Magnetic Separator Configurations
Two magnetic separator configurations used in e-waste mechanical recycling — the overhead magnetic belt (for large conveyor flows) and the magnetic drum (for continuous fine-material feed) — with how each works, indicative cost ranges, and where each is used in the processing line.
| Configuration | Function | Capacity / Throughput | Cost Range |
|---|---|---|---|
| Overhead Magnetic Belt | Installed above conveyor belts; powerful magnets attract and lift ferrous metals away from the material flow into a collection bin | Small/Medium ₹1L–3L; High Capacity ₹3L–10L | ₹1,00,000 – ₹10,00,000 |
| Magnetic Drum | Rotating drum with fixed magnet assembly inside; materials fed onto drum surface, ferrous metals stick to drum while non-magnetic falls away | Small/Medium ₹65k–2L; High Capacity ₹2L–5L | ₹65,000 – ₹5,00,000 |
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How to read this table
- Each row is one configuration; columns show function, capacity and cost notes, and total cost range.
- Both configurations are typically installed in series — the overhead belt first removes large ferrous pieces, then the drum handles the smaller ferrous particles in the finer stream.
- Cost ranges in the table include both small-medium and high-capacity notes — actual costs depend on magnet strength (gauss rating) and conveyor width.
About this table
Magnetic separation is the first metal-recovery step after shredding and secondary crushing — it pulls ferrous metals (iron and steel) out of the mixed material stream using permanent or electromagnetic magnet assemblies. Two configurations are used in e-waste plants: the overhead magnetic belt and the magnetic drum. Both exploit the same physics — ferrous particles are attracted to the magnetic field while non-ferrous metals and plastics pass through unaffected — but their physical arrangement suits different positions in the processing line.
The Overhead Magnetic Belt is installed above a moving conveyor belt at an angle. The magnet lifts ferrous particles off the conveyor belt surface and carries them away, dumping them into a separate collection bin as the belt cycles away from the magnetic field. This configuration is best for high-volume, high-speed conveyor lines where the material bed is relatively deep — the powerful overhead magnet penetrates the material layer to reach ferrous particles even when they are partially buried under non-ferrous or plastic material. It is typically the first magnetic separation step in the line, positioned after primary shredding.
The Magnetic Drum uses a rotating drum with a fixed magnet assembly inside. Material is fed onto the drum surface — ferrous particles stick to the drum due to the magnetic attraction and are carried to the side of the drum where the magnetic field weakens, then fall into a collection bin. Non-ferrous particles and plastics, unaffected by the magnet, drop off the drum face at the leading edge. The magnetic drum is effective for fine-particle streams (5–20 mm) and is placed after hammer mill reduction when particle sizes are smaller and the overhead belt configuration is less efficient. Both configurations are typically used in series — overhead belt first for bulk ferrous removal, then magnetic drum for fine ferrous polishing.
Key insights
- Both magnetic separator configurations are typically installed in series for maximum ferrous recovery — the overhead belt for bulk removal and the magnetic drum for fine-particle polishing of the residual ferrous fraction.
- Magnetic separators are among the lowest-cost equipment items in the processing line relative to their commercial value — ferrous metal recovery that they enable typically represents 10–20% of the plant's total revenue.
- Magnet strength (measured in gauss) is the primary performance specification — high-gauss magnets recover more deeply buried and finer ferrous particles, improving ferrous recovery rates from complex mixed-material streams.
- Magnetic drums are particularly effective after hammer mill reduction where particles are uniformly 5–20 mm — the drum surface contact ensures thorough ferrous extraction from the finer stream.
Methodology & sources
Configuration descriptions and cost ranges are based on equipment specifications as described in course materials and Indian market data as of 2024. Magnetic separator performance depends on material feed rate, particle size distribution, and magnet strength. Obtain vendor specifications for your plant's specific throughput and particle size before selecting configuration and sizing.
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