For efficient extraction of ferrous and tramp metals from conveyed product streams.
Suited to non-food related industries such as recycling and mining, overbelt and suspension magnets offer a safe, efficient, and effective method of removing ferrous tramp and iron pieces. The magnets are installed above conveyed product streams and extract contaminating ferrous and tramp metal as the belt proceeds past – thus improving product purity and reducing equipment damage.
Commonly extracted ferrous contaminants from these types of installations include nails, screws, nuts, bolts, wire, chain, hammers, and crowbars – all of which can cause thousands of dollars in equipment damage if not removed early in the process.
- Improve product purity
- Prevention of damage to expensive downstream machineries such as shredders, crushers, mills, pulverizers, and grinders
- Prevention of damage, and the consequent costly repair and downtime, to conveyor belts cause by sharp metal pieces – this is especially a risk at discharge points
- Low-maintenance and self-cleaning designs available
- Reduction of downtime, maintenance, and repair costs to damaged downstream equipment, caused by the entry of tramp metal
- Cost of product rejection through failure to remove metal inclusions
- Potential savings from avoiding unnecessary landfill
- Mining operations including washeries
- Recycling plants
- Resource recovery
- Plastic operation
- Glass cullet recycling
- Shipping ports, ship loading
- Fertilizer manufacturing
- Power stations
- Wood chip & timber waste recycling
- Bulk materials handling & conveying
- Mobile crushers, screens, & shredders
- MRF (Material Recovery Facility) plants
- Auto & appliances recycling
- Municipal solid waste
- Kerbside collection and skip waste recycling
- Tyre & rubber recycling
- Electronics recycling/e-scrap
- Shredded steel
- Cement manufacturing
- Concrete batching plants
- Bulk sand and soil handling
Overbelt and suspension magnets can be installed over the top of the conveyor (cross-belt style) or at the end of the conveyor at discharge location (inline style).
Overbelt and suspension magnets are available in either permanent magnetic or electromagnetic designs. Each design has its own benefits and can include quick or self-cleaning methods.
|ADVANTAGES OF ELECTRO-MAGNETS||ADVANTAGES OF PERMANENT MAGNETS|
Overbelt Magnets consist of a magnet box surrounded by a continuously moving belt. The magnet is installed above the product stream conveyor, either mid-stream or at the conveyor discharge. As the product stream travels under the overbelt magnet, ferrous and tramp iron pieces are extracted and retained to the magnetic belt. The belt proceeds around the overbelt magnet housing. When it reaches the point at which it is no longer affected by the magnetic field, the collected metal is discharged and dropped off into collection bins.
Overbelt Magnets are popular due to their self-cleaning operation, which allows interrupted metal extraction and eliminates the need for operator cleaning schedules. They are also suited to applications where the typical level of ferrous contamination is high.
Suspension Magnets are a much simpler design than Overbelt Magnets. They consist of a block magnet (square, rectangular, or round) suspended above the conveyor with chains. The magnet face is positioned directly above the product stream, either cross-belt or inline (above conveyor discharge).
Regardless of whether Suspension Magnets are of permanent or electromagnetic design, there is usually manual labor involved in the cleaning process. The magnet must be shifted away from the conveyor before the collected metal is removed, otherwise, it may drop back into the product stream and cause recontamination. Because this manual labor is required, Suspension Magnets are typically selected for applications where the level of ferrous contamination is low and only occasional cleaning is required.
MSA also supply complete new magnetic pulley systems and magnetic pulley lagging for existing pulley magnets. These systems are installed at the discharge terminus of a conveyor and are used to effectively separate magnetic contaminants from the main non-magnetic product stream.
QUALITY AUSSIE-MADE MACHINES
Overbelt and Suspension Magnets available from MSA are high-quality, durable machines manufactured in Australia. They conform to current engineering standards and best practices. They are designed to provide low maintenance, effective metal separation.
Contact our magnet experts today for your magnetic needs!
Are you serious about safety? We are. So we’ve developed a range of high-quality magnetic solutions designed to hold your cables and power cords up off the floor. These magnets are an effective and inexpensive way to not only prevent trip hazards but also tidy up your work areas! The range includes the MSA FRAS Cable-Mate, Standard Cable-Mate, Cable-Buddy, and Powr-Safe Lead Holder Magnets.
The tools are easy to use. Each of the magnetic lead holders features a high-strength rare earth magnet which will hold to any flat magnetic steel surface. Simply attach the magnet to the magnetic surface and redirect the cable through the tool.
- Keeps floor spaces and/or work areas tidy
- Provides a safer working area
- Assists in meeting WHS obligations
- Greatly reduces the risk of slips, trips, falls, and injury
- Reduces the risk of electrocution by holding cables up and out of wet areas
Protects cables/hoses from machine & foot traffic, resulting in a return on investment by ensuring:
- Less wear/damage
- Longer lifespan of cables
- Reduced maintenance costs in repairing/replacing damaged cables
- Fast, no-fuss rerouting of cables (time-saving)
- Ability to organise and store cables in a safe practical location
- Although strong, they are easy to remove and place elsewhere
- Holds cables out of the working area, providing ease of working.
