The standard design of a disc separator features up to three high-intensity electromagnetic discs, with each disc set at a different height from a feed conveyor. The first disc is positioned the furthest from the feed material, so as to extract only the particles that are most magnetically susceptible. The second and third discs are set at lower gaps, and by increasing the magnetic force at each disc, different grades of magnetic material are able to be effectively separated. To further adjust magnetic intensity, the current of the coil can be adjusted to suit specific mineral separation requirements. This feature means that each disc separator can be set up and designed for an individual mineral ore.
In operation, processing begins with a hopper dispensing feed material onto a vibratory feeder tray, which then distributes material onto a thin and even layer onto a moving conveyor. While material is being conveyed beneath the rotating electromagnetic discs, the high gradient magnetic zones on the discs attract magnetic particles. Next, the rotating discs carry these captured particles to discharge chutes, entering a non-magnetic area where material is then released. To ensure total discharge of magnetic particles, scrapers are mounted on the chutes. Any non-magnetic material then moves to the second magnetic separation zone, undergoing secondary separation before finally being discharged as a clean non-magnetic product. If necessary, a third stage of separation may be added.
