Background: At an iron ore processing plant, run-of-mine ore passes through crushing, screening and several belt conveyors before entering the ball mill and magnetic separation. Tramp iron — rock bolts, drill bits, bolts, wire rope ends and broken grinding balls — is unavoidably mixed into the ore flow. If it reaches crushers, mills or magnetic separators, it damages liners, belts and equipment, causes unscheduled stoppages and creates safety hazards.
The Challenge: The plant's original electromagnetic separators suffered from:
Heat-induced field decay — coil heating weakens the magnetic field, causing small grinding balls to be missed;
Power-cut discharge — when power is lost, collected iron falls back onto the belt and re-enters the ore;
High energy and maintenance costs — excitation coils and rectifiers run continuously, and electrical components fail frequently in dusty, humid conditions.
The Solution: The plant installed RCYD Series Suspended Belt-Type Permanent Magnetic Iron Removers (per JB/T8711) above the critical conveyor between screening and the mill.
| Configuration | Details |
|---|---|
| Model | RCYD (R-Magnetic separator / C-Iron remover / Y-Permanent magnet / D-Auto discharge) |
| Magnet material | Rare-earth NdFeB — no excitation coils, energy saving |
| Magnetic induction | Marked by model at rated height; approx. 70 mT usually not marked |
| Removal range | Ferromagnetic tramp iron of approx. 0.1–35 kg from non-magnetic bulk materials |
| Discharge | Belt-type automatic discharge; self-checking version (YCKN control cabinet) available |
| Options | Dust-explosion-proof motor and control cabinet for hazardous areas |
How It Works: The separator is suspended above the belt conveyor before the mill. Ore passes through the magnetic zone; tramp iron is attracted and carried away by the discharge belt without stopping material flow — constant magnetic field, no temperature-rise decay, and iron stays captured even during a power outage.
Results:
Stable constant magnetic field — small grinding balls and fine tramp iron are removed effectively;
Power-cut safe — no iron falls back onto the belt;
Energy saving — no excitation coils, only belt drive consumes power;
High reliability in harsh environments — no rectifier, integral epoxy-cast magnetic system;
Downstream equipment protected — mills, liners and magnetic separators run longer between maintenance.
Best Fit: Belt conveyors in mineral processing, metallurgy, power, paper, sugar, chemical and building-material plants handling non-magnetic bulk materials. Optional dust-explosion-proof configuration covers hazardous-area requirements.
