PERMANENT MAGNETIC ROLLER SEPARATORS

INTRODUCTION

STAR TRACE Magnetic Roller Separators are roll type dry magnetic separators with fixed magnet having high field intensity and gradient. The magnets used in the Roller Magnetic Separators and made of alloys of rare earth elements are more powerful as compared to other magnets. They generate high attraction forces on the magnetic roller due to their properties and special magnetic series. The obtained high magnetic attraction forces have low magnetic sensitivity and therefore they make it possible to separate very fine low magnetic minerals with a high recovery.

The most distinguishing property of Magnetic Roll Separators is the used magnets that are an alloy of rare earth elements produced domestically and more powerful. Magnetic Systems has a number of standard sizes in which the high gradient separator is produced, and all of these sizes only require a low installation height. It is also possible to make a system in accordance with customer specifications. Depending on the requirements made and the application, a choice can be made for a single stage system or for multiple magnet rollers under one another. This results in an even higher degree of iron separation.

Our latest developments in higher gauss value with star ultra super rare earth magnets with highest intensity,high gradient magnet arrangement in special proprietary configurations are now available after extensive research and development.

STAR TRACE is one of the Asia's leading manufacturing Company in Permanent Magnetic Equipments and Vibrating Equipments in Dry/Wet Separation of minerals and metals. The Dry Permanent Magnetic Roll Separator systems are unique in nature and we are supplying similar equipment throughout the world and more than 1000 Industries are having our Equipments. In our past 25 years of experience, we can separate from Coal to Gold in all minerals and metals from anywhere in the world, depending upon on their mining location, we are able to provide you complete solutions to upgrade your metals, minerals and your processes.

These Magnetic Roller Separators are highly effective of separating para magnetic particles and weakly para magnetic particles separately. These Rare Earth Magnetic Separators are made up of very high power specially developed Nickel, Iron Boron (Nd-Fe-B) with highest magnetic power available in the series to enable us to achieve very high gauss value compared to other similar products.

Right now, we have developed latest Magnetic Roll Separator with a diameter of 150mm which gives higher magnetic force and more contact area than the normal 100mm diameter magnetic rollers. These Magnetic Rollers are specially configured with configurations of suitable material sizes and its magnetic properties. The Magnetic Roll Separators have been passing through the belt which the material is running, is made of different materials with different thickness to suit effective beneficiation of separating minerals and metals.

These effective separators can be achieved with different thickness of belt ranging from 0.25mm to 2mm and some of the belt material which we have been using are having a non stick property and they are highly resistant to abrasiveness. Some of the belt material are coated with Nylon for its non stick property. These belts are basically made up of Kevlar, which is a Bullet Proof material and highest strength of its kind. These STAR TRACE Magnetic Roll Separators are having several passes to make sure of highest purity can be obtained by which several process repeatedly without much material handling. These Magnetic Roller Separators are primarily used in replacement of old technology of induced magnetic roller separators.

Magnetic Roller Separators Working Principle:

Magnetic Roller Separators consist of two rolls, one of which is magnetics. There is a belt between them to carry the ore into the magnetic field. The movement of the belt is controlled by a motor fixed to one of the rollers. The rotational speed of rollers can be adjusted according to the material properties

The material to be processed is conveyed to the belt by vibrating feeder at a required rate. Feeding rate can be controlled by adjusting the vibration on feeder. A Roller separator blade has been set in order to be able to collect separated products in different places and to adjust the product properties in a desired manner.

Magnetic Roller Separators Technical Features
  • Field strength (measured indirectly and controlled by amp adjustment of the electromagnet) typically up to 15,000 gauss.
  • Pole gap (closer the gap higher the field strength), typically 2mm.
  • Roller speed ( normally fixed and only adjusted by pulley and belt changes).
  • Splitter position (determined by visual observation of the fan).
  • Feed temperature will affect magnetic susceptibility.
  • Feed rate typically 2.5tph.
Magnetic Roller Separators Construction:

The magnetic rollers incorporated in our machines have been specially designed and developed to generate exceptionally high magnetic field and gradient. The rollers which are built using rare earth Nd-Fe-B are manufactured to very low dimensional tolerances. The magnetic rollers incorporated in our machines have been specially designed and developed to generate exceptionally high magnetic field and gradient. The rollers which are built using rare earth Nd-Fe-B is manufactured to very low dimensional tolerances.

Magnetic Roller Separators Operating variables are:
  • Field strength (measured indirectly and controlled by amp adjustment of the electromagnet) typically up to 15,000 gauss.
  • Pole gap (closer the gap higher the field strength), typically 2mm.
  • Roller speed (normally fixed and only adjusted by pulley and belt changes).
  • Splitter position (determined by visual observation of the fan).
  • Feed temperature will affect magnetic susceptibility.
  • Feed rate typically 2.5tph.

