Guide
Magnetic Separation Systems for Mineral Processing
In practice a magnetic separation system is a sequence of stages, not one machine. This guide shows where PTMS separators sit in kaolin, feldspar and quartz lines, and how the stages are sized around your ore.
Why a system rather than a single machine
Different iron needs different tools. Coarse or strongly magnetic iron is caught at low field. Fine and weakly magnetic iron needs a high-intensity field and a high-gradient matrix. Splitting the job protects the fine-iron stage: on a wet feldspar line a permanent magnetic separator goes first so the electromagnetic matrix is not loaded with coarse iron.
Kaolin wet line
- Dispersion Raw kaolin is dispersed in water to form a slurry.
- Classification A spiral classifier separates coarse particles from the fine fraction.
- Screening A vibrating screen removes grit and oversize.
- Magnetic separation A water-cooled or oil-cooled electromagnetic slurry separator captures fine iron and weakly magnetic minerals.
- Automatic iron discharge Valves close, slurry returns to the tank, the field switches off and the matrix is flushed.
- Dewatering A filter press dewaters the purified kaolin.
Details: kaolin iron removal guide and the kaolin application page.
Feldspar wet line and dry line
Conventional wet line: crushing and screening, pre-separation on a permanent magnetic separator, slurry pool for steady feed, electromagnetic slurry separation, then belt dehydration. On dry lines, dry electromagnetic powder separators and belt-type magnetic separators clean feldspar powder and granules without water. Details: is feldspar magnetic? and the feldspar application page.
Quartz sand line
Crushing, coarse magnetic separation with a magnetic roller to remove tramp iron, grinding and classification, fine magnetic separation, dewatering. For high-purity sand the optional pickling sequence is washing, magnetic separation, acid leaching, water washing, dehydration, drying. Magnetic separation comes before acid leaching. Details: silica sand iron removal.
Series and parallel layouts
The PTMS electromagnetic dry powder machine can run as a single unit, in series to push iron removal further, or in parallel to raise capacity. Each unit is PLC-controlled and completes excitation, feeding and iron discharge automatically; one iron-cleaning cycle takes about 10 seconds. How many units and which layout your line needs is confirmed with a sample test.
Equipment around the separator
PTMS also lists a vibratory sieve for dry grading and a membrane filter press for slurry dewatering. For kaolin and ceramic lines, SHMP and STPP are dispersants that help liberate iron so magnetic separators capture it more effectively. Matrices and grids are stocked as spare parts: kaolin and feldspar matrix, steel wool matrix, grids for slurry separators.
Reference plants
- ~1,000 t/day kaolin ore washing and fine-processing line, India: equipment list published.
- 200 t/day quartz pickling plate-sand line: equipment list published.
- Indian feldspar wet line, Morbi: 200 mesh, 750 model water-cooled separator, 10–15 t/h, whiteness 75–85 (China standard).
Magnetic Separation Systems for Mineral Processing: questions
What is a magnetic separation system?
A sequence of magnetic stages placed along a processing line, for example a permanent magnet pre-stage for strongly magnetic iron followed by an electromagnetic high-gradient stage for fine, weakly magnetic iron. The stages are chosen from your ore, particle size and target iron level.
Where does the magnetic separator go in a kaolin line?
After dispersion, classification and screening, and before dewatering. The electromagnetic slurry separator captures fine iron and weakly magnetic minerals, then flushes them out automatically.
Why put a permanent separator before an electromagnetic one on a feldspar line?
The permanent unit removes strongly magnetic material first, so the electromagnetic slurry separator can focus on fine and weakly magnetic iron such as biotite and tourmaline, and its matrix does not load up with coarse iron.
Can several dry powder separators work together?
Yes. The PTMS electromagnetic dry powder machine can run alone, in series for deeper iron removal, or in parallel for more capacity. The layout is confirmed after a free sample test.
Can a separator be added to an existing line?
Yes. PTMS designs in-line pipe, drawer, rotary and U-type units that drop into existing pipelines with no extra floor space.
Related guides
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