MAGNETIC SEPERATOR MACHINE

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ABSTRACT

The magnetic separator plays a role in improving the grade of ore, purifying solid
and liquid materials, and recycling waste. With the application and development of
magnetic separation technology, magnetic separation equipment is constantly
updating and replacing, and dry magnetic separation has experienced remarkable
technological progress over the past twenty years. There are many new ideas and
techniques applied in magnetic separators. So far, dry magnetic separators have
developed many different applications for mineral and coal processing, for induction
roller magnetic separators for chromite. Cross-belt magnetic separator for removing
harmful magnetic particles and paramagnetic particles. The lifting roller magnetic
separator is used in the heavy mineral industry to separate garnet from monazite and
rutile . Rare earth drum magnetic separator for fine feed dry magnetic separation
sorting process and rare earth roller magnetic separator for zircon and rutile in heavy
mineral sand industry. These magnetic separators have different

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 INDEX

Contents Pg. No.

Acknowledgements
Abstract
Chapter - 1

Chapter - 2

Chapter - 3

Chapter – 4

Chapter -5
Chapter -6
Chapter -7

Chapter -8

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 LIST OF FIGURES

FIG.NO DESCRIPTION

Fig .3.1 Introduction of Industry Define Problem

Fig.3.1.1 Conveyor Head Roller

Fig.3.1.2 Rods

Fig.3.1.3 Sampling Probe

Fig.3.1.4 Circular Grid

Fig.3.1.5 Square Grid

Fig.3.1.6 Sieve Magnet

Fig.3.1.7 Easy-Clean Grid Magnets

Fig.3.1.8 Strip Magnet

Fig.3.1.9 Hinged Strip Magnet

Fig.3.1.10 Underflow Magnet

Fig.3.1.11 Easy-Clean Single Row Grid Magnet

Fig.3.1.12 Easy-Clean Double Row Grid Magnet

Fig.3.1.13 Auto shuttle:Self-Cleaning Grid

Fig.3.1.14 Pneumag

Fig.3.1.15 Rota-Grid

Fig.3.1.16 Auto-Rota Shuttle:Self-Cleaning Rota-Grid

Fig.3.1.17 Bullet Magnet

Fig.3.1.18 Chute Magnet

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Fig.3.1.19 Liquid Filter

Fig.3.1.20 Magnetic Drum

Fig.3.1.21 Housed Drum

Fig.3.1.22 Plate Magnet

Fig.3.1.23 Over Band

Fig.4.3.1 Roller Type Magnetic Separator

Fig.4.1 Conveyor Belt

Fig.4.2 Magnetic Roller

Fig.4.3 Roller

Fig.4.7 Roller Bearing

Fig.4.8 DC Motor

Fig.4.10 Transformer

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1.INTRODUCTION

Selecting the proper magnetic separator requires an understanding of magnetic

properties, the process application and environmental elements that exist in each
specific installation. This guide provides a basic understanding of how to choose the
proper magnetic separator for different process requirements. Head roll magnets are
available in various magnetic strengths. A head roll magnet is mounted as a drive
roller in a conveyor belt. Next, it will attract iron particles present in the product and
deflect these to the bottom of the belt. There, the iron particles will be released from
the magnetic field and collected in a funnel or a slide plate. Over belt magnets can be
mounted both in line with and across the conveyor belt. All magnets have a short
weakening pole at the end of the main pole, in order to promote releasing of iron
particles.

A magnetic head roll is regularly used as a second deionization step in

combination with overhead magnets, in order to realize a finer separation after the first
separation of coarse steel particles. In this way, the head roll magnet will increase
effectiveness. Head roll magnets are available in various magnetic strengths. A head
roll magnet is mounted as a drive roller in a conveyor belt. Next, it will attract iron
particles present in the product and deflect these to the bottom of the belt. There, the
iron particles will be released from the magnetic field and collected in a funnel or a
slide plate. Over belt magnets can be mounted both in line with and across the
conveyor belt. All magnets have a short weakening pole at the end of the main pole, in
order to promote releasing of iron particles. The magnetic field will become steadily
weaker, as a result of which iron particles will be released easier and are less likely to
return to the magnetic pole.

CHAPTER-2
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2. INDUSTRY DEFINE PROBLEM

The main object of the project is manufacturing of magnetic separator which

can be able to sort ferrous and non ferrous metal.

