What is the technical progress of electromagnetic dry powder magnetic
separator?
As the key equipment for magnetic separation of materials, electromagnetic
dry powder magnetic separator is widely used in many industries such as mining,
chemical industry and food industry. With the continuous improvement of material
purification accuracy, production efficiency and energy conservation and
environmental protection requirements in various industries, the technology of
electromagnetic dry powder magnetic separator is also in continuous innovation.
The technological progress is mainly reflected in magnetic field optimization,
structural innovation, intelligent control, energy conservation and
environmental protection, etc. The following will discuss these remarkable
technological breakthroughs.
Magnetic field optimization technology innovation
Magnetic field is the core element of electromagnetic dry powder magnetic
separator to realize material separation, and optimizing the magnetic field
performance is of great significance to improve the separation effect. In recent
years, the technology of magnetic field optimization has been developed in many
aspects.
On the one hand, the magnetic circuit design is refined by computer
simulation technology. Through the finite element analysis software, the
distribution and size of the magnetic field can be accurately calculated, and
then the magnetic circuit can be reasonably planned. Taking the common closed
magnetic circuit structure optimization as an example, after simulation and
adjustment of the magnetic pole shape, magnetic yoke size and magnetic medium
arrangement, the magnetic field distribution is more uniform and concentrated in
the separation area, which can effectively improve the capture rate of magnetic
minerals. Studies show that the optimized magnetic circuit can increase the
magnetic field intensity of the separation area by 10% - 20%, and the background
field intensity can also reach a higher level. For example, the background field
intensity of some advanced magnetic separators can reach more than 0.6T, laying
a solid foundation for efficient separation of magnetic materials.
On the other hand, the technology of magnetic field gradient regulation is
becoming more mature. The magnetic medium with special material and different
structure can flexibly adjust the magnetic field gradient. For example, when
processing fine magnetic particles, the magnetic medium with high specific
surface area and special pore structure can form a strong magnetic field
gradient in a very small space, enhance the adsorption of fine magnetic
particles, and significantly improve the effect of removing fine magnetic
impurities such as iron. This technology of accurately regulating magnetic field
gradient according to different material characteristics greatly expands the
application scope of electromagnetic dry powder magnetic separator. Either the
enrichment of coarse particle magnetic minerals or the removal of trace magnetic
impurities in fine powder can realize more efficient separation.
Structural Innovation Improves Performance
The structural design of the magnetic separator directly affects its working
efficiency and stability. In recent years, innovative improvements have been
made in several key structural parts.
As the core component for magnetic field generation, the excitation coil is
continuously upgraded in design and manufacturing process. High-quality pure
copper coil is selected, and the surface is coated with high-performance
imported insulation materials, which not only improves the magnetic conductivity
and insulation effect, but also effectively reduces the heating, solves the
problem of the decrease of the magnetic field strength during the thermal
operation, and prolongs the service life of the coil. At the same time, in order
to speed up heat dissipation, three-dimensional winding structure oil duct and
oil-water combined cooling mode are adopted to speed up hot oil circulation
through large-flow oil pump, greatly reduce coil temperature rise, ensure the
stability and continuity of magnetic field, and maintain stable magnetic field
output even under long-time high load operation, so as to guarantee the sorting
effect.
There are also many innovations in material handling and separation
structures. For example, the vibration feeding device is widely used. By
accurately controlling the vibration frequency and amplitude, the constant speed
feeding can be realized, effectively preventing material blockage, improving the
passing capacity of non-magnetic materials, and increasing the amplitude during
iron unloading can ensure the clean removal of magnetic materials. Some advanced
magnetic separators are also provided with a unique stopping structure in the
material distribution box, which solves the problem of material leakage around
the traditional flap, so that the iron powder and basic materials can be
completely separated, further improving the product purity. In addition, some
new magnetic separators are designed with a modular structure. Each functional
module can be flexibly combined and replaced according to the actual production
requirements, which facilitates the installation, maintenance and upgrading of
the equipment and improves the universality and adaptability of the
equipment.
Intelligent control for accurate operation
With the development of automation and artificial intelligence technology,
the intelligent degree of electromagnetic dry powder magnetic separator is
continuously improved, and the intelligent control system becomes the key to
improve the production efficiency and separation accuracy.
The intelligent magnetic separator is equipped with a variety of
high-precision sensors, which can collect the material characteristics (such as
particle size, iron content, etc.) and equipment operating parameters (such as
magnetic field intensity, roller speed, feeding speed, etc.) in real time. These
data are transmitted via advanced transmitters to the controller, which uses
complex algorithms (e.g. fuzzy control, neural network control, etc.) to analyze
and process the data in depth. Based on the analysis results, the operating
parameters of the magnetic separator are automatically and accurately adjusted
to ensure that the best separation effect can always be maintained when the
material properties or production conditions change. For example, when the
content of magnetic minerals in the material increases, the system automatically
increases the magnetic field intensity; If the particle size of the material
becomes finer, the rotating speed of the roller shall be appropriately reduced
to extend the adsorption time of the magnetic particles in the magnetic
field.
Meanwhile, the intelligent control system has fault diagnosis and early
warning functions. Through continuous monitoring and analysis of equipment
operation data, the system can timely find out potential fault hazards, such as
abnormal rise of coil temperature, motor current overload, etc., and send
warning information in advance to remind operators of maintenance and overhaul,
so as to avoid production interruption due to sudden faults. In addition, with
the help of communication module, the intelligent magnetic separator can also
realize remote monitoring and management. The operator can check the equipment
operation status, adjust parameters in real time at the remote terminal, and
even carry out remote fault diagnosis and repair, greatly improving the
convenience and efficiency of production management.
Promotion of energy conservation and environmental protection technology
Under the background that environmental protection and energy conservation
have become the global development trend, the electromagnetic dry powder
magnetic separator has also made significant technical progress in energy
conservation and environmental protection.
In terms of energy saving, the energy consumption of equipment operation is
reduced by optimizing the magnetic field design and equipment structure. As
mentioned above, the high-efficiency magnetic circuit design and heat
dissipation structure not only ensure the strength and stability of the magnetic
field, but also reduce the power consumption of the exciting coil; Reasonable
material conveying and separation structure reduces the load of motor and other
driving parts, further saving energy. Compared with traditional equipment, the
energy consumption of some new magnetic separators can be reduced by 15% - 30%,
saving a lot of production costs for enterprises.
In terms of environmental protection, the dry magnetic separation
characteristics of electromagnetic dry powder magnetic separator avoid the water
resource consumption and sewage discharge problems caused by wet magnetic
separation. In addition, some magnetic separators have further optimized the
dust collection and treatment system in the design. Efficient dust collection
devices are provided at the material inlet and outlet, sorting area and other
parts prone to produce dust, and advanced dust filtration equipment is equipped
to effectively collect and purify the dust generated during the production
process, reduce the dust pollution to the working environment and the
atmosphere, and help enterprises to achieve green production.
To sum up, the technical progress of electromagnetic dry powder magnetic
separator in magnetic field optimization, structure innovation, intelligent
control, energy conservation and environmental protection has comprehensively
improved its separation performance, production efficiency, intelligent level
and environmental protection and energy conservation effect. These technological
breakthroughs not only meet the demands of all industries for high quality
material purification and efficient production, but also comply with the trend
of global green development, laying a solid foundation for the application and
development of electromagnetic dry powder magnetic separator in a wider field.
With the continuous innovation of technology in the future, its application
prospects will be broader.