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Iron removal for the Minera San José copper mine in Chile's Atacama Desert
one. Client Background and Core Pain Points
Our client, Minera San José, located in the world's driest region, the Atacama Desert in Chile, specializes in high-grade copper mining. Its core production process is located at a crushing station hundreds of meters underground, creating an extreme environment: confined space, limited ventilation, and air filled with explosive sulfide dust.
Under these conditions, iron debris mixed in the ore, such as broken drill rods, shovel teeth, and hardened steel balls, becomes the crusher's primary killer. Frequent iron jams cause equipment downtime, and each repair takes hours, resulting in significant production losses. Furthermore, the sparks generated by traditional non-explosion-proof equipment during operation can easily trigger dust explosions in this environment, with devastating consequences. The client previously relied on manual, scheduled power outages for cleaning, which was inefficient and placed workers at extreme risk.
two. Tailored Solutions
To meet the client's dual needs for absolute safety and ultimate efficiency, we provided a specialized RCDD-type explosion-proof overbelt magnetic separator for mining.
Processing Material: Primary copper ore after blasting, with a maximum size of no more than 400mm.
Processing Capacity/Operating Conditions: Installed on the underground main conveyor belt (B800), the system has a designed processing capacity of 150-200 tons/hour, fully meeting its production capacity requirements.
Core Equipment Configuration and Customization Features:
Highest Level Explosion-Proof Certification: The entire machine strictly complies with ATEX and IECEx standards, achieving "Ex d I Mb" explosion-proof certification. The explosion-proof casing can withstand internal explosion pressure and strictly seals out flames and high temperatures, fundamentally eliminating the possibility of ignition of external explosive atmospheres (methane, coal dust, and sulfur dust).
Fully Automatic Self-Unloading System: An integrated automatic unloading conveyor automatically unloads iron objects. Adsorbed iron objects are automatically removed from the strong magnetic field and deposited into a side iron collection bin. This entire process requires no downtime or human intervention, truly achieving "no-operation, no-load" safety.
Adaptable to high altitudes and harsh environments: The electromagnetic system utilizes H-class insulation and forced air cooling, ensuring stable magnetic force, efficient heat dissipation, and worry-free continuous operation even in thin air at altitudes of 3,000 meters.
Robust Structure and Anti-Corrosion Design: Core components utilize thickened steel plates and reinforced ribs to withstand ore impact. The surface is coated with a heavy-duty anti-corrosion paint to withstand the humid and corrosive environment underground.
three. Implementation and Outstanding Results
The equipment has been installed at a key station before the crusher in a Chilean mine, serving as an "intelligent sentinel" for underground safety.
Establishing an Intrinsically Safe Defense: Since its commissioning, the equipment has achieved zero safety incidents in potentially explosive environments, eliminating the customer's greatest safety hazard and enabling it to successfully pass rigorous local safety audits.
A Leap Forward in Production Continuity: The powerful magnetic force and automatic iron unloading function have reduced the crusher's failure rate due to iron jamming by over 98%, significantly improving the production line's continuous operation capacity and significantly increasing monthly copper ore processing volume.
Significant overall benefits:
Cost reduction: The system saves on the labor costs of dedicated iron ore cleaning workers and avoids tens of thousands of dollars in repair costs and production downtime due to crusher damage.
Efficiency improvement: The system streamlines production processes and significantly reduces maintenance workload.
The customer calculated that the payback period for the RCDD explosion-proof overbelt magnetic separator is only 5.2 months.
Customer testimonial: Mr. Carlos Rodríguez, Director of Underground Operations at Minera San José, commented: "Deep underground in the Atacama, we place no compromise on safety. This RCDD explosion-proof overbelt magnetic separator from China, with its exceptional reliability and innovative self-unloading design, has perfectly resolved a long-standing pain point for us. It's more than just a piece of equipment; it's a trusted safety partner for our underground team. Its stable operation has brought us unprecedented peace of mind."
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