FCX High-Frequency Pulsating Dry Magnetic Separator for Fine Ore
Product Overview
The Huate FCX High-Frequency Pulsating Dry Magnetic Separator is designed for the upgrading and purification of fine, strongly magnetic minerals produced by dry grinding processes, including high-pressure grinding rolls (HPGR) and ball mills. It is also suitable for the separation of fine-grained steel slag and other strongly magnetic materials.
Combining a multi-pole magnetic system, high magnetic coverage, magnetic pulsation and an optional air-knife system, the FCX separator promotes repeated particle movement on the drum surface and helps remove impurities and weakly liberated intergrowths from magnetic concentrates. This enables effective concentrate-grade improvement in dry mineral processing applications.
With variable-frequency drum-speed control, adjustable separation settings and multiple model options, the FCX series can be configured according to ore characteristics, feed size, processing capacity and target separation performance.
Key Benefits
• Dry separation of fine, strongly magnetic minerals.
• Multi-pole magnetic system with a large magnetic wrap angle.High-frequency magnetic pulsation to promote particle agglomeration and dispersion.
• Adjustable drum surface speed for different ore properties and separation targets.
• Optional air-knife and dust-removal arrangements, depending on material and process requirements.
• Non-metallic, wear-resistant drum construction.
• Multiple equipment models for different processing capacities.
Applications of the FCX Dry Magnetic Separator
Fine Iron-Bearing Minerals
The FCX separator is designed to upgrade fine, strongly magnetic mineral feeds generated by dry grinding or crushing processes. It can help improve concentrate grade by separating magnetic particles from impurities and weakly liberated intergrowths.
HPGR and Ball Mill Circuits
The equipment can be applied downstream of high-pressure grinding rolls or ball mills where fine mineral material is produced through dry processing. The final configuration should be determined by the actual feed characteristics and process test results.
Fine-Grained Steel Slag
The FCX series can also be used to separate fine-grained steel slag and other strongly magnetic materials. Equipment selection and operating settings should be verified against the composition, particle-size distribution and magnetic properties of the feed.
Working Principle
The material is evenly distributed onto the surface of the rotating drum through a vibrating feeding system. Strongly magnetic particles are attracted to the drum by the magnetic field and carried through the separation zone.
During drum rotation, the multi-pole magnetic system, magnetic pulsation and, when selected, the air-knife system work together to promote particle movement and remove impurities and weakly liberated intergrowths. This helps improve the grade of the magnetic concentrate.
After separation, the magnetic concentrate travels with the drum into a non-magnetic zone, where it is discharged and collected. Gangue, weakly liberated particles and non-magnetic material are discharged through the tailings outlet under the combined effects of gravity and centrifugal force.
Key Technologies and Design Features
1. Multi-Pole Magnetic System with a Large Wrap Angle
The magnetic system uses high-performance NdFeB permanent magnet materials and an alternating N-pole/S-pole arrangement around the drum. Its multi-pole configuration and small pole spacing promote repeated particle movement on the drum surface, supporting more effective concentrate upgrading.
The selection guide specifies a magnetic wrap angle of approximately 200°–260° and a magnetic induction range of 3,000–6,000 Gs as design options. The appropriate magnetic configuration should be selected according to ore properties and separation requirements.
2. High-Frequency Magnetic Pulsation
A magnetic pulsation device is installed inside the drum assembly. It repeatedly promotes agglomeration and dispersion of particles attached to the drum surface, helping improve separation performance and concentrate grade.
3. Optional Air-Knife System
The air-knife system uses a fan to generate airflow discharged through narrow slots or openings onto the drum surface. Working with the multi-pole magnetic system, it helps remove impurities and weakly liberated intergrowths.
The air-knife arrangement is optional and should be configured according to the material properties and target separation indicators.
4. Labyrinth-Sealed Drum Ends
A combined sealing arrangement featuring multi-groove labyrinth mechanical seals and lip seals helps prevent contaminants from entering the bearing area, supporting reliable operation.
5. Non-Metallic, Wear-Resistant Drum Surface
The drum uses high-strength non-metallic material to solve issues associated with eddy currents in metallic drum shells, which can increase drive power demand and drum heating. The drum surface can be protected with wear-resistant rubber or ceramic plates.
6. Uniform Vibrating Feed Distribution
The feeding system is designed to distribute material evenly across the drum surface. Depending on the configuration, it can use an extended feed trough with a leveling plate or a planetary leveling device combined with two-stage vibrating feeding.
Uniform feeding helps maintain a consistent material layer and supports stable separation performance.
