Air-Cooled Electromagnetic Separation | Automatic Iron Discharge

Air-Cooled Self-Unloading Electromagnetic Separator

Corvelan air-cooled self-unloading electromagnetic separators remove unwanted iron and steel from dry bulk material moving on a conveyor. These unwanted pieces are often called ferromagnetic tramp iron. The electromagnet pulls the metal out of the material, while the moving unloading belt carries captured metal away automatically.

CoolingAxial-flow fans move air around the electromagnet and coil to help control heat during operation.

TargetIron and steel pieces that respond to the magnetic field in dry conveyor-fed material.

Automatic dischargeThe moving belt carries captured metal away from the magnet and into the collection area.

Selection depends onConveyor width, material depth, working distance, belt speed, target iron and installation layout.

Request a Configuration Review See Selection Requirements

Coverlan air-cooled self-unloading electromagnetic separator

Quick Fit

Is this the right separator for your conveyor?

This separator is a good choice for dry material on a conveyor when you need continuous removal of iron and steel without stopping for routine manual cleaning.

A Good Choice When

Material moves on a conveyor, the unwanted metal is iron or steel, and the site has enough space for suspended installation and automatic discharge.

What We Need to Check

Distance from the magnet to the target, material depth on the belt (burden depth), belt speed, target iron size, ambient temperature, dust, support structure and discharge space.

Choose Another Separator When

The main target is aluminum, copper or another non-ferrous metal; the process is wet or slurry-based; or the project needs a hazardous-area or other certified design that has not been defined.

Corvelan selects the model from your actual conveyor conditions, not from belt width alone.

Applications

Where We Use Air-Cooled Self-Unloading Electromagnetic Separators

We use this equipment above conveyors where unwanted iron or steel can damage downstream equipment, enter the product stream or need continuous removal.

Mining & Ore Handling

Remove unwanted iron and steel before crushers, screens and downstream conveying equipment.

Cement & Aggregate

Protect crushing, milling and material-handling equipment from unwanted iron and steel.

Coal & Bulk Fuel

Continuously remove iron and steel from conveyor-fed bulk fuel and raw-material lines.

Recycling Lines

Remove iron and steel pieces from dry conveyed material when an electromagnet is the right separator type.

General Bulk Handling

Protect downstream process equipment where unwanted iron or steel may enter dry conveyed material.

Working Principle

How the separator removes iron from a conveyor

When power is supplied to the electromagnet, it creates a magnetic field. The field pulls iron and steel pieces out of the material moving below the separator.

Captured metal stays against the moving unloading belt while it passes over the magnet. The belt carries the metal away from the center of the magnet. As the magnetic force becomes weaker, the metal drops into the collection area. Cooling and unloading do different jobs: the fan removes heat from the electromagnetic coil, while the unloading belt removes the captured metal.

Electromagnetic captureAutomatic iron dischargeForced-air coolingCross-belt or inline installation

Front configuration view of an air-cooled self-unloading electromagnetic separator

Product Systems

Forced-air cooling and automatic unloading support continuous conveyor operation

electromagnetic separator showing forced-air cooling fan arrangement

Forced-Air Cooling for the Electromagnetic Coil

The cooling system removes heat from the electromagnetic coil during operation. Our design uses axial-flow fans to move air around the electromagnet and coil.

self-unloading electromagnetic separator showing automatic discharge belt arrangement

Continuous Self-Unloading

The unloading belt carries captured iron away from the center of the magnet. When the metal reaches a weaker part of the magnetic field, it drops into the planned collection area.

Selection Requirements

Information Needed for Your Separator Recommendation

We do not select this separator from conveyor width alone. We match the magnetic system, cooling, unloading arrangement and installation to the real conveyor conditions.

Conveyor Width

The belt width helps define the required coverage and the starting equipment size.

Material Depth

The deeper the material bed, the farther some iron pieces are from the magnet. This distance matters for capture.

Working Distance

We check the distance from the magnet face to the target iron, not only the mounting height above the conveyor structure.

Belt Speed

Faster material movement gives the magnet less time to attract and lift the target iron.

Tramp Iron Requirements

Size, shape and typical type matter. Tell us whether you expect bolts, bars, plates, broken equipment parts or other ferrous pieces.

Installation Conditions

Cross-belt or inline position, discharge side, service space, support and power supply all affect the final configuration.

Send us these conditions and we will narrow the equipment configuration for quotation. Exact dimensions, power, magnetic acceptance values and model designation are confirmed from the approved project data.

Send My Conveyor Data

Start With Four Numbers

Start With These Four Conveyor Values

These four values give us a practical starting point. We then check the target iron, available space, discharge direction, power supply and operating conditions before quotation.

