Magnetic Separators

Our overband magnetic separators are extensively used for installing above conveyor belts, vibratory feeders, chutes etc. Their function involves picking up of ferrous metal parts from bulk goods.

Usage:

• Overband magnet separators are used for the following purposes:
• For removing magnetic parts from non-magnetic materials. This is done applicable to project crushers, mills, processing plants and many other machines.
• These are also used for cleaning of non-magnetic bulk goods that have iron contamination. For example cleaning of foundry sand, coal etc.
• These machines are also used for recovering magnetic material from ore, steel mill slag and similar materials.

Factors Considered Before Installation:

Since each material and type of conveying has different problems, a number of factors are considered for different applications.

Process:

As a result of their shapes/ demagnetization factor, the long, bar-shaped & large iron parts are easy to separate as compared to short, cube shaped bulbous & small iron parts. The efficiency of these machines depend on many factors like the following:

• Pole size
• Pole distance
• Field intensity in the conveyor burden
• Lines of the material to be separated

Some of the features that have made separation a difficult process are:

Large burden depths
Large lump sizes
Sticky or humid material

We are one of the highly established manufacturer and supplier of overband permanent magnetic separators. These products are made from quality raw materials for reliability, durability and outstanding performance of products. We have highly top-notch manufacturing units and experienced engineers who making strong efforts with dedication for quality overband permanent magnetic separator. Our company, Star Trace manufactures and supplies top-class products to ensure complete satisfaction of the customers.  

Introduction:

Permanent magnets offer superior strength and reliability and are designed for separation  of Ferrous metal from a variety of belt conveyed products. Their heavy industrial design and construction make them ideal for use in foundry , recycling, fire shredding, wood chip, and demolition applications.

Features:

• Powerful deep reaching magnetic circuit design to penetrate heavy product burdens.    
• Similar or greater in strength to many small electromagnets.
• Uniform magnetic field across belt width for full coverage.
• Long magnetic field for extended magnetic exposure.
• Continuously operates at peak magnetic efficiency.
• No operating coast (manual clean units)
• Stainless steel housing
• Industrial welded construction
• Four rigid lift lugs for easy suspension

Optional Features:

• Cross- Belt or in-Line magnet configurations.    
• Stainless steel slider plate.
• Manual pull slider plate – roller guided design for easy, quick removal of collected metal.
• Slider plat with hand crank cleaning option.
• Self-Cleaning belt and drive package for continuous metal removal from the magnet.
• Cladded belt with 5 mm stainless steel cladding
• Vulcanized belt with vulcanized cleats & splice
• Special stainless steel guarding
• 380/50Hz motors
• Explosion proof motors 

Special Considerations:

The removal of  tramp metal can create many challenges and is dependent upon many factors. These in include product size, density, moisture, tramp metal geometry, orientation, magnet suspension height, entrapment by large product pieces, location  the burden, and many others. Let Star Trace help you assess your application and solve your metal separation needs with a properly selected magnet.

Self-Cleaning Magnets:

• Motor  starter.    
• Explosion proof motor & junction box.
• Stainless steel wear plate.
• Impact package: Stainless clad belt, lagged drive pulley.
• Zero speed switch 
• Tum buckles
  
• High temperature oil

Manual Clean Magnets:

• Easy clean stripper pan
• Fixed mounting frame.
• Turnbuckles
  

Note:  Technical data and specification subject to change. Special over band permanent magnetic separator can be made on request, customers have to just send their technical data and application required for our engineers.

We manufacture liquid line magnetic separators that are designed for use in heavy duty, large volume liquid & semi-liquid line flow systems. It employs a slip-in cage made of stainless steel permanent magnetic tubes that capture ferrous tramp metal particles & improve the product's purity. The range of our liquid line magnetic separators can be availed in 7 standard line sizes ranging between 2' to 18' in diameter. We can also custom manufacture them as per the special needs of the customers. It allows the products to flow through the housing without bridging of the products. Using an interior baffle the product flow is directed towards the plate magnet. These liquid line magnetic separators can be installed in any position, whether vertical position that eliminates the sump area or horizontal to make cleaning easier.

