Air-Cooled Suspended Electromagnetic Separator

Conveyor Tramp-Iron Removal

Corvelan air-cooled electromagnetic separators remove unwanted iron and steel from material moving on a conveyor. The electromagnet uses forced air to carry heat away while it runs. We choose the setup from your belt width, working distance, material depth, belt speed and target tramp iron.

Best ForConveyor-fed bulk material with unwanted ferrous tramp metal.

TargetIron and steel pieces that respond to the magnetic field.

Typical InstallationSuspended above a belt conveyor or transfer point after layout review.

Start WithBelt width, working distance, burden depth, belt speed and target tramp iron.

Ask Corvelan to Size It See How We Size It

Representative air-cooled suspended electromagnetic separator with forced-air cooling fan

Built Around Your Conveyor System: We do not choose this equipment from one surface-Gauss number or one catalog size. We check where the iron sits in the material, how the conveyor runs, how the iron will be removed and the site conditions. We then confirm the final setup in the quotation and general arrangement (GA) drawing.

Is It a Good Fit?

Is an air-cooled electromagnetic separator a good fit for your process?

This separator is a good option for dry or reasonably free-moving material on a conveyor. It removes unwanted iron and steel tramp metal. We also check how far the iron is from the magnet and how often cleaning is needed. The conveyor layout and site power conditions also matter.

Good fit when

Iron or steel tramp metal is the main contamination problem.
The material moves on a conveyor or through a transfer point.
There is space to suspend and support the separator.
Belt width, belt speed and burden depth can be defined.
The captured iron has a practical discharge or cleaning method.

Use another method when

The main target is aluminum or copper.
The process is a wet slurry or pressure pipeline.
The main job is separating fine, weakly magnetic minerals rather than removing tramp iron.
The required working distance or conveyor layout is not practical for a suspended separator.
The site has special hazardous-area or compliance needs that have not yet been defined.

Material & Tramp Iron

What material and tramp iron can this separator handle?

Corvelan uses this equipment to remove unwanted iron and steel from conveyor-fed bulk materials. Common tramp metal includes bolts, nuts, tools, chain pieces and scrap steel. The result depends on the size, shape, weight and position of the metal, plus the distance from the magnet.

We can review aggregate, ore, coal, clinker-related material, recycling feed, wood, biomass and other bulk solids. Send us the actual material and target metal so we can check the application.

Aluminum and copper need a non-ferrous separation method. Stainless steel can respond differently by grade and condition. If stainless steel is part of the target, send the grade or a sample requirement.

Working Principle

How does an air-cooled electromagnetic separator work?

When the coil is energized, it creates a magnetic field. Iron and steel pieces are pulled toward the magnet when they enter this field. The farther the iron is from the magnetic face, the harder it is to capture. Material depth, belt speed, and the size and shape of the iron also matter.

The coil creates heat while the magnet is energized. Fans move air around the electromagnetic assembly to carry this heat away. We choose the cooling setup from the required running time, site temperature and magnetic load. The final fan layout is confirmed with the selected separator.

The captured iron still has to be removed. Periodic cleaning can work when tramp loading is low and planned stops are acceptable. Choose a self-cleaning electromagnetic separator when the line needs automatic, continuous iron discharge.

Engineering diagram showing an air-cooled electromagnet lifting ferrous pieces from conveyor-fed material

Top-view representative air-cooled electromagnetic separator showing enclosure, fan position and lifting points

Air-Cooled Construction

What should the air-cooled design provide?

The fan, coil enclosure, lifting points and service space must work together. We check the required running time, site temperature and available space before we choose the cooling setup.

Cooling access: keep the air path clear and leave enough room to reach the fan.
Lifting and support: use the selected general arrangement (GA) drawing to confirm weight, lifting points and support loads.
Electrical package: match the magnet, fan and controls to the quoted design and site power supply.
Maintenance space: leave room for inspection, cleaning and service without blocking the conveyor or iron discharge area.

What Affects Capture

What affects tramp-iron capture?

Real working distance

Measure from the magnetic face to the iron at the hardest place inside the material bed. This is the real working distance. It matters more than the empty gap above the conveyor.

