The ever-growing demand for higher-purity industrial minerals, fueled by emerging global applications, poses a challenge for producers dedicated to delivering quality products. Yesterday's production runs are no longer sufficient to meet evolving requirements. To stay ahead, companies must embrace technological advancements, exploring state-of-the-art equipment that opens doors to new applications in dynamic markets.
In this context, magnetic separation emerges as a crucial technology, offering substantial enhancements in product and mineral quality through increased recovery. Magnetic separation equipment manufacturers actively pursue improvements and efficiency gains across processes to stay competitive and innovative.
A pivotal tool in this pursuit is the Dry High-Intensity Rare Earth (RE) Roll Magnetic Separator. This article delves into current trends and highlights the technological advancements shaping this essential piece of equipment.
Next-Generation Rare Earth Roll Separator (High-Intensity Magnetic Separator)
Rare earth roll separators effectively replaced induced magnetic roll separators (IMRs) because of their simple, compact design and low power consumption. Their performance was as good as or better than that of IMRs.
Early models were manufactured with samarium-cobalt rare earth magnets, and the maximum roll width at the time was 40 inches (1 m). Those units evolved into 60-inch (1.5 m) models. Now, Eriez has announced the development of an 80-inch (2 m) wide RE Roll.
The completely redesigned 80-inch-wide RE Roll features a state-of-the-art design. The housing has been upgraded from conventional welded construction to an innovative “bolt-on” design. The cantilever assembly has also been updated and now incorporates fewer components. These improvements enable the 80-inch RE Roll to provide improved durability and extended service life.
Bearing replacement has been simplified so operators do not have to struggle with the weight of a magnetic roll that will be magnetically attracted to any metallic part on or near the machine. The belt-tracking mechanism has been simplified to make the belt-replacement procedure even faster than with previous models, while Kevlar belts remain the longest-lasting option. Belts with diagonal splices, as well as finger splices, are also available.
The Rare Earth Roll, generating peak magnetic field strengths approaching 24,000 Gauss, is highly effective for concentrating or removing weakly magnetic minerals from a dry process stream. The Rare Earth Roll magnetic separator is designed to provide peak separation efficiency and is typically used when a high-purity product is required. The roll is constructed of discs of neodymium-boron-iron permanent magnets sandwiched between steel pole pieces. The steel poles are magnetically induced to a saturation point of approximately 24,000 Gauss.
Magnetic roll diameters are typically 3, 4, and 6 inches, although separators with diameters of up to 12 inches are available. The separator is configured as a head pulley. A thin belt, usually 5 to 20 mils thick, conveys the feed material through the magnetic field.
When feed material enters the magnetic field, the nonmagnetic particles are discharged from the roll in their natural trajectory. The paramagnetic, or weakly magnetic, particles are attracted to the roll and deflected out of the nonmagnetic particle stream. A splitter arrangement is used to segregate the two particle streams.
Performance Exceeds Expectations
Eriez built and commissioned the world’s first 80-inch Dry High-Intensity Rare Earth Roll Magnetic Separator to satisfy the unique requirements of a minerals-processing application. The supersized Rare Earth Roll Magnetic Separator was successfully installed at the customer’s site, and the results from upgrading the industrial mineral with the equipment have exceeded the expectations of both Eriez and its customer, even at feed rates higher than the design rate.
The Eriez Rare Earth Roll Magnetic Separator provides maximum efficiency in separating weakly magnetic particles for product-purification applications. Eriez applied sophisticated finite element analysis in its magnetic circuit design to produce an energy-free separator capable of generating the exceptionally high field strength needed to remove unwanted fine iron contaminants.
All Eriez Rare Earth Roll Magnetic Separators incorporate the highest-strength and best-quality magnet materials. They combine the best engineering and operational features to provide excellent performance with hassle-free operation, inspection, and maintenance.
Predictive Maintenance
Eriez offers predictive and preventive maintenance service programs to keep equipment functioning at optimum efficiency with minimal downtime. The Eriez Service team provides world-class support throughout the life of the equipment. Ongoing product testing and maintenance are essential, especially when equipment is operating in harsh environments with elevated temperatures or wet conditions.
