Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
Introducing the remarkable S99 Magnetic Separator, crafted from high-strength magnetic materials that promise unparalleled magnetism and an impeccable magnetic separation effect. Its operations are as smooth as they are reliable, making it an essential asset in the sand casting process, particularly for the separation of iron impurities in old sand. Integrating seamlessly with sand conveying belts, the S99 stands out by cross-crossing with the belt system to deliver superior impurity separation via robust magnetic adsorption.
S99 high-intensity magnetic separator: a cutting-edge solution designed to expertly extract iron impurities from casting sand.
In the intricate sand casting process, the efficiency of iron impurity removal from the old sand regeneration system is critical, influencing not only the reuse rate of molding sand but also the surface quality of the castings. The S99 high-intensity magnetic separator has established itself as the pivotal purification device within foundry workshops. Renowned for its outstanding magnetic separation capabilities and smart design, this analysis delves into how the S99 promotes efficient sand resource regeneration and enhances casting quality through magnetic principles, process adaptability, economic advantages, and intelligent system operation and maintenance.
1. Technical principles and core design breakthroughs
Leveraging the physical characteristics of ferromagnetic impurities in aged sand, such as iron beans, flash, and core residues, the S99 magnetic separator achieves exemplary separation through its sophisticated gradient magnetic field design and dynamic adsorption technology:
NdFeB permanent magnet matrix:
Utilizing premium N52-grade sintered NdFeB magnetic materials (remanence ≥1.45T, coercive force ≥1120kA/m), the magnetic roller's surface magnetic induction intensity soars to 18000 Gauss—fivefold the adsorption force of conventional ferrite magnetic separators, efficiently capturing iron particulates as small as ≥50μm.
The magnetic poles are ingeniously staggered at 45° to generate a gradient magnetic field (magnetic field gradient ≥0.5T/m), ensuring a comprehensive three-dimensional adsorption of iron impurities from sand flow, achieving a separation efficiency exceeding 99.5%.
Intelligent dynamic separation system:
The innovative crosswise installation of the magnetic roller and conveyor belt at a 75° angle, coupled with an adjustable sand flow speed of 0.8 to 2.5 m/s, facilitates the seamless separation of iron impurities from sand flow by harnessing both centrifugal and magnetic forces, enabling continuous and unmanned sorting.
The advanced self-cleaning scraper, coated with tungsten carbide (hardness HRA90), boasts a scraping rate exceeding 98%, effectively preventing any impurity backflow into the sand stream.
High temperature resistant and long-lasting design:
Equipped with an internal circulating water cooling system (flow rate 3m³/h), the magnetic roller withstands sand temperatures up to 150ºC with a magnetic performance attenuation rate of less than 0.1% annually.
The robust 304 stainless steel sealed housing (IP66 protection grade) and durable ceramic bearings are meticulously crafted for the demanding high dust and high humidity environments typical of foundry workshops.
2. Full-process integrated solution for foundry sand treatment
The S99 magnetic separator seamlessly integrates into the holistic process chain of de-sanding, screening, magnetic separation, and regeneration, establishing a pristine sand treatment ecosystem:
Old sand regeneration system:
In conjunction with the vibrating conveyor, it processes old sand with an iron content ranging from 0.5-5% (particle size AFS 40-100), supporting a single machine processing capacity of 10-80t/h.
Post magnetic separation, the iron content in old sand is reduced to ≤0.02%, with a stable loss on ignition (LOI) of 2.5-3.5%, significantly enhancing the reuse rate to an impressive 95%.
Casting quality assurance:
Successfully eradicates casting defects such as pores and slag inclusion caused by iron impurities, while refining surface roughness from Ra12.5μm to a smoother Ra6.3μm, ensuring superior casting quality.
Environmental Protection and Energy Conservation: An Overview of Benefits
Our innovative closed structure, featuring a state-of-the-art pulse dust collector with an impressive air volume capacity of 5000m³/h, ensures that dust emission concentrations remain astonishingly low at <5mg/m³, setting new standards in environmental care.
Remarkably efficient, the permanent magnet drive system boasts a power consumption of merely ≤0.3kW·h per ton of sand. This marks a staggering 60% energy savings compared to conventional electromagnetic magnetic separators, redefining energy efficiency.
3. Core Advantages and Economic Benefits: A Comparative Analysis
Through groundbreaking material innovation and the integration of intelligent control systems, the S99 magnetic separator surpasses traditional equipment, delivering unmatched performance leaps.
Industry-Leading Separation Accuracy: A Benchmark in Precision
Capable of capturing minimum iron impurity particles as small as 50μm, our magnetic separator achieves an extraordinary iron bean (Φ1-20mm) removal rate of over 99.8%, while also boasting a micro-iron powder removal efficiency of more than 97%, positioning us at the forefront of separation precision.
The adaptive speed control system intelligently adjusts the magnetic roller speed in response to sand flow variations with remarkable accuracy (±2%), while accommodating processing volume fluctuations with a generous tolerance of ±30%.
Revolutionary Reduction in Maintenance Costs: Unparalleled Efficiency
Our groundbreaking modular magnetic group design allows for the swift replacement of individual magnets, reducing maintenance times to under an hour and slashing annual maintenance costs by an impressive 70%.
Featuring lubricant-free, lifetime maintenance-free bearings, our equipment achieves an exceptional overall efficiency (OEE) of 96%, with a mean time between failures (MTBF) exceeding a remarkable 60,000 hours, redefining reliability and longevity in the industry.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
For over 14 remarkable years, we at Qingdao Sanzhuji Technology Co., Ltd. have been the vanguard in crafting state-of-the-art sand casting machinery. Our production lines offer bespoke solutions in green sand casting, furan resin sand casting, lost foam casting, and coated sand steel sand buried casting, setting the standard for innovation and excellence in the industry.
Contact Us
Address: Elegantly nestled north of G204 National Road, in the thriving Poli Town, West Coast New Area of Qingdao, China, our facilities are strategically positioned to serve your needs efficiently.
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