Magnetic Separation Equipment

Magnetic Head Pulley Separator for Belt Conveyors

Corvelan magnetic pulleys remove iron and steel as material leaves the end of a belt conveyor. They are also called magnetic head pulleys because they work at the conveyor head. We match the pulley to your conveyor, belt speed, material depth, target iron and discharge layout.

Request a Configuration Review See How It Works

Best ForBulk material moving on a belt conveyor

TargetTramp iron, steel pieces and other strongly magnetic iron-based (ferrous) material

InstallationAt the conveyor head / discharge end

We Size It FromConveyor size, belt speed, material depth, target iron and discharge layout

320–1250 mmRCTG reference drum diameter

500–1800 mmRCTG reference face length

≤ 2.5 m/sRCTG listed belt speed

1500–1800 GSGauss values in the listed RCTG models

Coverlan permanent magnetic pulley separator with drive shaft bearings and rubber-lagged drum

Permanent magnetic pulley assembly with drive, shaft and bearing supports. Final model and conveyor interface are confirmed for the project.

Quick Fit

Is a Magnetic Pulley the Right Separation Point?

A magnetic pulley works well when your material already moves on a belt conveyor. The conveyor head must also have enough space to keep the normal material and captured iron in separate discharge paths. We check these points before we define the pulley.

Good Fit

Your material already travels on a belt conveyor. The target is iron or another strongly magnetic metal, and there is room at the conveyor head for two discharge paths.

We Need to Check

Some jobs need a closer check. Watch for deep or uneven material layers, sticky material and high belt speed. Very small iron pieces, unusual belt contact or limited space for the divider plate, often called a splitter, can also change the result.

We Recommend Another Separator When

If the conveyor head is not the right place, we can review another option. This may be a suspended magnet, a magnetic drum or another magnetic separator.

Process Goal

What Are You Trying to Solve?

We start with the job you need the separator to do. That helps us check whether a magnetic head pulley is the right type of separator before we work on detailed dimensions.

Protect Downstream Equipment

Remove tramp iron before it reaches crushers, grinders or other downstream equipment that can be damaged by ferrous pieces.

See conveyor protection options →

Reduce Ferrous Contamination

Separate unwanted iron and steel from the bulk material stream at the conveyor discharge.

Recover Iron and Steel

Separate magnetic iron and steel into their own discharge stream when the recovered metal has process or recycling value.

See ferrous recovery applications →

Material & Contaminant Fit

Where Does a Magnetic Pulley Fit the Material Stream?

We normally use a magnetic pulley when material already moves on a belt conveyor and the target iron responds well to a magnetic field. There must also be enough space for the captured iron to leave through a separate discharge path. How the material sits on the belt also matters. A thin, even layer is easier to separate than iron buried under a deep or sticky layer.

Typical fit

Bulk material that moves on a belt conveyor and can fall freely at the head pulley.
Iron and steel pieces, fragments or particles that respond strongly to a magnetic field.
Jobs that need tramp-iron removal, equipment protection, iron recovery or lower ferrous contamination.

We review these limits

Aluminum and copper need a different separation technology unless they are attached to an iron-based magnetic part.
Very small or weakly magnetic particles may need a separator with a stronger magnetic gradient or a test-led separation route.
Sticky material, tightly mixed material or deeply buried iron may need a different feed setup or another type of separator.

Typical Applications

Where Can a Magnetic Pulley Be Used?

The RCTG and CXG product families cover conveyor iron removal, mineral pre-selection, building materials, steel, power, chemical processing, waste treatment and metal recovery. We still match the separator to the real material, target iron and conveyor condition.

Mining & Mineral Pre-Selection

Problem: Waste rock or magnetic ore must be separated after crushing.

Why it may fit: The CXG family is intended for dry pre-selection and can use the conveyor discharge as the magnetic separation point.

Aggregate & Building Materials

Problem: Tramp iron can damage crushers, screens or downstream equipment.

