Tag Archives: Bunting

Bunting on the importance of Permanent Overband Magnet selection for mineral separation

Permanent Overband Magnets are commonplace in mines and quarries, removing tramp ferrous metal and protecting crushers, screens and conveyors against damage. However, there are many different designs of Permanent Overband Magnet, developed to suit specific applications, with an understanding of installation being key to selecting the right one.

Bunting is a leading designer and manufacturer of magnetic separators, eddy current separators, metal detectors and electrostatic separators. The Bunting European manufacturing facilities are in Redditch, just outside Birmingham, and Berkhamsted, both in the United Kingdom.

Bunting designed and built the first Permanent Overband Magnets in the early 1980s and has since supplied thousands to companies operating across the world, it says. Although the basic technology has not changed, advances in magnet materials and manufacturing techniques have significantly enhanced the ferrous metal separation performance.

Overband Magnets lift and automatically remove tramp ferrous metal from conveyed mined or quarried rock. The permanent design features a magnet block mounted in a frame, with two or four pulleys, and a revolving self-cleaning rubber belt.

In operation, mined or quarried rock is conveyed underneath the Overband Magnet, which attracts, lifts and then removes damaging tramp ferrous metal. The size and type of magnetic system (Permanent or Electro) is dictated by the conveyor width, depth of material on the conveyor and the nature of the tramp ferrous metal.

Permanent Overband Magnets are commonly found on mobile plant such as crushers and screens.

Bunting’s range of Permanent Overband Magnets includes four different models to suit different installations. The heavy-duty PCB model suits quarry and small mining operations, operating at suspension heights of up to 400 mm on conveyors between 300 mm and 2,000 mm wide.

The PCB-C compact and lightweight model suits mobile plant installations, such as crushers and screens, and operations where space is limited. The PCB-C operates at suspension heights up to 250 mm, above 600 mm to 1,500 mm wide conveyors.

For installations where the Overband Magnet is located in a difficult location for regular maintenance, Bunting designed the QBC quick-belt change model. As the model implies, the self-cleaning belt is easy and quick to change, reducing downtime. This model operates at suspension heights up to 300 mm on conveyors between 600 mm and 1,500 mm.

The Tri-Polar Overband Magnet produces a different shaped magnetic field with increased power. Although commonly heavier, the deeper magnetic field means that the suspension height of the Tri-Pole is higher, up to 400 mm. The shape and depth of the magnetic field makes this model better suited for the separation of smaller or long and thin tramp ferrous metal.

Bunting concluded: “Selecting the correct Overband Magnet, in terms of permanent or electro and the specific model, is dictated by the application. Bunting’s applications engineers assess the ferrous metal separation objective (ie the plant being protected); the nature of the tramp ferrous metal (ie shape, size, etc); and the conveyed rock (ie size range, burden depth). These criteria assist the team in selecting the optimum Overband Magnet for any given application.”

Bunting ups the Electro Overband Magnet stakes for Agnico’s Kittilä gold mine

The largest Electro Overband Magnet ever built at the Bunting manufacturing plant in Redditch, England, is destined for installation at the Agnico Eagle-owned Kittilä gold mine, in northern Finland.

Over a 12-month operating period, the Overband Magnet will lift and separate damaging tramp metal from around 2.7 Mt of conveyed ore, protecting crushers, screens and other up-stream process plant, according to Bunting.

One of the world’s leading designers and manufacturers of magnetic separators for the recycling and waste industries, Bunting has European manufacturing facilities in Redditch, just outside Birmingham, and Berkhamsted, both in the UK.

The Electro Overband Magnet uses high-strength magnetic forces to lift and then automatically discard tramp ferrous metal present in conveyed ore, Bunting says.

“In operation, the large Electro Overband Magnet is suspended in a crossbelt orientation across the non-magnetic head pulley of a conveyor transporting mined ore,” the company explains. “Any tramp ferrous metal entering the deep and strong magnetic field is attracted to the face of the electromagnet and lifted up and onto the surface of a continuously-moving self-cleaning rubber belt.

