Magnetic separators are core equipment for material separation in mineral processing, non-metallic mineral purification, and secondary resource recycling. Different types of magnetic separators vary in their separation efficiency and applicable materials due to differences in structural design and magnetic field characteristics. This article focuses on four mainstream types of magnetic separators: vertical ring pulsating high gradient magnetic separator(VPHGMS), permanent magnet magnetic separator, high extraction magnetic filter, and belt type magnetic separator, analyzing their core advantages and suitable application scenarios to provide a reference for industrial production selection.
I. VPHGMS: An all-rounder for separating weakly magnetic minerals
SLon Vertical Ring Pulsating High Gradient Magnetic Separator(VPHGMS) has become an industry benchmark due to its high magnetic field strength and wide particle size adaptability. Its core advantages are concentrated in three aspects: First, excellent magnetic field performance, employing an optimized combination of excitation coils and magnetic matrix, achieving a background field strength of up to 1.8T, generating a stable high gradient magnetic field, and efficiently capturing weakly magnetic particles; second, advanced separation mechanism, with a vertical rotating ring combined with a slurry pulsating design, allowing minerals to be fully loosened under the combined effects of fluid force, pulsating force, and gravity, avoiding magnetic matrix blockage; and third, stable and efficient operation, with an equipment utilization rate exceeding 98%, a coil design life of over 10 years, and a single unit processing capacity covering 0.01⁓2500 t/h.
It has an extremely wide range of applications, primarily used for the separation of weakly magnetic metal ores such as hematite, limonite, manganese ore, and ilmenite, as well as rare metal ores such as rare earth ores and tantalum-niobium ores. In the field of secondary resource recovery, it has significant effects on the recovery of valuable metals from materials such as red mud, smelting steel slag, and fly ash. Its wide particle size range (2μm~6mm) allows it to handle both fine-grained slime and coarse-grained ore, making it particularly suitable for mass production in large-scale concentrators.
II. Permanent Magnetic Separator: A Cost-Effective Choice for Separating Strong Magnetic Minerals
The representative product of permanent magnetic separators is the SCT LIMS manufactured by SLon. With its simple structure and low energy consumption, it has become the mainstream equipment for separating strongly magnetic minerals. Its core advantages are: firstly, low operating costs, using rare earth permanent magnets or ferrite permanent magnet blocks as the magnetic source, resulting in a magnetic system with excellent anti-demagnetization capabilities; secondly, convenient operation and maintenance, with a simple overall structure, reliable transmission system, low failure rate, and only routine checks required daily; and thirdly, large processing capacity, designed for strongly magnetic materials, with a single unit capable of processing 0.05~240 t/h.
Depending on the type of tank, different models are suitable for various applications: Co-current models are suitable for roughing and cleaning of coarse-grained, strongly magnetic materials smaller than 6mm, offering high processing efficiency; counter-current models focus on roughing and scavenging of fine-grained, strongly magnetic minerals smaller than 1.5mm, with outstanding recovery rates; semi-counter-current models can process mineral particles smaller than 0.5mm, balancing concentrate grade and recovery rate, and are widely used in the separation of strongly magnetic minerals such as magnetite and pyrrhotite, making them core equipment in iron ore beneficiation plants. Furthermore, permanent magnetic separators can also be used in the ceramics industry for iron removal from ceramic clay and pre-enrichment operations after coarse crushing of lean iron ore.
III. HEMF: A “fine purification expert”
The SJ HEMF, manufactured by SLon, is specifically designed for wet fine separation. Its core advantages lie in its targeted optimization: First, it boasts an extremely high magnetic field, generating a strong magnetic force through magnetically conductive stainless steel matrix, effectively removing fine, weakly magnetic impurities from the slurry; second, it offers strong adaptability, with a background magnetic field reaching 1.5T, allowing for the selection of different magnetic matrix based on mineral type, and an water-cooling system ensures stable operation even in harsh environments; third, it provides precise iron removal, with outstanding magnetic field strength at matrix nodes, meeting the high-purity purification requirements of non-metallic minerals.
This product is designed for the fine processing of slurry-like materials, primarily used for the purification and iron removal of non-metallic minerals such as quartz, feldspar, and kaolin, significantly improving product whiteness and purity. In metallic ore processing, it is suitable for the wet separation of weakly magnetic minerals such as limonite and hematite, and can also be used for impurity removal from materials like silicon carbide and garnet. Its operation is wet and requires a slurry conveying system, making it particularly suitable for refined production scenarios with abundant water resources and high requirements for separation accuracy.
IV. Belt Type Magnetic Separator: A Highly Efficient Tool for Iron Removal from Non-metallic Minerals
The SPBC belt type magnetic separator, manufactured by SLon, is a representative product of the flat belt magnetic separators. Its unique structural design adapts to specific sorting needs, and its core advantages include: First, sufficient magnetic field coverage, using a composite magnetic system and a wide magnetic plate design to increase the contact area and tumbling frequency between the material and the magnetic field, resulting in high adsorption efficiency; Second, flexible operation, adapting to different material characteristics by adjusting the slope of the magnetic plate, and automatic cleaning of magnetic impurities by the unloading belt without manual intervention; Third, energy saving and environmental protection, requiring only a low-power drive motor and a controllable water supply system, resulting in significantly lower energy and water consumption than similar equipment.
Its applications are primarily in the wet processing of non-metallic minerals, particularly excelling in iron removal and purification of materials such as quartz sand and potassium-sodium feldspar. It can also be used for the separation of weakly magnetic minerals such as hematite, limonite, and siderite, as well as the enrichment of rare metal ores like tantalum mud. Its compact structure and small footprint make it suitable for production line configurations in small and medium-sized processing plants, and it can also serve as an auxiliary iron removal device in large-scale mineral processing plants.
V. Summary of Key Selection Points
Model selection should revolve around three core factors: material magnetism (permanent magnet separators are preferred for strong magnetism, while VPHGMS are suitable for weak magnetism), material state (permanent magnet separators are suitable for dry operations, while slurry-like materials are suitable for HEMF or flat plate magnetic separators), and production requirements (VPHGMS are suitable for large-scale separation, while HEMF are suitable for fine purification).
The differentiated designs of different magnetic separators essentially represent a precise match between the magnetic field characteristics and the material’s motion state. Appropriate selection can improve separation efficiency and product quality while reducing operating costs.
