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. This powerhouse boasts exceptional magnetism, ensuring superior magnetic separation capabilities, along with smooth, reliable performance. Perfectly designed for efficiently removing iron impurities from old sand in the sand casting process, this separator is seamlessly integrated with a sand conveying belt, utilizing robust magnetic adsorption to effectively segregate impurities during the belt's transit and separation process.
Discover the S99 High-Intensity Magnetic Separator, an avant-garde innovation engineered to meticulously extract iron impurities from casting sand, setting new standards in magnetic separation technology.
In the intricate world of sand casting, the efficiency of iron impurity removal is paramount for maximizing the reuse of molding sand and enhancing the surface quality of castings. Enter the S99 High-Intensity Magnetic Separator, the crowning jewel of sand treatment systems in foundry workshops. Its remarkable magnetic separation prowess and intelligent design have made it indispensable. Join us as we delve into an in-depth exploration of how this equipment revolutionizes sand resource regeneration and elevates casting quality, examining its magnetic principles, process adaptability, economic advantages, and intelligent operation and maintenance.
1. Technical Principles and Core Design Breakthroughs
Harnessing the unique physical characteristics of ferromagnetic impurities like iron beans, flash, and core bones present in old sand, the S99 Magnetic Separator excels in efficient separation. This is achieved through its ingenious gradient magnetic field design and cutting-edge dynamic adsorption technology:
NdFeB Permanent Magnet Matrix:
Employing the first-rate N52-grade sintered NdFeB magnetic material, with a remanence of ≥1.45T and a coercive force of ≥1120kA/m, the magnetic roller's surface magnetic induction intensity reaches a formidable 18,000 Gauss. This potency is fivefold greater than traditional ferrite magnetic separators, enabling it to capture minute iron powder particles as small as ≥50μm.
With magnetic poles strategically staggered at a 45° angle, the separator forms a gradient magnetic field with an intensity of ≥0.5T/m. This arrangement ensures a three-dimensional capture of iron impurities from the sand flow, achieving an impressive separation efficiency of over 99.5%.
Intelligent Dynamic Separation System:
Ingeniously, the magnetic roller and conveyor belt are aligned crosswise at a 75° angle. The sand flow velocity is customizable, ranging from 0.8 to 2.5 m/s. Under the combined influence of centrifugal and magnetic forces, iron impurities are effortlessly separated from the sand flow, enabling seamless, unmanned sorting operations.
Featuring a self-cleaning scraper coated with tungsten carbide, boasting a hardness of HRA90, the scraper achieves a remarkable scraping rate exceeding 98%, preventing any reintroduction of impurities into the sand flow.
High-Temperature Resistant and Long-Lasting Design:
The magnetic roller incorporates a sophisticated circulating water cooling system with a flow rate of 3m³/h. It is engineered to withstand sand temperatures of up to 150ºC while maintaining a magnetic performance attenuation rate of less than 0.1% annually.
Encased in a 304 stainless steel sealed housing with an IP66 protection grade and equipped with ceramic bearings, this design is perfectly suited for the challenging environments of foundry workshops, characterized by high dust and humidity levels.
2. Full-Process Integrated Solution for Foundry Sand Treatment
The S99 Magnetic Separator offers seamless integration into the comprehensive process chain of falling sand, screening, magnetic separation, and regeneration, creating an eco-friendly sand treatment ecosystem:
Old Sand Regeneration System:
In collaboration with the vibrating conveyor, it efficiently processes old sand containing iron concentrations ranging from 0.5% to 5% (particle size AFS 40-100), with a robust single-machine processing capacity spanning 10-80t/h.
Upon innovative magnetic separation, the iron content in old sand is reduced to ≤0.02%, while the loss on ignition (LOI) remains stable at 2.5-3.5%. This results in a remarkable reuse rate elevation to an impressive 95%.
Casting Quality Assurance:
By eliminating defects such as pores and slag inclusion caused by iron impurities, the surface roughness of castings is optimized, improved from Ra12.5μm to a superior Ra6.3μm, ensuring enhanced casting quality.
Environmental protection and energy saving:
With an ingeniously designed closed structure, our system is equipped with a pulse dust collector boasting an impressive air volume of 5000m³/h, ensuring dust emission concentration remains astoundingly low at <5mg/m³;
Our permanent magnet drive system showcases remarkable efficiency, with power consumption per ton of sand at ≤0.3kW·h, achieving a phenomenal 60% energy savings compared to conventional electromagnetic magnetic separators.
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:
Engineered to perfection, it captures the tiniest iron impurity particles down to 50μm. The removal rate for iron beans (Φ1-20mm) is an exceptional >99.8%, while the capture rate for micro-iron powder (50-200μm) is an impressive >97%;
Our cutting-edge adaptive speed control system dynamically adjusts the magnetic roller speed in synchronization with the sand flow rate (precision of ±2%), offering a remarkable tolerance for processing volume fluctuations of ±30%.
Revolutionary reduction in maintenance costs:
The innovative modular magnetic group design facilitates the replacement of individual magnets swiftly, slashing maintenance time to under 1 hour and curtailing annual maintenance expenses by a substantial 70%;
Our advanced lubricant-free lifetime maintenance-free bearings propel the overall equipment efficiency (OEE) to an extraordinary 96%, with time between failures (MTBF) exceeding a staggering 60,000 hours.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
Pioneers in the realm of sand casting machinery, Qingdao Sanzhuji Technology Co., Ltd. boasts a diverse portfolio of high-performance production lines. Our offerings include the innovative green sand casting production line, advanced furan resin sand casting line, cutting-edge lost foam casting line, and the precision-coated sand steel sand buried casting line. With 14 years of steadfast dedication and expertise, we continue to set benchmarks in the industry since our inception.
Contact Us
Address: Located strategically at the North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, our facility is positioned to serve you better.
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