Why it may fit: RCTG family data includes building-material applications where iron is removed at the conveyor head.

Review conveyor iron-removal options →

Steel & Steel-Slag Recovery

Problem: Metallic iron must be recovered from slag or a mixed bulk stream.

Why it may fit: The CXG application data includes metal recovery from steel slag and similar dry material streams.

See ferrous recovery applications →

Power, Coal & Bulk Handling

Problem: Tramp iron must be removed before the next process stage.

Why it may fit: The RCTG family is listed for power and other bulk-handling applications where automatic iron discharge is needed.

Review coal magnetic separation →

Waste Treatment & Recycling

Problem: Exposed ferrous pieces must be removed or recovered from waste material.

Why it may fit: Both family data sets include waste-treatment or metal-recovery uses where a conveyor-head separation point is practical.

See steel-wire recovery logic →

General Conveyor Protection

Problem: Iron or steel pieces threaten downstream equipment.

Why it may fit: A magnetic pulley can combine the conveyor head function with continuous ferrous removal when the discharge geometry is suitable.

Working Principle

How Does a Magnetic Pulley Separator Work?

As the belt moves around the magnetic head pulley, most non-magnetic material falls away in its normal path. Iron and other strongly magnetic metal stay with the belt for longer. They stay attached while they pass through the strong part of the magnetic field. Engineers often call this the active magnetic zone. The captured metal drops after it leaves this area. We position the divider plate or chute so the two material streams stay separate.

Engineering illustration showing ferrous material retained around a magnetic head pulley and discharged separately

Engineering concept. We confirm where the pulley holds the iron, where it releases and where the divider plate should sit from your conveyor layout.

1. Approach

Bulk material reaches the conveyor head on the belt.

2. Attract

The magnetic field pulls iron and other magnetic metal toward the pulley through the belt and any pulley covering. This covering is often called lagging.

3. Retain

The captured iron stays with the belt while the non-magnetic material leaves the head pulley.

4. Release

Captured metal drops after it leaves the strong magnetic area and is collected separately.

The RCTG and CXG families use permanent magnetic systems. The magnetic circuit does not require electrical excitation; conveyor or pulley drive power is separate from the magnetic system.

Performance Factors

What Controls Magnetic Separation Performance?

A single surface Gauss number cannot predict the final separation result. Gauss is a magnetic flux-density reading at a defined point. We also look at the target iron, the distance from the magnet, material depth, belt speed, feed condition and discharge layout.

What We Check	Why It Matters	What to Send Us
Distance From the Magnet	The magnetic field must reach through the pulley covering, belt and material layer. Engineers call the distance between the magnet and the target the working distance.	Belt and pulley-covering details, plus the material depth.
Material Depth	Iron buried under a deep material layer is harder for the magnetic field to reach. Engineers often call this layer the burden depth.	Normal and peak material depth if known.
Belt speed	Speed changes both the time available for magnetic response and the discharge trajectory.	Normal operating speed and any major variation.
Target Iron or Steel	Size, shape and magnetic response change how easily the iron or steel can be captured.	Photo, sample description, size range and the result you need.
How the Material Feeds	Uneven feed, moisture, sticky carryback and large lumps can hide the iron or make it harder to release cleanly.	Material description, photos and any known moisture or stickiness.
Magnetic Area & Discharge Layout	We check how long the pulley holds the iron, how much belt contacts the pulley, where the iron releases and where the divider plate sits.	A conveyor-head drawing, side view or clear site photos.

Gauss ≠ pull force ≠ separation efficiency. We only compare magnetic readings when the measurement point and method are clearly defined.

Gauss & Performance

Does Higher Gauss Mean Better Magnetic Separation?

No. A higher surface Gauss number does not automatically mean better separation.

Gauss

A magnetic flux-density reading taken at a stated point. The value changes with measurement position and distance.

