Magnetic separators: where to install to increase separation efficiency?

The efficiency of a magnetic separator does not depend solely on the strength of the equipment. The position in which it is installed, the distance in relation to the material and the flow characteristics also directly affect the separation performance.

In industrial lines that transport materials via belts, vibrating feeders or other systems, correctly choosing the installation point helps to increase the capture capacity of ferrous impurities and contributes to the protection of equipment present in the following stages of the process.

Why is the installation point so important?

Magnetic separators work by attracting ferrous materials present in a non-magnetic product stream.

According to ITAL, this equipment can be installed externally to the conveyor, capturing ferrous materials that pass over or under the separator, without requiring major changes to the existing system.

However, for this attraction to happen efficiently, it is necessary to consider how the material is distributed and what is the distance between the contaminant and the magnetic field.

The greater this distance or the layer of material transported, the greater the difficulty may be in reaching the ferrous particles present in the deeper regions of the flow.

What should be evaluated before installation?

There is no single position that works for all production lines.

Some factors need to be analyzed before defining the equipment and installing it.

Type of material transported

Particle size, density and behavior of the product during transport directly influence the choice of magnetic system.

A light, low-particle material presents different conditions than in an operation that moves large volumes or denser materials.

Amount of material

The line capacity also needs to be included in the sizing.

Information such as production in tons per hour or cubic meters per hour helps define the size and characteristics of the separator needed for that operation.

Flow peaks must also be considered.

Size of contaminants

Another important point is to understand which ferrous materials need to be removed.

Screws, nuts and larger pieces of iron have different characteristics of very small particles, rust or micro-residues.

ITAL works with different magnetic technologies precisely because each type of contaminant requires an appropriate solution.

Distance between separator and material

Distance is one of the most important factors in any magnetic application.

The separator must be positioned so that its field adequately reaches the ferrous material present in the flow.

When there is a very high layer of product on the belt, for example, contaminants present at the bottom can be further away from the equipment.

So just using a high-intensity separator doesn't necessarily solve the problem.

It is necessary to combine magnetic intensity, depth of field, working distance and material characteristics.

Installation on belts and conveyors

Magnetic separators are widely used in material transport systems.

In these applications, they can be installed suspended and work continuously while the product moves down the line.

This type of configuration allows you to remove ferrous materials without interrupting the production flow.

The choice between manual or automatic cleaning systems must also consider the amount of contaminants captured and the frequency required to remove these materials.

In operations with a higher volume of contamination, automatic systems can contribute to the continuity of production.

Installation at other points in the process

Not every operation uses only conveyor belts.

Depending on the process, magnetic equipment can also act on:

• vibrating feeders;
• pipes;
• ducts;
• gutters;
• silos;
• mills;
• points of material drop.

In some situations, more than one separation point may be needed along the line.

The objective is to identify where the contaminant poses the greatest risk or where there are better conditions for its removal.

A common mistake: choosing equipment before analyzing the process

A magnetic separator should not be specified by size or magnetic strength alone.

Before choosing, it is important to understand the entire process:

• which material will be treated;
• what is the granulometry;
• what is the density;
• what is the volume processed;
• what contaminants need to be removed;
• what is the distance available for installation;
• what is the speed of transport;
• how the equipment will be cleaned.

This information allows you to design a more appropriate solution and avoid installing equipment that cannot achieve the expected performance.

Each process requires specific analysis

ITAL develops standard magnetic separators and also custom-made equipment, according to the characteristics of each industrial application.

This happens because factors such as volume, distance, temperature, type of contaminant and line configuration can vary significantly from one operation to another.

Therefore, correct installation begins even before assembling the equipment: it starts with understanding the process.

Sizing and installation go hand in hand

A well-sized separator, but installed in an inappropriate position, may not deliver its full potential.

Similarly, choosing a good installation point without considering the necessary magnetic characteristics can also limit separation efficiency.

Evaluating the process as a whole is the way to obtain more efficient operation, reduce the presence of ferrous contaminants and protect the equipment present in the line.

ITAL develops magnetic and electromagnetic solutions for different industrial applications, considering the specific characteristics of each process.

Need to define the best separator and installation point for your operation? Speak to the ITAL technical team.