1. Conveyor Belt Width

Use the belt width to identify the first group of separator configurations to review. The final choice still depends on the distance to the iron and the material on the belt.

2. Material Depth

Material depth, often called burden depth, tells us how deeply iron may be buried. Deeper iron sits farther from the magnet and is harder to lift.

3. Suspension Height

Suspension height is the planned distance between the separator and the conveyor or material level. We compare this with the available product range and the real working distance to the target iron.

4. Belt Speed

Belt speed changes how long the iron stays inside the useful magnetic zone. Faster material movement gives the magnet less time to lift and hold a difficult piece.

Fastest way to narrow the model: send the belt width, material depth, planned suspension height and belt speed, plus the largest iron or steel piece you expect to remove.

Send the Four Selection Values See the Full RFQ Checklist

Dimensions & Installation

Confirm the Installation Envelope Before Production

Overall dimensions and mounting points depend on the selected configuration. We confirm the final general-arrangement (GA) drawing after the conveyor conditions and installation layout are reviewed.

Conveyor width and material path
Planned magnet position and working distance
Cross-belt or inline arrangement
Required discharge side and collection space
Support structure and service clearance
Power supply and cable routing

For layout planning

Send a conveyor drawing, photo or available-space sketch. We use it to check the mounting direction, service access and discharge path before the final project drawing is approved.

Use the approved Corvelan project drawing for final fabrication and installation. Final dimensions are confirmed after the selected configuration is reviewed.

Performance Factors

What makes iron easier or harder to capture?

Magnetic field strength matters, but it is not the only factor. We also check distance, material depth, belt speed, target size and the way material moves on the conveyor.

How Far Is the Iron From the Magnet?

Working distance is the real distance from the magnet face to the target. It includes the suspension gap, material depth and conveyor geometry. More distance usually makes capture harder.

How Deep Is the Material on the Belt?

Material depth, often called burden depth, affects how close the iron can get to the magnet. Deep or uneven material can hide the target farther from the magnetic field.

How Fast Is the Material Moving?

Higher belt speed gives the magnet less time to attract and lift the iron from the material stream.

What Size and Type of Iron Do You Need to Remove?

The size, shape, weight, position and amount of iron all affect how easily the magnet can capture it.

How Does the Material Move on the Conveyor?

Lump size, moisture, bulk density and flow pattern change the depth of material on the belt and how exposed the iron is to the magnet.

Where Will the Captured Iron Go?

Captured iron needs a clear path away from the magnet and into a safe collection area.

Gauss or mT does not equal pull force or separation efficiency. A magnetic reading describes the field at a defined test point. It does not by itself prove a removal percentage or throughput.

Separator Comparison

Which Suspended Magnetic Separator Fits Your Process?

Choose the separator type from the cleaning requirement, magnetic system, working distance, available power and installation conditions. The table below is a starting guide, not a substitute for the final conveyor review.

Separator Type	Good Starting Point When	Check Before Selection
Air-Cooled Self-Unloading Electromagnetic	Continuous conveyor operation needs an energized electromagnet and automatic discharge of captured iron.	Working distance, target iron, cooling airflow, power supply, unloading direction and collection space.
Air-Cooled Manual-Clean Electromagnetic	Iron loading is lower and planned cleaning stops are practical.	Safe cleaning access, iron accumulation, working distance, power supply and available headroom.
Oil-Cooled Electromagnetic	The project calls for an oil-cooled electromagnetic design rather than forced-air cooling.	Cooling arrangement, installation environment, maintenance access, working distance and electrical requirements.
Permanent Self-Cleaning Overband	Automatic iron discharge is required without electrical excitation for the magnetic field.	Required magnetic reach, target iron, belt drive, discharge path, installation space and maintenance access.

No separator type is automatically best for every conveyor. Send the conveyor width, material depth, working distance, belt speed and target iron so we can check the practical starting option.

Ask Corvelan to Compare the Options Back to Selection Requirements

Installation

Cross-belt or inline: which layout fits your conveyor?

Cross-Belt Arrangement

The separator sits across the conveyor. The unloading belt usually carries captured iron to the side. This setup needs enough side space, support strength and service access.

Inline Arrangement

The separator follows the direction of the conveyor, often near a discharge point. This position can bring the iron closer to the magnet as material leaves the belt. The actual conveyor layout still needs to be checked.

Send us the conveyor layout or a clear installation photo. We use it to check suspension height, support, service space and discharge direction before quotation.

Process Fit

Is this separator right for your process?

Works Well When

Dry conveyor-fed bulk material.
Responsive ferromagnetic iron or steel is the target.
Continuous automatic discharge is preferred.
An electromagnet is suitable for the required working distance and target iron.
The site has enough support, power, cooling airflow and discharge space.

