| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
S99 Magnetic separator is made of high strength magnetic material, featuring strong magnetism, good magnetic separation effect, smooth operation and reliable performance. It is used for separating iron impurities in old sand during sand casting process. When installed, it is cross-crossed with sand conveying belt, and the strong magnetic adsorption separates the impurities through the belt conveying and separating.
S99 high-intensity magnetic separator: an innovative solution for separating iron impurities from casting sand
In the sand casting process, the iron impurity removal efficiency of the old sand regeneration system directly affects the reuse rate of the molding sand and the surface quality of the castings. The S99 high-intensity magnetic separator has become the core purification equipment of the sand treatment system in the foundry workshop due to its excellent magnetic separation performance and intelligent design. This article will deeply analyze how this equipment can help enterprises achieve efficient regeneration of sand resources and improve the quality of castings from the dimensions of magnetic principles, process adaptability, economic benefits and intelligent operation and maintenance.
1. Technical principles and core design breakthroughs
Based on the physical properties of ferromagnetic impurities (iron beans, flash, core bones, etc.) in old sand, the S99 magnetic separator achieves efficient separation through gradient magnetic field design and dynamic adsorption technology:
NdFeB permanent magnet matrix:
Adopting N52-grade sintered NdFeB magnetic material (remanence ≥1.45T, coercive force ≥1120kA/m), the magnetic roller surface magnetic induction intensity reaches 18000 Gauss, which is 5 times higher than the adsorption force of traditional ferrite magnetic separators, and can capture micron-level iron powder (≥50μm).
The magnetic poles are staggered at 45° to form a gradient magnetic field (magnetic field gradient ≥0.5T/m), ensuring that iron impurities are adsorbed three-dimensionally from the sand flow, and the separation efficiency is >99.5%.
Intelligent dynamic separation system:
The magnetic roller and the conveyor belt are installed crosswise at 75°, and the sand flow speed is adjustable from 0.8 to 2.5 m/s. Iron impurities are separated from the sand flow under the synergistic effect of centrifugal force and magnetic force, realizing continuous unmanned sorting.
The self-cleaning scraper adopts tungsten carbide coating (hardness HRA90), and the scraping rate is greater than 98%, which prevents impurities from mixing into the sand flow again.
High temperature resistant and long-lasting design:
The magnetic roller is equipped with a circulating water cooling system (flow rate 3m³/h) inside, which can withstand sand temperature ≤150ºC and magnetic performance attenuation rate <0.1%/year;
The 304 stainless steel sealed housing (IP66 protection grade) and ceramic bearings are suitable for the high dust and high humidity environment of the foundry workshop.
2. Full-process integrated solution for foundry sand treatment
S99 magnetic separator can be deeply integrated into the process chain of falling sand-screening-magnetic separation-regeneration to build a clean sand treatment ecosystem:
Old sand regeneration system:
Linked with the vibrating conveyor, it can process old sand with an iron content of 0.5-5% (particle size AFS 40-100), with a single machine processing capacity of 10-80t/h;
After magnetic separation, the iron content of the old sand is ≤0.02%, the loss on ignition (LOI) is stable at 2.5-3.5%, and the reuse rate is increased to 95%.
Casting quality assurance:
Eliminate the pores and slag inclusion defects of the castings caused by iron impurities, and optimize the surface roughness from Ra12.5μm to Ra6.3μm;
Environmental protection and energy saving:
The closed structure is equipped with a pulse dust collector (air volume 5000m³/h), and the dust emission concentration is <5mg/m³;
The power consumption of the permanent magnet drive system per ton of sand is ≤0.3kW·h, which saves 60% energy compared with the electromagnetic magnetic separator.
3. Comparison of core advantages and economic benefits
Compared with traditional magnetic separation equipment, S99 has achieved a leap in performance through material innovation and intelligent control:
Separation accuracy is industry-leading:
It can capture the smallest iron impurity particle size of 50μm, the iron bean (Φ1-20mm) removal rate is >99.8%, and the micro-iron powder (50-200μm) removal rate is >97%;
The adaptive speed control system dynamically adjusts the magnetic roller speed according to the sand flow rate (accuracy ±2%), and the tolerance for processing volume fluctuation is ±30%.
Revolutionary reduction in maintenance costs:
The modular magnetic group design supports the replacement of a single magnet, maintenance time is <1 hour, and annual maintenance costs are reduced by 70%;
Lubricant-free lifetime maintenance-free bearings, equipment overall efficiency (OEE) reaches 96%, and the time between failures (MTBF) is >60,000 hours.
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