What is a magnetic drum separator?
In mineral processing, a magnetic drum separator, also known as a drum magnet, separates non-magnetic material from magnetic material by using magnetic differences.
Commonly used applications include iron ore beneficiation, industrial minerals, coal processing, and beach sand beneficiation. Let us look at each of these:
- Iron ore: In iron ore beneficiation, the magnetic particles, such as magnetite or hematite, are absorbed to the drum and carried along with it. Meanwhile, non-magnetic particles continue their trajectory and are discharged separately.
- Industrial minerals: Magnetic separators remove magnetic impurities from industrial minerals like feldspar, quartz, and mica, improving the purity and quality of the minerals, so they are more suitable for industrial applications.
- Coal processing: Magnetic impurities from coal are removed via magnetic separators, improving the purity and quality of the coal.
- Sand beneficiation: Magnetic minerals such as ilmenite, rutile, zircon and garnet in heavy mineral sands are collected by magnetic separators as magnetic concentrate.
Reliable magnetic drum separators manufacturer
FTM Machinery is committed to providing customers with solid and efficient magnetic separation equipment with a comprehensive understanding of customer needs. Factors to consider when customizing equipment for customers.
- Drum size and configuration: Customize magnetic drum separators based on specific processing needs, including drum size, diameter, length, and the option for single or multiple separators.
- Magnetic field strength: Determine the magnetic field strength to provide optimal separation efficiency based on the material characteristics and separation goals.
- Material and construction: Select the structural material of the separator, including the drum surface, outer shell, and internal components, based on factors like mineral abrasiveness and corrosion to ensure durability and extended service life.
- Adjustable parameters: Adjust parameters like drum speed, magnetic field strength or inclination to fine-tune the separation process allowing the operator to optimize separation performance for specific material properties.
- Automatic cleaning mechanisms: Configure automatic scraper system, self-cleaning belt or air blowing system to automatically complete the cleaning process of the drum surface without manual intervention.
- Power requirements: Power requirements for magnetic drum separators vary based on factors such as size, magnetic field strength, drum speed, design features, and available voltage, current, and frequency at the installation site.
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Why FTM Machinery magnetic drum separators?
- The permanent magnetic system adopts high-quality ferrite or composite including ferrite material and rare earth magnetic steel. The average magnetic induction intensity of the drum surface is at the range of 100–600 mt. The demagnetization rate of the magnetic density within 8 years is no more than 5%.
- The large wrap angle magnetic system with gradual field strength and smooth transition increases the length of the separation zone and the number of magnetic flips to achieve efficient separation.
- Covering the magnetic system with non-magnetic stainless steel ensures no peeling off of the magnet.
- The permanent magnets have a strong adaptability of production. It can bear large change of feeding amount, particle size and pulp concentration.
- Good processing indexes such as high grade and high recovery rate can be acquired at the same time.
- All the series of magnetic separators can be used cooperatively or singly. The good processing indexes can both be acquired.
Types of magnetic drum separators
Magnetic drum separators are divided into dry magnetic drum separators and wet magnetic drum separators.
Dry magnetic drum separators
A dry magnetic drum separator, as the name suggests, operates without the use of water or a liquid medium.
The dry feed with a particle size less than 3mm is fed onto the rotating drum, where magnetic particles adhere to the drum's surface. Non-magnetic particles are unaffected by the magnetic field and fall off the drum due to gravity or other forces. The separated magnetic particles are carried to a discharge point and released or brushed off the drum.
Dry magnetic drum separators use magnetic field strength, gradient, gravity, and other forces to separate and transport particles without the need for water or a liquid medium.
A model of dry magnetic drum separator includes a rare earth roll (RE Roll), which is a high-intensity magnet capable of separating strong and weak magnetic materials from non-magnetic material in a dry state.
Advantages of the dry magnetic drum separators
- 1No water requirement: Dry magnetic drum separators operate without a liquid medium, making them convenient and cost-effective. They are particularly advantageous in situations with limited water availability or a focus on water conservation.
- 2Versatility: By adjusting magnetic field strength, drum speed, and other parameters, dry magnetic drum separators can process various minerals including iron ore, chromite, garnet, tantalite, and other magnetic minerals.
- 3Easy maintenance: Dry magnetic drum separators generally have simpler designs and fewer components compared to wet separators, resulting in easier maintenance and lower maintenance costs.
Wet magnetic drum separators
A wet magnetic drum separator operates in the presence of water or a liquid medium.
The feed material is mixed with water and fed onto the rotating drum. Magnetic particles stick to the drum's surface as it rotates, while non-magnetic particles fall off due to gravity or other forces. Magnetic particles are eventually released or flushed off at the discharge point.
The presence of water or liquid medium in the wet magnetic drum separator facilitates the movement and separation of the magnetic and non-magnetic particles. It also aids in the transportation of the separated magnetic particles to the discharge point.
