Optical Sorting - Comex AS
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- 1. sortingsolutionsosxseparator series
2. sortingsolutions Comex offers a newly developed complex optical sortingThe particles identified as the waste fraction are removed system, in a user friendly platform, for the identification by the rejecting mechanism after the discharge end of the and separation of particles and materials, based on their belt. This allows for the maximum time interval between many physical properties. This is achieved underthe image grabbing and time of rejection, which allows recognition of individual response to : the image analyzing program to carry out sophisticated + Colourmathematical calculations before rejection takes place.+ X-Ray Fluorescence + Shape+ Conductivity 2. Routine Applications (where reject is readily + Texture+ Electromagnetic Inductionidentifiable). In this configuration the particles are + Transparency + Thermal Transfer analyzed just after the belt discharge end. In this case the + Density particles are rejected almost immediately after being analyzed. This option uses lighting from above (scanning The system is based on a flexible programming platform, light) or below (transmitted light) the particle stream. The which can be modified for a wide variety of demanding particles are rejected just after the analysing point while applications, using sophisticated processing functions. the computing system provides a quick mathematical Efficient separation of materials often requires multiple calculation and reaction performance. parallel or multistage processing with many separating units. Comex provides integrated solutions for theseThe main processing unit, based on the CPU, applications. is multiply tasked. It is used to: Generally, the new Comex separation system can+ Transfer images from the analyzing camera provide the following benefits: + Provide a basic analysis + Cost Savings+ Process advanced electronic filtration + Down-stream plant only processes saleable product + Define coordinates of the particles for rejection (especially when grinding costs are considered) + Calculate the time delay for initiating the rejecting + Increased capacity and performance of down-streammechanism (pneumatic nozzles plant, not tied up processing waste materialsor flaps) + Reduced contamination + Ore/material can be sorted at face, eliminating unnecessary transport costs + Improved Recovery + Best utilisation of recourse + Environmental responsibility + Minimise carbon and green-house foot print by not processing unwanted waste materials + Recycling Opportunity + Potential to reprocess waste stockpiles for efficient recovery + Beneficiate waste streams (metals, polymers, minerals, etc.) for efficient recoveryOperating Principle and ConfigurationsApplication example of the OSX-1000 separator The system consists of three major sections: + Vibratory feederThis last information related to the rejection function, is + Belt conveyor further processed in the FPGA hardware (field- programmable gate array). This allows the rejection + Optical separation unit. function to be totally separated from the main CPU The vibratory feeder provides a uniform particleoperation. In the FPGA area, the program related to distribution along the separator width when the rejection of particles is 'burned' in permanently and the processed material is discharged to the transport belt. main CPU device is not engaged in any activity related to The uniform particle distribution is of critical importance this action. Therefore, the CPU area can be used more for further efficient optical separation. accurately with image analysis and advanced electronic filtration. As a result the complete system provides much The optical separation unit can be built in two mainmore precise timing for rejecting waste particles thus configurations. improving the overall system performance. 1. Demanding Applications (where complex analysis isThe rejecting mechanism can employ air nozzles or necessary for particle identification). In this mechanical flaps. The air nozzles are used for finer configuration, the image analysis is carried out by anparticles up to 100 mm in size, and the mechanical flaps optical camera with lighting installed over the transport are employed for larger and heavier particles over 100 belt conveyor.mm. 3. sortingsolutions The most important design features of the Comex separator which make this equipment unique are: + Vibrating feeder for particle dispersion providing good particle distribution + Belt conveyor for precise particle trajectory control before separation stage + Special belt conveyor design providing stable particle orientation during analysis and separation + Advanced image analysis of the separated particles involving colour, shape, pattern, size, and other physical material characteristics + High intensity LED lighting providing reliable and stable light intensity over a long operating time period + Advanced shape