Most plant engineers know Mechani Mags for one product above all: the suspended belt magnet that lifts tramp metal off conveyors in mines and processing plants. This October the Boksburg manufacturer, which trades as African Magnets, wants buyers to see everything else it makes. That includes the rare earth Ferrochrome Magnet for recovering ferrochrome from slag, heavy duty lifting magnets for scrap and furnace loading, and a line of drum magnets, demagnetising coils and permanent magnet designs. Many South African sites schedule maintenance and upgrades for the year end shutdown, so now is a good time to look at what else magnetic equipment could do on a plant, beyond guarding a conveyor.
Recovering ferrochrome from slag
Its official name is the In-Line Style Rare-Earth Permanent Magnetic Agitating Field Separator, shortened to the MAFS machine, though most customers call it the Ferrochrome Magnet. It was designed for material that holds only small amounts of ferromagnetic particles, such as ferrochrome, banded ironstone and shales.
At its core are neodymium rare earth magnet elements of the highest available strength. In the agitating field section, the magnetic material is kept moving, which frees non-magnetic material caught between the ferromagnetic particles and gives a cleaner separation. Near the end of the separator the magnetic elements are weaker, so the magnetics let go more easily at discharge. Each unit has a wear plate of Mechani Mags’ own design, and the whole separator adjusts vertically so operators can set its position for the material on the line.
The machine is used in three main areas. Ferrochrome processors use it to recover ferrochrome particles from slag and raise the quality of their output. Mining and mineral processing operations use it to improve the purity of banded ironstone or shales. Recyclers use it to remove ferromagnetic contaminants from recyclable material.
Heavy duty lifting for scrap, mill balls and furnaces
For handling material, Mechani Mags builds circular heavy duty lifting electromagnets for on-off duty. When energised, the magnet picks up steel and moves it. When de-energised, it drops the load and goes back to the loading position. Its magnetic field is fairly shallow but very concentrated, which gives the most holding force on the steel being lifted. The magnets are mostly used for scrap handling, mill ball loading and furnace loading. They are not built to hang over conveyor belts.
Diameters run from 300 mm to 3,000 mm, and rectangular and oval versions can be made for particular applications. The units contain no oil and are fully sealed to IP66, so they keep out dust and water and can work submerged. The casing is reinforced to take knocks and drops. The coils are impregnated with high temperature resin and have Class H insulation, and a heavy duty wear plate protects the underside. A warning light or siren can be added to show when the magnet is live, and a heat shield plate is offered as an option for high heat work. They are built for high duty cycles and run on a wide range of DC supply voltages.
The company also supplies the equipment that goes with them: power supply units, control panels, remote control pendants and DC cable reeling drums.
Magnetic separators are made in several configurations. The right one for a plant depends on where the steel has to come out and how the site is laid out. Mechani Mags sells suspended overband magnets, and also drum magnets (also called magnetic pulleys), which separate material as it leaves the head end of a conveyor belt. Its demagnetising coils demagnetise material that passes through the middle of the coil. Custom permanent magnet designs can be built for specific needs and adapted to fit tight spaces.
A metal detector and a magnet do different jobs. Conveyor metal detector systems are common on plants and stop the belt when they find metal. That protects crushers and downstream equipment, but somebody still has to find the steel and take it out by hand. A suspended belt magnet lifts ferrous tramp metal off the moving material continuously instead. Mechani Mags’ suspended range covers fan cooled and oil cooled electromagnets, each available in self-cleaning and manual-clean versions, plus its newer dry-type design.
Dry magnetic separator is the name of the company’s latest suspended overband design. It has no oil and no fans, and its energy efficiency rating is equivalent to IE4. The company says it gives the same magnetic power as standard models from 50% less electrical input. It cleans itself, has a belt slip and tear detection system, and carries a PT100 temperature probe for monitoring. A low headroom model is available for plants with limited vertical space. The unit can be used underground and can be Ex certified for hazardous areas.
One supplier for auxiliaries and spares
A magnet needs reliable power, suspension and belting to work, and Mechani Mags supplies all three. Its auxiliary range includes:
- power supply units for mains voltages up to 1000 VAC at 50 or 60 Hz
- control panels that work with almost any electromagnet system
- three phase heavy duty solid state bridge rectifiers
- DC cabling
- adjustable suspension chain slings with rating tags and a certificate of compliance
- beam crawlers and trolleys
- cable reeling drums and festoon systems
In stock as spares are replacement belts, pulleys, gearboxes, motors, bearings, shafts, couplings and DC terminal poles. The company also stocks Type F flame retardant conveyor belting supplied with test certificates, and reinforced heavier duty belts made specifically for use with magnets.
Using the year end shutdown
Plants often use the slower weeks at the end of the year for maintenance they cannot do at full production. The Mechani Mags workshop in Jet Park, Boksburg repairs and upgrades magnets of any make or brand, takes units of up to 20 tons, and may have loan units available while a customer’s magnet is being repaired. It also does oil to dry conversions. These can usually turn an existing oil cooled electromagnet into a dry-type electromagnet of the same strength, with no change to the existing power supply.
A trained site service team is on standby all year and works worldwide. On site, it offers gauss testing and reporting, routine inspection reports, certificate of compliance inspections, help with commissioning and installation, fault finding, general repairs and servicing, and site assessments for new magnet applications. Training is available too. If a magnet is faulty, customers can either send it to the Jet Park workshop for a free assessment, strip and quote, or have the company collect it.
More than 50 years of experience
Mechani Mags’ designs draw on more than 50 years of experience with magnetic equipment. The company exports worldwide and supports clients in many countries. Because so much of its work is custom engineering, it can design a magnet around a plant’s constraints, whether that is limited headroom or an unusual mounting angle.
Engineers, buyers and plant managers who want to talk about ferrochrome separation, lifting magnets or any other magnetic separation need will find the full product range and support services at https://africanmagnets.com/.
About Mechani Mags
Mechani Mags is a South African manufacturer of conveyor magnets, magnetic separators and lifting magnets. It trades as African Magnets from its head office and workshop at 30 Bisset Road, Jet Park, Boksburg. Its products include dry-type, fan cooled and oil cooled suspended belt magnets, the rare earth Ferrochrome Magnet, lifting magnets, drum magnets, demagnetising coils, custom permanent magnet designs and a full range of auxiliaries and spares. It serves mining, processing and recycling customers in South Africa and around the world. Its services include repairs, upgrades, training, site inspections, compliance reports and gauss testing.
Media Contact
Mechani Mags
Email: info@mecmag.co.za
Phone: +27 11 397 6870
Website: https://africanmagnets.com/
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