Magnetic Head Pulleys operate much the same as non-magnetic Head Pulleys, except that the metal pieces are discharged separately to the non-magnetic product stream.
As the product stream reaches the conveyor discharge point, ferrous metal is attracted to the pulleys magnetic field and held to the belt. As the belt moves around the pulley, the non-magnetic material is discharged in a normal trajectory, however, the ferrous metal is still held to the belt.
When the belt passes out of the magnetic field, the magnetic material drops off into a separate chute or bin to the rest of the product. A non-magnetic splitter may be installed to separate the two discharges.
Ferrous metals commonly extracted from the product stream include nails, nuts, bolts, wire, cans, screws, tools, and so on.
MSA can supply complete new Magnetic Head Pulleys or can fit Magnetic Lagging Strips to your existing Pulley.
The addition of Magnetic Lagging Strips to your existing Pulley is not only a cost-effective solution (as opposed to purchasing a complete new Pulley System), but also assists with conveyor belt tracking. The lagging will only cause a small increase in the weight and diameter of the existing pulley.
Foreign tramp iron and metal fragments in stock feed can cause injuries to farm animals and handlers, cause customer complaints, and can also damage expensive processing equipment.
MSA’s Stock Feed Magnet Retrieval Systems comprises of powerful Overbelt Suspension Magnets and Magnetic Head Pulleys. Used in combination, these two magnets have numerous advantages, some of which include:
- Help maintain and increase the value of the stock feed
- Increase product purity and final product protection
- Reduce liability
- Protect expensive processing equipment, such as chaft cutters
- Protect livestock from injury
The MSA Stock Feed Magnet Retrieval Systems have been known to reduce reject bales by 75-90% and customers have reported filling at least 1 x 44-gallon drum with recovered tramp metal within one month.
- Australian Made
- Engineered for use in stock feed production
- Scalping magnet easily discharged using proprietary stainless-steel draw system
- Cost-effective long-life option for steel separation
- High energy RE80 Rare Earth magnets
- Design assists with conveyor belt tracking
- Reduces belt damage
- Highly effective magnetic field design for maximum lower burden penetration
MSA Magnetics can supply complete new Magnetic Head Pulleys or can convert your existing Head Pulleys into Magnetic Head Pulleys.
For more information on how you can reduce tramp metal in your stock feed production, or to request a quotation, please contact the MSA team of engineers.
Let us help you find out.
MAGNETS FOR WASTE AND RECYCLING FACILITIES
The recovery of metal from waste materials is extremely important for the recycling industry.
The filtering out and extraction of metals has 3 main purposes –
- Resource Recovery – Metals can be reused. They are often remelted and reshaped into new products.
- Product Purification – Waste products such as timber and glass are more suitable for recycling after tramp metal has been removed.
- Plant Protection – Tramp metal can cause damage to expensive recycling equipment if not removed (e.g. plastic granulators).
METAL SEPARATION EQUIPMENT
Metal separation equipment such as Eddy Current Separators, Overbelt/Suspension Magnets, and Pulley Magnets are used in recycling and waste facilities to extract metal pieces from the products.
Commonly extracted metals include:
- Ferromagnetic particles such as iron, steel, and work-hardened stainless steel (SS). These are usually extracted by Overbelt Magnets or Pulley Magnets.
- Nonferromagnetic particles such as aluminium and copper along with inert materials. These are extracted by Eddy Current Separators.
Often a number of separators are installed in various strategic locations around a plant. This ensures that both types of metals are removed and the risk of metal contamination is minimized.
Overbelt and Suspension Magnets are installed above belt conveyors to magnetically lift ferrous metal pieces out of the product stream. Contaminants are held against the magnet until cleaned (manual and self-cleaning designs are available).
Click here for more information on overbelt magnets
Magnetic Head Pulleys operate at the discharge of belt conveyors. As waste is dropped off the end of the belt, the metal that may be on the belt, under the burden of material, is held by the magnetic energy of the pulley and dragged around by the belt underneath the conveyors and dropped off into another bin. Magnetic Head Pulleys are ideal as a secondary complimentary magnet downstream of overbelt/suspension magnets.
MSA can provide new magnetic head pulleys or can transform your existing head pulleys to a highly magnetic pulley using MSA’s patented magnetic lagging system.
Click here for more information on magnetic head pulleys
Eddy Current Separators are essential in material recycling facilities and other general dry waste processing plants. They are used for the removal of non-ferrous metals from dry waste streams. They are typically part of the final stage of the process, removing the non-ferrous materials from the remaining plastics and small fragments of paper/cardboard.
