To provide an accurate quotation and solution for an iron remover (magnetic separator), the following key information must be considered to ensure proper selection, cost-effectiveness, and efficiency:
1. Material Characteristics
- Material Type: Ore, coal, food products, chemical raw materials, etc. Different materials require varying corrosion resistance and hygiene standards.
- Particle Size Distribution: Material granularity (e.g., 0-5mm or large ore chunks) affects magnetic penetration depth and the type of separator (e.g., belt-type for fine powder, drum-type for coarse particles).
- Moisture/Viscosity: Wet or sticky materials may require self-cleaning features or special surface treatments (e.g., Teflon coating).
- Temperature: High-temperature materials (e.g., cement clinker) need heat-resistant designs (e.g., permanent magnets ≤80°C, electromagnetic models for higher temps).
2. Iron Removal Requirements
- Type of Iron Contaminants: Iron oxide, metal fragments, bolts, etc. Different shapes and magnetic properties (ferromagnetic/weakly magnetic) influence magnetic strength needs.
- Removal Rate Target: For example, >99% efficiency may require higher magnetic intensity (e.g., permanent magnets: 8,000–15,000 Gauss; adjustable electromagnets).
- Residual Iron Content: Industries like food/pharmaceutical may demand ≤1ppm, necessitating high-gradient magnetic separation or metal detector integration.
3. Working Environment
- Installation Location: Conveyor belt (suspended type), chute (pipeline type), vibrating screen (drum type), etc., determining the separator’s structure and dimensions.
- Space Constraints: Compact areas may require flat or modular designs.
- Ambient Conditions: Outdoor use needs IP65 protection; corrosive environments require stainless steel housing.
4. Equipment Parameters
- Conveyor Specifications: Belt width (e.g., 500–2000mm), speed (typically 0.5–3.5m/s), material layer thickness (affects magnetic pole spacing).
- Throughput Capacity: E.g., 10 tons/hour vs. 100 tons/hour, dictating magnet size and power.
- Power Supply: Electromagnetic models need AC 380V or DC 24V; permanent magnets require no power.
5. Automation Needs
- Iron Discharge Method: Manual cleaning (economical) or automatic (motor-driven or vibratory mechanisms).
- System Integration: Syncing with metal detectors or PLCs for auto-stop/alerts.
6. Industry Standards & Certifications
- Food/Pharmaceutical Grade: Requires FDA/CE certification, 304/316 stainless steel.
- Mining/Heavy Industry: Explosion-proof (ATEX), wear-resistant designs.
7. Budget & Maintenance
- Initial Budget: Permanent magnets are cheaper (~thousands to tens of thousands), electromagnets cost more (but offer adjustable strength).
- Ease of Maintenance: Open structures for easy cleaning; remote monitoring (e.g., temperature sensors).
Solution Examples
Scenario 1: Removing fine iron from food powder
→ Choice: Pipeline permanent magnet (8,000 Gauss) + pneumatic self-cleaning, 316L stainless steel.
Scenario 2: Removing large iron pieces in mining crushing lines
→ Choice: Suspended electromagnetic separator (15,000 Gauss) + auto-discharge belt, IP67 rating.
Quotation Essentials
With the above details, suppliers can calculate:
- Required magnetic strength
- Equipment dimensions & power consumption
- Material & protection grade costs
- Automation add-on costs
For precision, provide site videos or material samples for testing.