Fig. 2.1 principle of operation

Below given fig. can show the principle of operation. Magnetic separator is
pinned inside the solenoid coil, placed with a certain number-magnetic stainless steel
wool (or metal mesh) sorting cans, coil excitation, the magnetization of the magnetic
stainless steel wool, the surface height uneven the magnetization of the magnetic field,
i.e. a high gradient magnetic field, paramagnetic materials through the steel wool in
the separation tank, will be a product of the applied magnetic field and the magnetic
field gradient is proportional to the magnetic force, adsorbed on the surface of the
steel wool, rather than the magnetic material directly via magnetic valves and pipes,
through a non-magnetic material, to flow into the non magnetic product tank. When
steel wool collector’s weakly magnetic material reaches a certain level (calling for a
decision by the process), stop to the mining. Disconnect the excitation power washing
the magnetic material, magnetic material magnetic material valves and piping, inflow
of magnetic products slot. Then a second job, and so on, again and again.

In the recent past the problem of removing the deleterious iron particles from a
process stream had a few alternatives. Magnetic separation was typically limited and
moderately effective. Magnetic separators that used permanent magnets could
generate fields of low intensity only. These worked well in removing ferrous tramp
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but not fine paramagnetic particles. Thus high intensity magnetic separators that were
effective in collecting paramagnetic particles came into existence. These focus on the
separation of very fine particles that are paramagnetic.

The current is passed through the coil, which creates a magnetic field, which
magnetizes the expanded steel matrix ring. The matrix material being paramagnetic
behaves like a magnet in the magnetic field and thereby attracts the fines. The ring is
rinsed when it is in the magnetic field and all the non-magnetic particles are carried
with the rinse water. Next as the ring leaves the magnetic zone the ring is flushed and
a vacuum of about – 0.3 bars is applied to remove the magnetic particles attached to
the matrix ring.

CHAPTER-3

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3.DETAIL DESCRIPTION OF IDP

Magnetic separator is one of the most widely used in the aircraft industry, high
versatility, is suitable for the powder particle removal of iron powder. Magnetic
separator is widely used for resource recycling timber industry, mining, ceramics,
chemical, food and other plants in. The magnetic separator is suitable for particle size
below 3mm Manganese mine, Magnetite, Pyrrhotite Ore, roasting, Ilmenite Other
materials wet or dry magnetic separation, but also for Coal, non Metal ore, Building
material In addition to iron and other materials. Magnetic separator The magnetic
system, use of high quality ferrite materials or with Rare earth Magnetic Compound
and into, before the drum table average The magnetic induction intensity For 800-
4000mT. With the development of technology, magnetic separator can be made into a
roller shape, the strength of the magnetic field is increased to 8000mT is already
present in the measured maximum field strength.

The use of magnetic fields for separation purposes is an old stuff. Its working
principle is remarkably simple: it relies on the fact that materials with different
magnetic moments experience different forces in the presence of a magnetic field
gradient. It’s usually accepted that the magnetic separation was born in 1792, when
William Fullerton filled the first patent about its use in iron manufacturing. The earlier
application is dated 1852 and was located in New

York: its aim was the separation of magnetite from apatite. Following this first
application a huge number of industries involved in metal transformations adopted
some kind of magnetic separator. Consequently a large amount of patents has been
filled on that topic, both in Europe and in the USA.

After Heike Kamerlingh Onnes discovered superconductivity in 1911 an

intense work in this field led, in 1962, to the first commercially available
superconducting magnets. That meant the availability of large magnetic fields (more
than 1T) over tents of cubic decimeters: the High Gradient Magnetic Separation

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(HGMS) was born. The HGMS is identical, in its working principles, to the traditional
magnetic separation, but it takes advantage of a much greater gradient (104T/m are
usually achieved). The gradient is usually enhanced by a special porous bed, located
inside the magnetic field source, typically made with ferromagnetic material, such as
spheres, rods, plates, wires or wool. Inside the packet bed the material that is going to
be separated impacts the ferromagnetic material and is retained. This strong
interaction means that also paramagnetic and even diamagnetic particles could be
separated from flow streams. HGMS resulted faster and reliable if compared to
traditional motion techniques so that it is a critical technique in industrial plant where
ferrous material is managed. More recently magnetic separation have become
commonplace in biotechnology where it is used for both protein purification and flow
cytometry. Indeed, in biology, the need for magnetic beads that are coated so as to
bind particular components arises. Commercial sources for magnetic beads have
grown substantially in the past decades and a wide variety of substances may
nowadays be selectively removed. The high working rate and selectivity are peculiar
of HGMS as well as the lack of high pressure drop encountered by the stream in
comparison to the ones involved in traditional separation. Moreover HGMS filters are
usually smaller and safer. For these reasons HGMS has been intensely studied in the
last decades leading to a large improvement mostly on the experimental side. Despite
all, a wide lack of knowledge still persists. This is mainly due to the intrinsic
complexity of the system: on one side there is the whole filter seen as a big device and
on the other side there are the pollutant particles moving on a scale in which only an
unknown and chaotic small system is involved.