The permanent magnetic drum wet separator is suitable for the ores like magnetic pyrite, roasted ore, ilmenite, and other materials with a particle size of less than 3mm.
Types of wet magnetic drum separators
It can be divided into three types according to the various tanks:
Cocurrent: The slurry feed direction is the same as the drum rotating direction. The magnetic concentrate is discharged from the concentrate launder, while the tailings are directly released from the bottom.
This method is ideal for coarse selection of strong magnetic minerals (0–6 mm), offering high recovery rate and grade.
Countercurrent: The slurry feed direction is opposite to the drum rotating direction. The magnetic concentrate is discharged on one side of the feed opening, while the tailings are discharged on the other side.
This configuration is typically employed for coarse separation and scavenging of materials ranging from 0–0.6 mm, ensuring a high recycling rate.
Semi-countercurrent: The slurry feed direction is partially the same and partially opposite to the drum rotation. The slurry circulates within the tank, ensuring thorough washing and prevention of inclusions. This method promotes further recycling as the slurry moves in line with the magnetic force.
Semi-countercurrent operation is beneficial for obtaining high-grade magnetic concentrate from strong magnetic ore (0.5–10 mm) through coarse separation and scavenging, maintaining stable slurry surface and operation.
Advantages of the wet magnetic drum separators
- 1Full magnetic design shows large contact area between the pulp and the effective working surface.
- 2The magnetic content of tailings is significantly reduced, which is 1–3% lower than that of ordinary magnetic separation equipment.
- 3The separating process is lengthened to make concentrate grade increase by 2–4%.
- 4They can process varying slurry densities, feed rates, and particle sizes without compromising separation performance. This makes them suitable for operations with fluctuating feed characteristics.
- 5They can be easily integrated into existing mineral processing circuits like grinding and classification circuits to enhance the overall efficiency of the mineral processing operation.
The key parts of a permanent magnetic drum separator
FTM Machinery is committed to providing customers with quality permanent magnetic drum separators. They consist mainly of a permanent magnet system, a rotating drum, a separating chute, a feed tank, and a flushing pipe.
Permanent magnet system
The magnetic system uses permanent magnets arranged in a specific pattern to create a strong and lasting magnetic field. These magnets are made of high-quality ferrite or composite including ferrite material and rare earth magnetic steel. They attract and retain magnetic particles as the drum rotates.
Drum
The drum, made of stainless steel, serves as the magnetic field generation and separation zone. It rotates on a horizontal axis. If necessary, cover the surface of the drum with rubber mats.
Separating chute
The permanent magnetic drum separator has one or more separating chutes to direct the separated magnetic and non-magnetic fractions to their respective discharge points.
Feed tank
The feed tank, a container or reservoir located above the drum separator, stores materials and facilitates a controlled and consistent supply to the separator. It acts as a storage and feeding system, ensuring a reliable and regulated material flow for optimal operation.
Flushing pipe
The flushing pipe introduces water or liquid media to the drum to assist in the removal of magnetic contaminants, or magnetic concentrate from the drum surface.
Frequently asked questions about magnetic drum separators
1. Can the magnetic drum separator handle high-temperature materials?
- Magnetic drum separators have temperature limitations based on design and construction materials used. Standard separators can handle temperatures up to 80–150℃ (176–302°F), but this can vary. For high-temperature materials, use heat-resistant materials or implement a cooling system to prevent damage caused by overheating.
2. What are the maintenance requirements for a magnetic drum separator?
- Magnetic drum separators generally have low maintenance requirements. Here are some common maintenance tasks associated with magnetic drum separators:
- a. Regular cleaning: Periodically clean the drum surface to remove accumulated iron contaminants. When performing this task, it is important to follow proper safety procedures to prevent injury.
- b. Inspection and maintenance: Periodically inspect the condition of magnetic elements, drum surfaces, bearings, seals, and other components to identify any signs of wear, damage, or misalignment that may affect their performance. Repair or replace promptly to maintain optimum function.
- c. Follow manufacturer's guidelines: Follow the specific maintenance guidelines provided by the drum separator manufacturer. These guidelines may include recommendations for cleaning procedures, maintenance intervals, inspection criteria, and any specific requirements for the particular model of separator you are using.
3. What are the safety considerations and precautions?
- To ensure personal safety and prevent potential accidents or injuries, please observe the following safety precautions:
- a. Electrical safety: Ensure electrical safety measures, including grounding, circuit protection, and adherence to electrical codes, are implemented for magnetic drum separators with electrical components.
- b. Pinch points and entanglement hazards: Rotating parts can create pinch points or entanglement hazards. Implement safety procedures, guards, and barriers to prevent accidental contact with moving parts of magnetic drum separators.
- c. Material handling precautions: Follow proper material handling procedures when feeding material onto the drum surface or removing captured magnetic particles. Use appropriate personal protective equipment (PPE), such as gloves or safety glasses, when handling materials or performing maintenance tasks.