Star Trace is a highly known and established manufacturer and supplier of eddy current separators, which are ready to be installed in your separation facility. This separator uses a highly powerful eddy current separators, conveyor belt, two variables discharge area and support frame. The optional vibratory feeder provides a consistent flow of material to the Eddy Current Separators. These top-class non-ferrous eddy current separators are highly reliable, durable, high performing and available at reasonable prices. Our eddy current separators is manufactured using the best quality raw materials to ensure satisfaction of customers. 
 
These eddy current separator devices are perfect and effective work for removing non - ferrous metals from other products. Applications of eddy current separators are aluminum cans from municipal waste, aluminum flakes from shredded PET, brass and aluminum from foundry sands, and metals from shredded automobile scrap. Other metals, such as lead can also be removed. For successful non-ferrous separation, a magnet should be installed prior to an eddy current separators.

Eddy Current Rotor:

Star Trace eddy current rtotor utilizes an alternate magnetic field for producing electrical currents in conductive metal. The electrical current produces its own magnetic field around an object, which opposes the magnetic field from the Eddy Current. This repulsion diverts the object from the product stream. Mass, conductivity and density influence the force and distance an object will repel.

Eddy Current Separation System:

Eddy current separation system manufactured and supplied by Star Trace encompasses all the equipments above necessary to separate non - ferrous metals and add ferrous metal separation equipment. It is significant for removing ferrous metal prior to exposure to the eddy current separators. Strong magnetic field magnetizes and holds ferrous metal. The Ferrous Metal will heat up and could burn holes in belt and cause significant damage to the eddy current rotor.

Note: Technical data and specification subject to change. Special non ferrous eddy current metal detector can be made on request of customers, they have to just send technical data and application, required for our engineers.

We at star trace are recognized manufacturer, supplier and producer of wet high intensity magnetic separator (whims). Wet high intensity magnetic separator designs, develops, manufactures and markets magnetic separation equipment for beneficiating weakly magnetic minerals, and for purifying non-metallic minerals. Star trace professionals have specializes in the field of magnetic separation technology. We have been manufacturing and supplying these equipments since 1983. It became a leading supplier of whims in india in 1980s, and it has become a leading supplier of high gradient magnetic separators since 1990s.

Applications:

Star trace on vphgms is suitable for processing fine, weakly magnetic minerals, such as hematite, limonite, ilmenite, manganese, wolframite, tantalum-niobium, and etc. It is also suitable for removing iron and titanium from non-metallic minerals such as quartz, feldspar, nephline, fluorite, ceramic material, and etc.   our company vertical ring and pulsating high gradient magnetic separator uses combined force field of magnetism, pulsating fluid and gravity to beneficiate weakly magnetic minerals with the advantages of large beneficial ratio, high recovery, matrix not easy to be blocked and excellent performance.

The star trace on-1000, stpl-1250, stpl-1500, stpl-1750, stpl-2000 and stpl-2500 have developed. The maximum feed capacity is up to 120t/h. Owing to its unique design and its excellent performance for mineral beneficiation, stpl vphgms has successfully applied in several industries.

Note: technical data and specification subject to change. Special wet high intensity magnetic separator can be made on request, customers have to just send their technical data and application required for our engineers.

These type of high intensity drum separators, high gradient drum separators are extensively used in:

• Non electric separators to separate tramp iron from non magnetic materials that are processed in bulk quantity for the purity of end products
• Recovery of metals having commercial value
• Protection of processing plant and machinery

These machines are also used in the processing industry for separating iron contamination from the following:

• Mineral
• Chemicals
• Food
• Flour plastics
• Grains
• Sand
• Cement
• Fertilizers
• Abrasives
• Glass
• Slag
• Ores
• Rock
• Refractors

Size range:

• Standard drum diameters: 300 mm, 400 mm
• Drum width range: 300 mm to 1200 mm
• Other sizes as per requirement

Salient features:

• Drum consisting of high energy rare earth neodymium permanent magnets
• Strong and rugged construction
• Automatic separator of iron impurities
• Completely enclosed design that avoids dusting & pollution

Our company was the pioneer in the manufacturing of indigenous high intensity & high gradient roll separators. These are extensively used for dry material in the domestic market and can separate different types of materials in diverse industries efficiently & economically. Our company makes use of high energy rare earth Neodymium permanent magnets, which are assembled in a proprietary configuration. This configuration generates a force of magnetic attraction that can be utilized for processing different materials from ferromagnetic to weakly paramagnetic.

