Abstract: To address the issues of limited processing capacity and low intelligence level of existing dry separators, which are difficult to meet the coal separation requirements of modern large-scale coal mines, a large-scale intelligent dry separator is developed. This equipment adopts a crank-rocker drive mode, is equipped with a 32 m² large sorting bed and a serrated screen plate, and integrates a air supply and dust removal system, which can achieve efficient sorting. Meanwhile, intelligent technologies such as fault diagnosis technology, process control systems and digital twin platforms is developed, enhancing the intelligence level of the equipment. These technologies are put into operation and application at the Shengli No.1 Open-pit Coal Mine of the National Energy Group. The research and application results show that its maximum processing capacity can reach 600 t/h when sorting fine coal ranging from 0 to 25 mm, and 500 t/h when sorting lump coal ranging from 25 to 70 mm, which is about 40% higher than that of the existing dry separator. The dust emission concentration is lower than 10 mg/m³, far below the national standard. The electricity consumption per ton of coal is approximately 1.37 kW, achieving energy savings of over 30%. The gangue content of the selected block clean coal is 1.85%, that of the fine clean coal is 2.52%, and that of the clean coal in the gangue is 2.49%. The separation performance is good. The annual income increases by 32.917 million yuan, with remarkable economic benefits. Moreover, the intelligent system significantly reduces the number of production personnel and their labor intensity, effectively solving the problem of lignite sorting.