7. Adjustable Magnetic System and Variable-Frequency Drive
The magnetic-system adjustment mechanism uses a geared arrangement for convenient and precise adjustment. The drum drive uses variable-frequency speed control, allowing the operating speed to be matched to ore properties and separation targets.
Technical Specifications
The FCX series offers multiple drum sizes and processing capacities. The following figures are provided in the product selection manual.
| Model | Drum Dimensions (Diameter × Length) |
Magnetic Induction (Gs) | Processing Capacity (t/h) | Motor Power (kW) | Total Weight (kg) |
|---|---|---|---|---|---|
| FCX0665 | 600 × 650 | Determined by mineral properties | 10–15 | 5.5 | 1650 |
| FCX1010 | 1000 × 1000 | 20–30 | 7.5 | 2750 | |
| FCX1024 | 1000 × 2400 | 60–80 | 11 | 6300 | |
| FCX1030 | 1000 × 3000 | 80–100 | 15 | 7400 | |
| FCX1230 | 1200 × 3000 | 90–120 | 18.5 | 9500 | |
| FCX1530 | 1500 × 3000 | 120–180 | 22 | 10700 | |
| FCX1830 | 1800 × 3000 | 160–220 | 30 | 13500 |
Technical Notes
- Drum surface speed: adjustable within 1–20 m/s according to the selection manual.
- Magnetic induction: selected according to ore properties and process requirements; the manual lists a design range of 3,000–6,000 Gs.
- Air-knife and dust-removal arrangements: optional, depending on material characteristics and separation targets.
- Processing capacity: indicative values. Actual throughput depends on feed properties, particle size, magnetic characteristics and required separation performance.
- Final equipment configuration should be confirmed through material testing and technical evaluation.
Industrial Test Results and Application References
The following results are reported in Huate’s FCX product presentation and are intended as reference data for specific test conditions. Actual results may vary with feed composition, particle size, drum speed and process configuration.
Case 1: Hami Fuhong Mining, Xinjiang, China
- An FCX1030 was tested on feed with a particle size of -3 mm at a drum surface speed of 3 m/s.
- Feed MFe grade: 4.23%
- Concentrate MFe grade: 21.96%
- Tailings MFe grade: 0.47%
- Concentrate yield: 18.27%
- MFe recovery: 90.83%
Case 2: Hami Taiyuan Mining, Xinjiang, China
An FCX1030 was tested on feed with a particle size of -3 mm at a drum surface speed of 3 m/s and 5 m/s.
At 3 m/s:
- Feed MFe grade: 6.45%
- Concentrate MFe grade: 19.60%
- Tailings MFe grade: 0.60%
- MFe recovery: 93.56%
At 5 m/s:
- Feed MFe grade: 6.81%
- Concentrate MFe grade: 28.34%
- Tailings MFe grade: 0.85%
- MFe recovery: 90.23%
Case 3: KBH Phosphate Tailings, South Africa
Industrial testing was conducted on feed with a particle size of -1 mm.
At 6 m/s:
- Feed TFe grade: 51.75%
- Concentrate TFe grade: 60.60%
- Concentrate yield: 81.86%
- TFe recovery: 95.86%
At 8 m/s:
- Feed TFe grade: 51.75%
- Concentrate TFe grade: 62.10%
- Concentrate yield: 78.82%
- TFe recovery: 94.58%
These results illustrate the potential of the FCX separator to upgrade specific iron-bearing materials under the tested conditions. They should not be interpreted as guaranteed results for other ores or operating conditions.
How to Select the Right FCX Model
Selecting a dry magnetic separator requires more than matching nominal throughput. Huate recommends considering the following factors:
1. Feed particle size: Provide the full particle-size distribution and the proportion of fine particles.
2. Mineral properties: Include feed composition, magnetic susceptibility or magnetic characteristics, and liberation conditions where available.
3. Required performance: Define the target concentrate grade, recovery, tailings grade and other process indicators.
4. Required throughput: Specify dry feed capacity and expected operating conditions.
5. Magnetic configuration: Determine the required magnetic field strength and magnetic-system arrangement based on material tests.
6. Installation environment: For overseas projects, confirm power supply voltage and frequency, altitude, climate and other relevant site conditions.
Where the material is difficult to separate, the selected processing capacity may need to be reduced. Laboratory or industrial testing is recommended before final equipment selection.
Request Technical Support for Your Project
Looking for a dry magnetic separator for fine iron-bearing minerals, HPGR or ball mill circuits, or fine-grained steel slag?
Contact Huate with your feed particle size, material composition, required throughput and target concentrate specifications. Our team can assess the application and recommend a suitable FCX model and separation configuration based on your process requirements.
Contact Huate for FCX Model Selection and Technical Consultation.