analysis involving over 50 Inlet to the OSX-1000 separator parameters describing each processed particle + High resolution cameras providing clear image ofThis results in the following benefits from application of particles the Comex separation system: + Hardware flexibility allowing application of different camera types (IR, Line Scan, X-Ray, etc)+ High separation efficiency up to 99.9% + Precision valves allowing accurate rejection of waste + Large processing capacity particles and limited losses of the product particles + Possibility to process a wide range of particle sizes + High speed electronic system for rejecting of waste without necessary pre-screening particles allowing precise separation within short time + Possibility to process material with high moisture intervals content + Compact modular design allowing easy+ Efficient separation of particles having small transportation and mechanical modificationdifferences in colour or greyness level + Optional particle washing over the belt allowingThe new Comex optical system has already been tested limited cleaning of the particle surface being analyzed and applied for sorting of: glass, diamonds, metals and mineral particles. camera vibrating feedchutematerial lightstransportbelt rejecting valvesnon-rejectedor flaps main controlsplitter fraction unit rejectedgatefractionView of the new generation OSX-series separator 4. sorting solutions Camera interface CL/IEEE1394 Camera Control unit Trigging PC + software FPGA Hardware Particle rejection control FPGA HardwareLow current digital Lights control outputsCommunication modules forexternal system interfacing like: Ethernet, Profibus, High current digitalUp to 320 digitalOPC, etc. outputsoutputsElectronic system architecture Size Ranges and Technical SpecificationsThe optical separation systems can be manufactured in different size ranges. Dimensions of the equipment will mainly depend on the processing capacity. The table below shows the general dimensions of the separation equipment. Separator specification dataSystem parameter OSX-600 OSX-1000 OSX-1500Transport belt width [mm]60010001500 Belt velocity [m/s] 3-53-53-5 Image identification Digital frame grabbing or line scan Scanning principle Progressive scan or line scan Camera type CCD, CMOS, IR, X-ray Lighting type High power LED Identyfication functionColor, size, shape, structure, textureAir nozzles for particles below 100 mm; Rejection mechanism Pneumatic flaps for particles over 100 mm Minimal particle size [mm]10 1520Typical capacity for particles having 15-50 mm size [t/h] 5-2010-50 15-80Typical capacity for particles having 50-250 mm size [t/h] 20-8050-15080-250 5. sortingsolutions FEEDINPUT C DE FRACTION FRACTION21F GHB A Dimensions and weights of the separation systemsParameterUnitOSX-600 OSX-1000 OSX-1500A[mm] 12801680 2180 B[mm] 66507050 7650 C[mm] 22002500 3600 D[mm] 18501850 1850 E[mm] 16001600 1600 F[mm] 710710710 G[mm] 730730730 H[mm] 610610610 Weight[t]0.6 1.6 2 6. sortingsolutions Applications Configuration Options:The Comex optical separation equipment has beenThe optical separation unit can be manufactured successfully tested and applied for different materialsaccording to the following code reflecting the system with varying physical properties. Comex has provided configuration. separation systems mainly for separating particles like minerals in connection with their further processing, and+ OSX-xxx is the optical separator having xxx belt for the recycling industry where the high purity of the endwidth defined in mm product is of critical importance for most successful appli-+ /F - rejection mechanism realized cations. Separation efficiencies varied from 95 to 99.9%by mechanical flaps depending on the processed material and separation difficulty.+ /N - rejection mechanism realizedby pneumatic nozzles Research and Development + OA image analysis over the belt+ DA image analysis at the belt discharge Comex offers extensive test and development facilities + S M- scanning mode where different separating units can be accurately + TM transmission mode tested, for determination of the optimal process prior to final design. Extensive instrumentation on the pilot scaleExample: OSX-1000/F-DA-SM is the Optical Separator units, combined with different types of cameras andfrom ComeX having 1000 mm belt width, image analysis lighting, provides a facility to search for the optional set-at the belt discharge and the camera with lights above the up for each individual application.belt (scanning mode). Separation examples of different materials Calcite particles in size range 65-125 mm FeedProduct Waste Feldspar particles in size range 25-65 mm FeedProduct Waste 7. sorting solutions Feldspar particles in size range 15-30 mm FeedProduct Waste Quartz particles in size range 20-50 mm FeedProduct Waste Quartz particles in size range 15-45 mm FeedProduct Waste Glass (curlets) particles in size range 15-45 mm FeedProduct Waste 8. Comex AS P.O.Box 53 1309 Rud Norway tel.