The origins of the Disc Magnetic Separator date back to the early 1900s. Although manufacturing techniques have significantly changed and more advanced machines have now been incorporated, the basic function design remains virtually the same. The Disc Magnetic Separator is widely used to ensure an accurate separation of dry minerals that have varied magnetic susceptibilities.
Typically, a Disc Magnetic Separator features up to three high-intensity electromagnetic discs, each set at a different height from a feed conveyor.
- Disc 1 – This will be set the furthest from the feed material. The objective is to extract only the most magnetically susceptible particles;
- Discs 2 and 3 – The second and third discs are set at lower gaps. This increases the magnetic force at each disc and enables the separation of different grades of magnetic material.
The magnetic intensity can be further adjusted by varying the current of each coil. This allows each Disc Separator to be designed and set-up for an individual mineral ore.
In this video, Dr Neil Rowson, a respected mineral processing engineer from the University of Birmingham, explains the operation of a Disc Magnetic Separator.
On camera, Dr Rowson explains how feed material is discharged from a hopper onto a vibratory feeder tray. The vibratory feeder presents an even and thin layer of material onto a moving conveyor. As the material is conveyed under the rotating electromagnetic discs, magnetic particles are attracted up to the high gradient magnetic zones on the discs. The rotating discs then carry these captured particles to the discharge chutes where they are move into a non-magnetic area and are released. Scrapers mounted on chutes ensure the total discharge of magnetic particles.
Non-magnetic material continues to the second magnetic separation zone where secondary separation occurs, and is finally discharged at the end of the machine as a clean non-magnetic product. A third stage of separation can be added if required.
The physical action of the Disc Magnetic Separator lifting the magnetic minerals off the conveyor belt produces a very clean magnetic fraction.
The Disc Separator is used in many applications including:
- Beach Sands – Separating ilmenite, garnet, monazite, and zircon sand;
- Tin processing
- Wolframite recovery
- Abrasive minerals separation
- Tantalite and Columbite separation
Mineral Processing Laboratory
The video shows Dr Rowson undertaking test work at the Master Magnets laboratory in Redditch, UK. Tests are conducted on mineral materials from deposits all over the world. From the tests it is possible to confirm what separation is possible on what equipment. This then forms the basis of a separation guarantee for any equipment order. The Master Magnets laboratory houses one of the most extensive ranges of high intensity magnetic separation equipment in the world.
For further information on Master Magnets and our range of magnetic separation equipment designed for purifying ceramics and non-metallic minerals, please contact us on:
Telephone: +44 (0) 1527 65858
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