Solutions for classifying and separating copper from ... - Wurzner.pdf · Solutions for classifying...

IWCC TECHNICAL SEMINAR

Stefan Würzner

Engineering Manager & Application Specialist

Santiago, Chile – March, 4th 2013

Solutions for classifying and separating copper from

recyclable materials using

magnetic and sensor sorting systems

Welcome ...

March, 4th 2013 2 IWCC Technical Seminar, Santiago

Steinert Elektromagnetbau, Germany

Manufacturing

Sales

Service

FOCUS RECYCLING

Steinert US

Manufacturing Sales

Service

FOCUS RECYCLING

Steinert Japan

Sales Service

FOCUS RECYCLING

Steinert Latinoamericana,

Brasil

Manufacturing Sales

Service

FOCUS MINING

Steinert Australia

Manufacturing Sales

Service

FOCUS MINING

RTT Steinert, Germany

Manufacturing Sales

Service

FOCUS RECYCLING

STEINERT Group 2011

March, 4th 2013

• Family owned Enterprise

• > 200 employees

• Factories in 4 countries

• Worldwide presence

3 IWCC Technical Seminar, Santiago

JV - China

JV - India JV – South

Africa

STEINERT – Group, Global Support: Through S & Joint Venture‘s (JV)


March, 4th 2013 5

General – Applications

Scrap Recycling

Mining Electro-technical Applications

IWCC Technical Seminar, Santiago

March, 4th 2013 6

General – Applications

Recycling Scrap Mining Miscellaneous

Household waste

Bulky waste

Commercial waste

Compost and organic waste

RDF - refuse derived fuels

Lightweight packaging material

Paper and cardboard

Plastic recycling

Demolition scrap

Recycled wood

Used/scrap tyres

Glass

Electronic scrap

Shredder scrap

Heavy non-ferrous metal

Wire-recycling

Copper-recycling

Coal

Minerals

Salt

Sand

Other industrial minerals

Iron ore

Other metal ores

Refuse incineration slag

Metallurgical slag

Used foundry sand

Degreasing baths

etc.

Shredder scrap

PCB-Recycling


STEINERT – Separation Equipment for Dry Metal Recovery

Suspension Magnets

UME / AME

Magnetic Drums

MTE / MTP

Magnetic Head Pulleys

BRE / BRP

High Gradient Magnetic

Separators

HGS

Eddy Current Separator

NES

Sensor Sorting Systems

ISS

3DS

FSS

NIR

XSS / XRF


March, 4th 2013 8

Magnetic Separators

Static magnetic field

Suspension magnets Magnetic drums Magnetic pulleys, etc.

Function: Separation of ferrous metals

Application: Equipment protection (crusher, mills, etc.)

Metal recycling

Municipal waste

Electronic scrap

Foundry sand

Mining etc.

Technology Generating magnetic field using permanent

ferrite or rare earth magnets or coils in

combination with DC-current


March, 4th 2013 9

Rotating Magnetic System

Function: Separation of non-ferrous metals

from 1 mm up

Application: Copper-recycling

Municipal waste

Electronic scrap

Shredder material

Foundry sand etc.

Technology Rotating system of permanent magnets (special

eccentric pole system)

Generation of strong eddy-currents in non-ferrous

metals

Eddy Current Separator ECS


Eddy Current Separator – Working principle

March, 4th 2013 10

N

• Conductive metals are expulsed and forced out of their discharge trajectory.

Conveyor Belt

Dicharge pulley

High speed rotor with permanent magnets

Alternating magnetic field

• Material is introduced to the magnetic field using a conveyor belt. • The rotating pole system generates an alternating magnetic field close to the discharge point of the material. • A pole system made of permanent magnets is incorporated into the discharge drum of the belt conveyor.

• The alternating field induces eddy currents in conductive metal pieces, with the induced magnetic field being opposite to the magnetic field of the pole system.

