Electro Crossbelt Magnet Protects Gold Mine
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June 21 07:06:46, 2025
In a remarkable achievement in engineering, Bunting's manufacturing plant based in Redditch, UK, has crafted the largest Electro Crossbelt (Overband) Magnet ever built. Weighing a staggering 13 tons, this colossal magnet now resides in a gold mine located in Northern Finland. Over the span of twelve months, it will diligently remove and isolate harmful tramp metal from around 2.7 million tons of conveyed ore, protecting essential equipment like crushers, screens, and other critical upstream processing machinery.
The Electro Crossbelt Magnet functions on the principle of strong magnetic forces, quickly lifting and automatically discarding any ferrous tramp metal present in the conveyed ore. Suspended above the non-magnetic head pulley of the conveyor in a crossbelt setup, it generates a powerful magnetic field. Tramp metal pulled into this field is magnetically attracted and lifted onto a self-cleaning rubber belt that moves continuously. Equipped with heavy-duty rubber wipers, the belt effectively clears the captured metal, redirecting it away from the conveyed ore and into a designated collection area.
This groundbreaking Electro Crossbelt Magnet is part of a major expansion project at the Kittila Gold Mine in Northern Finland. Working closely with mine operators, Bunting's engineers designed a custom solution addressing the mine's unique challenges. Conveyor width, ore volume, and the properties of tramp ferrous metal were carefully considered during the design phase. Using their 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 vital for maintaining the magnet's efficiency since magnetic strength decreases with rising coil temperature. Standing at 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.
The Electro Crossbelt Magnet is expertly engineered for perfect placement in a crossbelt configuration, specifically placed above the non-magnetic head pulley of a 1600mm wide conveyor. Operating at a 12-degree incline and a speed of 0.75 meters per second, the conveyor carries ore particles ranging in size from 70mm to 400mm. With capacities varying between 450 and 765 tons per hour, the total annual throughput reaches approximately 2.7 million tons.
Tramp iron, which varies in size and composition, includes steel rebar (measuring 2400 x 20mm diameter), cable bolts (measuring 600 x 15mm diameter), steel mesh, and broken drill bits. The Electro Crossbelt Magnet can handle a maximum working gap of 600mm, the distance between the magnet face and the bottom of the ore conveyor. It is capable of lifting and segregating tramp metal within a spread burden of up to 500mm, requiring a robust magnetic field with high force density.
"Large mining projects, such as this one, often demand bespoke solutions," says Adrian Coleman, the General Manager of Bunting's Redditch facility. "Over 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, which we successfully overcame. And the entire design and manufacturing process occurred during the Covid-19 pandemic."
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