Magnetic Separator FAQ: Selection, Testing, Installation & Ordering

No. Gauss is magnetic flux density at a defined measurement point and method. Separation performance also depends on working distance, magnetic gradient, target properties, burden depth, feed presentation, separator geometry and operating conditions.

A surface reading is taken at or very near the magnetic surface. A working-distance reading is taken at a defined gap away from that surface. The two values describe different positions and should not be compared as though they were the same measurement.

No. A Gauss reading can verify a defined magnetic condition. Removal efficiency, recovery, purity and product loss require representative material testing or production validation with a defined sampling and calculation method.

Material magnetic response, liberation, particle size, moisture, feed distribution, burden depth, working distance, separator geometry, magnetic field profile, operating speed, residence time and discharge arrangement can all affect the result.

Particle size changes liberation, mass, drag, contact behavior and the force required to alter a particle trajectory. A wide size distribution can also cause fine and coarse fractions to behave differently, so particle range should be part of the selection and test plan.

Moisture can change flowability, agglomeration, carryover and how particles present themselves to the magnetic field. Sticky or wet feed may need a different equipment route, feed presentation or cleaning approach than free-flowing dry material.

A deeper material bed increases the distance between the magnet and particles lower in the burden. It can also shield or physically restrain target pieces. This is why conveyor selection should use the real burden depth rather than belt width alone.

No. A process result should be tied to the actual material, separator configuration, installation and operating conditions. Where a numerical result is important to purchasing, define the acceptance metric and test method before treating it as a requirement.

Use material testing when the actual magnetic response, contaminant behavior, separator route or required process result cannot be judged responsibly from drawings, photos or catalog data alone.

No. Start with the material, target, process position, test question and acceptance metric. Testing can help narrow the separator principle, while the final equipment choice still needs to fit the production installation and operating conditions.

No. Pull force is a defined mechanical comparison using a specific test piece, fixture and motion. It can be useful for controlled comparison or monitoring, but it does not reproduce a moving bulk-material stream or the separation of real fractions.

Define the decision to be supported, sample identity, sample condition, equipment configuration, feed method, working distance or gap where relevant, operating variables, fraction collection method, sampling method and acceptance metric.

No. The result applies to the tested sample, method, separator configuration and operating window. Production scale-up must consider material variability, feed presentation, working distance, equipment geometry, operating rate and the final acceptance method.

There is no responsible universal sample quantity for every application. The required amount depends on material variability, particle size, test equipment, number of conditions to compare and the measurement that must be made. The sample plan should be defined before material is shipped.

At minimum, it should identify the sample, test question, separator configuration, relevant operating conditions, measurement or sampling method, observed result and the boundary of what the result can support.

Confirm the approved installation position, working distance, supports, surrounding steel, service access, material trajectory, discharge clearance, lifting or handling needs, power and control interfaces where applicable, and the direction of movement.

Magnetic field strength and gradient change with distance from the magnetic source. If the installed gap differs from the design or test condition, the magnetic force acting on target material can also change.

Ferromagnetic structures can influence magnetic flux paths, installation clearance and the behavior of captured metal. Surrounding steelwork should therefore be considered during layout review, particularly near strong magnetic circuits.

There is no single interval for every plant. A practical program should reflect contamination risk, process severity, audit requirements and the consequence of failure. Baseline testing is especially useful after installation, maintenance, impact, suspected overheating or when performance is questioned.

Maintenance should focus on the components that can change separation conditions or safe operation: cleanliness, build-up, belt or drum condition, bearings, scrapers, splitters, fasteners, guards, working clearance, drive components and repeatable magnetic checks where the application requires them.

Recheck when the equipment is installed, after repairs or changes that may affect the magnetic system, after severe impact or overheating, and whenever contamination control or separation performance appears to have changed. Use the same method and test points if the goal is to compare against a baseline.

Send the order or equipment reference, photos or video, material and operating conditions, installation measurements, description of the symptom, when it started, and any changes made before the issue appeared. Providing photos, operating conditions and problem details helps us identify the cause faster and provide an effective solution.

Spare-part needs depend on the separator design. Driven systems may use belts, bearings, scrapers, motors, gearboxes, sensors or electrical components, while passive magnetic assemblies have a different service profile. The recommended list should follow the supplied configuration.

Magnetic assemblies can be affected by excessive temperature, severe impact, corrosion, physical damage or changes to the working geometry. Apparent performance loss can also come from build-up, increased working distance, changed feed conditions or mechanical wear, so diagnosis should separate magnetic condition from process changes.

Establish a baseline using a repeatable method when the equipment is new or accepted. Later checks should use the same test piece or probe, measurement points, orientation, gap and method so the trend can be compared meaningfully.