Pull Force

Depends on the test object, contact condition, magnetic circuit and test setup. It is not the same as a Gauss reading.

Separation Result

Also depends on target iron, working distance, material depth, belt speed, feed condition and discharge layout.

That is why Corvelan does not select a magnetic pulley from one Gauss number alone. We compare magnetic readings only when the measurement point and method are defined, then review them with the real conveyor condition.

What the RCTG reference data shows: the 16 listed RCTG reference models use surface magnetic-flux-density values from about 1500 to 1800 GS, material-layer references from 40 to 260 mm, and a listed belt speed of ≤2.5 m/s. The published technical specifications also state that other magnetic-strength versions from 800 to 8000 GS can be specified when ordering. These values describe the available magnetic-pulley configurations. Separation performance also depends on working distance, material depth, target metal and operating conditions.

Surface Gauss ≠ working-distance field ≠ pull force ≠ separation efficiency.

Configuration

How We Configure Your Magnetic Pulley

We do not select a magnetic pulley from belt width alone. The pulley must fit the conveyor, the magnetic system must suit the target iron, and the discharge area must keep the two material streams separate.

Mechanical Fit: Pulley diameter, face width, shaft, bearings, mounting centres and drive connection.
Operating Conditions: Belt width, speed, load, belt wrap and material depth.
Magnetic Requirement: Target iron, working distance and the internal magnetic circuit.
Discharge & Service: Iron release point, divider or chute, collection space, guarding and service access.

Have the basic conveyor data already?
Send the belt width, speed, current pulley details and target iron. We can identify the missing inputs before detailed sizing.

Discuss Your Separation Point

Product Construction

What Parts of a Magnetic Pulley Matter to the Project?

A magnetic pulley must do two jobs at once: support the conveyor belt and create a useful magnetic separation zone. The product photos show the finished pulley, internal permanent-magnet assembly and workshop magnet-block construction.

Pulley Shell

The rotating shell supports the conveyor belt and forms the working surface around the magnetic system.

Magnetic Circuit

The internal segmented permanent-magnet assembly creates the useful magnetic area around the shaft.

Shaft

The shaft connects the pulley to the bearings and drive arrangement. Final dimensions must match the selected model and conveyor.

Bearings

Bearing type and mounting centres must fit the conveyor structure and mechanical load.

Pulley Surface / Lagging

The RCTG and CXG families include smooth and rubber-lagged configurations. Surface selection affects belt grip, wear and working distance.

Divider Plate / Chute

The divider keeps the normal material and captured iron in separate paths after discharge.

Rubber-lagged permanent magnetic pulley with shaft and bearing supports — Finished rubber-lagged magnetic pulley reference.

Permanent magnetic pulley internal magnetic assembly and shaft — Internal permanent-magnet assembly around the central shaft.

Permanent magnet blocks assembled around a magnetic pulley shaft in the workshop — Workshop reference showing magnet blocks assembled around the shaft before the outer shell is fitted.

RCTG Reference Range

RCTG Permanent Magnetic Pulley Reference Models

The current RCTG reference range includes 16 listed models. Use these values as a starting point for model matching; final pulley, shaft and magnetic details are confirmed against the project technical data before production.