Burden depth

Burden depth means how deep the material bed is on the conveyor. A deeper or uneven bed makes the magnet work through more material and can hold buried iron in place.

Belt speed

Belt speed changes how long the iron stays in the magnetic field. It also changes the material path at transfer points.

Target tramp iron

The size, shape, weight, position and amount of tramp iron all affect how hard it is to capture.

Nearby steelwork

Steel beams, idlers and chutes near the magnet can affect the magnetic field and the space available for installation.

Running time & site temperature

We check how long the magnet needs to run, how much heat the coil makes and the site temperature.

We do not select by Gauss alone. Gauss is magnetic flux density at a defined point. It is not the same as pull force, working-distance capability, removal efficiency or throughput. The useful question is whether the selected field can act on your target at the real operating distance.

Choose the Right Magnetic Separator Configuration

Which setup fits your conveyor?

We evaluate the magnetic solution, cleaning method and installation position separately. We check each one against your conveyor and target tramp iron.

Compare Magnetic Separation Options First. Air-cooled, oil-cooled and permanent suspended magnets solve similar conveyor problems in different ways. We check the target tramp iron, real working distance, running time and site conditions before recommending the suitable solution.

Air-cooled vs oil-cooled vs permanent suspended magnet

Magnetic Solution	What it means	When we review it
Air-cooled electromagnetic separator	An energized coil creates the magnetic field. Forced air carries heat away from the electromagnetic assembly.	Review it when an electromagnetic solution fits the target and working distance, and the site can provide the required electrical supply and airflow.
Oil-cooled electromagnetic separator	An energized coil creates the magnetic field. An oil cooling circuit carries heat away from the electromagnetic assembly.	Compare it when the running condition, site environment or service needs point to an oil-cooled design.
Permanent suspended magnet	A permanent magnetic circuit creates the field. Electrical power is not used to create the magnetic field.	Compare it when a permanent field can meet the target and working distance, and the process does not need an energized coil.

Then choose the cleaning and mounting route

Your situation	Option to consider	What we check
Iron appears only occasionally, and planned cleaning stops are acceptable	Air-cooled separator with periodic cleaning	We check safe access, how much iron can collect and how often the line can stop.
Frequent tramp iron or automatic discharge is required	Self-cleaning electromagnetic separator	We check the discharge belt, drive, guarding, iron path and service space.
There is room to discharge iron to the side	Crossbelt layout	We check orientation, discharge side, support and clearance.
The separator is near a head pulley or transfer point	Inline layout	We check the material path, working distance, head-pulley layout and iron discharge path.
You prefer an air-cooled design without an oil cooling circuit	Air-cooled electromagnetic separator	We check running time, site temperature, airflow and the electrical package.
Long running hours, hot conditions or a difficult working distance	Compare electromagnetic cooling options	We check magnetic reach and heat load first, then choose the cooling method.

Send Your Conveyor Layout

Data We Need

What information do we need to size it?

One separator size does not fit every conveyor. Send us your conveyor and material details. We use them to choose the equipment and confirm the final values in the quotation and general arrangement (GA) drawing.

What we need	Why it matters	What we confirm
Conveyor belt width	Sets the magnetic coverage and the equipment width needed above the conveyor.	Selected equipment width and layout.
Burden depth / real working distance	Shows how far the magnetic field must reach to the hardest target position.	Selected setup checked against the stated distance.
Belt speed	Changes how long the iron stays in the magnetic field and how the material moves.	Selected setup checked against the belt speed.
Target tramp iron	Piece size, shape, weight and amount affect how hard the iron is to capture.	Target Tramp Iron listed in the sizing notes.
Cleaning requirement	Shows whether periodic cleaning or automatic discharge is the better choice.	Cleaning and discharge method in the proposal.
Electrical supply	The magnet, fan and controls must match the site power supply.	Electrical scope for the selected equipment.
Ambient / dust condition	Dust and site temperature affect cooling and equipment protection.	Equipment checked against the stated site conditions.
Installation position	Crossbelt and inline layouts need different space and iron discharge paths.	GA drawing for the selected installation.
Dimensions & weight	Needed for support steel, lifting and service space.	Final values in the quotation and GA drawing.
Acceptance requirement	If you need a measured result, the target and test method must be defined.	Agreed test or inspection plan when needed.

