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Best Magnetic Separators for the Rock Crushing Industry

Magnetic Separation

MSA Magnetics has two magnetic separators that are very well-suited to the rock crushing industry. These include the Overbelt & Suspension Magnets and the Magnetic Head Pulley Conversion.

In this blog post, we will be exploring each of these two options and what makes them a good fit for the rock crushing industry.

Overbelt & Suspension Magnets

Overbelt and Suspension Magnets are a great choice for rock crushing applications. Usually installed on fixed or mobile plants, these magnetic separators are mostly used for product purity purposes. Both the quality and the value of the processed product increases when magnetic metal fragments are extracted. Magnetic separators are a great solution that will quickly pay for itself!

Overbelt Magnets are also installed for machine protection purposes, as they can remove large magnetic fragments that can cause damage to expensive equipment and reduce the need for replacements. The damage caused by large magnetic rocks and scrap metal usually costs thousands of dollars, so removing them ahead of time not only prevents these large expenses, but it also allows for the process to go a lot more smoothly and with less challenges.

About the Overbelt Magnets

These magnetic separators are available in self-cleaning or manual-clean options, as well as inline or crossbelt applications.

The manual-clean suspension magnet is supplied with a stainless-steel drawer, which is used to clean the magnet. By simply pulling the drawer, the fragments are released from the bottom of the magnet!

Watch our salesman Michael clean a static manual-clean overbelt:

Our self-cleaning magnets are also a great choice for rock crushing plants. Designed, tested, and assembled in Australia using as many local components as possible, these magnetic separators remove magnetic material from the conveyor belt and discharge it into a separate contamination collection area.

Benefits of Overbelt & Suspension Magnets

Protection of crushers and expensive plant equipment
Improve product purity by effective extraction of contaminants such a roof bolts, pins, drill rods, earthmoving equipment parts and scrap metal, etc.
Designed and manufactured in Australia in accordance with Australian Std 3556-1998
Design options for remote locations
Prevention of downtime and reduction of maintenance as a result of damage to equipment or contamination of product

MSA Overbelt & Suspension Magnets

Watch this animation video to learn how Self-Cleaning Overbelt Magnets work in a processing line:

Magnetic Head Pulley Conversion

MSA Magnetic Head Pulleys are another fantastic choice for the rock crushing applications.

MSA apply a proprietary RE80 magnet conversion system to convert your existing head pulleys into high strength magnetic head pulleys. This enables the increase of unwanted tramp iron and metal fragment removal from your product lines without manual labour.

You can provide us with your own pulley for conversion, which is a more cost-effective option, but we also provide complete new magnetic head pulley solutions.

Magnetic Head Pulleys are usually installed on fixed or mobile plants, with the aim to improve product purity. The neodymium Magnetic Pulley has the ability to collect a broader range of materials, and both smaller and larger magnetic fragments. The magnetic separator captures a higher percentage of metal than an Overbelt Magnet, and operates on a higher speed.

Check out our Magnetic Head Pulley in action and Redding Crushing, and the metal fragments it is pulling out!

With MSA Magnetics, local support is available – before, during or after the purchase. Site visits and assessments are also available where required – contact us today.

MSA Magnetics – Your Source For Force

Are you aware there are deep field and shallow field Lifting Magnets available?

Deep field (Passive Shunting) Lifting Magnets have been used for many decades in Australia. In the last ten years shallow field (Active Shunting) Lifting Magnets have been gaining in Popularity.

To understand why we need to look at the differences and what that means in the workplace.

Deep field magnets are generally durable robust pieces of equipment, but many people are not aware that they will only lift their advertised capacity at the depth of their magnetic field.

This depth varies between sizes. An average PML 500kg magnet has a 40mm deep field. This means it is only rated to lift 500kg if the material you are handling is 40mm thick. If the material is 20mm thick this 500kg magnet is rated to lift 350kg. A 1-tonne deep field magnet typically has a 60mm deep field, so on 20mm material thickness, it is rated to lift 350kg which is the same as a PML 500kg magnet.

A shallow field magnet rated to lift 400kg has a 12.7mm deep field so it can lift 400kg of 12.7mm material. When you are handling 20mm plate it is still rated to lift 400kg.

Interestingly, most deep field magnets are not rated to lift material less than 10mm thick while many shallow field magnets are rated on material as thin as 0.5mm thick.

So, what that means in the workplace when you are using deep field magnets, is there is more potential to mismatch the magnet to the load.

A mismatch like using a 1-tonne PML with a 60mm field to lift 15mm plate will result in the lever being very hard to actuate and very hard to turn off. The lever will be very forceful on release resulting in a risk of wrist injuries.

Furthermore, a calculation is required by the operator to ensure the magnet is rated to lift the material at the given thickness.

Using a shallow field magnet on material from 0.5mm to 25mm thick will ensure that the levers actuate in a gentle manner, reducing potential wrist injuries while reducing the risk of operator error due to misunderstanding their magnets capacity on various thickness’s.

At MSA we supply both types and are looking forward to offering advice on which type suits your requirements.

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