Model	Surface Flux Density	Reference Material Layer	Max. Belt Speed	Drum Ø D	Face Length L	Weight
RCTG-32/40	1500 GS	≤40 mm	≤2.5 m/s	320 mm	500 mm	150 kg
RCTG-32/50	1500 GS	≤60 mm	≤2.5 m/s	320 mm	600 mm	198 kg
RCTG-40/50	1550 GS	≤80 mm	≤2.5 m/s	400 mm	600 mm	250 kg
RCTG-50/50	1600 GS	≤100 mm	≤2.5 m/s	500 mm	600 mm	370 kg
RCTG-32/65	1500 GS	≤70 mm	≤2.5 m/s	320 mm	750 mm	245 kg
RCTG-40/65	1550 GS	≤100 mm	≤2.5 m/s	400 mm	750 mm	405 kg
RCTG-50/65	1600 GS	≤130 mm	≤2.5 m/s	500 mm	750 mm	520 kg
RCTG-50/80	1550 GS	≤100 mm	≤2.5 m/s	500 mm	950 mm	610 kg
RCTG-65/80	1650 GS	≤130 mm	≤2.5 m/s	650 mm	950 mm	720 kg
RCTG-80/80	1800 GS	≤150 mm	≤2.5 m/s	800 mm	950 mm	980 kg
RCTG-65/100	1700 GS	≤130 mm	≤2.5 m/s	650 mm	1150 mm	910 kg
RCTG-80/100	1700 GS	≤170 mm	≤2.5 m/s	800 mm	1150 mm	1200 kg
RCTG-65/120	1800 GS	≤100 mm	≤2.5 m/s	650 mm	1400 mm	1500 kg
RCTG-100/120	1800 GS	≤200 mm	≤2.5 m/s	1000 mm	1400 mm	1890 kg
RCTG-100/140	1800 GS	≤230 mm	≤2.5 m/s	1000 mm	1600 mm	2160 kg
RCTG-125/160	1800 GS	≤260 mm	≤2.5 m/s	1250 mm	1800 mm	2800 kg

Magnetic strength note: the RCTG sheet also states that other magnetic-strength versions from 800 to 8000 GS can be specified when ordering. This does not mean every diameter and face length automatically uses every Gauss value; the final combination must be confirmed for the project.

View RCTG reference interface dimensions

All interface dimensions in the table below are in mm.

Model	A	D	L	L1	K	Shaft Ø d	h	b
RCTG-32/40	728	320	500	926	100	45	48.5	14
RCTG-32/50	850	320	600	1097	115	50	53.5	14
RCTG-40/50	850	400	600	1097	115	55	60	16
RCTG-50/50	850	500	600	1097	115	55	60	16
RCTG-32/65	1000	320	750	1280	135	65	69	18
RCTG-40/65	1000	400	750	1280	135	65	69	18
RCTG-50/65	1000	500	750	1280	135	70	76	20
RCTG-50/80	1300	500	950	1580	135	70	76	20
RCTG-65/80	1300	650	950	1661	175	70	76	20
RCTG-80/80	1300	800	950	1661	175	90	76	24
RCTG-65/100	1500	650	1150	1861	175	90	97	24
RCTG-80/100	1500	800	1150	1954	215	90	97	24
RCTG-65/120	1750	650	1400	2195	215	110	119	32
RCTG-100/120	1750	1000	1400	2270	255	110	119	32
RCTG-100/140	2000	1000	1600	2446	255	110	119	32
RCTG-125/160	2150	1250	1800	2600	255	120	129	32

Heavy-Duty Dry Pre-Selection Family

CXG Permanent Magnetic Pulley for Mineral Pre-Selection

The CXG family is a permanent dry pre-selection magnetic pulley for mineral and metal-recovery applications. It uses a high-strength permanent magnetic system, a stainless-steel drum shell and non-magnetic stainless material between the shaft and magnetic system.

NdFeB permanent magnet500–1400 mm drum diameter600–1600 mm drum length380–7535 kg reference weight

Can be configured as a drive pulley or a driven pulley.
Reference data includes smooth and rubber-lagged surfaces.
The CXG reference note lists a typical rubber-lagging thickness of 14 mm, with other requirements available by project.
Applications include mineral pre-selection, waste-rock rejection, steel-slag metal recovery and waste-treatment metal separation.
Published CXG technical specifications state that drum-surface magnetic intensity is determined by testing the actual material rather than by one fixed value for every model.

Smooth-shell permanent magnetic pulley in workshop assembly — Smooth-shell magnetic pulley reference.

