Three-discs High-intensity Magnetic Separator

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Product Details

Three-Disc Dry High-Intensity Magnetic Separator

The Three-Disc Magnetic Separator (also known as a Dry High-Intensity Magnetic Separator) is a highly specialized and precise mineral sorting machine. It is specifically engineered for the dry separation and purification of complex, weakly magnetic heavy mineral sands. Because it features three independent rotating magnetic discs, it can simultaneously separate up to four different minerals in a single pass.

This equipment is the global standard for processing Ilmenite, Tantalum-Niobium (Coltan), Rare Earth Ores (Monazite), and Tungsten-Tin mixtures. By independently adjusting the excitation current (magnetic field strength) and the physical gap of each disc, operators can dial in the exact magnetic intensity required to extract specific minerals at each stage.

Beyond rare metal concentration, this Dry High Intensity Magnetic Separator is also highly effective for the iron-removal and purification of valuable non-metallic minerals like quartz sand and feldspar.

Industrial three-disc high intensity dry magnetic separator for rare earth minerals

Core Technology & System Features

System Component	Technical Characteristics
Ore Feeding Device	Equipped with a vibrating feeder and screen pretreatment to ensure a thin, uniform, and continuous monolayer of dry ore enters the magnetic field.
Weak Magnetic Drum (Pre-cleaner)	A primary low-intensity drum (0.3-0.5T) located at the feed entrance removes highly magnetic minerals (like magnetite) so they don't clog the downstream high-intensity discs.
Three-Disc System	Features three rotating discs. The magnetic field strength of each disc is independently adjustable from 0.8 Tesla up to 1.5 Tesla (15,000 Gauss).
Electromagnetic Coils	Heavy-duty, oil-cooled electromagnetic coils ensure continuous operation without overheating (temperature rise ≤ 65°C), maintaining stable magnetic intensity.
Electric Control System	PID intelligent regulation (accuracy ±1%) with a silicon rectifier cabinet outputting DC 0-220V. Includes digital current/voltage meters and fault alarms.

How the Three-Disc Magnetic Separator Works

The separation process is a continuous, multi-stage operation. The raw material must be completely dry before feeding.

[Image of three disc magnetic separator working principle showing multi stage magnetic fields]

Pre-Treatment: The dry sand is fed onto a vibrating stainless-steel conveyor trough. It first passes under the weak magnetic drum, which immediately extracts strongly magnetic minerals (e.g., Magnetite).
Primary Disc (Medium Magnetic): The remaining sand travels under the first rotating disc. This disc is usually set to a medium intensity to lift out medium-magnetic minerals (e.g., Ilmenite). The rotating disc carries the mineral out of the magnetic field where it drops into a collection chute.
Secondary & Tertiary Discs (Weak Magnetic): The material continues under the second and third discs, which are set to increasingly higher magnetic intensities (up to 15,000 Gauss). These discs extract weakly magnetic minerals (e.g., Garnet, Monazite, Tantalite).
Non-Magnetic Discharge: Whatever is left on the vibrating trough at the end of the line (e.g., Zircon, Quartz, Cassiterite) falls off the end into the non-magnetic tailings bin.

Dry high intensity magnetic separator control cabinet and electromagnetic coils

Typical Applications

Heavy Mineral Sands (HMS): The ultimate machine for separating complex beach sand concentrates into pure products (Ilmenite, Monazite, Garnet, and Zircon).
Rare Metal Ores: Precise separation of Tantalum-Niobium (Coltan) ores and Tungsten-Tin (Wolframite/Cassiterite) mixtures.
Non-Metallic Purification: Removing trace iron impurities from high-purity quartz sand, feldspar, and kaolin clay for the glass and ceramics industry.

Basic Technical Parameters

Item	Specification Indicator
Processing Capacity	0.5 - 3 t/h (Depending on mineral properties & feed size)
Optimum Feed Size	0.1 - 3 mm (Material must be completely dry)
Pre-cleaner Drum Intensity	0.3 - 0.5 Tesla (3,000 - 5,000 Gauss)
Three-Disc Magnetic Intensity	0.8 - 1.5 Tesla (8,000 - 15,000 Gauss) - Independently Adjustable
Total Power Consumption	Main Machine: 5.5 kW \| Control System: 2.0 kW
Power Supply Requirement	Three-phase 380V ± 10%, 50Hz (Custom voltage available)

Frequently Asked Questions (FAQ)

Q1: Does the ore need to be dry before entering this machine?

A: Yes, absolutely. This is a dry magnetic separator. The raw sand must be dried in a rotary dryer before feeding. If the material is wet, the surface tension of the water will cause the fine particles to stick together, making precise magnetic separation impossible.

Q2: Why is the weak magnetic drum necessary at the feed entrance?

A: If highly magnetic minerals like Magnetite enter the high-intensity magnetic fields (the discs), they will violently snap to the discs, clogging them and potentially damaging the machine. The weak magnetic drum acts as a safety pre-cleaner to extract these strong magnetics first.

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