3.1 TYPES OF MAGNETIC SEPARATORS

3.1.1 Conveyor Head Roller

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 Fig. 3.1.1 Conveyor Head Roller

Installed at the outlet of the conveyor, the head roller removes tramp iron and
small steel parts that cannot be extracted with over band or strip magnets placed above
the product. It should be used in conjunction with these units for the fullest protection.
Available in two strengths: standard, for removing large pieces of steel and high
power, for removing large and small parts. The shaft of the roller can be machined for
easy installation on existing bearings.

3.1.2 Rods

Fig. 3.1.2 Rods

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 High-intensity rare-earth magnetic rods are highly effective at removing
ferrous contaminants from free-flowing products, sugar, grain, tea, plastic granules,
chemical powders or liquids. These bars are ideal for technicians wishing to design
and build their own magnetic separators.

3.1.3 Sampling Probe

Fig. 3.1.3 Sampling Probe

The sampling probe enables quality control personnel to quickly and easily
inspect powders, pellets and liquids for contamination. These probes are used for
inspection of product on arrival at goods inwards, before final shipping and at key
stages of processing.

3.1.4 Circular Grid

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 Fig. 3.1.4 Circular Grid

Grid magnets are extremely efficient at removing ferrous contaminants from

the flow of dry goods such as sugar, grain, tea, plastic pellets and chemicals powders.
Circular grids are easily installed in hoppers, silo entry points and the exit point of
finished product. Grids can be quickly installed to provide effective protection against
contaminants such as rust particles and stainless steel, resulting from mechanical wear
of processing machinery. These particles are often too small to be detected by a metal
detector but can be easily removed by Eclipse Magnetics magnetic grids.

3.1.5 Square Grid

Fig. 3.1.5 Square Grid

Grid magnets are extremely efficient at removing ferrous contaminants from

the flow of dry goods such as sugar, grain, tea, plastic pellets and chemicals powders.
Grids are easily installed in hoppers, silo entry points and the exit point of finished

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product. Grids provide effective protection against contaminants such as rust particles
and stainless steel resulting from mechanical wear of processing machinery. These
particles are often too small to be detected by a metal detector but are easily removed
by Eclipse Magnetics magnetic grids

3.1.6 Sieve Magnet

Fig. 3.1.6 Sieve Magnet

Sieve magnet is specially designed for use in vibrationary sieving machines.

Our sieve magnets are lightweight, reducing the stress on the seal. The magnet is
positioned below the screen for total security; the strong magnetic field is capable of
attracting particles less than a micron in size. High-intensity grid magnets that can be
cleaned in seconds. Simply release the locking mechanism, remove the magnetic
cores from their stainless steel housings and the contaminants fall away. Replace the
magnetic cores in their housings and the grid is again ready for use. The process
takes less than 30 seconds. Easy-clean grid magnets are extremely effective at
removing ferrous contaminants. Install where stoppage time has to be kept to a
minimum.

3.1.7 Easy-Clean Grid Magnets

Fig.3.1.7 Easy-Clean Grid Magnets

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 High-intensity grid magnets that can be cleaned in seconds. Simply release the
locking mechanism, remove the magnetic cores from their stainless steel housings and
the contaminants fall away. Replace the magnetic cores in their housings and the grid
is again ready for use. The process takes less than 30 seconds. Easy-clean grid
magnets are extremely effective at removing ferrous contaminants. Install where
stoppage time has to be kept to a minimum.

3.1.8 Strip Magnet

Fig. 3.1.8 Strip Magnet

Strip magnets are very versatile. They can be placed above conveyors, at chute
exits or at final product release points. Rare earth magnets are fully protected by
stainless steel cladding, allowing use in wet environments. A magnetic field is
generated on one face and attracting contaminants as they pass through. To optimize
performance, magnets above conveyors must be placed as close as possible to the belt.
Depth of field is 80 mm.

3.1.9 Hinged Strip Magnet

Fig. 3.1.9 Hinged Strip Magnet

Hinged strip magnet is designed to be installed above conveyor belts to remove

ferrous contaminants from a wide range of products. High intensity rare earth magnet
material is enclosed in stainless steel. A hinged cleaning plate covers the face of the
magnet. The face emits a powerful magnetic field that attracts ferrous contaminants.

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3.1.10 Underflow Magnet

Fig. 3.1.10 Underflow Magnet

‘Primary’ magnet which is positioned at the angle of chutes. Designed to

remove large contaminates such as nuts, bolts and washers etc., which could enter the
process line and damage machinery, resulting in significant repair costs. The magnet
is provided with a hinge and locking clasps with hook for easy installation. Ideal for
removing ferrous and Para-magnetic contaminants in a variety of free-fl owing
products such as sugar, grain, tea, plastic granules and chemical powders. The housing
is available with a rectangular or circular flange, to customer specifications, for easy
installation. Cleaning is exactly the same as for the Easy-clean grid. For even more
effective contamination removal, or for processes with a high level of contamination,
a double row unit is available.

