continuous, unmanned sorting.
The self-cleaning scraper, coated with tungsten carbide (hardness HRA90), achieves a scraping efficiency greater than 98%, preventing impurities from re-entering the sand flow.
High Temperature Resistant and Long-Lasting Design:
Equipped with a state-of-the-art circulating water cooling system (flow rate 3m³/h), the magnetic roller withstands sand temperatures up to 150ºC, with a magnetic performance attenuation rate of less than 0.1% per year, ensuring longevity and resilience.
The 304 stainless steel sealed housing (IP66 protection grade) alongside ceramic bearings is engineered for the high-dust, high-moisture conditions typical of foundry workshops.
2. Full-Process Integrated Solution for Foundry Sand Treatment
The S99 Magnetic Separator harmoniously integrates into the process chain of falling sand, screening, magnetic separation, and regeneration, crafting a pristine sand treatment ecosystem:
Old Sand Regeneration System:
Seamlessly linked with the vibrating conveyor, it adeptly processes old sand with an iron content ranging from 0.5-5% (particle size AFS 40-100), boasting a single machine processing capacity of 10-80t/h.
Following magnetic separation, the iron content in the old sand diminishes to ≤0.02%, with the loss on ignition (LOI) stabilizing between 2.5-3.5%, thereby elevating the reuse rate to an impressive 95%.
Casting Quality Assurance:
The system eradicates the casting defects such as pores and slag inclusions caused by iron impurities, and refines the surface roughness from Ra12.5μm to Ra6.3μm, significantly enhancing the quality of the final product.
Environmental Protection and Energy Efficiency: A New Era of Sustainability
The state-of-the-art closed structure comes with a pulse dust collector, boasting an impressive air volume of 5000m³/h. This ensures dust emission concentrations remain remarkably low at less than 5mg/m³, delivering superior environmental performance.
The cutting-edge permanent magnet drive system offers exceptional efficiency, consuming only ≤0.3kW·h per ton of sand. This translates to an extraordinary 60% energy savings compared to conventional electromagnetic magnetic separators, making it a leader in energy conservation.
3. Unmatched Core Advantages and Economic Benefits
In comparison to traditional magnetic separation equipment, the S99 model achieves groundbreaking performance thanks to innovative material use and intelligent control systems, setting a new benchmark in the industry:
Unparalleled Separation Accuracy: Setting New Standards
The S99 excels in precision, capturing iron impurities as small as 50μm. It boasts an iron bean (Φ1-20mm) removal rate exceeding 99.8%, complemented by a micro-iron powder (50-200μm) removal rate of over 97%.
The adaptive speed control system intelligently adjusts the magnetic roller speed with outstanding accuracy (±2%) in response to sand flow rate changes, accommodating processing volume fluctuations with a tolerance of ±30%.
Revolutionary Decrease in Maintenance Costs: Cutting-Edge Cost Efficiency
Featuring a modular magnetic group design, the system allows for the easy replacement of individual magnets. This results in maintenance times of less than 1 hour and slashes annual maintenance costs by an impressive 70%.
With lubricant-free, lifetime maintenance-free bearings, the equipment ensures overall efficiency (OEE) reaches a stellar 96%. Additionally, the mean time between failures (MTBF) is over an astounding 60,000 hours, signifying superior durability and reliability.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With over 14 years of dedicated expertise, Qingdao Sanzhuji Technology Co., Ltd. has mastered the art of manufacturing cutting-edge sand casting machinery. Our extensive range includes the green sand casting production line, advanced furan resin sand casting systems, pioneering lost foam casting technology, and the innovative coated sand steel sand buried casting production line. Experience unmatched quality and precision with our industry-leading solutions.
Contact Us
Address: Situated in the strategic location of North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, our facility offers easy accessibility and is equipped with state-of-the-art technology to cater to your casting needs.
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