Magnetic Separator's Wear Problems and Solutions

（Magnetic separator）

Magnetic separator is one of the commonly used mineral processing equipment in concentrators, which can effectively separate magnetic substances from non-magnetic minerals. When separating the ore with high hardness, the magnetic separator often wears out.

If the wear problem is not resolved in time, it may affect the operating efficiency and production efficiency of the equipment. Therefore, it is very important to solve the wear problem of the magnetic separator. The wear of the magnetic separator mainly exists in the two parts of the magnetic separator, the cylinder and the tank. Below we will analyze the wear problems from two aspects and discuss its solutions.

#1. Wear of the Magnetic Separator Tank

The wear of the magnetic separator tank body is mostly like concave piece. The main reason is that there are hard particles or protrusions on the metal surface. After a period of use, the surface material falls off and forms abrasion.

In addition, the surrounding humidity and on-site installation may also cause the magnetic separator tank to wear.

In terms of the characteristics of the equipment itself, in the process of use, the magnetic separator feeds the material for a certain distance, which makes the tank body have a gravitational force point that is easy to wear. Besides, the flow of flushing water also causes the tank body prone to wear.

#2. Wear of the Magnetic Separator Cylinder

The abrasion of the cylinder of the magnetic separator is mainly located in the middle part of the cylinder, which is concave piece similar to the abrasion of the tank.

During operation, the magnetism of the magnetic separator is fixed. Under the action of magnetic stirring, the non-magnetic materials fall off, and the magnetic materials are adsorbed on the surface of the cylinder and follow the rotation of the cylinder. At the edge of the magnetic system where the magnetism is weak, these magnetic materials fall off and are separated by the washing action of the unloading water pipe. This unloading position is subjected to various forces and is prone to wear.

If the cylinder is severely worn and damaged, the ore pulp will enter the magnetic surface of the drum, causing the cylinder and the magnetic system to lock, damaging the bearing and the magnetic system, and even causing the entire magnetic separation equipment to fail to work, seriously affecting normal production.

In view of the abrasion problem of the trough and cylinder of the magnetic separator, wear-resistant treatment is one of the maintenance operations that the magnetic separator must perform. The measures mainly include the following: spraying organic wear-resistant coating, covering rubber coating, covering wear-resistant ceramic Sheets, and covering other polymer wear-resistant materials.

#1. Spraying Organic Wear-Resistant Paint

Spraying organic wear-resistant paint is a common technical method in the wear-resistant treatment process of the tank and cylinder of the magnetic separator. It can be used on curved, inclined, and other tank surfaces. It has a fast curing speed and is not easy to stream down. Besides, this paint generally has high wear resistance.

However, special spraying equipment is required during the spraying process to ensure that the surface of the tank is dry and free of grease; otherwise it will cause damage to the wear-resistant coating.

Its service life is 8-12 months, and it is easy to repair after partial abrasion. It is mainly suitable for wet magnetic separation.

#2. Covering the Rubber Coating

The rubber coating treatment technology has low cost and simple operation. It is also a common method to increase the wear resistance of the tank and cylinder of the magnetic separator. It has the characteristics of simple construction and easy maintenance.

But it will have a certain impact on production efficiency, and partial wears are not easy to repair.

#3. Covering the Wear-Resistant Ceramic Sheet

Wear-resistant ceramic sheets have relatively good wear resistance, high hardness, and at the same time have certain corrosion resistance, long service life, and low density. This material can reduce the equipment load of the magnetic separator. Besides, wear-resistant ceramic sheets also have non-magnetic properties and are suitable for iron ore beneficiation.

However, wear-resistant ceramic sheets are not resistant to impact and are prone to cracks. The ore pulp enters from the cracks will cause the ceramic sheets to fall off.

 #4. Covering the Polymer Wear-Resistant Materials

Polymer wear-resistant materials are mostly wear-resistant alloy materials with strong adhesion, good wear resistance, and easy repair of partial wear.

In addition to the methods of improving the wear resistance of the equipment, in the separation process, reducing the particle size and concentration of the ore pulp, reducing the slurry liquid level, and standardizing the use of flushing water pipes can also reduce the wear problem of the slurry on the magnetic separator, and effectively extending the service life of the magnetic separator.

The above are two common wear problems of magnetic separators and their solutions. In actual production, maintenance personnel of the magnetic separator are required to perform periodic inspections on the magnetic separator. When wear is found, measures should be taken in time to avoid serious wear.

At the same time, when operating the magnetic separator, the operation should be standardized to ensure that the operating efficiency of the magnetic separator is not affected.

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