3.1.11 Easy-Clean Single Row Grid Magnet

Fig. 3.1.11 Easy-Clean Single Row Grid Magnet

All the same benefits as the single row Easy-clean grid magnet but holds more
contamination and can therefore go longer between cleans. Ideal for removing ferrous
and paramagnetic contaminants in a variety of free-flowing products such as sugar,

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grain, tea, plastic granules and chemical powders. The housing is available with a
rectangular or circular flange, to customer specifications, for easy installation.
Cleaning is exactly the same as for the Easy-clean grid.

3.1.12 Easy-Clean Double Row Grid Magnet

3.1.12 easy-Clean Double Row Grid Magnet

Developed to work continuously without manual intervention. The cleaning of

the magnetic rods is done automatically without stopping the flow of product. PLC
controlled. Ideal for ATEX environments. Application, performance and benefits are
identical to the Easy-clean grid. Available in single row, double row and multiple row
versions, as required by your application.

3.1.13 Auto-Shuttle: Self-Cleaning Grid

Fig.3.1.13 Auto-Shuttle: Self-Cleaning Grid

Developed to work continuously without manual intervention. The cleaning of

the magnetic rods is done automatically without stopping the flow of product. PLC
controlled. Ideal for ATEX environments. Application, performance and benefits are
identical to the Easy-clean grid. Available in single row, double row and multiple row
versions, as required by your application

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3.1.14 Pneumag

Fig. 3.1.14 Pneumag

High intensity magnetic separator for use in pneumatic conveying lines. The
Pneumag removes ferrous and Para-magnetic contaminants from free-flowing
powders conveyed at speeds of up to 25m/s. It purifies the transported product and
reduces the risk of spark or piercing of filter sleeves. It is designed not to affect
product flow. It incorporates an Easy-clean magnetic grid and quick release closures
so it can be cleaned very quickly.

3.1.15 Rota-Grid

Fig. 3.1.15 Rota-Grid

Primarily designed to extract contaminants from high humidity products, such

as starch, which are liable to ‘cake’ or ‘bridge’. The rods are arranged in a circle
which rotates, gently agitating the product and maintaining flow. The magnetic
surfaces of the rods come into contact with more product than those of a fixed grid,
meaning the Rotagrid can be used where extremely efficient contamination removal is

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required. The housing is available with rectangular or circular flanges. Cleaning works
on the same principle as the Easy-clean.

3.1.16 Auto-Rota Shuttle: Self-Cleaning Rota-Grid

Fig.3.1.16 Auto-Rota Shuttle: Self-Cleaning Rota-Grid

Combines the advantages of the Rota-grid with the continuous operation of the
Auto-shuttle. It is also well suited to ATEX environments.

3.1.17 Bullet Magnet

Fig.3.1.17 Bullet Magne

Housed bullet magnets remove ferrous elements, especially nuts, bolts,

washers, staples, etc., from pneumatic feed and conventional supply lines. Usually
installed where ingredients enter the line as well as at the first processing stage. The
unit is designed to prevent ferrous items damaging equipment expensive equipment

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such as grinders, mixers and screw conveyors. A ‘bullet’ magnet is mounted in the
centre of a casing of stainless steel. The magnetic element is designed to not affect
product flow.

3.1.18 Chute Magnet

Fig. 3.1.18 Chute Magnet

‘Primary’ separator usually installed in gravity pipes and chutes to remove

larger items such as nuts, bolts and washers, preventing damage to process machinery.
With this unit there is virtually no reduction in product flow rate.

3.1.19 Liquid Filter

Fig. 3.1.19 Liquid Filter

Designed to remove contaminants from liquids and syrups. The high intensity
neodymium magnet rods are contained in an Easy-clean assembly. The rod
configuration guarantees maximum exposure of contaminants to the magnetic field
without impeding flow. Filters are available in two versions: single wall or insulated.
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Insulated filters are used for applications where high line temperature is essential to
maintain the viscosity of the product e.g. chocolate, syrups, jams, sauces. Both
versions are tested and certified with a maximum pressure of 6 bar standard. A 20 bar
maximum pressure version is available on request.

3.1.20 Magnetic Drum

Fig. 3.1.20 Magnetic Drum

Magnetic drums remove ferrous contaminants and tramp iron from bulk
materials used in processing food, chemicals, minerals and other products. The drums
are mounted at the outlet of the carrier or directly above a vibrationary feed. High
intensity rare earth magnets are mounted in a wear resistant stainless steel drum. The
shell of the drum is supported by high-quality sealed bearings that provide reliable and
smooth rotation around the magnetic element.