600–1600 mmCXG reference drum length

500–1400 mmCXG reference drum diameter

14 mmTypical listed rubber lagging

380–7535 kgCXG reference weight range

Magnetic-field note: the CXG reference table does not assign one universal drum-surface magnetic intensity to every model. It states that the value should be confirmed through testing based on the actual on-site material. This supports a test-led selection route for mineral pre-selection.

View CXG reference model dimensions, torque and weight

Model	Drum Length L	Drum Ø D	Smooth-Pulley Allowable Torque	Rubber-Lagged Allowable Torque	Weight
KS-CXG50	600 mm	500 mm	1.63 kN·m	2.5 kN·m	380 kg
KS-CXG65-1	750 mm	500 mm	2.12 kN·m	3.26 kN·m	580 kg
KS-CXG65-2	750 mm	630 mm	2.96 kN·m	4.54 kN·m	800 kg
KS-CXG80-1	950 mm	500 mm	2.62 kN·m	4.01 kN·m	765 kg
KS-CXG80-2	950 mm	630 mm	3.67 kN·m	5.61 kN·m	1090 kg
KS-CXG80-3	950 mm	800 mm	5.59 kN·m	8.55 kN·m	1480 kg
KS-CXG100-1	1150 mm	630 mm	4.57 kN·m	7.01 kN·m	1285 kg
KS-CXG100-2	1150 mm	800 mm	6.96 kN·m	10.68 kN·m	1865 kg
KS-CXG100-3	1150 mm	1000 mm	—	17.75 kN·m	2795 kg
KS-CXG120-1	1400 mm	630 mm	5.49 kN·m	8.4 kN·m	1610 kg
KS-CXG120-2	1400 mm	800 mm	8.37 kN·m	12.81 kN·m	2465 kg
KS-CXG120-3	1400 mm	1000 mm	—	21.3 kN·m	3560 kg
KS-CXG120-4	1400 mm	1250 mm	—	30 kN·m	5230 kg
KS-CXG140-1	1600 mm	800 mm	9.76 kN·m	14.92 kN·m	2865 kg
KS-CXG140-2	1600 mm	1000 mm	—	24.925 kN·m	4405 kg
KS-CXG140-3	1600 mm	1250 mm	—	35.0 kN·m	6005 kg
KS-CXG140-4	1600 mm	1400 mm	—	47.0 kN·m	7535 kg

Table note: “—” means the source table does not list a smooth-pulley torque value for that model. We do not infer a value that is not provided.

Project Data

Match the Reference Model to Your Conveyor

The RCTG and CXG ranges give us a real starting point, but the selected pulley still has to fit your conveyor correctly. Send the existing drawing, dimensions and operating data so we can match the reference model and confirm the final shaft, bearings, drive and discharge layout before production.

What We Need	What We Check
Pulley & belt size	Diameter, face width, belt width, belt contact and edge clearance.
Shaft, bearings & drive	Shaft size, mounting centres, bearing arrangement and drive connection.
Belt speed & wrap	Operating speed and how much the belt contacts the pulley.
Material depth	Normal and peak depth where available.
Target iron or steel	Type, size, shape, approximate amount and required result.
Magnetic requirement	Target response, working distance and required magnetic area.
Divider / chute	Space for two discharge paths and material collection.
Surface & environment	Belt grip, wear, temperature, dust, moisture, corrosion and site limits.

Choosing the Right Separator

When We Recommend Another Separator

Quick Fit already tells you when a magnetic pulley is a strong starting point. We move to another route when the conveyor head cannot present the target or discharge the captured iron cleanly.

Deep or Sticky Material Layer

If the iron stays buried too far from the pulley, we may review an upstream separation point or a suspended conveyor magnet.

Need a Controlled Feed Stage

If the process needs its own feed, rotating separator and controlled splitter, a magnetic drum may be the better route.

Main Target Is Non-Ferrous

Aluminum, copper and similar metals need another separation method unless they are attached to a strongly magnetic iron-based part.