We are established company involved in designing, developing and supplying excellent quality Industrial Electrostatic separator and offer it at market leading prices.  Electrostatic drum separators are designed for separating mixtures of bulk materials, which are differing by their electrical properties. These superior quality high tension electrostatic drum separator are manufactured following international norms and standards to satisfy the customers and maintaining products quality.

Features:

This high tension electrostatic drum separator is capable of producing high grade concentrators with fast recovery of valuables owing to three -step re-cleaning and facility for heating materials. Besides these feature, it also consumes little electric power and is environment-friendly.

Application:

• Beneficiation of ferrous, non -ferrous and rare metal ones.
• Recovery of metals from industrial wastes (electronic or electrical engineering scrap, cables etc.
• Recovery of dielectric materials (e. g. plastics) for recycling.
• Purification of metal and non -metal powders.
• Separation of industrial minerals (quarts, feldspar, mica etc.).
• Shape and size classification.

For Technical Specifications Click for PDF

The star trace distinguished manufacturer and supplier of induced roll separators, which are used for the continuous extraction of small magnetic particles from certain minerals to produce mineral purification for a wide range of mineral and ceramic processing industries.  The material being treated is fed from a hopper or vibratory feeder at a controlled rate onto a high intensity magnetic. Magnetic material attaches itself onto the roll face or is deflected towards the roll. Non magnetic material is thrown off the face at a normal trajectory. Magnetic material is discharged off the roll face at a point of lower magnetic intensity aided by a brush. A splitter plate is interposed between the two product streams. We offer an extensive range of contemporary induced roll magnetic separators to customers across India. These induced roll separators are easily available in market at budget friendly prices.

Note:  Technical data and specification subject to change. Special induced roll separators can be made on request, customers have to just send their technical data and application required for our engineers.

We are one of the pioneer companies engaged in manufacturing and supplying the most celebrated quality of cyclic magnetic separators, which are made from superior quality raw materials for outstanding performance of products. Our company, Star Trace has well-educated and experienced professionals who carefully implementing latest technology and modern machines to ensure quality products and customers’ satisfaction. These best performing products are available at very economic prices. 

Specifications:

Star Trace-HGMS Magnetic separators include magnetic assembly separators include magnetic (magnetic coil, magnetic return frame), canister with matrix and support structure, process flow distribution system, process controller and instrumentation. A closed loop cooling system may be provided for the magnet and power supply if suitable cooling water is not available.

The system is provided with a fail-safe protection through thermal switches and a flow switch in the main cooling system; fail safe alarm triggering circuitry, operational in the events of component failure; and external interlocks to protect the system in the event of equipment failure. Power supply (rectifier) is built in accordance with the customer’s requirements (voltage, frequency). Appropriate feed system and means for product collection and handling are provided by the customer or are available.

Applications & Purification:

Star Trace-HGMS magnetic separators have capability to remove even very weakly paramagnetic materials. A number of extremely effective applications include:

Clay Benefits: High gradient magnetic separator is unique in its ability to brighten clays be removing fine, weakly magnetic color body particles. This new technology may be used for:

• Reduction of Fe2o3 in: glass sands; feldspars, barites
• Reduction of copper in molybdenum concentrates
• De-ashing and desulfurization of coal
• Phosphates upgrading
• Wet or dry separations

Manufacturing industry, power generation:

• Filtration of feed water and condensates in nuclear and fuel power stations
• Recovery/recycling of lubricants and continuous removal of wear particles

Industrial and waste waters:

• Filtration of steel mill process and waste waters
• Purification of industrial and municipal waste waters

Chemical, food and petroleum industries:

Applications exist for STR HGMS magnetic separator in the filtration of pregnant liquors, recovery and purification of catalysts (wet or dry), other valuable materials.

