Separators Of The Shot Blasting Machine Classification

Separators of the shot blasting machine classification
I. Classification by separation principle (core mainstream classification)​
1. Air separation type (the most widely used)​
Working principle: Achieve separation through the difference in airflow dynamics - When the mixed material of pellets and slag falls from the elevator into the separator, it forms a uniform "full curtain" and falls horizontally. When the horizontal airflow passes through the curtain, the denser qualified pellets (such as steel balls) fall vertically to the pellet storage bin due to gravity, while the crushed pellets, oxide scales, and other medium-density impurities deviate from the settling trajectory and fall into the waste area, and the dust is sucked into the dust removal system by the airflow.​
Key parameters: The separation efficiency can reach over 99.5%, the optimal wind speed is controlled at 4-6m/s, and it needs to be matched with the dust removal system air volume (usually 100kg/min pellet material corresponds to 10000m³/h air volume).​
Representative type: Full curtain flow curtain type air separation separator (mainstream model), by adjusting the position of the counterweight and the angle of the strainer plate to optimize the separation effect, it is suitable for large-scale production equipment such as stainless steel belt hammering machines and chain-type hammering machines.​
Advantages and limitations: Simple structure, low maintenance cost, suitable for various pellet types; precise control of airflow parameters is required, otherwise, incomplete separation may occur.​
2. Magnetic separation type (targeted separation of metal impurities)​
Working principle: Utilize electromagnetic induction to adsorb ferromagnetic pellets, achieving the separation of steel balls from non-magnetic impurities (such as sand, aluminum shavings), and is often combined with air separation to form a "magnetic separation + air separation" two-stage separation system.​
Core components: Built-in high-strength magnet groups (double-layer design), the adsorption surface uses wear-resistant liners to avoid pellet impact wear, the separation accuracy can be controlled at the 0.1mm level.​
Typical application: The pre-treatment stage of the chain-through hammering machine, first removes over 90% of metal impurities through magnetic separation, then through air separation for purification, improving the purity of the pellet circulation.​
Advantages and limitations: High pellet recovery rate (≥98%), fast separation speed; only applicable to ferromagnetic pellets, cannot separate mixtures of magnetic impurities and steel balls.​
3. Vortex separation type (high-efficiency energy-saving)​
Working principle: Through high-frequency vortex-generated electromagnetic force for layering, using the conductivity difference of different particles to achieve precise separation, it can distinguish three types of substances: qualified pellets, crushed pellets, and dust.​
Technical characteristics: The pellet utilization rate is increased to 95%, compared to traditional air separation, it is 18% more energy-efficient, suitable for high-speed continuous operation scenarios, such as batch cleaning of castings by crawler-type hammering machines.​
Advantages and limitations: High separation efficiency, strong automation; higher equipment cost, suitable for large-scale production enterprises.​
4. Screening type separator (basic coarse separation)​
Working principle: Use multiple layers of screens (commonly with a 0.8-2.0mm hole size) for分级 filtration, the upper layer screen intercepts large particles (such as casting riser residues), the lower layer screen separates crushed pellets, and the qualified pellets pass through the screen holes into the circulation system.​
Structural form： Includes two types of screens - drum screens and vibrating screens, the drum screen is suitable for continuous operation (such as belt-through hammering machines), the vibrating screen has higher separation efficiency (processing capacity ≥ 50t/h).​
Advantages and limitations： Simple structure, low cost; screens may wear, regular replacement is required, suitable for scenarios with lower separation accuracy requirements (such as coarse sand recovery in road hammering machines).​
II. Classification by structural form​
1. Vertical separator (main installation form)​
Structural characteristics： Vertically arranged at the top of the bucket elevator, the floor area is small (usually ≤1.5㎡), adopts the design of curtain falling from top to bottom, suitable for most hammering machine models (such as chain-type, hook-type).​ Core Components: Comprising a fabricator, a regulating baffle, a wind separation channel, and a pellet storage bin. The thickness of the curtain can be controlled by adjusting the angle of the baffle (0-30°) to optimize the separation effect.
2. Horizontal Separator (for large processing capacity scenarios)
Structural Features: Arranged horizontally, with a length typically ranging from 3 to 6 meters. It separates by using multiple wind separation channels in parallel, with a processing capacity of up to 100t/h or more, suitable for large-scale shot blasting cleaning lines (such as the 4 parallel separators designed for stainless steel belt shot blasting machines).
Advantages: High separation efficiency, less prone to blockage, suitable for batch processing of heavy-duty workpieces (such as locomotive bogies, large-scale steel structures).
3. Combined Separator (for high precision requirements)
Structural Features: Integrates two or more separation principles, such as "screen coarse filtration + magnetic separation + wind separation" (standard for chain suspension type shot blasting machines), "vortex + wind separation" (high-end intelligent models).
Performance Indicators: The purity of the shot can reach 99.8%, the dust emission concentration is ≤ 15mg/m³, in line with the GB16297 environmental protection standard, suitable for high-precision cleaning scenarios such as automotive components, aerospace components, etc.
III. Classification by Application Scenarios
1. General-purpose Separator
Applicable Equipment: Track-type, inclined drum-type shot blasting machines, processing workpieces including castings, forgings, general mechanical parts.
Core Requirements: Compatible with various shots (steel balls, steel sand, quartz sand), separation efficiency ≥ 95%, maintenance cycle ≥ 300h.
2. Precision Separator
Applicable Equipment: Mechanical hand-type, mesh belt-through type shot blasting machines, processing workpieces including automotive engine blocks, aerospace components, thin-walled castings.
Core Requirements: Separation accuracy ≤ 0.05mm, shot uniformity ≥ 99%, avoiding surface scratches on workpieces caused by shot impurities.
3. Special-purpose Separator for Large Components
Applicable Equipment: Chain suspension type, road surface shot blasting machines, processing workpieces including bridge steel structures, containers, road surfaces.
Core Requirements: Large processing capacity (≥ 80t/h), wear-resistant design (flange thickness ≥ 12mm), suitable for high-load continuous operation.
IV. Key Selection Points
Matching Shot Type: For ferromagnetic shots, prioritize magnetic separation + wind separation combination; for non-ferromagnetic shots (such as aluminum shots), only wind separation or vortex separation can be selected;
Processing Capacity Requirements: Small equipment (such as desktop shot blasting machines) can choose screening type; medium equipment (processing capacity 20-50t/h) can choose vertical wind separation; large equipment (≥ 50t/h) can choose horizontal or combined type;
Environmental Protection and Energy Saving: In sensitive dust scenarios, select wind separation separators with dust removal integration; for high energy-saving requirements, select vortex separation type;
Maintenance Cost: Small enterprises prioritize simple vertical wind separation or screening type; large-scale production can choose intelligent combined type to reduce labor maintenance costs.