Magnetic Separator with Rotating Magnet Roll for Thick Layer Processing
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Solution Overview
Problem
Conventional magnetic separators face challenges in efficiently separating ferromagnetic particles from powdery and granular materials, especially when the material is processed in large amounts or forms a thick layer, leading to adhesion issues and reduced processing speed, and require complex processes or liquid waste disposal.
Innovation Solution
A magnetic separator design featuring a guide roll with alternating magnetic poles and a rotating magnet roll that changes magnetic field strength and direction, combined with a shield wall to prevent adhesion, allows for efficient separation of ferromagnetic particles even with thick layers without complex processes or liquid waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the powdery and/or granular material is supplied in large amounts to form a thick layer, then the processing speed increases, but the ferromagnetic particles and non-magnetic particles become hard to separate due to adhesion
Solution Approach 1:
The patent employs a rotating magnet roll that dynamically changes the magnetic field strength and direction as it rotates. This dynamic magnetic field prevents ferromagnetic particles from adhering to the conveyor belt by continuously altering the magnetic attraction, enabling efficient separation even when material is supplied in large amounts as a thick layer.
Solution Approach 2:
The rotating magnet roll creates periodic magnetic field variations that cycle through different strength and direction states. This periodic action prevents continuous adhesion of ferromagnetic particles to the belt, allowing high processing speeds while maintaining separation efficiency through repeated magnetic field cycles.
2Device complexity
If stationary magnets are used in the guide roll, then the structure is simple, but ferromagnetic particles adhere to the guide roll surface reducing operational efficiency
Solution Approach 1:
The patent replaces stationary magnets with a rotating magnet roll that dynamically changes magnetic field strength and direction. This eliminates adhesion of ferromagnetic particles to the guide roll surface while maintaining relatively simple structure, improving operational efficiency without significant complexity increase.
Solution Approach 2:
The rotating magnet roll provides continuous magnetic field variation that continuously prevents adhesion of ferromagnetic particles. This continuous action maintains operational efficiency throughout the entire processing cycle without requiring periodic interruptions for maintenance or particle removal.
3Manufacturing precision
If mechanical crushing is repeatedly performed to promote liberation, then iron recovery rate improves, but processing time and energy consumption increase
Solution Approach 1:
The patent replaces repeated mechanical crushing operations with a magnetic field-based separation system. The rotating magnet roll uses magnetic field variations to separate ferromagnetic particles from non-magnetic particles, achieving high iron recovery rates without the time-consuming mechanical crushing processes.
Solution Approach 2:
The patent changes the separation mechanism from mechanical force to magnetic field strength variations. By controlling magnetic field parameters through the rotating magnet roll, the system achieves effective separation and high iron recovery rates without requiring repeated mechanical crushing, thus reducing processing time.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient separation of ferromagnetic particles from thick layers at high processing speeds, reducing adhesion and operational costs, and improving iron recovery rates in steelmaking slag processing.
Implementation Method 1
a rotating magnet roll that changes magnetic field strength and direction
Implementation Method 2
efficient separation of ferromagnetic particles from thick layers
Implementation Method 3
a shield wall that covers a circular arc region of an outer peripheral surface of the guide roll except a circular arc region around which the conveyor belt is wound, to block magnetic lines of force from the magnets
Data Source
Figure 1
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Figure 3A~3D
AI summary
A magnetic separator that can, even in the case where a powdery and/or granular material containing ferromagnetic particles is processed in a large amount or the layer of the supplied powdery and/or granular material is thick, efficiently separate the ferromagnetic particles from the powdery and/or granular material by magnetic separation at low cost without requiring complex processes or liquid waste disposal and also can resolve the adhesion of ferromagnetic particles which is a problem specific to a magnetic separator of belt conveyor type is provided. A magnetic separator comprises: at least one pair of guide rolls; and a conveyor belt that extends between the pair of guide rolls, and conveys a powdery and/or granular material containing ferromagnetic particles, wherein one guide roll of the pair of guide rolls is a hollow roll, and includes, in a hollow part thereof, a magnet roll including a plurality of magnets that are arranged along an inner peripheral surface of the guide roll in lines at intervals so that different magnetic poles alternate in a circumferential direction, and the magnetic separator further comprises a shield wall that covers a circular arc region of an outer peripheral surface of the guide roll except a circular arc region around which the conveyor belt is wound, to block magnetic lines of force from the plurality of magnets.