No Clean Discharge Space

If the head cannot provide two stable material paths, we review another installation point or separator type.

Not sure which type of separator fits?
Send us the material, target iron and conveyor layout. We can check the separation route before you spend time on detailed pulley dimensions.

Send Your Conveyor Layout

Separator Comparison

Magnetic Pulley vs Magnetic Drum vs Suspended Magnet

These separators can all remove ferrous material, but they solve different layout problems. Choose from the process position, material presentation, working distance and the place where captured iron can be discharged safely.

Question	Magnetic Pulley	Magnetic Drum	Suspended Magnet
Where does it work?	At the conveyor head / discharge end.	At a separate controlled feed and discharge stage.	Above a conveyor or transfer point.
Does it replace the head pulley?	It can, when the conveyor dimensions and discharge layout allow it.	No. It is a separate rotating separator.	No. It works above the main conveyor.
Good starting point when	The head end is already a practical separation point and two discharge paths can be created.	The feed can be controlled and split into magnetic and non-magnetic discharge paths.	Tramp iron must be removed before the conveyor discharge or before vulnerable equipment.
Deep or uneven material layer	Needs careful review because buried iron is farther from the magnetic source.	Can be reviewed with a controlled feed and drum arrangement.	Working distance and burden depth are key selection inputs.
Retrofit impact	May replace the existing head pulley when the shaft, bearings, belt and discharge layout can be matched.	Usually adds a separate separator stage.	Needs overhead mounting space and a suitable support structure.
Main project inputs	Pulley fit, belt speed, material depth, target iron and discharge layout.	Feed condition, layer depth, drum arrangement, speed and splitter position.	Burden depth, working distance, belt speed, target iron, cleaning method and mounting space.
Where to learn more	This page.	Review the controlled-feed separator route during the application review.	See conveyor magnet selection →

Selection Example

Example: Reviewing a Conveyor Head Pulley Application

Suppose a belt conveyor carries aggregate toward a crusher and the target is tramp iron. This example shows how target metal, material depth and conveyor conditions affect preliminary magnetic-pulley selection.

1. Check the Target

Is the target strongly magnetic iron or steel, and what size and shape must be removed?

2. Check the Material Layer

Can the target get close enough to the magnetic field through the belt, pulley covering and material depth?

3. Check the Conveyor

Can the head pulley, shaft, bearings, belt contact and drive arrangement be matched to the magnetic pulley?

4. Check the Discharge

Is there enough space for the normal material and captured iron to leave through separate, stable paths?

If these conditions are workable, we move to pulley dimensions, magnetic circuit selection and the final check requirements.

Retrofit & Installation

Replacing an Existing Head Pulley?

A magnetic pulley can replace an existing head pulley in some projects, but we first confirm the mechanical fit and the space for two discharge paths.

1. Existing Pulley

Send the drawing or the diameter, face width, shaft, bearings and drive details.

2. Conveyor Fit

We check belt width, speed, belt contact, tracking and available space.

3. Discharge Paths

We check where normal material and captured iron will fall and where the divider should sit.

4. Final Pulley

We confirm the final dimensions and any required checks before production.

Mechanical Fit Comes First

Before magnetic performance, we check the pulley body, shaft, bearings, belt contact and surrounding structure.

Match shaft and bearing positions to the conveyor.
Confirm pulley diameter, belt contact and drive-side space.
Leave enough room for service access and two discharge paths.

Magnetic pulley body shaft and bearing workshop reference

Workshop product reference showing the pulley body, shaft and bearing support points. Final construction and installation details vary by project.

What to Send for a Retrofit Review

If Available	Send Us
Existing pulley & drive	Drawing or main dimensions, shaft, bearings and drive-side details.
Belt	Width, normal speed and known tracking or load information.
Material & target iron	Material description plus target-iron photo, size and shape if available.
Available space	Side-view photo or layout showing the head, chute, frame and collection area.

