Abstract
Purpose. This research investigates the separation process performed by a magnetic separator. The magnetic separation process is used to isolate ferrous materials from those which are not. Hence, a prototype of a dry magnetic separator is designed. It should be said that this study defines the effect of different parameters (roll speed, magnetic force, and mass of silica sand particle) on separation efficiency. Methodology. The influence of several parameters of the magnetic separator such as magnetic force, centrifugal force, and properties of particle (mass, shape, etc.) were studied theoretically and simulated by SolidWorks software. The optimum conditions of the magnetic separator were obtained, and several trials were performed to find the point that results in a lower effect of roller speed and a higher effect of the magnetic force on the particle in order to achieve higher separating efficiency. Findings. The results show that the centrifugal force are the most important variable influencing separating efficiency. Moreover, it was found that blade angle magnitude of (174) degree with magnetic force between (1.71E-05 to 6.3E-05 N) and roll speed from (84 to 105 rpm) are the optimum separating conditions to reach higher rate of the separating process. Originality. This is the first time that the effect of the gap distance between the magnet and the feeding particles on the magnetic force has been studied. Furthermore, the effect of centrifugal force on magnetic separator force is investigated theoretically and numerically in order to be compared for different parameters. Practical value. The new prototype design of the magnetic separating unit is promising and efficient since the parameters can be varied based on the type and characteristics of materials. It is also revealed that separating time of the materials is reduced. Hence, this type of construction of a magnetic separator is recommended for industrial applications.
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