- d. Cleaning procedures: Prioritize safety when cleaning the drum surface of magnetic separators. Shut down, lock out/tag out the equipment, and follow recommended cleaning procedures using proper tools and PPE to minimize injury risks.
- e. Hot surface: Take precautions to prevent contact with hot surface and ensure proper ventilation in the operating area to manage heat generated by magnetic drum separators.
FTM Machinery magnetic separation plants
1. Dry magnetic drum separator processes iron ore in India
This Indian customer purchased a dry magnetic separator to process iron ore sand. The process of separating using the permanent dry magnetic drum separator involves the following steps:
- 1Crush and grind the iron ore into a fine powder to increase the surface area of the ore, allowing for better magnetic separation.
- 2Evenly feed the iron powder to the magnetic separator with an electric vibration feeder.
- 3Magnetic particles on the drum's surface are released at a discharge point and collected as magnetic concentrate. Magnetic concentrate undergose additional processing steps such as drying, grinding, magnetic separation, and gravity separation to further upgrade the iron content and remove impurities.
- 4The non-magnetic particles that do not adhere to the drum's surface continue their path and are discharged separately. This fraction, known as the non-magnetic tailings, may still contain valuable minerals and can undergo additional processing steps if desired.
2. Wet magnetic drum separator processes tailings in Australia
This customer wanted to separate vanadium titanium magnetite tailings. To reduce production costs, FTM Machinery provided the Australian client with a method to separate vanadium titanium magnetite tailings. The method involves the following steps:
- 1Grind the tailings to a suitable particle size to liberate the valuable minerals in a wet ball mill.
- 2Feed the slurry into the wet magnetic separator to recover magnetic minerals, such as magnetite.
- 3Treat the magnetic concentrate using various techniques, such as flotation, leaching, and roasting, to extract vanadium and titanium minerals.
- 4The vanadium and titanium concentrates obtained from the beneficiation process undergo smelting, leaching, or chemical refining to obtain higher-purity vanadium pentoxide and titanium dioxide products.
This solution for separating titanium ore concentrate not only ensures quality but also increases the recovery rate by 10–25 percentage points. The customer's annual output of titanium concentrate has increased from 50,000 tons to 500,000 tons.
Facts have proven that the magnetic drum separator manufactured by FTM Machinery improves classification efficiency, particularly by increasing the concentration of underflow and reducing overflow and roughness. It significantly raises the recovery rate, improves product quality, and greatly enhances the comprehensive utilization rate of resources.
Parameter
| Model |
Shell diameter （mm） |
Shell lenght （mm） |
Shell rotation speed（r/min） |
Feeding size （mm) |
Processing capacoty （t/h） |
Power（kw） |
| CTB6012 | 600 | 1200 | <35 | 2-0 | 10-20 | 1.5 |
| CTB6018 | 600 | 1800 | <35 | 2-0 | 15-30 | 2.2 |
| CTB7518 | 750 | 1800 | <35 | 2-0 | 20-45 | 2.2 |
| CTB9018 | 900 | 1800 | <35 | 3-0 | 40-60 | 3 |
| CTB9021 | 900 | 2100 | <35 | 3-0 | 45-60 | 3 |
| CTB9024 | 900 | 2400 | <28 | 3-0 | 45-70 | 4 |
| CTB1018 | 1050 | 1800 | <20 | 3-0 | 50-75 | 5.5 |
| CTB1021 | 1050 | 2100 | <20 | 3-0 | 50-100 | 5.5 |
| CTB1024 | 1050 | 2400 | <20 | 3-0 | 60-120 | 5.5 |
| CTB1218 | 1200 | 1800 | <18 | 3-0 | 80-140 | 5.5 |
| CTB1224 | 1200 | 2400 | <18 | 3-0 | 85-180 | 7.5 |
| CTB1230 | 1200 | 3000 | <18 | 3-0 | 100-180 | 7.5 |
| CTB1530 | 1500 | 3000 | <14 | 3-0 | 170-280 | 11 |
| Model | Feeding size （mm） |
Processing capacity （t/h） |
| CTB6012 | 2-0 | 10-20 |
| CTB6018 | 2-0 | 15-30 |
| CTB7518 | 2-0 | 20-45 |
| CTB9018 | 3-0 | 40-60 |
| CTB9021 | 3-0 | 45-60 |
| CTB9024 | 3-0 | 45-70 |
| CTB1018 | 3-0 | 50-75 |
| CTB1021 | 3-0 | 50-100 |
| CTB1024 | 3-0 | 60-120 |
| CTB1218 | 3-0 | 80-140 |
| CTB1224 | 3-0 | 85-180 |
| CTB1230 | 3-0 | 100-180 |
| CTB1530 | 3-0 | 170-280 |