Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
The S99 Magnetic Separator is crafted with premium high-strength magnetic materials that boast extraordinary magnetism, delivering unparalleled magnetic separation performance. This robust machine assures seamless operation and dependable performance. It is specifically engineered to eliminate iron impurities from used sand during the sand casting process. Ingeniously designed, it is installed in a cross-layout with the sand conveying belt, where the powerful magnetic adsorption effectively extracts impurities as the sand is transported and separated by the belt.
Introducing the S99 High-Intensity Magnetic Separator, a groundbreaking solution in efficiently extracting iron impurities from casting sand, setting new standards in the industry.
In the intricate sand casting process, the efficiency of iron impurity removal in the old sand regeneration system is crucial. It directly influences the molding sand's reuse rate and the casting's surface quality. The S99 High-Intensity Magnetic Separator stands as the cornerstone of the sand treatment system in foundry workshops, thanks to its outstanding magnetic separation capabilities and smart design elements. This comprehensive analysis explores how this advanced equipment empowers enterprises to achieve efficient sand resource regeneration and enhance casting quality, focusing on magnetic principles, process adaptability, economic advantages, and intelligent operation maintenance.
1. Technical Principles and Core Design Breakthroughs
Utilizing the physical characteristics of ferromagnetic impurities found in old sand, such as iron beans, flash, and core bones, the S99 Magnetic Separator employs an innovative gradient magnetic field design combined with dynamic adsorption technology to achieve remarkable separation efficiency:
NdFeB Permanent Magnet Matrix:
Incorporating the N52-grade sintered NdFeB magnetic material, boasting a remanence of ≥1.45T and a coercive force of ≥1120kA/m. The magnetic roller surface achieves a magnetic induction intensity of 18000 Gauss, which is five times stronger than traditional ferrite magnetic separators. This enables it to capture micron-level iron particles (≥50μm) with unmatched precision.
With magnetic poles staggered at 45°, a gradient magnetic field is created, exceeding a magnetic field gradient of ≥0.5T/m. This ensures that iron impurities are captured in a three-dimensional manner from the sand flow, achieving a separation efficiency greater than 99.5%.
Intelligent Dynamic Separation System:
The magnetic roller and conveyor belt are strategically aligned crosswise at a 75° angle. The sand flow speed is adjustable, ranging from 0.8 to 2.5 m/s. Through the combined forces of centrifugal and magnetic action, iron impurities are continuously and autonomously separated from the sand flow, ensuring uninterrupted sorting.
The self-cleaning scraper is enhanced with a tungsten carbide coating, achieving a hardness of HRA90. With a scraping rate exceeding 98%, it effectively prevents impurities from re-entering the sand flow, ensuring purity.
High Temperature Resistant and Long-Lasting Design:
The magnetic roller is ingeniously designed with an internal circulating water cooling system, capable of handling a sand temperature of up to 150ºC. It maintains its magnetic performance with a minimal attenuation rate of <0.1% per year, reflecting endurance.
The unit features a 304 stainless steel sealed housing with an IP66 protection grade and ceramic bearings, making it perfectly suited for the challenging high-dust and high-humidity conditions found in foundry workshops.
2. Full-Process Integrated Solution for Foundry Sand Treatment
The S99 Magnetic Separator can be seamlessly integrated into the sand treatment process chain, encompassing falling sand, screening, magnetic separation, and regeneration, to establish an immaculate sand treatment ecosystem.
Old Sand Regeneration System:
When linked with the vibrating conveyor, it efficiently processes old sand with an iron content ranging from 0.5-5% and a particle size of AFS 40-100. It boasts a single machine processing capacity of 10-80t/h, exemplifying performance.
Post magnetic separation, the iron content in the old sand is reduced to ≤0.02%, with the loss on ignition (LOI) stably maintained at 2.5-3.5%. This elevates the reuse rate to an impressive 95%.
Casting Quality Assurance:
Experience unparalleled casting excellence with our cutting-edge solution that effectively eradicates pores and slag inclusion defects caused by iron impurities. Witness a remarkable enhancement in surface roughness, refined from an initial Ra12.5μm to a smooth Ra6.3μm.
Leading the charge in environmental sustainability and energy conservation:
Our state-of-the-art closed structure seamlessly incorporates a pulse dust collector with an impressive air volume capacity of 5000m³/h, ensuring dust emission concentrations that remain below an exceptional <5mg/m³.
Achieve an astonishing 60% energy savings with our permanent magnet drive system, boasting a power consumption per ton of sand of ≤0.3kW·h, a significant advancement over conventional electromagnetic magnetic separators.
3. Unveiling the Core Advantages and Economic Benefits
Elevating performance benchmarks to new heights, our S99 model revolutionizes the industry with groundbreaking material innovation and intelligent control, setting a new standard for magnetic separation technology.
Pioneering Separation Accuracy at the Forefront of the Industry:
Achieve precise separation with our leading-edge technology, capturing the tiniest iron impurity particles as small as 50μm. Enjoy removal rates exceeding 99.8% for iron beans (Φ1-20mm) and >97% for micro-iron powder (50-200μm).
Our adaptive speed control system showcases superior intelligence by dynamically adjusting the magnetic roller speed in real-time, based on sand flow rate, maintaining an accuracy of ±2% and accommodating processing volume fluctuations of ±30%.
Experience a groundbreaking reduction in maintenance costs:
Our innovative modular magnetic group design allows for single magnet replacement, minimizing maintenance time to less than 1 hour and slashing annual maintenance costs by an impressive 70%.
With our lubricant-free, lifetime maintenance-free bearings, the equipment overall efficiency (OEE) soars to 96%. The time between failures (MTBF) extends beyond a remarkable 60,000 hours, ensuring top-notch reliability and performance.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With a legacy of excellence spanning 14 glorious years, Qingdao Sanzhuji Technology Co., Ltd. stands as a beacon of innovation in the world of sand casting machinery. Our expert craftsmanship is showcased through our diverse range of production lines, including the green sand casting production line, the sophisticated furan resin sand casting production line, the versatile lost foam casting production line, and the innovative coated sand steel sand buried casting production line. Each product reflects our unwavering commitment to quality and exceptional service.
Contact Us
Address: Nestled in the heart of Poli Town, along the strategic corridor of G204 National Road, Qingdao's vibrant West Coast New Area, China, our location offers optimal accessibility and convenience.
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