“Reinforced and heavy-duty rubber wipers on the belt catch the captured metal, transferring it to the side and away from the conveyed ore. As the wipers move the ferrous metal out of the Overband Magnet’s magnetic field, it drops under gravity into a collection area.”

This latest Electro Overband Magnet is part of a major plant expansion and upgrade at Kittilä, Bunting said. This will see ore production go from 1.6 Mt/y to 2 Mt/y, with gold output expected to rise by 50,000 oz/y to 70,000 oz/y when completed.

When initially contacted, Bunting engineers worked closely with the mine operator to design a bespoke Overband Magnet for the difficult application, it said. Design considerations included the width of the conveyor, the volume of conveyed ore, and the size and shape of the tramp ferrous metal. With these details, the Bunting design team calculated the minimum magnetic field and force density for optimum separation using an in-house developed Electro Overband Magnet Selection program.

These criteria provided the basis for the design of the electromagnetic coil by the Bunting-Redditch engineering team.

The final design is a model 205 OCW50 Crossbelt Electro Overband Magnet, with the 17 kW electromagnetic coil, generating the strong magnetic field, cooled using recirculated oil. Efficient cooling of the electromagnet is critical as the magnetic force decreases proportionally to the rising temperature of the coil, Bunting said.

The Overband Magnet is 4.2 m long, 3 m wide and 2.2 m high, and weighs just over 13 t.

The Electro Overband Magnet is designed for positioning in a crossbelt orientation over the non-magnetic head pulley of a 1,600 mm wide conveyor, inclined at 12° and travelling at 0.75 m/s. The conveyed ore has a particle size range of between 70-400 mm, Bunting said, varying in conveyed capacity between 450-765 t/h (equating to 2.7 Mt/y).

“The tramp iron ranges widely in size and nature and includes steel rebar (2,400 x 20 mm diameter), cable bolts (600 x 15 mm diameter), steel mesh, and broken drill bits,” Bunting said. “With a maximum working gap of 600 mm (distance between the magnet face and the bottom of the ore conveyor), the Electro Overband Magnet is designed to lift and separate the tramp metal through a splayed burden of up to 500 mm. This requires a substantially deep and strong magnetic field and related force density.”

Adrian Coleman, General Manager of Bunting’s Redditch facility, said large mining projects, such as this, often require bespoke solutions.

“Over 40 years, we have gained considerable experience in designing and building large Electro Overband Magnets,” he said.

“However, this was the largest we have ever manufactured at Redditch, presenting many challenges, which were overcome. And the design and manufacturing process all took place during the COVID-19 crisis.”

Bunting expands Permanent Overband Magnet range

Bunting has released a new model Permanent Overband Magnet that, it says, is specifically developed for use on mobile plant such as crushers and screens used in mining, quarrying and recycling.

The PMax model is a lighter and more compact design that meets specific requirements of reduced maintenance time and lighter weights, it said. It has been released alongside the Easibelt Permanent Overband Magnet for recycling and bulk handling terminal applications. These models come on top of the classic PCB model in the Overband range.

The design of the Overband Magnet is simple with two pulleys mounted on a frame either side of a permanent magnetic block, according to Bunting. It is positioned above a conveyor, either over the head pulley, or more commonly across the belt. In operation, conveyed material passes under the Overband where the strong magnetic field attracts, lifts and then automatically discards tramp ferrous metal.

The PMax is 15% lighter than the standard PCB model across the range and 12% shorter in length, according to Bunting. These reductions result in a 14% higher magnetic force to weight ratio. It operates at a maximum working height of 300 mm (above the conveyor) on belts with widths between 600 and 1,500 mm.

The reduction in weight and size is achieved through adopting new manufacturing processes, including investing in new production plant, the company said. The new design release was in response to customer requests across Europe, it added.

Adrian Coleman, the General Manager of Bunting-Redditch, said: “Our PCB model has been an industry-standard for several decades and remains the optimum design for many applications. However, the PMax is specifically designed as a lower weight option for mobile plant, whilst the Easibelt offers significantly reduced maintenance time.”