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, boasting unparalleled magnetism, exceptional magnetic separation efficiency, seamless operation, and steadfast reliability. This cutting-edge device plays a pivotal role in the sand casting process by meticulously extracting iron impurities from old sand. Ingeniously designed to be strategically aligned with the sand conveying belt, the separator employs formidable magnetic adsorption to efficiently isolate and remove impurities, ensuring a pristine and impurity-free sand flow through its conveyor belt system.
The S99 High-Intensity Magnetic Separator: your ultimate innovative ally in the precise eradication of iron impurities from casting sand.
Within the realm of sand casting, the capability of the old sand regeneration system to efficiently remove iron impurities has a profound impact on the reuse rate of molding sand and the surface finish of castings. The S99 High-Intensity Magnetic Separator has emerged as the linchpin of the sand treatment system in foundry workshops, thanks to its superior magnetic separation prowess and ingenious design. This comprehensive analysis will delve into how this remarkable equipment empowers enterprises to achieve efficient sand resource regeneration and elevate casting quality. From magnetic principles and process adaptability to economic advantages and intelligent operation and maintenance, discover the multifaceted benefits of this transformative technology.
1. Technical Principles and Core Design Breakthroughs
Harnessing the distinctive physical traits of ferromagnetic impurities—such as iron beans, flash, and core bones—present in old sand, the S99 Magnetic Separator ensures superior separation through its innovative gradient magnetic field design and dynamic adsorption technology:
NdFeB Permanent Magnet Matrix:
Utilizing the N52-grade sintered NdFeB magnetic material, characterized by remanence ≥1.45T and coercive force ≥1120kA/m, the magnetic roller's surface magnetic induction strength reaches an impressive 18000 Gauss. This potency is a staggering 5 times greater than traditional ferrite magnetic separators' adsorption force, enabling it to capture even micron-level iron powder particles (≥50μm) effectively.
The ingenious arrangement of magnetic poles at a 45° angle creates a gradient magnetic field (with a magnetic field gradient ≥0.5T/m), ensuring comprehensive three-dimensional adsorption of iron impurities from the sand flow, achieving an outstanding separation efficiency of over 99.5%.
Intelligent Dynamic Separation System:
Ingeniously positioned, the magnetic roller and conveyor belt are cross-installed at a 75° angle, with adjustable sand flow speeds ranging from 0.8 to 2.5 m/s. Utilizing the combined forces of centrifugal force and magnetic attraction, iron impurities are thoroughly separated from the sand flow, enabling a continuous and unmanned sorting process.
The self-cleaning scraper, fortified with a tungsten carbide coating (hardness HRA90), boasts a scraping rate exceeding 98%, effectively preventing impurities from reentering and contaminating the sand flow.
High Temperature Resistant and Long-Lasting Design:
The magnetic roller, ingeniously equipped with a circulating water cooling system (flow rate 3m³/h), is capable of withstanding sand temperatures up to 150ºC, with a negligible magnetic performance attenuation rate of less than 0.1% per year.
Encased within a robust 304 stainless steel housing with IP66 protection and ceramic bearings, the unit is perfectly suited for the demanding high dust and high humidity conditions typically found in foundry workshops.
2. Full-Process Integrated Solution for Foundry Sand Treatment
The S99 Magnetic Separator seamlessly integrates into the comprehensive process chain of falling sand, screening, magnetic separation, and regeneration, crafting a pristine and efficient sand treatment ecosystem:
Old Sand Regeneration System:
In synergy with the vibrating conveyor, the system adeptly processes old sand containing iron content between 0.5-5% (with particle size AFS 40-100), boasting a single machine processing capacity ranging from 10 to 80 tons per hour.
Post magnetic separation, the iron content in the old sand is reduced to a minimal ≤0.02%, with the loss on ignition (LOI) consistently maintained at 2.5-3.5%, and the reuse rate impressively elevated to 95%.
Casting Quality Assurance:
Our advanced Magnetic Separator effectively eliminates casting defects such as pores and slag inclusions caused by iron impurities. It significantly enhances surface quality, refining roughness from Ra12.5μm to a smoother Ra6.3μm.
Unparalleled Environmental Protection and Energy Efficiency:
Designed with a closed structure, equipped with a high-capacity pulse dust collector handling air volumes of up to 5000m³/h, ensuring dust emission concentrations remain below an impressive <5mg/m³, promoting a cleaner environment.
Our state-of-the-art permanent magnet drive system boasts a remarkably low power consumption of ≤0.3kW·h per ton of sand, delivering an extraordinary 60% energy savings in comparison to conventional electromagnetic magnetic separators.
3. Unrivaled Core Advantages and Economic Gains
The S99 model stands out against traditional magnetic separators, heralding a revolution in performance with cutting-edge material innovations and sophisticated intelligent control systems:
Achieves industry-leading separation accuracy:
Capable of capturing iron impurities as minuscule as 50μm, with an iron bean (Φ1-20mm) removal rate surpassing >99.8% and a micro-iron powder (50-200μm) removal efficiency of over >97%; demonstrating superior precision.
Featuring an adaptive speed control system that dynamically calibrates the magnetic roller speed to the sand flow rate with an accuracy of ±2%, and can handle processing volume fluctuations with a tolerance of ±30%.
Revolutionary Reduction in Maintenance Overheads:
The innovative modular magnetic group design allows for the swift replacement of individual magnets, with maintenance time reduced to under 1 hour, slashing annual maintenance costs by an outstanding 70%;
Incorporating lubricant-free, lifetime maintenance-free bearings, ensuring equipment operates at peak efficiency with an OEE of 96%, and providing an exceptional MTBF of over >60,000 hours.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
Qingdao Sanzhuji Technology Co., Ltd. stands as a beacon of excellence in the realm of sand casting machinery. Proudly specializing in the intricate art of crafting a wide array of sand casting solutions, our expertise spans the green sand casting production line, furan resin sand casting production line, lost foam casting production line, and the coated sand steel sand buried casting production line. With a rich legacy of 14 years dedicated to precision and innovation, our establishment has been at the forefront of delivering cutting-edge technology and unparalleled craftsmanship.
Contact Us
Address: North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China
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