Magnetic Force

Aggregate, Quarrying and Mining Industries

Quarrying and mining is effectively a recycling industry.

Aggregate Quarying

Taking minerals and ores that naturally occur – often deep underground, bringing them to the surface and then processing the raw materials so that they can be repurposed and eventually re-used in other industries, such as building materials or concrete. It all starts by extracting the various raw materials from the relevant locations – deep underground through mining and surface materials from quarrying. Varying techniques are employed to gain access to these materials, such as explosions and excavation equipment. In order to complete the process, the raw material is then crushed and screened before it is deemed ready for its future use.

Tramp metal (broken pieces of machinery, nuts, bolts and tool tips etc.) is often a problem found in these particular industries, as these bits and pieces lay in the ground and then dug up during the mining or quarrying process. This tramp metal is known as a contaminant and needs to be removed in order for the finished product to achieve purity. The unwanted metal can also cause damage to equipment (conveyor built tears etc.) if it isn’t removed. The overall effect of not removing tramp metal can be very costly – with production downtime and vital repairs all adding up. This is where magnetic separators pay their way, eliminating these often unseen but highly damaging problems.

Recycling is also a rich source of material for the aggregates industry with demolished buildings providing more in the way of raw materials. However, inevitably there is more tramp metal found within the concrete rubble with things like old wires, nuts, bolts and even reinforcing structures to contend with before the materials hit the crushing and screening process. As with the content unearthed from mining and quarrying, magnetic separators can be used to help remove these impurities and reduce the chances of damage to any machinery and equipment.

Bunting Magnetics produce a range of strong and durable magnetic separators for effective use in industries involving quarrying, mining and aggregates. Not only are they really sturdy but they are also extremely versatile – they can be retrofitted with ease into most existing process lines with little disruption, certainly in terms of rearranging any of the existing equipment. They are also available in varying strengths to fall into line with the current burden depths of conveyor belts. With contaminants needing to be removed as soon as possible, it makes sense to install magnetic separators before the process begins. Metal detectors are often used in tandem with the separators, making the metal separation itself even more effective. If you are unsure of what equipment will best suit your particular requirements, we are more than happy to offer advice and guidance in this respect.

Magnetic Separators for Aggregate, Quarrying & Mining Industries

Cross Belt Separators are designed to remove large pieces of metal as they move along a conveyor belt. These separators are also referred to as suspended magnets or overband magnets and to be effective they are usually – as the name suggests – suspended over a conveyor belt or head pulley and in this position they are ideally placed to remove the aforementioned pieces of metal.

Using a magnetic separation pulley you can convert a conveyor into a self-cleaning magnetic separator. Switch the head pulley for a strong magnetic one and debris or contaminants such as nails, nuts and bolts will stay attached to the belt and be filtered out, away from the main product. This metal contamination can then be gathered up and disposed of.

Another such separator is one which uses an eddy current. Mainly used during the recycling process of materials gathered from demolished buildings, the eddy current separators are fed the aggregate materials and the eddy current itself causes non-ferrous metals to repel the magnetic rotor, and any non-aggregate materials are collected separately away from the main product.

Metal detectors can also be fitted to conveyor belts, which will add another layer of protection, in terms of any contaminants getting through. The metal detectors, which Bunting Magnetics also manufacture, will identify any stray metal that the separation process may have missed and the conveyor can be programmed to stop (for removal purposes) as soon as any tramp metal is detected in this way.