Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
Introducing the S99 Magnetic Separator: Engineered with high-strength magnetic materials, it promises superior magnetism, exceptional magnetic separation, and seamless operation with assured reliability. Primarily designed to extract iron impurities from old sand in sand casting processes, it operates by a strategic cross-configuration with the sand conveyor belt, utilizing its potent magnetic force to efficiently detach impurities, guided smoothly along the belt for effective separation.
S99 High-Intensity Magnetic Separator: A groundbreaking innovation specifically crafted to extract iron impurities from casting sand efficiently, ensuring pristine sand quality and optimal casting results.
Within the intricate sand casting process, the effective removal of iron impurities is crucial for the regeneration system's success, directly influencing both the molding sand's reuse rate and the castings' surface excellence. The S99 High-Intensity Magnetic Separator stands as the pivotal solution in the foundry's sand treatment arsenal, celebrated for its outstanding magnetic separation capabilities and smart design. This comprehensive review delves into its transformative impact on sand resource regeneration efficiency and casting quality enhancement, examining its magnetic principles, adaptability to processes, economic advantages, and intelligent operational management.
1. Technical Principles and Core Design Breakthroughs
Understanding the ferromagnetic impurities (such as iron beans, flash, core bones) in old sand, the S99 Magnetic Separator employs an innovative gradient magnetic field design paired with dynamic adsorption technology for optimum separation:
NdFeB Permanent Magnet Matrix:
Utilizing advanced N52-grade sintered NdFeB magnetic material (remanence ≥1.45T, coercive force ≥1120kA/m), the magnetic roller achieves an intense surface magnetic induction intensity of 18000 Gauss. This is fivefold the adsorption strength of traditional ferrite separators, adept at capturing micron-level iron powder down to ≥50μm.
The magnetic poles are artfully arranged at 45° to create a gradient magnetic field (gradient ≥0.5T/m), ensuring comprehensive three-dimensional adsorption of iron impurities from the sand flow with a remarkable separation efficiency exceeding 99.5%.
Intelligent Dynamic Separation System:
Configured with the magnetic roller and conveyor belt installed crosswise at a precise 75°, the sand flow speed remains adjustable between 0.8 to 2.5 m/s. This setup, under the combined influence of centrifugal and magnetic forces, enables seamless, continuous unmanned sorting of iron impurities from the sand flow.
The self-cleaning scraper, enhanced with a tungsten carbide coating (hardness HRA90), achieves a scraping rate exceeding 98%, effectively averting any reintroduction of impurities into the sand flow.
High-Temperature Resistant and Long-Lasting Design:
Incorporating a sophisticated circulating water cooling system (flow rate: 3m³/h), the magnetic roller endures sand temperatures up to 150ºC with a magnetic performance deterioration rate of less than 0.1% annually.
Constructed with a robust 304 stainless steel sealed housing (IP66 protection grade) and ceramic bearings, it thrives in the challenging high-dust, high-humidity conditions of the foundry environment.
2. Full-Process Integrated Solution for Foundry Sand Treatment
The S99 Magnetic Separator seamlessly integrates into the comprehensive processing chain of falling sand, screening, magnetic separation, and regeneration, establishing a pristine sand treatment ecosystem:
Old Sand Regeneration System:
In collaboration with the vibrating conveyor, it adeptly handles old sand containing 0.5-5% iron content (particle size AFS 40-100), with an impressive processing capacity ranging from 10 to 80t/h per machine;
Post-magnetic separation, the iron content in old sand is impressively reduced to ≤0.02%, while the loss on ignition (LOI) remains consistently stable at 2.5-3.5%, significantly boosting the reuse rate to a notable 95%.
Casting Quality Assurance:
This exceptional technology eradicates casting imperfections such as pores and slag inclusions caused by iron impurities and refines the surface roughness from a previous Ra12.5μm to a smoother Ra6.3μm.
Environmental Protection and Energy Efficiency: Leading the Way to a Greener Future
The innovative closed structural design is enhanced with a high-capacity pulse dust collector, boasting an impressive air volume of 5000m³/h. This ensures our dust emission concentration remains remarkably low at less than 5mg/m³, significantly contributing to cleaner air.
Our cutting-edge permanent magnet drive system is a marvel of energy efficiency, consuming a mere ≤0.3kW·h per ton of sand. This translates to an outstanding 60% energy savings compared to conventional electromagnetic magnetic separators, positioning us as leaders in sustainable technology.
3. Comparative Analysis of Core Advantages and Economic Benefits: Setting New Standards
The S99 is a beacon of innovation, surpassing traditional magnetic separation equipment by leaps and bounds. Through pioneering material innovation and intelligent control systems, it offers unmatched performance and efficiency.
Industry-Leading Separation Accuracy: Precision Redefined
Our advanced technology can capture even the smallest iron impurity particles, down to a size of 50μm. With an iron bean removal rate exceeding 99.8% and a micro-iron powder removal rate surpassing 97%, we set the bar for precision.
The state-of-the-art adaptive speed control system intuitively adjusts the magnetic roller speed to match the sand flow rate with exceptional accuracy (±2%). It also accommodates significant fluctuations in processing volume, with a tolerance of ±30%, ensuring seamless operations.
Revolutionizing Maintenance Cost Reduction: Efficiency and Savings Combined
Thanks to our modular magnetic group design, maintenance becomes effortless. Single magnets can be replaced in under an hour, slashing annual maintenance costs by a remarkable 70%, ensuring your operations remain smooth and cost-effective.
Our equipment features lubricant-free, lifetime maintenance-free bearings, achieving an astonishing overall equipment efficiency (OEE) of 96%. With an outstanding time between failures (MTBF) exceeding 60,000 hours, reliability and uninterrupted performance are guaranteed.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With a legacy spanning 14 successful years, Qingdao Sanzhuji Technology Co., Ltd. has firmly established itself as an industry leader in the realm of sand casting machinery. We specialize in the sophisticated production of various sand casting machinery lines, tailored to meet diverse industrial needs. Our offerings include state-of-the-art green sand casting production lines, advanced furan resin sand casting production lines, innovative lost foam casting production lines, and meticulously designed coated sand steel sand buried casting production lines. Trust in our extensive experience and expertise to elevate your production capabilities.
Contact Us
Address: Conveniently located at the North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, our factory is strategically positioned to serve our clients efficiently and effectively.
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