3.1.21 Housed Drum

Fig. 3.1.21 Housed Drum

Magnetic drum protected by a robust stainless steel casing, flanged to customer

specification. Designed for the continuous removal of tramp iron and fine iron
particles in dry bulk materials used in food, chemical, mineral and other processes.
The shell of the drum is supported by high-quality sealed bearings that provide

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reliable and smooth rotation around the magnetic element. The drum is powered by a
high quality geared motor block with single or three phase power.

3.1.22 Plate Magnet

Fig.3.1.22 Plate Magnet

Positioned above conveyors to prevent foreign bodies being introduced to

grinders, screws and other valuable tools. These magnets generate a strong magnetic
field that penetrates deep into transported product to extract metal contaminants. Can
be used in harsh environments, humidities and temperatures. The magnet has five
stainless steel sides and a painted steel plate with attachment points for attaching
suspension chains.

3.1.23 Overband

Fig. 3.1.23 Overband

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 Widely used in the recycling, quarrying and heavy industries where it is placed
over a conveyor plate to continuously extract metal contaminants from bulk products.
The large permanent magnet generates a strong magnetic field that pulls ferrous
contaminants from the conveyor. A rubber belt is drawn continuously between two
rollers and around the magnet pack. The contaminant is attracted to the magnet then
carried on the belt to be released into a hopper can be supplied with electric or
hydraulic drive for mobile machines.

3.2 CLASSIFICATION

 In accordance with the magnet species can be divided into:

permanent magnetic separator
Electromagnetic Removing iron machine

 According to mine classification can be divided into:

dry and wet to dry iron removing machine,
wet iron remover

 According to the classification of magnetic system can be divided into:

Drum type magnetic separator Machine,
roll type magnetic separator machine
roller type magnetic separator machine.

 According to the number of magnetic system classification can be divided into:

single drum magnetic separator,
magnetic separator with double cylinder
multi cylinder magnetic separator.

 According to mine classification can be divided into:

the upper to lower to mine ore separator,
magnetic separator.

 According to the strength of the magnetic field classification can be divided

into:
weak magnetic separator,
magnetic separator
magnetic separator.

 According to the classification of magnetic system can be divided into:

open type magnetic separator,
closed magnetic circuit magnetic separator.

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  Wet Permanent magnetic drum separator is Iron ore A magnetic separator
plants commonly used, it is applicable to choose don't strong magnetic
minerals.

 According to the different structure types of body, magnetic separator consists

of concurrent flow, countercurrent, half counter current type three. Three kinds
of magnetic separator with different groove type inclusion size as follows:
downstream trough ≤ 6mm
countercurrent trough, ≤ 1.5mm
semi countercurrent trough ≤ 0.5mm.

 The downstream separator processing capacity, rough election and selection of

magnetic materials suitable for coarse grain, can also be multiple serial work.
The downstream separator when given a large quantity of ore, magnetic
mineral grains easily lost in Tailings Therefore, to strengthen the operation
management, low control Pulp Level.

 Countercurrent magnetic separator is suitable for Fine Strong magnetic

minerals of roughing and scavenging operation, high recovery rate, but
concentrate grade is low. Because of the coarse material deposited blockage
choose don't space, so the countercurrent magnetic separator is not suitable for
the processing of coarse material.

 Semi countercurrent magnetic separator can obtain high quality iron ore
concentrate, but also can get better recovery rate, so the semi countercurrent
magnetic separator is widely used in production practice. It is suitable for
processing 0.5mm ore roughers to use gravity-flotation and select, also can
have multiple series and parallel, multiple scan and pick.

3.3 FEATURES

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 Magnetic separator the whole device by magnetic separation machine (host),
coil cooling system, rectifier power supply, pneumatic control systems and machine
electrical control system composed of five parts. The host includes a magnet (coil,
outsourcing iron yoke), equipped with a magnetic medium and the support structure of
the sorting box, the distribution system of the feed stream. Coil cooling system
comprises a cooling water distribution pipe, the internal cooling and the external
cooling circuit system and the heat exchanger, etc. including dry type rectifier,
transformer rectifier and power thyristor rectifier cabinet. The gas control system
including gas control valve, pneumatic control cabinets and air compressor. The
control system includes a manual and automatic operation control system, cooling
system, overvoltage, loss of pressure and overheating protection devices, peripherals
interlock operation and fault alarm and automatic shutdown system.

Fig3.3.1 Roller Type Magnetic Separator

CHAPTER-4

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4 HARDWARE USED

4.1 Conveyor Belt

A belt conveyor consists of an endless belt of a resilient material connected

between two pulleys and moved by rotating one of the pulleys through a
drive unit gearbox, which is connected to an electric motor. The driving pulley
end is called as head

Fig. 4.1 conveyor Belt

end, and the pulley is called as head pulley. Conversely, the other pulley is
at the tail end and is referred to as the tail pulley as shown in figure.