Where It Works

Where can we install air-cooled electromagnetic separators?

Before crushers

Remove iron and steel tramp metal before it reaches the crusher. We check the target metal and working distance first.

Before mills

Remove iron and steel pieces before they reach downstream grinding equipment.

At transfer points

A transfer point can be a good location. It can reduce the working distance and give captured iron a clear discharge path.

On bulk conveyors

We can configure the separator for mining, aggregate, coal, recycling, biomass and other conveyor-fed bulk materials that may contain tramp iron.

Installation

How should the separator be installed above the conveyor?

Keep the magnetic face as close as practical to the tramp iron. You still need enough space for safe material flow, iron discharge and maintenance. We also check nearby steelwork because it can affect the magnetic field.

Measure from the magnetic face to the hardest target position inside the material.
Record the normal and maximum material depth, not only the empty-belt gap.
Check whether crossbelt or inline installation gives enough room to discharge the captured iron.
Keep unnecessary steel away from the active magnetic area where practical.
Use the selected GA drawing for final support loads, lifting points and service space.

Diagram showing working distance, burden depth, conveyor motion and service clearance for suspended electromagnet selection

Representative suspended electromagnetic separator enclosure with alternative mounting bracket arrangement

Send a layout before you build the support frame

Send us a conveyor side view, belt width, material depth and available headroom. We can then check the magnet position, iron discharge direction and service space before the support frame is built.

Ask Corvelan to Size the Separator

Representative air-cooled electromagnetic separator showing external cooling fan and equipment enclosure

Cleaning & Maintenance

How do you clean and maintain it?

Plan fan access and iron removal when you plan the installation. The separator also needs enough room for safe cleaning, inspection and service.

Keep the cooling-air path and fan service area clear.
Use periodic cleaning only when tramp loading is low enough and planned stops are practical.
Use a self-cleaning separator when the line needs automatic, continuous iron discharge.
Provide a clear discharge area so removed iron cannot fall back into the material.
Follow site lockout/tagout requirements and the supplied operating instructions before inspection or service.

Diagram comparing periodic-cleaning and self-cleaning electromagnetic separator routes as project alternatives

Before You Order

What should be checked before you approve the separator?

We keep the conveyor data, drawing and any agreed test condition tied to the same setup. This helps prevent a mismatch between the quoted separator and the real installation.

Application record

Record belt width, belt speed, material depth, real working distance and the target tramp iron.

GA and interface check

Check overall size, support points, lifting points, service space and electrical interfaces on the selected general arrangement drawing.

Inspection points

Define which dimensions, cooling parts, wiring items and identification details need to be checked before shipment.

Agreed test condition

If a magnetic or capture test is needed, define the target piece, distance, position and pass condition before the order.

Keep the test condition with the result: A Gauss reading or capture result needs a clear test condition. Record the measurement position, working distance and test target.

Drawings and Inspection Records

What evidence can support the selected setup?

Tell us which drawings, inspection records or performance tests your purchase requires. We will confirm what is included in the quotation. We only publish measured results with the test condition stated.

Drawing

General arrangement drawing

Use the GA drawing to confirm the final size, lifting points, support position, service space and quoted interfaces.

Product

Real equipment photos

Use real product views to check the enclosure, cooling-fan arrangement, suspension points and service access.

Inspection

Dimension and interface checks

Where required, the inspection scope can identify the dimensions and interfaces that must match the approved drawing.

Electrical & Cooling

Electrical and cooling checks

Project checks can cover the quoted electrical package, fan arrangement and the items agreed before shipment.

Magnetic

Magnetic field measurement

If a field reading is required, the record should state the measurement point and distance. Surface Gauss alone does not show conveyor performance.

Capture

Defined capture test

If capture testing is part of the project, define the test before the order. State the test piece, weight, working distance, orientation and running condition.

Installation Examples

How should you compare a real separator application?

Do not compare projects by industry name alone. A useful case should show the conveyor conditions, target tramp iron, selected setup and the way the result was checked.

