Ghaziabad Online

In mineral processing and non-metallic purification, separating fine, weakly magnetic particles has long been a technical challenge. Conventional low-intensity magnetic separators (LIMS) excel at capturing strongly magnetic minerals like magnetite but fail to efficiently recover weakly magnetic materials such as hematite, ilmenite, and chromite, or remove micron-sized iron impurities from non-metallic ores. The Wet High Intensity Magnetic Separator (WHIMS) emerges as a game-changing technology, delivering high-gradient, high-field-strength separation in wet slurry conditions to address these critical industrial needs.

Working Principle of WHIMS

WHIMS operates on the synergy of high-intensity magnetic fields, high-gradient magnetic matrices, and wet slurry dynamics, enabling precise separation of weakly magnetic particles. At its core lies an electromagnetic coil system generating a background magnetic field of 1.0–2.0 Tesla (10,000–20,000 Gauss)—far stronger than LIMS—paired with a magnetic matrix (typically high-permeability stainless steel rods, expanded nets, or grooved plates) that amplifies the local magnetic gradient to extreme levels.

The process unfolds in continuous steps:

1.Slurry Feeding: Fine ore slurry (particle size 2 μm to 1 mm) is uniformly fed into the separation zone, ensuring optimal particle dispersion in water to avoid aggregation.

2.Magnetic Capture: As slurry flows through the rotating vertical ring housing the magnetic matrix, the matrix becomes magnetized by the background field. Weakly magnetic particles are attracted to the matrix surface by the intense magnetic force, overcoming hydrodynamic drag and gravity.

3.Non-Magnetic Rejection: Non-magnetic gangue particles (e.g., quartz, feldspar) pass through the matrix unimpeded, discharging as tailings or purified non-magnetic product.

4.Magnetic Discharge: The vertical ring rotates, carrying the trapped magnetic particles out of the magnetic field. A high-pressure water flush then rinses these particles into the concentrate launder, completing the separation cycle.

Many WHIMS models integrate a pulsation mechanism that vibrates the slurry vertically, dislodging entrained non-magnetic particles from the matrix and significantly improving separation efficiency and concentrate grade.

Key Advantages of WHIMS

WHIMS stands out from traditional separation equipment with unique technical and operational strengths:

• Superior Weak Magnetic Separation: Captures micron-sized weakly magnetic particles (down to 2 μm) that LIMS and gravity separation cannot recover, with separation efficiency exceeding 90% for most weakly magnetic ores.
• High Throughput & Scalability: Industrial models handle slurry volumes from 0.01 to 1,500 t/h, with modular designs supporting large-scale mining and non-metallic processing plants.
• Anti-Clogging Design: The rotating vertical ring and reverse flushing system prevent matrix blockage— a common issue in wet magnetic separation—ensuring continuous, stable operation with uptime up to 98%.
• Energy & Cost Efficiency: Modern WHIMS feature optimized magnetic circuits and low-voltage, high-current coil designs, reducing energy consumption by 20–30% compared to legacy high-intensity separators.
• Wide Particle Size Adaptability: Processes materials from fine slimes (2 μm) to coarse particles (1 mm), accommodating varying ore grain sizes without performance degradation.

Industrial Applications

WHIMS is indispensable across diverse sectors, driving efficiency in mineral recovery and material purification:

• Weakly Magnetic Ore Beneficiation: Enriches hematite, limonite, siderite, ilmenite, chromite, manganese ore, and rare earth minerals, boosting concentrate grades by 20–30% and improving resource utilization.
• Non-Metallic Mineral Purification: Removes iron impurities from quartz sand, feldspar, kaolin, fluorite, and talc, critical for ceramics, glass, and advanced materials production where iron contamination causes discoloration and quality defects.
• Secondary Resource Recovery: Recovers valuable weakly magnetic minerals from industrial waste like red mud, smelting slag, and fly ash, promoting circular economy and reducing environmental impact.
• Tailings & Wastewater Treatment: Purifies mine wastewater by removing magnetic heavy metals and recovers fine valuable minerals from tailings, maximizing resource recovery and minimizing waste.

LONGi Magnet’s LGS Series WHIMS: Innovation Redefined

Among global WHIMS manufacturers, LONGi Magnet (Shenyang LONGi Magnet Technology Co., Ltd.) stands as a leader in high-performance magnetic separation equipment, with its LGS Series Vertical Ring High Gradient Magnetic Separator setting industry benchmarks.

The LGS Series is a next-generation WHIMS engineered for weak magnetic mineral enrichment and non-metallic iron removal, integrating 30+ years of LONGi’s magnetic technology expertise and R&D collaboration with Northeastern University. Designed for wet processing of 0–1 mm fine minerals, it delivers exceptional performance across mining, ceramics, and glass industries.

Core Features of LGS Series WHIMS

• Ultra-High Magnetic Field Strength: Generates a 1.0–1.8 Tesla (10,000–18,000 Gauss) background field and up to 2.0 Tesla high-gradient field, efficiently capturing ultrafine weakly magnetic iron impurities and improving concentrate grade by 3–5% vs. peer equipment.
• Energy & Water Savings: Pioneers energy and water conservation tech, cutting power and water consumption by 20%+ compared to traditional WHIMS; the flagship LGS-5000 model reduces tonnage energy use by 69% while boosting throughput to 12x older models.
• Anti-Clogging & Stable Operation: Equipped with a patented air-water combined ore discharge system and a pre-slagging box for ore-discharge water, enabling uninterrupted removal of impurities and preventing pipeline blockages. The optimized magnetic matrix arrangement ensures no dead zones in the separation area, maximizing recovery.
• Smart & Modular Design: Features an intelligent operation management system for real-time monitoring of running data, health status, and maintenance alerts, reducing labor costs and enhancing management efficiency. Modular construction shortens installation time and simplifies maintenance.
• Global Market Recognition: The LGS Series has been exported to 70+ countries, including Australia, Brazil, Russia, and Spain—where it operates in Europe’s largest non-metallic processing plant, meeting strict EU standards. It is widely trusted for high efficiency, reliability, and low operational costs.

Youtube: https://youtu.be/1PMCXX0ayS4?si=4YBK9bma43FOv1l

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Conclusion

As global demand for high-purity minerals and efficient resource recovery grows, WHIMS remains a cornerstone technology for wet magnetic separation. Its ability to process fine, weakly magnetic materials with high efficiency and scalability makes it vital for modern mining and non-metallic industries. LONGi Magnet’s LGS Series WHIMS, with its innovative magnetic design, energy efficiency, and smart features, exemplifies the future of magnetic separation—delivering sustainable, high-performance solutions for global mineral processing challenges.

Media Contact
Company Name: LONGi Magnet Co.,Ltd
Contact Person: Lucy Ding
Email: Send Email
Country: China
Website: https://www.longimagnetics.com