Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
The S99 Magnetic Separator, crafted from high-strength magnetic materials, stands out with its powerful magnetism and superior magnetic separation capabilities. Its seamless operation paired with its reliable performance makes it an indispensable tool in the sand casting industry. Specifically designed to eliminate iron impurities in old sand, it seamlessly integrates with sand conveying systems. The robust magnetic pull ensures efficient removal of contaminants as they traverse along the belt, promising a cleaner casting process.
Discover the S99 High-Intensity Magnetic Separator, a groundbreaking advancement in the efficient removal of iron impurities from casting sand, ensuring pristine results.
Within the sand casting arena, the effectiveness of iron impurity extraction from old sand is crucial for the reuse of molding sand and the aesthetic quality of castings. The S99 high-intensity magnetic separator shines as the pivotal purification asset in foundry workshop sand treatment systems, thanks to its outstanding magnetic separation prowess and cutting-edge design. This exposition delves into how this remarkable equipment aids businesses in maximizing sand resource regeneration and enhancing casting excellence through insights into magnetic principles, process adaptability, economic gains, and smart operation and maintenance.
1. Technical Principles and Core Design Innovations
Harnessing the unique physical attributes of ferromagnetic impurities like iron beans and flash in old sand, the S99 magnetic separator ensures precise separation with its innovative gradient magnetic field design and advanced dynamic adsorption technology:
NdFeB Permanent Magnet Matrix:
Utilizing N52-grade sintered NdFeB magnetic material, with a remanence of ≥1.45T and a coercive force of ≥1120kA/m, the magnetic roller achieves a surface magnetic induction intensity of 18000 Gauss. This force is fivefold that of traditional ferrite separators, enabling the capture of micron-sized iron particles (≥50μm) with ease.
The staggered magnetic poles at 45° create a gradient magnetic field (gradient ≥0.5T/m), ensuring iron impurities are effectively captured in three dimensions from the sand flow, boasting a separation efficiency of >99.5%.
Intelligent Dynamic Separation System:
Engineered with a 75° crosswise alignment between the magnetic roller and conveyor belt, along with an adjustable sand flow speed ranging from 0.8 to 2.5 m/s, the system leverages centrifugal and magnetic forces for seamless, continuous, unmanned sorting of iron impurities from sand.
The self-cleaning scraper, enhanced with a tungsten carbide coating (hardness HRA90), achieves a scraping rate exceeding 98%, preventing impurities from re-entering the sand flow and ensuring pristine sand quality.
High Temperature Resistant and Durable Design:
Equipped with a circulating water cooling system (flow rate 3m³/h), the magnetic roller withstands sand temperatures up to 150ºC while maintaining a magnetic performance attenuation rate of <0.1% per year.
The robust 304 stainless steel sealed housing with an IP66 protection rating and ceramic bearings are built to endure the challenging high dust and humidity conditions typical of foundry workshops.
2. Comprehensive Foundry Sand Treatment Solution
The S99 Magnetic Separator is seamlessly integrated into the comprehensive process chain of sand treatment, encompassing protocols like falling sand, screening, magnetic separation, and regeneration, forming a holistic clean sand treatment ecosystem:
Old Sand Regeneration System:
In conjunction with the vibrating conveyor, it adeptly processes old sand containing iron levels of 0.5-5% (particle size AFS 40-100), with an impressive processing capacity of 10-80t/h per unit.
Following magnetic separation, old sand is refined to an iron content of ≤0.02%, achieving a stable loss on ignition (LOI) of 2.5-3.5%, while boosting the reuse rate to an impressive 95%.
Ensuring Casting Quality Excellence:
Eradicate casting defects like pores and slag inclusions caused by iron impurities, while refining surface roughness from Ra12.5μm to an exceptional Ra6.3μm, guaranteeing high-caliber castings.
Environmental Protection and Energy Efficiency:
Our cutting-edge closed structure comes equipped with a state-of-the-art pulse dust collector boasting an impressive air volume capacity of 5000m³/h. This advanced design ensures that dust emission concentrations are maintained at an environmentally friendly level of less than 5mg/m³, promoting a cleaner and healthier working environment.
The energy-efficient permanent magnet drive system requires a minimal power consumption of ≤0.3kW·h per ton of sand, which represents a remarkable 60% energy savings compared to conventional electromagnetic magnetic separators, offering both cost-effective and sustainable operation.
3. Unveiling Core Advantages and Economic Benefits
The S99 model represents a groundbreaking advancement in magnetic separation technology, achieving a performance leap over traditional equipment through revolutionary material innovation and intelligent control systems:
Leading the Industry in Separation Accuracy:
Our system is engineered to capture even the smallest iron impurities, with a remarkable capability to target particles as small as 50μm. The proficient removal rate for iron beans (Φ1-20mm) is an exceptional >99.8%, while micro-iron powder (50-200μm) achieves a removal rate of over 97%, setting a new standard in precision.
The adaptive speed control system intelligently and dynamically adjusts the magnetic roller speed in response to the sand flow rate with exceptional precision (accuracy ±2%), and it adeptly handles processing volume fluctuations with a tolerance of ±30%.
Revolutionizing Maintenance Cost Efficiency:
Thanks to the innovative modular magnetic group design, replacing a single magnet is a breeze, taking less than an hour. This streamlined process reduces annual maintenance costs by an impressive 70%, maximizing operational uptime.
With lubricant-free, lifetime maintenance-free bearings, our equipment achieves an outstanding overall efficiency (OEE) of 96%, while the mean time between failures (MTBF) exceeds an incredible 60,000 hours, ensuring reliable, long-term performance.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With an impressive legacy spanning over 14 years, Qingdao Sanzhuji Technology Co., Ltd. is a distinguished leader in the realm of sand casting machinery production. Our expertise encompasses a comprehensive range of specialized machinery including the green sand casting production line, the innovative furan resin sand casting production line, the advanced lost foam casting production line, and the cutting-edge coated sand steel sand buried casting production line. Each of these products is meticulously engineered to perfection, ensuring unparalleled efficiency and quality for our valued clients.
Contact Us
Address: Situated north of the renowned G204 National Road, in the industrious Poli Town, West Coast New Area, Qingdao, China, our state-of-the-art facility stands as a beacon of innovation and excellence in the casting industry.
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