From a technical standpoint, the Bunting production plant based in Redditch, UK, has successfully created the biggest Electro Crossbelt (Overband) Magnet to date. Weighing 13 tons, this massive magnet now resides in a prominent gold mine in Northern Finland. Over the span of a year, it will systematically extract and isolate harmful tramp metal from around 2.7 million tons of conveyed ore, thus protecting crushers, screens, and other critical upstream equipment.

Operating on the principle of high-strength magnetic forces, the Electro Crossbelt Magnet swiftly picks up and automatically disposes of any ferrous tramp metal present in the conveyed ore. Positioned in a crossbelt orientation over the non-magnetic head pulley of a conveyor, it generates a strong magnetic field. Any tramp metal caught in this field is magnetically attracted and lifted onto a continuously moving self-cleaning rubber belt reinforced with heavy-duty rubber wipers. These wipers efficiently remove the captured metal, diverting it from the conveyed ore and into a specific collection area.

This revolutionary Electro Crossbelt Magnet is part of a major expansion project at the Kittila Gold Mine in Northern Finland.

Working closely with mine operators, Bunting engineers designed a custom solution tailored to the mine's unique requirements. Factors like conveyor width, ore volume, and the characteristics of tramp ferrous metal were thoroughly analyzed during the design phase. Using an in-house developed Electro Crossbelt Magnet Selection Program, the design team calculated the optimal magnetic field and force density needed for efficient separation.

The outcome is the model 205 OCW50 Electro Crossbelt Magnet, featuring a 17 kW electromagnetic coil cooled by recirculated oil. This cooling system is essential for maintaining the magnet's efficiency since magnetic force decreases as coil temperature rises. With dimensions measuring 4.2 meters in length, 3 meters in width, and 2.2 meters in height, this impressive magnet was assembled at Bunting’s manufacturing site in Redditch.

“Large-scale mining projects, such as this one, often demand bespoke solutions,” says Adrian Coleman, the General Manager of Bunting’s Redditch facility. “Over the past 40 years, Bunting has accumulated extensive experience in designing and building large Electro Crossbelt Magnets. However, this was the largest we’ve ever manufactured at Redditch, presenting numerous challenges that we managed to overcome. And the entire design and manufacturing process happened during the Covid-19 crisis.”

Get in touch with us today to discuss your application or to request a quote.