Case information	Why it matters	What should be recorded
Material and Installation Location	Shows what the separator is protecting or cleaning.	Material type and whether the unit is before a crusher, mill, transfer point or other conveyor position.
Belt width and belt speed	Defines conveyor coverage and exposure time.	Actual operating width and speed.
Burden depth and real working distance	Shows how far the magnetic field must reach.	Normal and maximum material depth plus the distance to the hardest target position.
Target tramp iron	Different pieces are not equally easy to capture.	Material, size, shape, weight and expected frequency.
Installation and cleaning method	Changes discharge space and service needs.	Inline or crossbelt position and periodic or self-cleaning method.
Result evidence	Shows what was actually checked.	Measured test result, inspection record, captured-iron photo or other stated evidence.

A photo is not enough by itself: A project example is most useful when the working distance, target tramp iron and operating condition are known. If the result is measured, the test method should be stated with it.

Why Corvelan

How does Corvelan select the right separator?

You do not need to choose a separator from Gauss alone. Send us the conveyor and tramp-iron details. We use them to choose the magnetic setup, cooling method and cleaning method. The quoted equipment is then tied to the drawing and agreed checks.

Review the conveyor

Belt width, speed, burden, headroom and installation position.

Define the tramp iron

Target material, piece size, weight and expected loading frequency.

Choose the setup

Air-cooled electromagnetic setup, cleaning method and installation direction.

Check integration

Support, clearance, discharge, electrical interface and service access.

Confirm the equipment and checks

The quotation and GA drawing define the selected equipment. Agreed inspection or test items are listed with the project scope.

What matters most: We size the separator for the real working distance and target tramp iron, not from one surface-Gauss number alone.

Common Questions

Air-cooled electromagnetic separator questions

What is an air-cooled electromagnetic separator?

It uses electrical power to create a magnetic field that pulls iron and steel from conveyor-fed material. Fans carry heat away from the electromagnetic assembly while it runs.

What is the difference between air-cooled and oil-cooled electromagnetic separators?

Both use an energized coil to create the magnetic field. Air-cooled designs use forced air to carry heat away. Oil-cooled designs use an oil cooling circuit. We compare the cooling method with the running time, site temperature, working distance and service needs.

Is air-cooled the same as self-cleaning?

No. Air cooling tells you how the electromagnet removes heat. Self-cleaning tells you how captured iron is discharged. We check these two needs separately.

How high should the separator be above the conveyor?

There is no single height for every conveyor. We use the real working distance: the distance from the magnetic face to the hardest target position inside the material. We also check safe clearance and the conveyor layout.

Does higher Gauss mean better tramp-iron removal?

Not always. Gauss tells you the magnetic field strength at one measured point. It does not tell you by itself whether the separator can lift iron through your material bed. Working distance, iron size and shape, material depth and belt speed also matter.

What tramp iron can the separator remove?

The main targets are iron and steel pieces such as bolts, tools, chain pieces and scrap. Send the expected size, shape, weight and amount so we can check the application.

When should I choose a self-cleaning electromagnetic separator?

Choose a self-cleaning separator when tramp iron is frequent, the line needs automatic discharge or repeated cleaning stops are not practical. We then check the discharge belt, drive, guarding and discharge space.

What data should I send Corvelan to size the separator?

Start with the material, target tramp iron, belt width, belt speed, material depth or working distance, and one installation photo or drawing. Add throughput, lump size, moisture, bulk density, site conditions, power supply and test requirements when available.

Can Corvelan provide a magnetic or capture test for my project?

If your project needs a defined test, tell us before quotation. Give us the target piece, working distance and test condition. We can then confirm whether the selected equipment can include that test.

Get a Recommendation

Send us your conveyor data

You do not need a finished specification. Send the belt width, belt speed, material depth or working distance, target tramp iron and one installation photo. That is enough for us to start.

Send first

Material and physical form
Target Tramp Iron / steel contamination
Conveyor belt width
Belt speed
Material depth or real working distance
Installation photo or drawing

Add when available

Normal and peak throughput
Particle or lump size
Moisture and bulk density
Target size / weight / loading frequency
Ambient and dust conditions
Power supply, cleaning preference and acceptance requirement
Existing site photos, previous captured-iron photos or test requirements

We use this information to check magnetic reach, cooling needs, installation direction and the iron-cleaning method before we confirm the equipment.

Send Your Conveyor Data