Shot blasting machine magnetic separation separator
I. Working principle of magnetic separation separator
Utilizing the magnetic field of permanent magnets and relying on magnetic differences for separation:
When the shot sand mixture falls, the steel balls / cast steel balls (ferromagnetic) are adsorbed by the magnetic drum and rotate with the drum to automatically fall into the recycling bin and enter the circulation bin; the molding sand, oxide scale, dust, and non-metallic slag, which have no magnetism, directly fall into the waste bin; the main model is a single-stage + double-stage magnetic separation, further reducing the loss of steel balls in the waste.
II. Core advantages of magnetic separation separator
1. High separation accuracy and high steel ball recovery rate
The efficiency of the double-stage magnetic separation separation can reach over 99.5%, with extremely low residual steel balls in the waste;
It has significant advantages in difficult-to-process mixed conditions: when the shot sand mixture contains sand and impurities > 10%, the separation effect is far better than that of ordinary air separation separator;
It is not affected by the moisture of the material, and wet sand materials can still be stably separated.
2. Reduces steel ball consumption and saves raw material costs
Traditional air separation is prone to sucking fine and intact steel balls along with dust into the dust collector; magnetic separation relies on magnetic force to capture, and fine qualified steel balls are less likely to be lost, reducing steel ball consumption by 10% to 25%.
3. Purifies the recycled shot sand, protects the shot blasting machine
The recycled shot sand contains a large amount of molding sand and hard impurities, reducing the wear of the shot blasting machine blades, guards, and directional sleeves; the lifespan of vulnerable parts can be extended by 1.5 to 3 times;
Reducing the repeated impact of hard sand particles on the workpiece surface, avoiding the appearance of spots and scratches on the surface, and improving the cleaning surface quality.
4. Strong adaptability to working conditions, stable operation
No strict control of the material layer thickness is required; large flow, large batch casting parts cleaning conditions are not prone to blockage;
Permanent magnetic structure, no need for electrical excitation, low energy consumption; continuous 24-hour production is stable and reliable.
5. Easy adjustment, simple maintenance
There is a magnetic pole adjustment mechanism, which can adjust the magnetic force range to adapt to different shot materials;
The outer layer of the drum is a wear-resistant protective sleeve, and only regular cleaning of adhered dust is required, and the lifespan of the permanent magnet can reach 5 to 8 years.
6. Improves the working condition of the dust removal system
Reduce the amount of sand and slag entering the dust collector pipeline, reduce dust blockage and bag wear, and extend the service life of dust removal filter bags.
Limitations of magnetic separation separator: It can only distinguish magnetic projectiles from non-metallic impurities, and cannot separate broken steel balls, oxide scale (also magnetic); High-end production lines often combine air separation to form a magnetic separation + air separation composite system.
III. Main application scenarios
1. Casting industry
After shot blasting cleaning of gray iron, ductile iron castings, and cast steel castings (resin sand, sodium silicate sand, lost foam castings);
When a large amount of molding sand and sticky sand enter the elevator after the casting parts fall, the processing load of ordinary air separation is insufficient, and magnetic separation separators should be preferred.
Applicable equipment: tracked shot blasting machine, hook-type shot blasting cleaning machine, through-type profile shot blasting machine.
2. Steel structure / steel plate pre-treatment line
Steel rust removal, shot blasting of profiles, generally magnetic separation + air separation is used: magnetic separation first separates large pieces of oxide scale and sand, and air separation then removes dust and broken shot.
3. Large-scale casting cleaning of engineering machinery, valve bodies, pump bodies
The workpieces have severe sticking sand, and the continuous amount of impurities is large. Using magnetic separation can stably ensure the purity of the shot sand and ensure the consistency of the surface quality of batch workpieces.
Unsuitable scenarios
Using non-magnetic abrasive materials such as stainless steel sand (austenitic), glass beads, ceramic sand, and plastic sand, magnetic separation separators cannot be used.
IV. Practical selection suggestions
When the shot blasting cleaning is severe, → Prefer double-stage magnetic separation separator;
When the impurities are mainly oxide scale and broken shot → Recommend magnetic separation + air separation composite separator;
When the impurities are few, the budget is limited, and only rust removal is required without a large amount of molding sand → Ordinary air separation separator is sufficient;
Pursuing long-term comprehensive cost: Although the initial purchase price of magnetic separation equipment is higher than that of air separation, the steel balls saved + the increased lifespan of wear-resistant parts enable most foundries to recover the price difference within about half a year.