Current Status and Development Requirements of Electromagnetic Iron Removers in the Ceramic Industry
Architectural and sanitary ceramic manufacturers have shown increased attention to iron removal, with many companies placing it on their agendas. Responsible personnel or designated managers are often involved in overseeing the process. The application of iron removers has gradually expanded from glaze to body materials. The variety of products requiring iron removal has increased, including household ceramics, sanitary ware, light-colored glazed floor and wall tiles, and polished tiles. Iron removal requirements have also risen. A single production line, which previously used no iron remover, now may install one, and in some cases three to four units in series. The number of magnetic rods in a single iron removal trough has increased from ten to twenty to as many as two to three hundred, with corresponding increases in investment.
Due to the accelerated depletion of mineral resources, some companies have difficulty sourcing low-iron standard raw materials locally or affordably. As a result, they have adopted downstream processing methods and are using iron removers extensively. In some cases, more than ten workers are assigned to iron removal tasks on a single production line, leading to higher iron removal costs.
Cleaning methods largely rely on manual labor, and quality stability can be inconsistent. A typical set of magnetic rods consists of 100 to 300 pieces, with 1 to 3 workers per shift cleaning them in rotation, approximately every 1 to 2 hours. When raw materials contain high levels of iron, thick layers of iron sludge tend to accumulate around the rods, reducing iron removal efficiency. Additionally, factors such as worker conditions can make quality management more challenging.
The quality of magnetic rods on the market varies. There are many manufacturers and brands, some of which produce rods with poor workmanship, using inferior materials and inadequate sealing at both ends. The circulation of such products has contributed to a decline in the average service life of magnetic rods used by companies. Furthermore, the labeled B-value of magnetic rods is often higher than the actual measured value, in some cases by 50% to 100%.
Dry powder iron removal is commonly carried out using drawer-type vibrating frame permanent magnetic separators and belt-driven separators. These are mainly used to remove rust and iron particles that may enter the powder during long-distance conveying. Their performance is generally satisfactory, and the number of users is gradually increasing.
Electromagnetic iron removers have been developed and trialed for some time, with generally acceptable feedback from users. They perform reasonably well in separating weakly magnetic materials from raw ores under high-intensity magnetic fields. However, their relatively high investment cost, significant power consumption, and relatively short service life have limited their wider adoption.
In developed regions, ceramic raw materials are typically processed centrally and produced to standardized specifications. The iron removal equipment used there is often large-scale, high-capacity, high-power, and fully automatic electromagnetic iron removers. These units are large in size and expensive, with prices ranging from hundreds of thousands to several million yuan.
Architectural and sanitary ceramic manufacturers have shown increased attention to iron removal, with many companies placing it on their agendas. Responsible personnel or designated managers are often involved in overseeing the process. The application of iron removers has gradually expanded from glaze to body materials. The variety of products requiring iron removal has increased, including household ceramics, sanitary ware, light-colored glazed floor and wall tiles, and polished tiles. Iron removal requirements have also risen. A single production line, which previously used no iron remover, now may install one, and in some cases three to four units in series. The number of magnetic rods in a single iron removal trough has increased from ten to twenty to as many as two to three hundred, with corresponding increases in investment.
Due to the accelerated depletion of mineral resources, some companies have difficulty sourcing low-iron standard raw materials locally or affordably. As a result, they have adopted downstream processing methods and are using iron removers extensively. In some cases, more than ten workers are assigned to iron removal tasks on a single production line, leading to higher iron removal costs.
Cleaning methods largely rely on manual labor, and quality stability can be inconsistent. A typical set of magnetic rods consists of 100 to 300 pieces, with 1 to 3 workers per shift cleaning them in rotation, approximately every 1 to 2 hours. When raw materials contain high levels of iron, thick layers of iron sludge tend to accumulate around the rods, reducing iron removal efficiency. Additionally, factors such as worker conditions can make quality management more challenging.
The quality of magnetic rods on the market varies. There are many manufacturers and brands, some of which produce rods with poor workmanship, using inferior materials and inadequate sealing at both ends. The circulation of such products has contributed to a decline in the average service life of magnetic rods used by companies. Furthermore, the labeled B-value of magnetic rods is often higher than the actual measured value, in some cases by 50% to 100%.
Dry powder iron removal is commonly carried out using drawer-type vibrating frame permanent magnetic separators and belt-driven separators. These are mainly used to remove rust and iron particles that may enter the powder during long-distance conveying. Their performance is generally satisfactory, and the number of users is gradually increasing.
Electromagnetic iron removers have been developed and trialed for some time, with generally acceptable feedback from users. They perform reasonably well in separating weakly magnetic materials from raw ores under high-intensity magnetic fields. However, their relatively high investment cost, significant power consumption, and relatively short service life have limited their wider adoption.
In developed regions, ceramic raw materials are typically processed centrally and produced to standardized specifications. The iron removal equipment used there is often large-scale, high-capacity, high-power, and fully automatic electromagnetic iron removers. These units are large in size and expensive, with prices ranging from hundreds of thousands to several million yuan.
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