Material is conveyed by placing it on the belt, through a feeder. As the

belt rotates, the material is carried with it on the other end, where it is then
dropped in the discharge chute. It should be noted that discharge can be arranged
at any point along the run by means of special discharge devices.

As the belt rotates, due to the weight of the belt and the conveyed material,
the belt will sag. To support this sag, rollers called as idlers or idler pulleys are
placed on both sides (carrying side and the return side). Closely spaced idlers are placed
at the loading point, as there is some impact due to the falling material and
overcrowding of the material in this regio

4.2 Magnetic Roller

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 Fig.4.2 Magnetic Roller

Magnetic separators that used permanent magnet rolls could generate fields
of low intensity only. These worked well in removing ferrous tramp but not fine
paramagnetic particles. Thus high intensity magnetic separators that were effective
in collecting paramagnetic particles came into existence. These focus on the
separation of very fine particles that are paramagnetic. The current is passed through
the coil, which creates a magnetic field, which magnetizes the expanded steel matrix
ring. The matrix material being paramagnetic behaves like a magnet in the magnetic
field and thereby attracts the fines. The ring is rinsed when it is in the magnetic field
and all the non-magnetic particles are carried with the rinse water. Next as the ring
leaves the magnetic zone the ring is flushed and a vacuum of about – 0.3 bars is
applied to remove the magnetic particles attached to the matrix ring.

Permanent magnetic pulleys are important magnetic products which are used as
head pulleys in belt conveyors for removing ferrous contaminants from material flow.
The magnetic field generated by the pulley attracts the ferrous fines which are held to
the belt until it reaches the underside. After passing out of the magnetic field the
ferrous material is collected separately into a chute or bin. The cleaned material is
discharged normally over the pulley in a vertical drop.

4.3 Roller

Gravity conveyors are used as a level push line or down grade by utilizing the
natural force of gravity. The use of gravity to convey the selected class of packages to
move by their own weight, on a bed of rollers or wheels, is, perhaps, the most widely
used means for conveying in industry. The weights to be conveyed may vary from a
few ounces to several tons.

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 Fig. 4.3 Roller

For example, in department stores, conveyors are used for handling light
weight boxes of hosiery and the same conveyors handle heavier boxes of dishes and
appliances.

4.4 Roller Construction

Thin wall rollers are perfectly satisfactory for most package handling, but
should not be used for handling extremely heavy packages with steel strapping or
filled steel drums regardless of the indicated roller capacity. Thin wall rollers may be
easily bent, dented or cut, thus impairing their usefulness.

4.5 Live Roller Conveyor

A series of rollers over which objects are moved by the application of power to
all or some of the rollers. The power-transmitting medium is usually belting or chain.

A round part free to revolve about its outer surface. The face may be straight,
tapered or crowned. Rollers may also serve as the rolling support for the load being
conveyed.

4.6 Roller Bed

A series of rollers used to support a conveying medium.

4.7 Bearing

A machine part in or on which a shaft, axle, pin or other part rotates.

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 Fig.4.7Roller Bearing

A bearing is a machine element that constrains relative motion between moving

parts to only the desired motion. The design of the bearing may, for example, provide
for free linear movement of the moving part or for free rotation around a fixed axis;
or, it may prevent a motion by controlling the vectors of normal forces that bear on the
moving parts. Many bearings also facilitate the desired motion as much as possible,
such as by minimizing friction. Bearings are classified broadly according to the type
of operation, the motions allowed, or to the directions of the loads (forces) applied to
the parts.

The term "bearing" is derived from the verb "to bear" a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings
are bearing surfaces, cut or formed into a part, with varying degrees of control over
the form, size, roughness and location of the surface. Other bearings are separate
devices installed into a machine or machine part. The most sophisticated bearings for
the most demanding applications are very precise devices; their manufacture requires
some of the highest standards of current technology.

 There are at least 6 common principles of operation:

 plain bearing, also known by the specific styles: bushing, journal bearing,
sleeve bearing, rifle bearing
 rolling-element bearing such as ball bearings and roller bearings
 jewel bearing, in which the load is carried by rolling the axle slightly off-center

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  fluid bearing, in which the load is carried by a gas or liquid
 magnetic bearing, in which the load is carried by a magnetic field
 Flexure bearing, in which the motion is supported by a load element which
bends.

4.8 Dc Motor

Dc motor is an electric motor converts electrical energy into mechanical

motion. The reverse task that of converting mechanical motion into electrical energy,
is accomplished by a generator or dynamo. In many cases the two devices are
identical except for their application and minor construction details. DC motors are
used when there is positioning requirement and also changes in load and torque. DC
motors can be conveniently interfaced to Bipolar DAC, or MPUs can generate PWMs
to control them.

