Product Parameters
| Model |
S995 |
S997 |
S998 |
S9910 |
| Belt width:mm |
500 |
650 |
800 |
1000 |
Detailed Photos
Product Description
Introducing the S99 Magnetic Separator—a powerful marvel crafted from high-strength magnetic materials. This exceptional device boasts unparalleled magnetism and superb magnetic separation capabilities, ensuring flawless operation and unwavering reliability. Primarily designed for the sand casting process, it expertly extracts iron impurities from old sand, enhancing the purity of your materials. Ingeniously installed in a crosswise alignment with the sand conveyance belt, it employs robust magnetic adsorption to lift and segregate impurities seamlessly during conveyance, offering an optimal and efficient solution for your sand purification needs.
Discover the S99 High-Intensity Magnetic Separator: a groundbreaking innovation that revolutionizes the purification of casting sand by effectively removing iron impurities. This state-of-the-art equipment elevates efficiency and ensures superior casting results.
During the intricate sand casting process, the removal efficiency of iron impurities in the old sand regeneration system significantly impacts the reuse rate and the overall surface quality of castings. The S99 High-Intensity Magnetic Separator has emerged as the cornerstone of purification in the foundry workshop's sand treatment system. With its superior magnetic separation prowess and sophisticated design, it aids enterprises in achieving efficient sand resource regeneration and elevates casting quality. This article delves into how this equipment excels in magnetic principles, process adaptability, economic benefits, and intelligent operation and maintenance, offering a comprehensive insight into its transformative impact.
1. Technical Principles and Core Design Breakthroughs
Leveraging the distinct physical properties of ferromagnetic impurities like iron beans, flash, and core bones in old sand, the S99 Magnetic Separator employs a gradient magnetic field design paired with dynamic adsorption technology to ensure efficient separation:
NdFeB Permanent Magnet Matrix:
Utilizing N52-grade sintered NdFeB magnetic material, with impressive remanence of ≥1.45T and coercive force ≥1120kA/m, the magnetic roller achieves a surface magnetic induction intensity of 18,000 Gauss. This force is five times more potent than traditional ferrite magnetic separators, adept at capturing micron-level iron powder at ≥50μm.
The magnetic poles are meticulously staggered at a 45° angle creating a gradient magnetic field with a magnetic field gradient of ≥0.5T/m. This ensures a three-dimensional adsorption of iron impurities from the sand flow, achieving a separation efficiency of over 99.5%.
Intelligent Dynamic Separation System:
The innovative crosswise installation of the magnetic roller and conveyor belt at a 75° angle allows for an adjustable sand flow speed ranging from 0.8 to 2.5 m/s. This configuration, coupled with centrifugal and magnetic forces, facilitates the continuous and unmanned sorting of iron impurities, optimizing the separation process.
A self-cleaning scraper, boasting a robust tungsten carbide coating (hardness of HRA90), achieves a superior scraping rate of over 98%, effectively preventing impurities from contaminating the sand flow post-separation.
High-Temperature Resistant and Long-Lasting Design:
The magnetic roller incorporates a sophisticated internal circulating water cooling system with a flow rate of 3m³/h, capable of withstanding sand temperatures up to 150ºC. Its magnetic performance remains remarkably stable, with an attenuation rate of less than 0.1% annually.
The durable 304 stainless steel sealed housing, rated at IP66, and ceramic bearings are expertly engineered to thrive in the high dust and humid environment characteristic of 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, establishing a pristine sand treatment ecosystem.
Old Sand Regeneration System:
In synergy with the vibrating conveyor, this system expertly processes old sand with iron content ranging from 0.5-5% (particle size AFS 40-100), boasting a single-machine processing capacity of 10-80t/h.
Following magnetic separation, the iron content in the old sand is reduced to a mere ≤0.02%, with the loss on ignition (LOI) consistently stable between 2.5-3.5%, enhancing the reuse rate to an impressive 95%.
Casting Quality Assurance:
Eliminate casting defects such as pores and slag inclusion caused by iron impurities, and achieve optimized surface roughness, refining it from Ra12.5μm to an impressive Ra6.3μm, thereby ensuring superior casting quality.
Environmental protection and energy saving:
Embrace a sustainable future with our innovative closed structure design, which features a pulse dust collector capable of handling an impressive air volume of 5000m³/h. With a dust emission concentration kept at a mere <5mg/m³, this ensures your operations remain clean and environmentally friendly.
Experience significant energy savings with our cutting-edge permanent magnet drive system. Consuming ≤0.3kW·h per ton of sand, it achieves a remarkable 60% energy reduction compared to conventional electromagnetic magnetic separators, paving the way for a more cost-effective and eco-friendly operation.
3. Comparison of core advantages and economic benefits:
Step into the future with the S99, a magnetic separator that stands head and shoulders above traditional equipment. Leveraging material innovation and intelligent control, the S99 delivers an unprecedented leap in performance, redefining industry standards.
Separation accuracy is industry-leading:
Achieve unparalleled precision with our system, capable of capturing even the smallest iron impurity particles as tiny as 50μm. Boasting a removal rate of >99.8% for iron beans (Φ1-20mm) and >97% for micro-iron powder (50-200μm), this sets a new benchmark in separation accuracy.
Our adaptive speed control system takes precision to the next level by dynamically adjusting the magnetic roller speed in real-time according to the sand flow rate with an accuracy of ±2%. This technology accommodates processing volume fluctuations with a tolerance of ±30%, ensuring consistent efficiency.
Revolutionary reduction in maintenance costs:
Our innovative modular magnetic group design allows for swift replacement of individual magnets, reducing maintenance time to under 1 hour. This results in an impressive 70% reduction in annual maintenance costs, freeing up resources for other critical tasks.
Benefit from the reliability of our lubricant-free lifetime maintenance-free bearings, contributing to an outstanding overall equipment efficiency (OEE) of 96%. Furthermore, with a mean time between failures (MTBF) surpassing 60,000 hours, your operations are ensured of uninterrupted productivity and reduced downtime.
Certifications
Factory Panorama
Factory Address
QINGDAO SANZHUJI
With a stellar legacy spanning over 14 glorious years, Qingdao Sanzhuji Technology Co., Ltd. is an eminent leader in the realm of sand casting machinery production. Our expertise is unparalleled, crafting sophisticated solutions like the green sand casting production line, the innovative furan resin sand casting production line, and the pioneering lost foam casting production line. Additionally, we engineer the advanced coated sand steel sand buried casting production line, ensuring each product is a masterpiece of precision and ingenuity.
Contact Us
Address: Situated conveniently at the North of G204 National Road, Poli Town, West Coast New Area, Qingdao, China, our state-of-the-art facility is strategically located to serve both domestic and international markets with efficiency and ease.
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