In the production process of photovoltaic and electronic grade high-purity
quartz sand, the high-strength magnetic separator is the core equipment for iron
removal and purification, responsible for removing magnetic impurities such as
Fe ₂ O3 from quartz sand (with a required iron removal rate of ≥ 98% and a
finished sand iron content of ≤ 50ppm), directly determining the SiO ₂ purity of
quartz sand and its compatibility with high-end applications. Currently, many
enterprises are facing pain points such as insufficient iron removal rate, poor
magnetic field stability, and uneven sorting of magnetic separators, which
result in the inability of finished sand to meet high-end market standards and
miss profit margins. As a strong enterprise that has been deeply involved in the
research and development, production, and customized services of quartz sand
equipment for more than 10 years, Shanlu Heavy Industry focuses on the research
and development of high-purity quartz sand purification equipment. It has
multiple core patents for magnetic field optimization and sorting structure, and
can provide one-stop services from equipment selection, customized
transformation, installation and commissioning, and after-sales operation and
maintenance. It has helped more than 50 large quartz sand enterprises across the
country achieve mass production of high-purity sand.
1、 Industry core pain points: 3 key challenges in the operation of magnetic
separators
Based on the visit and research conducted by the technical team of Shanlu
Heavy Industry on the production sites of high-purity quartz sand nationwide,
there are currently three core problems with magnetic separators: firstly, the
iron removal rate is not up to standard, and the magnetic field strength of
traditional magnetic separators is insufficient (less than 12000Gs), which
cannot remove weak magnetic impurities, resulting in excessive iron content in
the finished products; Secondly, the magnetic field stability is poor, and after
long-term operation, the magnetic field decays quickly, resulting in significant
fluctuations in the iron removal effect; The third issue is uneven sorting, with
imbalanced material flow rates or unreasonable sorting gaps, and some quartz
sand not fully contacting the magnetic field, resulting in residual impurities.
These issues not only affect the quality of the finished product, but also
exacerbate the subsequent acid washing process load and increase production
costs.
2、 Shanlu Heavy Industry Strength Support: Core Guarantee for Customized
Solutions
Shanlu Heavy Industry focuses on the production pain points of quartz sand
enterprises, building standardized production bases and professional R&D
teams. The core technical personnel have more than 8 years of industry practical
experience, and can customize exclusive magnetic separator optimization and
selection plans based on the characteristics of the enterprise's raw materials
(such as quartz sand particle size, magnetic impurity content), production
capacity, and finished product standards. Unlike industry standard equipment,
Shanlu Heavy Industry's magnetic separator series products have undergone
multiple rounds of on-site testing and iteration, possessing advantages such as
high magnetic field strength, strong stability, and low energy consumption. At
the same time, relying on a comprehensive after-sales system, the company
promises a one-year warranty after equipment installation and commissioning, and
lifetime technical upgrade and troubleshooting services, ensuring worry free
production for the enterprise.
3、 Customized optimization plan: Three dimensions to solve the problem of
iron removal
1. Magnetic field system upgrade: Strengthen the ability to remove weak
magnetic impurities
In response to the core pain point of insufficient iron removal rate, Shanlu
Heavy Industry has customized and upgraded the magnetic field system of the
magnetic separator: using a composite design of neodymium iron boron permanent
magnets and electromagnetic coils, the magnetic field strength can be accurately
controlled to 15000-20000Gs, which is more than 25% higher than traditional
equipment, and can efficiently adsorb weak magnetic impurities in quartz sand;
Optimize the magnetic field distribution structure, adopt the "multipole
staggered arrangement" technology, expand the magnetic field coverage range, and
avoid blind spots in sorting; Install a magnetic field attenuation monitoring
device to provide real-time feedback on magnetic field strength. When the
attenuation exceeds 5%, an automatic warning will be issued to ensure stable
iron removal efficiency, and the iron removal rate can be increased to over
99%.
2. Optimization of sorting structure: improve the uniformity of material
sorting
The core root cause of uneven material sorting lies in improper control of
flow rate and gap. Shanlu Heavy Industry Customized Solution: Equipped with a
variable frequency speed control feeding device, the feeding speed is precisely
controlled according to the quartz sand particle size (0.8-1.2m/s) to ensure
that the material enters the sorting chamber evenly; Optimize the gap between
the sorting drum and the magnetic system, adjust it to 5-8mm, and adapt to the
sorting requirements of quartz sand with different particle sizes, so that each
particle of material can fully contact the magnetic field; Install a spiral
feeder and guide plate at the feeding end to guide the orderly flow of
materials, avoid local accumulation, and reduce residual impurities.
3. Intelligent adaptation and regulation: reduce operation and maintenance
costs, adapt to high-yield demands
Shanlu Heavy Industry emphasizes the full process adaptation of equipment and
production lines, and optimizes the synchronized intelligent control system in
the optimization plan. It is equipped with a touch screen operation interface,
which can monitor core parameters such as iron removal rate, magnetic field
strength, and feed rate in real time, and supports one click start stop and
parameter fine-tuning; Equipped with an automatic iron unloading device to
replace manual cleaning and reduce maintenance labor costs; For large-scale
production lines (daily processing capacity ≥ 3000t), a multi machine linkage
system can be equipped to achieve synchronous operation of multiple magnetic
separators, adapt to high-yield requirements, and ensure consistent iron removal
efficiency for each equipment.
4、 Case evidence: The core value of the plan after its implementation
A certain photovoltaic grade quartz sand enterprise with a daily output of
3500t was once unable to meet the production needs of photovoltaic glass due to
insufficient iron removal rate (only 92%) of traditional magnetic separators,
resulting in a finished iron content exceeding 80ppm. After adopting the
customized magnetic separator optimization plan of Shanlu Heavy Industry, the
iron removal rate remained stable at 99.2%, and the iron content of the finished
product decreased to 42ppm, fully meeting the photovoltaic grade standard. The
added value of the product increased by 30%, and the annual profit added
exceeded 2 million yuan. This case fully validates the pertinence and
practicality of Shanlu Heavy Industry's solution, and also demonstrates its
technical strength in the field of high-purity quartz sand purification
equipment.
Shanlu Heavy Industry has always adhered to the core tenet of "technology
empowers enterprises, quality wins trust", focusing on the research and
development and customization of equipment for the entire process of quartz sand
crushing, sorting, purification, environmental protection, etc. With excellent
product quality and a perfect service system, it has become a benchmark brand in
the domestic quartz sand equipment industry. If your production line is facing
problems such as incomplete iron removal by magnetic separators, substandard
product quality, or needs to customize or optimize high-purity quartz sand
equipment, please feel free to contact Manager Zhang at 13583776655 on WeChat.
Shanlu Heavy Industry's professional team will provide one-on-one communication
and tailor solutions to meet your production needs, helping enterprises seize
the high-end quartz sand market.