The classic DC motor has a rotating ligature in the form of an electromagnet. A

rotary switch called a commentator reverses the direction of the electric current twice
every cycle, to flow through the armature so that the poles of the electromagnet push
and against the permanent magnets on the outside of the motor. As the poles of the
armature electromagnet pass the poles of the permanent magnets, the commentator
reverses the polarity of the armature electromagnet. During that instant of switching
polarity, inertia keeps the classical motor going in the proper direction. (See the
diagrams below.)

A simple DC electric motor. When the coil is powered, a magnetic field is

generated around the armature. The left side of the armature is pushed away from the
left magnet and drawn toward the right, causing rotation.

The armature continues to rotate.

Fig.4.8 Dc Motor

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 When the armature becomes horizontally aligned, the commutator reverses the
direction of current through the coil, reversing the magnetic field. The process then
repeats Wound field DC motor

The permanent magnets on the outside (stator) of a DC motor may be replaced

by electromagnets. By varying the field current it is possible to alter the speed/torque
ratio the motor. Typically the field winding will be placed in series (series wound)
with the armature winding to get a high torque low speed motor, in parallel (shunt
wound) the armature to get a high speed low torque motor, or to have a winding partly
in parallel, and partly in series (compound wound) for a balance that gives steady
speed over a range of loads. Further reductions in field current are possible to gain
even higher speed but correspondingly lower torque, called "weak field" operation.

4.9 Shaft

We are using aluminium shaft in roller.

Alignment Needle Roller with Inner Ring: Alignment type needle roller
bearings have a convex outside surface which is located in a plastic seating ring with a
concaved inner face to match that of the bearing which is located in a drawn sheet
steel outer ring allowing for some degree of self alignment.

Benefits: Supplied with the inner ring, tolerates misalignment.

4.10 Transformer

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 Fig.4.10 Transformer

A transformer is a device that transfers electrical energy from one circuit to

another through inductively coupled electrical conductors. A changing current in the
first circuit (the primary) creates a changing magnetic field; in turn, this magnetic field
induces a changing voltage in the second circuit (the secondary). By adding a load to
the secondary circuit, one can make current flow in the transformer, thus transferring
energy from one circuit to the other. It is the phenomenon of mutual induction.

The secondary induced voltage VS, of an ideal transformer, is scaled from the
primary VP by a factor equal to the ratio of the number of turns of wire in their
respective windings:

 Transformers are of two types:

 Step up transformer

 Step down transformer

In power supply we use step down transformer. We apply 220V AC on

the primary of step down transformer. This transformer steps down this voltage
to 12V AC. We give this 12 V AC to rectifier circuit, which convert it to 5V
DC.

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4.11 PERFORMANCE AND CHARACTERISTICS

Necessary Condition

The magnetic particles in the magnetic, except by the magnetic effect, but also
by the competitions effect. Competitiveness can be defined for all mechanical force
opposite magnetic direction, including gravity, centrifugal force, inertial force and the
hydrodynamic resistance etc.. In the magnetic separation process, Magnetic is
collecting magnetic particle force, also known as the force of magnetic trap;
Competitiveness the magnetic particles from the magnetic force, also known as the
detachment force. Obviously, the necessary conditions of magnetic particles and the
non magnetic particle separation by the magnetic particles larger than the competition.
If you want to make two kinds of magnetic particles from different, it is a necessary
condition for the magnetic particles, magnetic strong competitiveness should be larger
than the weak magnetic particles, magnetic force should be less than the competition.
To illustrate, absolutely pure magnetic products and non magnetic products is not
possible in the magnetic separation in practice, in addition to the product purity
intergrowth relationship does not monomer dissociation, the number of single
magnetic particles with non magnetic products, the number of single nonmagnetic
particles mixed with magnetic products. The first case, leading to recovery of
magnetic component rate drop, main reason is the size of the magnetic particles is too
thin, not enough to overcome the resistance of the magnetic fluid in competitiveness;
after a magnetic product quality decline, because most is the existence of strong
interaction force between particles, the particle size interest, slurry concentration
particle interactions, the more obvious.
Electromagnetic coil can make the magnetic separator and magnetic pole iron core
magnetization, produces a magnetic field around it. Between the poles of magnetic
field and make the particle magnetization, show magnetism, and then generates a
magnetic force; while the non magnetic particle can only receive the magnetic effect
observed by naked eye not to faint, resulting in magnetic mineral grains and non
magnetic particle separation. Therefore, further understanding of the magnetization of
magnetic material, including the measurement of material structure, the magnetic field

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in the behavior and magnetization degree, is essential to understanding the nature of
the magnetic separation process.