Choose Another Option When

Aluminum, copper or other non-ferrous metal is the main target.
The process is wet, slurry-based or requires a wet magnetic separator.
The purpose is fine weakly magnetic mineral purification rather than tramp-iron protection.
Hazardous-area, food, sanitary or other certification requirements still need to be defined.
The distance or material depth places the target too far from the magnet for practical capture.

Maintenance & Safety

What should you check during operation and maintenance?

Unloading Belt & Tracking

Check the unloading belt for wear, tracking, tension and smooth movement. The supplied design uses a crowned drive drum to help the belt stay on track.

Cooling Airflow

Keep fan inlets and airflow paths clear. Dust buildup or blocked airflow can make the electromagnet run hotter.

Electrical & Mechanical Isolation

Before inspection or belt adjustment, isolate electrical power and stop moving parts using your site's lockout and electrical-safety procedure.

Our Recommendation Process

How We Choose the Right Configuration

Step 1

We Check the Conveyor Conditions

Send us the belt width, material depth, belt speed, planned suspension height and the largest iron or steel piece you expect to remove. A conveyor photo or drawing also helps us see the available space.

Step 2

We Narrow the Equipment Configuration

We compare those values with the separator configuration range, then check mounting direction, discharge side, support, power supply, cooling airflow and service access.

Step 3

We Confirm the Quotation Configuration

Before production, we confirm the selected model, dimensions, mounting, power supply, discharge direction and any inspection or test that forms part of the agreed order scope.

Product Details

Real Product Photos and Manufacturing Details

These photos show the equipment features described on this page: the complete unit, forced-air cooling side, mechanical layout and self-unloading belt.

Side mechanical view of air-cooled self-unloading electromagnetic separator

Production reference showing multiple self-unloading electromagnetic separator units

Production Reference for This Separator Family

Multiple self-unloading electromagnetic separator units are shown during production and assembly. We use model-specific data and project drawings to define the final equipment for each conveyor.

This photo shows units from the same separator family during production and assembly. Final equipment details depend on the selected model and project requirements.

FAQ

Air-Cooled Self-Unloading Electromagnetic Separator FAQ

How do you select the right air-cooled self-unloading electromagnetic separator?

We start with the material, target iron, conveyor width, material depth, belt speed and planned working distance. We then check the installation layout, discharge direction, power supply and operating conditions before confirming the equipment configuration.

Does conveyor belt width alone determine the separator size?

No. Belt width is only one input. Material depth, working distance, belt speed, target iron and the installation layout also affect the required configuration.

How is the electromagnet cooled?

The air-cooled design uses fans to move air around the electromagnet and coil. We also check ambient temperature, dust, airflow and operating conditions before confirming the cooling arrangement.

How does the self-unloading system work?

The moving discharge belt carries captured iron away from the center of the magnet. As the magnetic force becomes weaker, the metal drops into the collection area. This supports continuous discharge without routine manual cleaning of the magnet face.

Does a higher magnetic field value always mean better separation?

No. A magnetic field value alone does not guarantee better iron removal. Working distance, material depth, belt speed, iron size, shape and separator position also affect capture. Compare measured magnetic values only when the test position and method are defined.

Should the separator be installed cross-belt or inline?

Both arrangements can work. Cross-belt usually sends captured iron to the side, while inline follows the conveyor direction. We review the conveyor layout before confirming the mounting direction and discharge side.

What information should I send for selection?

Start with the material, target iron or steel, throughput, conveyor width and installation condition. Belt speed, material depth, planned working distance, target size and a drawing or photo help us narrow the configuration faster.

How is an electromagnetic separator different from a permanent self-cleaning overband?

An electromagnetic separator uses an energized coil to create the magnetic field, while a permanent overband uses permanent magnets. Both can use a moving belt to discharge captured iron. The practical choice depends on working distance, target iron, available power, operating conditions and maintenance needs.

Request a Quote

Send Us These Details for Our Recommendation Process

You do not need a finished specification to start. Send the process data you already have. We compare it with the range and tell you what else, if anything, we need before quotation.

MaterialMaterial name, physical form and relevant process condition.

Largest Expected Iron PieceType, size and shape of the largest expected tramp iron, such as a bolt, bar, plate, wire bundle or broken machine part.

ThroughputNormal and peak material rate, with units.

Conveyor / InstallationConveyor location, available space, photo or layout drawing, and the proposed separator position.

Next Step

Get the Right Configuration for Your Conveyor

Send your conveyor width, material, material depth, proposed suspension height and target iron. We will match these conditions to the equipment configuration and prepare the configuration for quotation.

Send Your Separation Requirement