Have an existing head-pulley drawing?
Send it with the material and target iron. If not, send clear photos and the dimensions you already have.

Send Your Conveyor Drawing

Service

Routine Service Points

The magnetic pulley separates continuously, but the conveyor and discharge area still need routine inspection. The main checks are the parts that can change the distance from the magnet, belt tracking or the two discharge paths.

Belt & Tracking

Inspect the belt condition, alignment and pulley covering. Wear or buildup can change the distance between the magnet and the target iron.

Bearings & Shaft

Maintain the bearings, shaft and mounting parts as part of the conveyor service plan. The RCTG family data also describes a detachable shaft arrangement intended to simplify service.

Divider Plate / Chute

Remove buildup and make sure captured iron cannot fall back into the normal material stream.

Iron Collection

Keep the collection area clear and large enough for the amount of captured iron.

Follow the final conveyor guarding, lockout and site safety requirements during inspection and service.

Validation

How We Check the Final Selection

Before we use a test result, we agree on the test method. This keeps dimensions, magnetic readings and separation checks tied to the real conveyor condition.

What We Check	How We Check It
Pulley Fit and Dimensions	Compare pulley, shaft, bearing and installation dimensions with the agreed project data.
Magnetic Field Check — if required	Define the instrument, probe direction, measurement point and distance first.
Separation Test — if required	Define target iron, material depth, belt speed, test passes and pass/fail rule.
Discharge Check	Check the divider or chute, both material paths and the collection area.
Final Check Record	Record the dimensional, magnetic or separation checks included in the project.

We tie any performance number to a defined pulley setup and test condition.

CXG family example: the CXG technical data specifically states that drum-surface magnetic intensity is determined through testing based on the actual material. That is why target material and operating condition come before a final magnetic value.

If you need a drawing, magnetic record or separation test record, include it in the quotation scope before production.

Corvelan Engineering Support

What You Get From Corvelan Before We Finalize the Pulley

Send the material and conveyor information. We turn it into a defined separator route, pulley fit and final check plan.

Select the Product Family

We first decide whether the RCTG conveyor-head route, the CXG dry pre-selection route or another separator is the better fit.

Match a Reference Model

We compare drum diameter, face length, material depth, belt speed and the available reference sizes.

Confirm the Conveyor

We check shaft, bearings, drive, belt contact, installation space and discharge paths.

Finalize the Checks

We confirm the drawing and any required dimensional, magnetic or separation check before production.

FAQ

Magnetic Pulley Separator FAQ

These are the questions we most often answer before we select and size a magnetic pulley for a conveyor.

What is a magnetic pulley separator?

A magnetic pulley is a conveyor head pulley with magnets inside. Non-magnetic material leaves normally; iron stays with the belt longer and drops into a separate path.

What is the difference between a magnetic pulley and a magnetic drum separator?

A magnetic pulley works at the conveyor head. A magnetic drum is a separate separator with its own feed and discharge. We choose from your process layout and material presentation.

Magnetic pulley or suspended magnet — which one should I use?

Use a magnetic pulley when the head is the right separation point. Use a suspended magnet when iron should be removed from above the belt before discharge.

Can a magnetic pulley replace my existing conveyor head pulley?

Yes, in some projects. We first confirm pulley size, shaft, bearings, drive, belt conditions and discharge space. We do not assume a size-for-size swap.

Does higher Gauss mean better magnetic separation?

No. Gauss is one reading at one point. Working distance, target iron, material depth, belt speed, feed condition and discharge layout also affect separation.

What RCTG magnetic pulley sizes are listed in the reference range?

The RCTG reference range covers drum diameters from 320 to 1250 mm and face lengths from 500 to 1800 mm. The 16 listed models use a reference maximum belt speed of 2.5 m/s. Final model selection still depends on the conveyor, material depth and target iron.

What magnetic strength is available for the RCTG family?