APPLICATIONS OF MAGNETIC ROLL SEPARATOR

Rare Earth Magnetic Separators are made up of very high power specially developed Nickel, Iron Boron (Nd-Fe-B) with highest magnetic power available in the series to enable us to achieve very high gauss value compared to other similar products.

  • Silica
  • Carbide
  • Chromite recovery
  • Graphite Upgrading
  • Silica Sand
  • Alumina
  • Abrasive and refractory
  • Raw materials cleaning
  • Magnesite beneficiation
  • Copper-nickel ore Pre- Concentration
  • Manganese and glass send beneficiation
  • Andalusite and pyrophyllite beneficiation
  • Diatomaceous earth cleaning and kyanite cleaning
  • Iron ore beneficiation
  • Diamond beneficiation
  • Feldspar
  • Dolomite
  • Glass raw materials cleaning
  • Wollastonite beneficiation
  • Magnesite, Quartzite etc.
  • Bauxite cleaning
  • Feldspar cleaning
  • Bauxite Upgrading
  • Recovery of Metals from Slag.
  • Ceramic raw materials cleaning
  • Metal value recovery from waste
  • Ultra High Purity Quartz Cleaning.
  • Flint clay and Graphite beneficiation
  • Removal of ferro silicates from limestone Magnesite etc
  • Selective separation of garnet/ilmenite/rutile/zircon recovery

FEATURES OF MAGNETIC ROLL SEPARATORS

Rare Earth Magnetic Separators are made up of very high power specially developed Nickel, Iron Boron (Nd-Fe-B) with highest magnetic power available in the series to enable us to achieve very high gauss value compared to other similar products.

  • Compact construction.
  • Single or multi stage separation.
  • Fully enclosure with dust extraction port.
  • Designed for easy maintenance.
  • Automatic belt tensioning and tracking.
  • Tool free belt change.
Magnetic Roller Separators Uses

Induced Roller Separators are primarily used for separating or concentrating minerals or materials of low magnetic susceptibility. Uses include extraction of iron or chromium bearing minerals from silica sand, the concentration minerals such as wolframite, the removal of paramagnetic minerals such as Iron Titanium Oxide (Ilmenite, FeTiO3), Iron Carbonate (siderite, FeCO3), etc., from valuable non-magnetic minerals, and purification of dry granular chemical compounds and abrasives.These self-cleaning magnetic separator selectively removes magnetic components out of a conveyed material and discharges them as distinct and clean material. Field intensity is adjustable for selective recovery. Very high gauss of 20,000 is achieved by the magnetic separator.

The throughput and degree of separation depends upon the following factors:
  • The susceptibility of the magnetic fraction - throughput is reduced for materials of lower magnetic susceptibility.
  • The particle size - for most materials the maximum size which can be satisfactorily treated is 3mm. For the treatment of dry materials up to 50 mm in size, electromagnetic multi-channel Pulley or Drum Separators are available (details available upon request). The presence of fine particles (particularly those less than 30 microns) reduces throughput.
  • The bulk density - higher values increases throughput.
  • The flow characteristics - these are determined by particle shape, surface condition and moisture content. Better flow characteristics increase throughput.
  • The proportion of magnetics - a high percentage of magnetics may reduce throughput.

Specification Of Magnetic Roll Separator

Single Roll Separator
Specification for Single Roll Separator
Model No. Belt Width A B C D E
STR-RS-250 250 250 450 1070 1035 1200
STR-RS-500 500 500 700 1070 1035 1200
STR-RS-1000 1000 1000 1200 1070 1035 1200
STR-RS-1500 1500 1500 1700 1070 1035 1200

Double Roll Separator
Specification for Double Roll Separator
Model No. Belt Width A B C D E
STR-DRS-250 250 250 500 1795 1755 1610
STR-DRS-500 500 500 750 1795 1755 1610
STR-DRS-1000 1000 1000 1250 1795 1755 1610
STR-DRS-1500 1500 1500 1750 1795 1755 1610

Contact Star Trace

Corporate Headquarters

Star Trace Pvt. Ltd,Chennai
Mr. P. R. Maheswaran
#7, Jeevanandham street,
Redhills,Chennai - 600 052,
Tamil Nadu, India.

Works

No: 11,
Moorthasa Ussian
Sahib Street, Redhills,
Chennai - 600 052.
Call Us 0091- 9841015456
Phone 0091- 044 26418456,
0091- 044 26419439.
0091- 044-26323356,
0091- 044-26321356.
TeleFax 0091-044-26419439
Toll Free 1800-103-9066.
Mobile 0091-9380521567,
0091-9380521576
Email ID sales@startrace.in
CIN NO: U51103TN1998PTC041085