Metal sorting

Only if the metal fraction is produced with enough purity can it be ensured that previous expensively recovered materials are not lost and that additional use with the best possible result is feasible.

Through the use of the INCODECS sorting equipment the quality of the metal fraction increases. Furthermore, it is possible to fulfil the landfill regulations laid down by statute.

Copper from iron scrap (“Meatballs”)

With the youngest generations of EMCAM systems,sorting exercises which cannot be handled by conventional metal detectors are now solvable. Expensive x-ray or other more appropriate laboratory methods were previously used in order to be able to solve at least a part of the analytical tasks. But we have opened a new door: the identification of metals or to be precise their characteristic compounds by means of a more energy saving and completely safe alternating current magnetic field technique.

There is now a new solution to an age old problem within the steel industry. The EMCAM has a uses new mathematical techniques for the sorting decision and can almost fully recognise and then separate, in an iron and steel fraction, copper and copper connected to FE sheet metal such as transformers and electric motors. In such a way, contrary to other solutions, it does not matter whether the copper is visible from the outside. Even encapsulated motors and transformers (e.g. in connector power supplies) can now be safely recognized.

Of course the INCODECS – Sorter i120-MSE can manage that with serious industrial throughputs.

Stainless steel from incinerator ash and slag

The ash and slag from incinerators contain a high percentage of metallic materials which however are hardly visibly recognisable after the incineration of the residual waste.Only a fraction of the metal can be separated from the slag and recycled using conventional techniques such as magnetic separators for iron scrap and eddy current separators for loose non-ferrous metals (mainly aluminium). Other valuable metals, currently stainless steel, copper, brass, zinc and lead end up nowadays in landfill sites. Conventional sorting machines which rely on metal detectors cannot solve this task because they unfortunately separate in addition to the heavy metals a significant amount of non recyclable slag rust and thereby heavily impurify the metal fraction.
The sensor technology developed by INCODECS is accurately positioned: only the heavy stainless steel and non-ferrous metals with clear edge parts are separated, yet the rust and burned iron are eliminated. The rust-containing minerals remain in the slag and can also be used for landfill. The metal proportion of the landfill fraction remains well below 1% by weight and a high level of non-magnetic metal particles are spared being used for landfill. That is rigorous recycling under the most difficult conditions.

Electronic scrap

Electronic scrap contains valuable materials which can be recovered as secondary raw materials. In the processing there are various tasks to manage:
  • Separation of metals and synthetics, e.g. from casings
  • Separation of non-ferrous materials and hard steels such as screws and bolts, which could cause damage in the subsequent shredder process
  • TSeparation of solid non-ferrous metals such as heat sinks, casing parts and printed circuit boards.

EMCAM based sorting is eminently suited to performing these tasks.

Processing of shredder light fraction e.g. from old motor vehicles

The processing of shredder light fraction (SLF) from old motor vehicles is becoming increasingly more important. According to the EU directive 2000/53/EG 80% of the average vehicle weight should be reused or recycled. This percentage is set to increase from the year 2015.

The legal requirements and the increased cost of raw materials make the processing of shredder light fraction not only a necessity but also lucrative. In combination with conventional technologies such as magnet- and eddy current separators, EMCAM based sorting allows the separation of unmixed material flows from the shredder light fraction for later material recycling.

Shredder heavy fraction

The output from shredders and in particular after the stage of steel scrap removal contains a large part of dense particles which cannot be separated by a common ferrous separation technique. The EMCAM sorting equipment can be employed to excellent effect in several stages. They can sort stainless steel alloys or simply the non ferrous metals or free up at the end of the chain the organic remains of what was once metal in order to produce the early stages of alternative fuels. Fixed installations for large annual throughputs can also be designed and implemented.

With the help of a refined and very fast calculation process, the sensor system is already able to ascertain from the raw data the typical finger print of scrap iron parts which are somewhat less magnetisable and a poor electrical conductor – 2 reliable factors for the identification of stainless steel. One should also consider the fractions of an EMCAM sorting machine: highest quality stainless steel at very high throughput levels up to 20 tons/hour on a 1.200 mm machine. We have mastered vice versa the separation of heavy non-ferrous metals which a non-ferrous separator cannot do. The EMCAM plays here a decisive role compared to the eddy current performance due to the high conductivity of the non-ferrous part. In the process it makes absolutely no difference to the sensor whether the non-ferrous part is coated, corroded, anodized or anything similar.

Heavy fractions from float – sink plants (heavy non-ferrous, stainless steel)

Float- sink heavy fractions, actually the material components which on density separation sink to the bottom, are furthermore a mix of different metals and compounds but also of stones and metals with mineral adhesions. For the sorting company, the metal groupings stainless steel and non-ferrous metals are also here the most valuable groupings to be separated.

The EMCAM works reliably with sink plant output materials. From this large density mix all the heavy non-ferrous metals such as copper, brass, bronze and lead can be selectively sorted in 2 steps in a group … hence the stainless steel from the residues. An expensive and water-consuming pre-cleaning of the fraction is not necessarily required – in comparison with the requirements of the sorting techniques based on surface –based measurement processes. Here the salts interfere so significantly that the application of all FA procedures is immediately ruled out.

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