Concentration:

Successful beneficiation to final quality products has been proved for rare earth minerals, beach sands and other minerals.

Note:  Technical data and specification subject to change. Special cyclic magnetic separator can be made on request, customers have to just send their technical data and application required for our engineers.

We are one of the leading manufacturers and suppliers of the highest quality concentrator separator, which are manufactured using the finest quality raw material to ensure quality of products and customers’ satisfaction. These concentrator separator are machined according to customers’ needs and requirements of customers following international quality guidelines for perfection of high capacity concentrator separator. Our reliable, durable and the best performing products are available in the market at market leading prices.    

Application:

Permanent magnetic concentrator separator is extensively used for advancing or concentrating material containing a very high percentage of magnetic or where magnetic/mechanical agitation is required for the separation of many difficult materials. It is perfect for the improving sponge iron/cast iron borings, steel/brass aluminum turnings, chips and for mineral beneficiation application such as the purification of dry ceramic and refractory materials, reclamation of abrasive grains, removal of iron contamination from chemical powders and grains and for many other such applications requiring maximum separation with minimum production loss etc.

Description:

The Separator basically consists of:

• An electromagnetic Vibratory Feeder (with sub-hopper), which provides step less regulation of feed for even flow.
• Two Conveyor belts The Upper belt running ahead of the lower conveyor belt and in the same direction.
• Permanent Magnet unit for picking Tramp Iron.
• Magnetic and Non-Magnetic collection Hopper
• The Drive.
• The Supporting Structure.

The material to be treated is fed from the vibratory feeder on to lower belt where after traveling a short distance it comes under the belt conveyor. The upper belt conveyor runs under a series of powerful concentrator separator arranged in such a manner so that the material is exposed during its travel through a number of magnetic fields of alternating polarity. Due to the continuous repetitive agitation of the material nonmagnetic material falls back on to the lower conveyor belt, while the magnetic material is retained on the upper conveyor belt due to the force of magnetic attraction. The separated material are carried and deposited into the respective magnetic and non-magnetic discharge chutes.

Manufacturing Range:

The concentrator separator is available in a wide range of sizes and capacities up to approx. 100 TPH and 650mm belt width up to 2000mm belt width.

Options Available at Extra Price:

• A variable speed drive motor can be furnished in place of the slandered constant motor if varied products are to be handled.
• The built-in feeder and motor starter can be furnished separately for remote mounting where remote control is desired.
• Multiple-stage units can be supplied for unusually difficult materials.
• Other sizes on request.

Note: Technical data specification subject to change. Special concentrator separator can be made on request, customers have to just send us their technical data and application.

We are one of the leading manufacturers and suppliers of the highest quality suspension electromagnets, which are machined using most reliable raw materials to ensure excellence of products. These suspension electromagnets are manufactured by highly qualified and experienced professionals who always strive for perfection of products. These Electromagnetic Suspensions offered by us are sent for stringent quality check-up before supplying to the customers to ensure their satisfaction. Our range of suspension electromagnets is easily and cheaply accessible in the markets. 

Benefits:

• Powerful ferrous metal separation
• On / Off capability

Introduction:

Our suspension electromagnets are designed for separating of ferrous metal from a variety of over- the- belt conveyor purposes. Proven in industries such as mining, recycling, tire shredding, pulp & paper and construction & demolition. Star Trace’s suspension electromagnets offer superior strength and reliability. These suspension electromagnetsare used in high volume low (less than 150mm) product depth applications, suspended electromagnets offer “deep reach” capacity and the ability to be turned on & off. Installation options include In-Line and Cross-Belt configurations to meet the specific needs of your applications.