It is critical when dealing with unsorted recyclables to utilize magnetic screening upstream from the Eddy Current Separator (ECS). The ECS, unless it has an incorporated Drum Magnet, cannot remove ferrous materials. It is ideal to have magnetic screening upstream from the ECS to reduce load and wear and tear on the ECS.
RECYCLING AND WASTE APPLICATIONS
Magnetic separators are often used to filter out metal pieces from waste applications such as –
- Construction and demolition debris. Asphalt, bricks, concrete, plasterboard, timber, building waste, and other excavated demolition waste is often contaminated with metal pieces – from large pieces of concrete reo, wear plates, and bucket teeth, to smaller items such as nails, nuts, and bolts. These contaminants must be removed before the demolition material is processed to be used for pavements, earthworks, and drainage, amongst other uses.
- Material Recovery Facilities (MRF). All the stuff you’d find in a yellow recycling bin.
- Glass. Glass fines can be used as a replacement for virgin sand when manufacturing new glass objects, or for civil construction projects such as in the embedment of residential sewerage pipes and water mains – concrete aggregate and cement mix. It is essential that metal contamination is removed before it becomes an issue.
- Timber recycling such as utility poles, cable spools, and pallets. The need for high-quality timber products means that recycling timber is now more useful and viable than disposing it at landfill or using it as fuel. Wooden pallets are mostly recycled for poultry bedding. Timber products must be inspected for metal pieces such as nails and bolts before processing, otherwise, equipment is damaged easily.
- Tyres and rubber
- General waste
- Shredder floc
The Australian Government has committed to working with the Environment Protection Authority (EPA) over 9 years to assist in maintaining a clean environment and reducing landfill. Funding has been made available, through grants, to all sectors of the recycling industry to help improve best practice systems.
This includes funding for waste and resource recovery initiatives, such as improved recycling facilities. New and improved recycling infrastructure and equipment will allow waste processors to develop more innovative and efficient methods for processing materials.
A key target of the EPA is to increase the amount of waste processed and decrease the amount of waste sent to landfill by 75%. The EPA is aiming to increase the reuse, recycling, and reprocessing of materials such as timber, cardboard/paper, plastics, and packaging. Processed waste must therefore be high quality and free of any contaminants, such as metal pieces, that will have a negative effect on the recycling process and potentially damage plant equipment.
Between 2017-21, the NSW EPA initiative, ‘Waste Less Recycle More’ has allocated a total of $48 million to improving recycling infrastructure. Similarly, the Victorian Sustainability Fund has allocated $30.4 million to waste and resource recovery.
Magnets and Eddy Current Separators are critical components in any resource recovery application. Improvements to ferrous and non-ferrous metals sorting lines are able to be considered for partial funding under these current EPA grants.
Waste Initiatives have partnered with MSA to assist recycling companies’ with collecting unwanted tramp iron and metal pieces from their waste product lines.
Based in Singleton NSW, Waste Initiatives are leading suppliers of quality recycling solutions including balers, shredders, and compactors. They are also approved resellers of MSA equipment.
Magnetic separators are available direct through MSA, or from Waste Initiatives.
MSA Magnetics offers full-service support to all Waste Initiatives Magnet customers, so no matter who you decide to buy MSA products through you are covered!
MAKE AN ENQUIRY
Have a need regarding tramp iron and metal removal in your recycling facility? Contact us today for assistance and a quote on high-quality magnetic separation equipment.
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MSA were recently contacted by a recycling company Waste Initiatives. They had a client who needed prompt assistance with collecting unwanted tramp iron and metal fragments in their waste production lines.
After assessing their application and a number of possible solutions, it was decided that the most effective action to take was to install a high intensity, rare earth magnet pulley. The company had an existing head pulley available so they sent it to MSA for the addition of their special ‘magnetic pulley lagging’.
This system causes no disruption to the process line, but instead of dropping contaminates into the same bin as the clean material, the pulley carries the contaminates underneath the conveyer belt and drops them off into separate bin underneath the head pulley.
This was met with high praise from Managing Director Peter Smith, who says “We recently needed a Magnetic Pulley with a very quick turnaround. When we started making enquiries, many companies couldn’t make one or import one in less than a month. We made contact with MSA Magnetics and couldn’t believe the difference! They discussed the situation with us and gained an understanding of what we needed to do. We were able to make a simple Pulley and ship to MSA overnight. They had promised a 3-day turnaround to convert the Pulley to a Magnetic Pulley… we had it back on a truck within 24 hrs! I have no hesitation in recommending MSA for their high level of expert and professional assistance and engineering, quality workmanship and most of all, exceptional service”.
MSA provides complete new magnetic head pulley solutions OR magnetic lagging upgrades to your existing pulleys, any width and any diameter above 150mm.