The 16 listed RCTG models show approximately 1500 to 1800 GS at the stated reference condition. The RCTG published product family specifications also notes that other magnetic-strength versions from 800 to 8000 GS can be specified when ordering. Gauss is a configuration value, not a direct separation-efficiency rating.

What information should I send for magnetic pulley selection?

Start with material, target iron, throughput and process condition. For a retrofit, add belt details and the current head-pulley drawing or dimensions if available.

Initial RFQ

Send Us These Four Details First

You do not need a finished specification before contacting us. Send what you already know. We will tell you what else we need after the first review.

MaterialName, typical size and any moisture or stickiness that matters.

Target ContaminantIron or steel type, approximate size and whether it must be removed or recovered.

ThroughputNormal and peak flow if known.

Installation / Process ConditionHead location, pulley details, belt width and speed, material depth and discharge space.

If Available, Add These Details

Existing head-pulley drawing or clear site photos.
Current pulley diameter, face length, shaft size and bearing arrangement.
Belt width, belt speed and how much the belt wraps around the head pulley.
Normal and peak material depth plus target-iron size or sample photos.
Smooth or rubber-lagged surface preference if already known.
Drive connection, available installation space and discharge layout.
Any required drawing, dimensional inspection, magnetic reading or separation test record.

Send the information already available and we will identify the remaining data required for final selection.

Next Step

Ready for a Magnetic Pulley Configuration Review?

Send us your material, target iron, throughput and the conveyor information you already have. We will check whether a magnetic pulley fits the job and tell you what we need next.

Send Your Separation Requirement

Magnetic Head Pulley Separator for Belt Conveyors

Is a Magnetic Pulley the Right Separation Point?

Good Fit

We Need to Check

We Recommend Another Separator When

What Are You Trying to Solve?

Protect Downstream Equipment

Reduce Ferrous Contamination

Recover Iron and Steel

Where Does a Magnetic Pulley Fit the Material Stream?

Where Can a Magnetic Pulley Be Used?

Mining & Mineral Pre-Selection

Aggregate & Building Materials

Steel & Steel-Slag Recovery

Power, Coal & Bulk Handling

Waste Treatment & Recycling

General Conveyor Protection

How Does a Magnetic Pulley Separator Work?

1. Approach

2. Attract

3. Retain

4. Release

What Controls Magnetic Separation Performance?

Does Higher Gauss Mean Better Magnetic Separation?

Gauss

Pull Force

Separation Result

How We Configure Your Magnetic Pulley

What Parts of a Magnetic Pulley Matter to the Project?

Pulley Shell

Magnetic Circuit

Shaft

Bearings

Pulley Surface / Lagging

Divider Plate / Chute

RCTG Permanent Magnetic Pulley Reference Models

CXG Permanent Magnetic Pulley for Mineral Pre-Selection

Match the Reference Model to Your Conveyor

When We Recommend Another Separator

Deep or Sticky Material Layer

Need a Controlled Feed Stage

Main Target Is Non-Ferrous

No Clean Discharge Space

Magnetic Pulley vs Magnetic Drum vs Suspended Magnet

Example: Reviewing a Conveyor Head Pulley Application

1. Check the Target

2. Check the Material Layer

3. Check the Conveyor

4. Check the Discharge

Replacing an Existing Head Pulley?

1. Existing Pulley

2. Conveyor Fit

3. Discharge Paths

4. Final Pulley

Mechanical Fit Comes First

What to Send for a Retrofit Review

Routine Service Points

Belt & Tracking

Bearings & Shaft

Divider Plate / Chute

Iron Collection

How We Check the Final Selection

What You Get From Corvelan Before We Finalize the Pulley

Select the Product Family

Match a Reference Model

Confirm the Conveyor

Finalize the Checks

Magnetic Pulley Separator FAQ

Send Us These Four Details First

If Available, Add These Details

Ready for a Magnetic Pulley Configuration Review?

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