Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
The S99 Magnetic Separator from Qingdao Sanzhuji Technology Co., Ltd. is a state-of-the-art solution crafted from high-strength magnetic materials, exhibiting exceptional magnetism and superior separation capabilities. This powerhouse delivers seamless operation and unmatched reliability, specifically designed to extract iron impurities from recycled sand in the sand casting process. Ingeniously installed crossways to the sand conveying belt, it employs powerful magnetic forces to cleanly separate impurities with ease and precision, enhancing the purity of your sand and optimizing your casting process.
Introducing the S99 high-intensity magnetic separator, an innovative and cutting-edge solution for extracting iron impurities from casting sand, setting new standards in foundry efficiency and product excellence.
Within the intricate sand casting process, the efficiency of iron impurity removal in the old sand regeneration system is pivotal to the sand's reuse rate and the castings' surface quality. The S99 high-intensity magnetic separator has firmly established itself as the cornerstone of the sand treatment system in foundry workshops, thanks to its stellar magnetic separation capabilities and intelligent design. This article will delve deep into the ways this equipment empowers enterprises to achieve superior sand resource regeneration and casting quality. We will explore multiple facets, including magnetic principles, process adaptability, economic advantages, and the benefits of intelligent operation and maintenance.
1. Technical principles and core design breakthroughs
Leveraging the unique physical characteristics of ferromagnetic impurities like iron beans, flash, and core bones found in old sand, the S99 magnetic separator harnesses an advanced gradient magnetic field design coupled with dynamic adsorption technology to achieve outstanding separation efficiency:
NdFeB permanent magnet matrix:
Utilizing top-tier N52-grade sintered NdFeB magnetic materials with a remanence of ≥1.45T and a coercive force of ≥1120kA/m, the magnetic roller's surface magnetic induction intensity surges to an impressive 18000 Gauss. This force quintuple surpasses the adsorption power of conventional ferrite magnetic separators, ensuring even micron-level iron powder (≥50μm) does not escape capture.
Ingeniously arranged magnetic poles at a 45° angle form a dynamic gradient magnetic field (gradient ≥0.5T/m), proficiently capturing iron impurities in a three-dimensional manner from the sand flow, achieving an impressive separation efficiency exceeding 99.5%.
Intelligent dynamic separation system:
With the magnetic roller and conveyor belt strategically installed at a 75° angle, and an adjustable sand flow speed range from 0.8 to 2.5 m/s, iron impurities are effortlessly extracted from the sand flow through the combined forces of centrifugal and magnetic forces, facilitating continuous and unmanned sorting operations.
The self-cleaning scraper, clad in tungsten carbide coating with a hardness of HRA90, boasts an impressive scraping rate greater than 98%, ensuring that impurities are expertly prevented from re-entering the sand flow.
High temperature resistant and long-lasting design:
Equipped with a cutting-edge circulating water cooling system (flow rate 3m³/h), the magnetic roller withstands sand temperatures up to 150ºC with remarkable resilience, boasting a magnetic performance attenuation rate of less than 0.1% per year, ensuring enduring performance.
Encased in a durable 304 stainless steel sealed housing with an IP66 protection grade and robust ceramic bearings, the design is tailor-made to endure the challenging high dust and high humidity environments 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, paving the way for an impeccably clean sand treatment ecosystem:
Old sand regeneration system:
In synergy with the vibrating conveyor, it skillfully processes old sand with iron content ranging from 0.5-5% (particle size AFS 40-100), boasting a substantial single machine processing capacity of 10-80t/h.
Following magnetic separation, the old sand's iron content impressively drops to ≤0.02%, with loss on ignition (LOI) consistently stable at 2.5-3.5%, significantly elevating the reuse rate to an exemplary 95%.
Casting quality assurance:
Enhance the quality and integrity of your castings by effectively eliminating pores and slag inclusion defects caused by iron impurities. Experience a marked improvement in surface finish, reducing roughness from Ra12.5μm to an impressively smoother Ra6.3μm, ensuring superior performance and aesthetics.
Leading the charge in eco-friendly and energy-efficient solutions:
Our advanced closed structure boasts a highly efficient pulse dust collector with a remarkable air handling capacity of 5000m³/h, ensuring that dust emissions remain minimal at concentrations of less than 5mg/m³, promoting a cleaner and healthier environment.
Experience the future of energy conservation with our state-of-the-art permanent magnet drive system, consuming a mere ≤0.3kW·h per ton of sand. This represents an impressive 60% energy savings when compared to traditional electromagnetic magnetic separators, significantly lowering operational costs.
3. Discover the unparalleled core advantages and economic benefits
Through groundbreaking material innovation and cutting-edge intelligent control, the S99 represents a revolutionary advancement over conventional magnetic separation equipment, offering unprecedented performance enhancements.
Precision in Separation that's Unmatched in the Industry:
Achieve extraordinary separation precision with our technology, capable of capturing iron impurities as minute as 50μm. Benefit from a remarkable iron bean (Φ1-20mm) removal rate exceeding 99.8%, and an exceptional micro-iron powder (50-200μm) removal rate of over 97%, ensuring unparalleled purity.
The innovative adaptive speed control system automatically calibrates the magnetic roller speed in real-time according to the sand flow rate, maintaining an accuracy of ±2%. This system accommodates processing volume fluctuations with a tolerance of ±30%, ensuring consistent, reliable performance.
Experience a groundbreaking decrease in maintenance costs:
Our modular magnetic group design allows for swift replacement of individual magnets, reducing maintenance time to less than 1 hour and slashing annual maintenance costs by 70%. This design is engineered to minimize downtime and enhance operational efficiency.
With our lubricant-free, lifetime maintenance-free bearings, achieve an outstanding overall equipment efficiency (OEE) of 96%. Benefit from extended operational reliability, with a time between failures (MTBF) exceeding 60,000 hours, maximizing uptime and productivity.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With an impressive legacy spanning 14 years, Qingdao Sanzhuji Technology Co., Ltd. has garnered a reputation for excellence in crafting top-of-the-line sand casting machinery. Our diversified portfolio includes the sophisticated green sand casting production line, cutting-edge furan resin sand casting production line, innovative lost foam casting production line, and the highly precise coated sand steel sand buried casting production line. We are dedicated to pushing the boundaries of technology and innovation in the sand casting industry.
Contact Us
Address: Nestled in the bustling hub of Qingdao, our factory is strategically located at North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, ensuring easy access and connectivity.
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