Operation:

As the product on a conveyor belt runs under the powerful magnetic field, ferrous material is pulled out of the product flow and held to the face of the magnet. While using a manual-clean model, the collected tramp metal is held in place for as long as the unit has power. For cleaning the unit, the power source must simply be turned off, which instantly releases the metal from the magnets hold.

With self-cleaning models, continuous cleaning is made possible by a heavy duty clad belt that encircles the magnet on a series of rotating pulleys. As ferrous metal is attracted and held by the magnet, the moving belt carries the collected metal outside of the magnetic field where it is then released beyond the product flow.

Options:

• Self-Cleaning package
• Custom Sizes and designs
• Special power supplies

Specifications:

• Non-combustible coolant
• External expansion tank
• Insulated copper coils / Aluminium coils
• Manganese impact plate
• Lift lugs
• 1 year limited warranty on coils.

Note: All dimensions are stated in mm.

Note: Technical data specification subject to change # Electro Magnet can be made on request of customers, they have to just send us their technical data and application, required for our engineers.

We are a pioneer name engaged in manufacturing and supplying advanced electromagnetic scrap drum separator. star trace always offers highest quality products, which are engineered by our skilled team of technocrats using superb quality raw materials. star trace's electromagnetic scrap drum separator opens the way to new efficiency in handling big volumes of large-sized material encountered in today’s material processing and mineral concentration applications.

The patented coil construction produces a much deeper field than can be produced on electro or permanent pulleys or any other type of magnetic drum separator. In addition, the magnetic collecting pole area has been increased to give the drum greater ability to carry heavy magnetic loads. The surface holding force developed by this drum is also higher than any drum or magnetic pulley. Our electromagnetic scrap drum separator does not only achieve better separation than was previously possible but also extend the range of magnetic treatment to meet larger requirements.

typical applications:

• Foundries

• Blast furnace and bof slag

• Open hearth slag

• Dry magnetite ore cobbing

• Auto fragmentizing and processing

 

Features

• Deep, powerful magnet assembly, combined with high surface holding power

• Deep field pattern, improved surface area, and greater magnetic pole area

• Extended range of magnetic treatment

• Simple installation and minimum space requirements

• Low dc power costs and extremely efficient performance

• Rugged construction for virtually maintenance-free operation

• Sealed cylinder o-ring construction a "must" for unprotected outdoor operation

• Heavy-duty, weatherproof manganese-steel cylinder

• Low drive hp requirements

• Steel support bearings

• Flexibility in application

 

INTRODUCTION
STL is one of the leading manufacturers of ore dressing equipment. The present range of STL
process equipment enables us to provide complete packages. Magnetic wet separators constitute
an important part of the product range and are known for advanced engineering design and
excellent performance.
As a result of continuous development in separator technology STL can offer a complete line of
magnetic wet separators to the mining and mineral industries.

PRODUCT MODELS AND SIZES
STL's wet permanent magnetic separators are offered in sizes of dia.1200 mm and 916mm in Lengths of up to 3000mm. Three basic separator designs are available for cobbing, roughing and finishing/cleaning applications. Each type can be supplied in single drum or multiple drum stages of taconite or magnetite and also for recovery for magnetic medium in dense media plants. The stationary magnet yoke is an assembly of strontium-ferrite permanent ceramic magnets. The rotating drum is available with optional rubber or stainless steel covers. The magnetic flux pattern will match the tank configuration for optimum performance. STL's magnetic wet separator dia 916 x 300 mm is the smallest full scale separator in the 916 series and is primarily used for pilot plant tests. The separator can be delivered in concurrent, countercurrent and counter rotation versions.STL's magnetic wet separator for laboratory use have drum dimensions dia. 600 x 285 mm and dia.200 x 100 mm and are suitable for batch or continuous testing. The test results from the STL laboratory

• separators correspond closely to those obtained in full scale operation.
• Pilot unit dia. 916 x 300mm. Left.

