High Intensity Magnetic Roller Separator

The XPRM High Intensity Magnetic Roller Separator is engineered with a rare-earth, high-gradient magnetic circuit to separate weakly magnetic and paramagnetic particles in dry processing. It is ideal for low-grade iron ores, ilmenite, paramagnetic fractions, glass batch and cullet, abrasives, ceramics, chemical powders, plastics recycling, and electronic waste. The precise magnetic field layout combined with adjustable feed and roller speed systems makes it highly effective for fine particle (micron to sub-millimeter) separation for both online purification and pre-concentration.

Main Selling Points

● Rare-earth high-gradient magnetic circuit up to 15,000 Gs to capture weakly magnetic micro-particles.

● Dry separation — water-free processing reduces operating costs. Permanent magnet option requires no power for magnetic field.

● Modular roller arrangements (1 to multiple layers), roller diameters 4", 6", 9.5" available, roller widths up to 66" (~1676 mm).

● Variable frequency drive, vibrating feeder, and expansion hopper ensure thin-layer uniform feed to improve recovery and stability.

● Full stainless-steel construction; 0.35 mm quick-change belt (replacement in ~5 minutes) for minimal downtime.

Applications

● Mining & mineral processing: low-grade iron ores, fines, ilmenite pre-concentration

● Glass & ceramics: glass batch de-iron, cullet purification, ceramic glaze de-iron

● Chemical & pharmaceutical powders (with hygienic material options)

● Recycling & e-waste: plastics, powder metallurgy scraps, shredded electronic waste

● Metallurgy & powder metallurgy: powder de-iron to protect downstream equipment

Product Advantages

● High purity: optimized for weakly magnetic materials to significantly reduce iron contamination and improve product quality.

● High efficiency: continuous online processing with single-unit capacities up to 12 TPH.

● Low maintenance: permanent magnet versions have low running costs and minimal wear parts.

● Customizable: roller diameter, width, layers, housing material, and control systems can be tailored.

Note: Capacities are indicative and depend on material density, feed thickness, particle size distribution, and roller layers. Magnetic field values are surface peak ranges; higher gradients or electromagnetic options are available upon request. 

Typical recommended ranges / additional specifications

● Typical feed particle size: 20–500 μm (customization possible for finer or coarser ranges)

● Preferred material moisture: dry preferred (moisture < 5%); wet configurations with wash systems can be customized

● Roller speed range: typically 10–120 rpm (adjustable via VFD)

● Reference recovery range: 60%–95% for weakly magnetic materials (varies by material and configuration; recommend sample testing)

● Example overall dimensions (XPRM-800): L ~1800 × W 900 × H 1200 mm (including feeder and frame; subject to configuration)

● Approximate weight: 200–1200 kg (model and layers dependent)

● Standard material: SUS304 stainless steel (optionally SUS316 for food-grade or enhanced corrosion resistance)

● Power supply: 220V/50Hz single-phase or 380V/50Hz three-phase (customizable)

● Standard accessories: vibrating feeder, expansion hopper, 0.35 mm belt, cleaning brush/scraper, VFD control

● Optional: electromagnetic adjustable magnetic source, PLC + HMI touchscreen, automatic discharge grading, onsite installation & commissioning, sample testing report

The XPRM separator forms a high-gradient magnetic field across the separation zone so weakly magnetic particles follow a different parabolic trajectory than non-magnetic particles (trajectory deflection). A thin layer of material passes over the magnetic roller surface: magnetic particles adhere and move with the roller to the discharge point for magnetic product collection, while non-magnetic material falls off to the non-magnetic discharge. Adjustable roller speed (via VFD), multiple roller layers, and customizable spacing enable tuning of recovery and grade.

Key components:

● Magnetic system: NdFeB rare-earth permanent magnets (standard). Electromagnetic options available for adjustable field strength.

● Roller surface: wear-resistant coating or stainless steel cover.

● Frame & housing: SUS304 stainless steel standard; SUS316 or special coatings optional.

● Belt: 0.35 mm wear belt, quick-release for fast replacement.

FAQ

Q1: Is XPRM suitable for wet or dry materials?

A1: XPRM is standardly a dry high-intensity magnetic roller, optimized for low-moisture powders. Wet processing or wash/dewatering systems can be provided as custom solutions (often electromagnetic wet variants).

Q2: What particle sizes can be processed?

A2: Standard best performance is for 20–500 μm. For ultra-fine (sub-micron) materials, lab sample tests and potentially multi-layer high-gradient configurations are recommended.

Q3: How to choose between permanent magnet and electromagnetic options?

A3: Permanent magnet (rare-earth) provides low operating cost and minimal maintenance. Electromagnetic systems allow adjustable magnetic strength for variable feed conditions and development/testing purposes. Hybrid/custom solutions are also possible.

Q4: Typical recovery rate?

A4: Recovery depends on magnetic susceptibility, particle size, feed condition, and operational settings. Typical ranges: 60%–95%. We recommend sending samples for accurate evaluation.

● Glass recycling plant — XPRM-900: Reduced iron content in glass batch from 0.12% to 0.02% after dry magnetic separation, improving product whiteness and lowering downstream processing issues.

● Ceramic glaze supplier — XPRM-800: Pre-treatment of glaze powders reduced defect rates by ~30%, improving final product consistency and brightness.

After-sales Service & Technical Support

● Sample testing and performance evaluation reports (free or paid depending on testing scope).

● Onsite installation, commissioning, and operator training included.

● Standard 12-month warranty (consumables excluded); lifetime technical support and spare parts supply.

● OEM/ODM customization services: food-grade materials, enclosed/dust-proof configurations, remote monitoring, and automatic cleaning systems.