Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
Experience unmatched magnetic prowess with the S99 Magnetic Separator, crafted from high-strength magnetic materials that offer formidable magnetism and excellent magnetic separation efficiency. This robust machine ensures seamless operation and dependable performance, specifically designed to effectively eliminate iron impurities during the sand casting process. Installed in a cross-cross fashion with the sand conveying belt, it employs powerful magnetic adsorption to segregate impurities, offering a refined and efficient belt conveying and separating process.
Introducing the S99 high-intensity magnetic separator: a cutting-edge, innovative marvel tailored to impeccably remove iron impurities from casting sand with unparalleled precision and efficiency.
The efficiency of iron impurity removal within the old sand regeneration system is pivotal in the sand casting process, directly influencing the reuse rate of molding sand and the pristine surface quality of castings. The S99 high-intensity magnetic separator stands as the cornerstone of the foundry workshop's sand treatment system, renowned for its superior magnetic separation performance and intelligent design. This comprehensive analysis will delve into how this remarkable equipment enables enterprises to achieve optimal sand resource regeneration and elevate casting quality by exploring its magnetic principles, process adaptability, economic benefits, and intelligent operation and maintenance.
1. Technical principles and core design breakthroughs
Leveraging the innate physical properties of ferromagnetic impurities such as iron beans, flash, and core bones in old sand, the S99 magnetic separator accomplishes exceptional separation through its advanced gradient magnetic field design and state-of-the-art dynamic adsorption technology:
NdFeB permanent magnet matrix:
Utilizing premium N52-grade sintered NdFeB magnetic material with remanence of at least 1.45T and coercive force no less than 1120kA/m, the magnetic roller's surface magnetic induction intensity soars to an impressive 18000 Gauss. This is a staggering fivefold increase over traditional ferrite magnetic separators, enabling it to capture iron powder particles as fine as 50μm.
The magnetic poles are meticulously staggered at a 45° angle to compose a potent gradient magnetic field (gradient ≥0.5T/m), ensuring comprehensive three-dimensional adsorption of iron impurities from the sand flow, achieving a remarkable separation efficiency exceeding 99.5%.
Intelligent dynamic separation system:
Installed with the magnetic roller and conveyor belt crosswise at a precise 75° angle, the sand flow speed is finely adjustable between 0.8 to 2.5 m/s. This allows iron impurities to be meticulously separated from the sand flow through the synergistic forces of centrifugal and magnetic action, facilitating a seamless and continuous unmanned sorting process.
The self-cleaning scraper, fortified with a tungsten carbide coating with a hardness of HRA90, achieves a scraping rate exceeding 98%, effectively preventing impurities from re-entering the sand flow.
High temperature resistant and long-lasting design:
The magnetic roller is ingeniously equipped with an internal circulating water cooling system with a flow rate of 3m³/h, capable of enduring sand temperatures up to 150ºC while maintaining a minimal magnetic performance attenuation rate of less than 0.1% per year.
Protected by a robust 304 stainless steel sealed housing (IP66 protection grade) and equipped with ceramic bearings, the system is expertly crafted to withstand the demanding high dust and high humidity environment prevalent in foundry workshops.
2. Full-process integrated solution for foundry sand treatment
The S99 magnetic separator is seamlessly integrated into the process chain, encompassing falling sand, screening, magnetic separation, and regeneration, to meticulously construct a pristine sand treatment ecosystem.
Old sand regeneration system:
Ingeniously linked with the vibrating conveyor, it adeptly processes old sand with an iron content ranging from 0.5% to 5% (particle size AFS 40-100), with a formidable single machine processing capacity spanning from 10 to 80 tons per hour.
Post-magnetic separation, the iron content in old sand is reduced to a mere ≤0.02%, with the loss on ignition (LOI) consistently stabilized between 2.5% and 3.5%, boosting the reuse rate to an impressive 95%.
Casting quality assurance:
Achieve flawless casting surfaces by eliminating pores and slag inclusion defects caused by iron impurities, significantly refining surface roughness from Ra12.5μm to a superb Ra6.3μm.
Environmental protection and energy saving:
The innovative closed structure is equipped with a powerful pulse dust collector boasting an air volume capacity of 5000m³/h, ensuring that dust emission concentration remains impeccably low at <5mg/m³.
Enjoy significant energy savings with our permanent magnet drive system, where power consumption per ton of sand is ≤0.3kW·h—this represents a remarkable 60% energy savings compared to traditional electromagnetic magnetic separators.
3. Comparison of core advantages and economic benefits
Experience a transformative leap in performance with the S99, surpassing traditional magnetic separation equipment through groundbreaking material innovation and cutting-edge intelligent control:
Separation accuracy is industry-leading:
Our system captures even the smallest iron impurities with unmatched precision, handling particle sizes as minute as 50μm. The removal rate for iron beans (Φ1-20mm) exceeds an impressive 99.8%, while micro-iron powder (50-200μm) achieves a removal rate of over 97%.
With an adaptive speed control system, the magnetic roller speed is dynamically adjusted in response to sand flow rates with pinpoint accuracy (±2%), accommodating processing volume fluctuations up to ±30%.
Revolutionary reduction in maintenance costs:
Thanks to our modular magnetic group design, replacing a single magnet is a swift process, taking less than an hour. This innovation cuts annual maintenance costs by an astounding 70%.
Our lubricant-free, lifetime maintenance-free bearings ensure that equipment overall efficiency (OEE) reaches an outstanding 96%, with the time between failures (MTBF) extending beyond an impressive 60,000 hours.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
Pioneers in the sand casting machinery industry, Qingdao Sanzhuji Technology Co., Ltd. proudly specializes in the innovative production of diverse sand casting machinery. Our offerings include high-efficiency green sand casting production lines, cutting-edge furan resin sand casting production lines, state-of-the-art lost foam casting production lines, and advanced coated sand steel sand buried casting production lines. With a rich heritage spanning 14 years, our company stands as a beacon of excellence and expertise since its inception.
Contact Us
Address: Strategically located at the North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, our facility is positioned to serve our clients with unparalleled accessibility and convenience.
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