STL's magnetic wet separators have been developed in close cooperation with the Swedish mining industry for treatment of magnetite. A prime consideration in its advanced engineering design has been high capacity, improved metallurgical performance and highest availability. The separator is constructed as a separate unit consisting of drum with magnet yoke, tank and drive package, all mounted on a heavy-duty frame. The design of the frame allows any number of units to be connected in series as multi-stage installation. This design offers a flexible flow sheet layout.
The drum shell is made of non-magnetic stainless steel with abrasion-resistant wear cover and sealed heads of cast rigid aluminium alloy. The drum shaft runs in spherical, self-aligning antifriction bearings.

ADJUSTMENT OF MAGNET YOKE AND DRUM
The magnet yoke is mounted on the stationary drum shaft and its position can be adjusted (+/-35) by a lever at the end of the drum shaft to optimize runing conditions in accordance with tank design and type of ore. The gap between tank and drum, which determines the pulp  flow speed, can be adjusted vertically by shims inserted under the bearing housing and shaft support. Horizontal adjustment is by slotted holes.

DRIVE UNIT
The standard drive train consists of a shaft end mounted torque arm speed reducer outside the tank with V-belt pulley driven from a standard electric motor. This arrangement provides a smooth protected transmission and has several advantages compared to chain drives. Also other drive arrangements can be supplied.
The V-belt drive is protected by a steel guard. As an alternative the separator drive unit can be supplied with an easily removable fiberglass cover. These covers protect the entire drive unit and motor, with opening for lubrication maintenance and inspections.
The Steel V-belt guard is preferred for users in extreme climatic conditions, e.g. tropical and subtropical.

Permanent Magnetic Drum Separator
Permanent Drum Type Magnetic Separator is most useful non electric separator for separating tramp iron from non magnetic material processed in bulk quantity for the purity of end products, recovery of metal having commercial value and protection of processingplant and machinery. These are widely used in all the processing industry for separation of iron contamination from mineral, chemicals, food, flour plastics, grains, sand, cement, fertilizers, abrasives, glass, slag, ores, rock, Refractor and any other Products.

Size range
The permanent drum separators are available in standard drum diameters of 300mm, 400 mm. Drum width range from 300mm to 1200mm. Other sizes can be made as special to your requirement. The larger the diameter and width of the drum the greater is the volume of material which can be handled.

Salient features

• Drum consists of high energy Rare Earth Neodymium Permanent Magnets.
• Strong & rugged construction. Automatic Separator of iron impurities.
• Completely enclosed design to avoid dusting and pollution.

Working Principle & Magnetic System
The  Permanent  Magnetic  drum  consists  of  stationery  Permanent  Magnetic assembly having uniform and everlasting Magnetic field across the entire width of the drum, which is effective over approximately half the drum circumference. Drum shell made of non magnetic stainless steel revolves around the magnetic field. As the material feed evenly from the chute falls over the drum, Powerful-magnetic, field attracts and holds ferrous particles to the revolving shell. As the revolving shell carriers the iron particles through the stationery magnetic field, the non magnetic material falls freely from the shell while ferrous particles are firmly held till carried beyond divider and out of magnetic field. The strength of the Permanent Magnetic Drum is guaranteed to be grater than corresponding Electromagnetic Drum.

CLOSED TYPE DRUM SEPARATOR  
The totally enclosed type drum comes complete with a chute type feeder, hopper, adjustable feed regulation gate, magnetic drum and geared motor drive in a ready for use condition. Inlet and outlet openings are flanged for ease of connection to customers duck work. Double or triple totally enclosed machines can also be supplied if required by clients.

WET DRUM SEPARATOR
STAR TRACE's Wet Permanent Magnetic Separators are offered in size of dia 1200mm (48`) and 916mm (36`) ion lengths of up to 3000mm (10`). Three basic separator designs are available for copping, roughing and finishing / cleaning applications. Each type can be supplied in single drum or multiple drum stages of taconite or magnetic and also for recovery for magnetic medium in dense media plants.

The stationery magnet yoke is an assembly of Rare Earth Neodymium Permanent Mmagnets. The rotating drum is available with optional rubber or stainless steel covers. The magnetic flux pattern will match the tank configuration for optimum performance.