CHAPTER-5

5. EXPECTED OUTCOME

 This serious problem we try to magnet is more efficiency and less maintenance
of drives and bearings.
 We try to reduce power consumption of roll drives In magnetic circuits. Also
we use more lubricant to reduce friction but not more.
 We try to improve performance of rare earth magnetic separators and
separators due not suffer from similar drawback.
 Magnetic separator greatly reduce by nails, scrap iron particles
 The permanent magnetic drum separator is remove ferrous metal and dry bulk
products.
 Magnetic separator is one of the ways of separating heterogenous solid by
mixtures.
 Carefully removed the plastic bag around the magnetic bar and scrap of the
iron fillings.
 Long hair and loose scarves must be tacked away or tied up.
 The coarse separation of the lean iron ore after coarse crushing or medium
crushing eliminates the barren rocks such as surrounding rock , improves the
taste of the iron ore and eases reload of the next procedure.
 Magnetic separator can be used in the closed circuit firing work for restoring
the hematite .and it can separator the rawore that are not fully restored and
return it for firing again.

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  In the ceramic industry, magnetic separator can remove the iron mixed in the
petuntse and improve the quality of the ceramic product.
 Magnetic separator can also be used in coal firing sand making , refractory and
other industries that need de-ironing.

CHAPTER-6
6.1 Application

Magnetic separator is used in the removal of iron powder in mitochondria;

magnetic separator is widely used for resource recovery, the timber industry, mining
industry, ceramics, chemical, food and other workshops, applied to particle size below
3mm magnetite, pyrrhotite, roasted ore, ilmenite etc. Material Wet magnetic
separation, but also for coal, Non metallic minerals In addition to iron, building
materials and other materials, is one of the most widely used in the aircraft industry,
high versatility.

6.2 Advantages

Magnetic separator greatly reduces the possibility of costly dangerous flat tires and
injuries caused by nails, scrap iron particles, staples. Magnetic separator, brooms,
lifting magnets, conveyor magnets and magnetic separator for metal debris removal.
Magnetic separator used in industry. Magnetic separator simply hangs it from your
vehicle and sweeps your entire road or parking lot clean of tire damaging magnetic
separator. More industrial use involve magnetic separator

 Steady performance
 Large capacity

 Low cost

 Easy maintenance

The permanent magnetic drum separator is important to remove ferrous metal

from dry bulk products in free-flowing processing systems.

6.3 Disadvantages

A serious disadvantage of induced electromagnetic roll separators used for

beneficiation of weakly magnetic ores is the need for frequent maintenance of drives
and bearings.

In addition, power consumption of the roll drives used in the Ukraine and
Russia is often greater than that of the magnetic circuits of these separators.
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 Rare-earth permanent magnetic roll separators and drum separators suffer from
similar drawbacks

CHAPTER-7

7.CONCLUSION

Head roll magnets are available in various magnetic strengths. A head roll
magnet is mounted as a drive roller in a conveyor belt. Next, it will attract iron
particles present in the product and deflect these to the bottom of the belt. There, the
iron particles will be released from the magnetic field and collected in a funnel or a
slide plate. Magnetic separator is widely used for resource recovery, the timber
industry, mining industry, ceramics, chemical, food and other workshops, applied to
particle size below 3mm magnetite, pyrrhotite, roasted ore, ilmenite etc.

Magnetic separation is a process in which magnetically susceptible is extracted

from a mixture using a magnetic forces. This separation technique can be useful in
mining iron as it is attracted to a magnet.

Developments is magnetic separators have produced user friendly wet and dry
separator which are suitable for the economic processing of silica sands at high
capacity to produce superior grade materials or open up new reserves which were
previously unusable.

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 CHAPTER-8

8. REFERENCE

1. D.V.S. Rao, Crc Pr Inc, Belkema(2011)

2. W. A. P .J. Premaratne, N.A. Rowson, Phys. Sep. Sci. Eng. 12(2003), 215–
222.

3. S. K. Tripathy, P. K. Banerjee, N.Suresh,Int.J.Min.Met Mater, 22(2015) ,

661

4. V. Singh, S. Nag, S. K. Tripathy, Powder.Technol, 244(2013), 85–92.

5. S. K. Tripathy, V. Singh, Y. R. Murthy, P. K. Banerjee, N. Suresh,

Int.J.Miner.Process, 160(2017), 16–31.

6. S. K. Tripathy, Y. R. Murthy, V. Singh, N. Suresh, Miner.Process. Extr M,

37(2016),196–210.

7. F. H. El-Rehiem, A. El-Rahman, Min.Proc.Extmet. Rev, 117(2008), 171–

174 .

8. S. S. Ibrahim, H. A. Mohamed, T.R.Boulos, Physicochem Probl Mi, 36,

173–183.

9. D. A. Norrgran, J. A. Marin, Miner.Metall. Proc, 11(1994), 41–45. 10. J.

Svoboda, T. Fujita, Miner Eng, 16(2003), 785–792. 11. O. Y.

10. J. Svoboda, T. Fujita, Miner Eng, 16(2003), 785–792.

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