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SB 501 UK

EDDY CURRENT SEPARATORS Principle and practice

The Theory
The use of Eddy Current Induction has been known and used for well over 100 years in the design of electric motors, dynamos and transformers. The principle is that an electrical charge is induced into a conductor by changes in magnetic flux cutting through it. Such changes in magnetic flux can be achieved by moving permanent magnets past a conductor.

Fig 2

The effect of these currents is to induce a secondary magnetic field around the particle; this field reacts with the magnetic field of the rotor, resulting in a combined driving and repelling force which literally ejects the conducting particle from the product stream (see Fig 1). In the Eriez Eddy Current Separators, a high speed magnetic rotor is fitted within a nonmetallic drum which travels much more slowly than the rotor so as to produce flux variations at the surface of the drum; the drum also acts as the head pulley of the conveyor carrying the product to be separated (see Fig 2). As the conducting particles (any metallic objects) are carried by the conveyor over the drum, the magnetic field passing through the particles induces currents into them. Since these particles are of random shapes, it is difficult for the induced current to flow within them in an orderly manner and the currents therefore tend to swirl around within the particles - hence Eddy Current. It is not possible to provide an instant ECS specification for a given application - most

materials being separated are roughly sized, randomly shaped and have variable material mixes; laboratory testing is therefore vital to predict the best type of machine and range of settings for a given range of products. The following variable factors can influence separation: q Particle shape q Particle size Non-ferrous metals q Particle conductivity q Density q Moisture content q Stickiness q Size distribution q Fibrous content q Metallics content In addition, the performance of the Eriez ECS can be optimised by varying the following parameters: q Belt speed q Rotor speed q Throughput q Feed method q Splitter(s) setting The magnetic flux and magnetic frequency is determined by the design of the rotor. All of the above factors must be considered before any design recommendation can be produced.

Ferrous removal
Magnets used in the Eriez ECS impart a strong magnetic pull on ferrous material which can override Eddy Current induction and can result in a violent, vibrating, attractive force which can cause high belt wear. This can be minimised by the use of special belts and wipers to ensure quick discharge of the particles. However, it is preferable to remove ferrous items from the product prior to the ECS. This can be achieved using a suitable magnetic separator. In all cases, Eriez personnel will be able to provide specialist advice on the correct method of dealing with the potentially damaging problem of ferrous contaminants.

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EDDY CURRENT SEPARATORS PRINCIPLE AND PRACTICE

Theory into practice

The Rotor
Eriez tests have shown that there is an optimum magnetic frequency at which high separation efficiency is achieved. This requires a high rotor speed, and Eriez has evolved a successful - and safe - method for holding the magnet assembly together at these speeds. In fact, Eriez units have been successfully tested at up to 4000rpm. The design of the rotors magnetic circuit - using top quality Rare Earth magnet material provides both a high flux density and a sharp change in polarity when balanced with field depth. The rotor is concentric with the head drum (see Fig 1) in order to maximise the magnetic effect over the whole of the drum surface; this provides the largest possible magnetic arc. The full rotor does not require change of position within the drum to suit different material types as with the eccentric models.

Splitters
The Eriez ECS units incorporate a number of different splitter arrangements. As particle sizes reduce, the splitter can be positioned higher up, and closer to the drum. A rear splitter can be fitted to scalp off any weakly magnetic materials from the non-metal if required.

A) Particle size 50mm - 100mm

For coarse duties, such as fragmented scrap, a comparatively wide and low splitter is required to allow for pieces to fully separate their trajectories (see Fig 4); if higher driving forces are imparted to the non-ferrous metallic particles, the splitter can be positioned higher, giving a cleaner separation process.

Rotor Direction
The rotor can be powered in both directions (see Fig 1): q Forward - in the same direction as the Head Drum q Backward - in the opposite direction to the Head Drum For normal medium to large materials (over 10mm), a forward rotation is preferable. Smaller particles tend to rotate when exposed to a moving magnetic field; this rotation is opposite to that of the rotor, and greatly outweighs any forward forces causing the particle to jump backwards out of the separation zone. By reversing the rotor, the particle then jumps forward (see Fig 3).

B) Particle size 10mm 50mm

For these middle sizes, the splitter settings can be gradually tightened up (see Fig 5).

C) Particle size below 10mm

For these sizes, reverse rotation is used and the splitter positions change. The optimum frequency for reverse rotation can differ greatly from the forward rotation mode. A special nonmetallic nose is fitted and the splitter is positioned as close as possible to the drum in order to catch the particles on their first jump (see Fig 6). For more difficult small materials a secondary splitter is positioned just after the first, and above the trajectory of the non-metallic material (see Fig 3), to extract nonferrous metal which, having just missed the first splitter, returns to the drum and receives a second kick.

For advice on individual applications, contact Eriez engineers at: Eriez Magnetics Europe Limited European Manufacturing, Design and Test Laboratory Headquarters Bedwas House Industrial Estate, Bedwas, Caerphilly CF83 8YG, UK

Telephone: 029 2086 8501 Fax: 029 2085 1314 Int Tel: +44 29 2086 8501 Int Fax: +44 29 2085 1314 E-mail: eriez@eriezeurope.co.uk www.eriez.com
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