Non ferrous metals

Non conductive material


Eddy Current Separator – Separation possibilities

March, 4th 2013 11

Metals Conductivity in

S/m = A/(Vm)

Desnity in

kg/m³

Conductivity/

Density

Aluminum Al 37.800.000 2.700 14.000

Magnesium Mg 22.700.000 1.740 13.045

Copper Cu 56.000.000 8.920 6.278

Silver Ag 61.700.000 10.490 5.882

Gold Au 47.600.000 19.300 2.466

Zinc Zn 16.900.000 7.140 2.367

Platinum Pt 10.200.000 21.450 476

Lead Pb 4.800.000 11.340 423


March, 4th 2013 12

Sensor Sorting Systems - From Manual to Automated Material „Sorting“

Agricola

21st century


Singularize Detect Eject

STEINERT – Working principle


Sensor Sorting System – Equipment layout

March, 4th 2013 14

feeder acceleration belt catcher hood

with splitter

sensor air valves


March, 4th 2013

STEINERT – Sensor portfolio

Sensor Type Physical Material Properties

3D Laser in combination with camera – Surface shape, topological

properties, particle presence

ISS Metal detectors – Conductivity, Magnetic susceptibility

KSS CCD camera – Reflection/absorption of visible light on the material

surface, surface colour, brightness, light transmission

NIR NIR sensor – Reflection/absorption of near infrared light on the

material surface

XSS-T X-Ray transmission – Absorption of x-ray energy in material, density

and atomic density

XSS-F X-Ray Fluorescence – Elemental composition, spectroscopy


March, 4th 2013






FSS CCD camera – Reflection/absorption of visible light on the material



material surface


and atomic density



March, 4th 2013

STEINERT – 3D Laser scanning

• Measure the three-dimensional shape using

projected light patterns and

a camera

• On-line measurement

• Object recognition

• 1 m working width per camera, max 3 m wide

• Requires clean material surfaces

Source: RWTH Aachen, Dr. Dirk Killmann


March, 4th 2013

STEINERT – 3D Laser Scanning


March, 4th 2013









material surface


and atomic density



March, 4th 2013

STEINERT – Electro-Magnetic Sensor

• Detects conductive or magnetic material

• Ferrous and non-ferrous metals as well as

magnetite can be distinguished


• Object recognition in combination with 3D

• Smallest particles for detection

all-metal mode: Ø3 mm, wires Ø0,8 x 6 mm

matter selective mode: Ø6 mm, wires Ø2,2 x 10 mm

Sensor bar

One pair of detecting coils each ½” or 1” and one external coil

External coil emits magnetic field at ~ 100 kHz inducing secondary fields in the sensor coils

Adjustment of the detector coil pairs to 0V

Conductive or magnetic particles interfere with the field, thus generating a signal

Emitter coil Detector coil pair


March, 4th 2013









material surface


and atomic density



March, 4th 2013

STEINERT – Colour Sorting

• Measures reflected light from material

surface


• Object recognition in combination with 3D

• Requires clean material surfaces

Criteria for separation:

- Hue (Color angle) H

- Saturation S

- Value (Brightness) V

-Alternatively RGB


March, 4th 2013

STEINERT – Colour sorting – Incident Light Colour Camera

Sensor specification

• Lights: 1 or 2 lines of LED‘s, included in the camera

housing

• Sensors: multiple line scan CCD cameras (up to 3) in

one housing

• 1000 mm working width per camera (1120 pixels)

• Resolution 0,9 mm/pixel - 80 valves per camera

• Scan rate of 1 ms (one line per ms)

• 500 mm focus


March, 4th 2013









material surface


and atomic density



March, 4th 2013

STEINERT – X-Ray Sensors

X-Ray tubes

• X-Ray wave length around 1 nm (visible light 400 to 700 nm)

• Voltage (kV) defines frequency of emitted X-Rays

• Current (typically 35 mA) defines intensity

• No radioactive substances used

• X-Ray absorption depends on

particle thickness

material density

• Typical life time of X-Ray tube: 5 years


March, 4th 2013

STEINERT – X-Ray Transmission

X-Ray transmission

• 160 kV X-Ray emitter tube and CCD line camera sensor

• Measures X-Ray energy absorption in material at two different energy levels to

eliminate thickness factor (“Dual energy”)

• Absorption based on atom weight of the individual elements forming the particle

• Volume analysis



March, 4th 2013

STEINERT – X-Ray Fluorescence

X-Ray fluorescence

• Detection based on specific fluorescence of each element

• Possible separation of minerals which can not be separated by density characteristics

• Limitations for especially for light metals (Na, Al, Mg ..)

• Superficial analysis of chemical composition

Electrons are removed from inner shells or atom

by primary X-Ray radiation hv

Electrons from outer shells fills these gaps

emitting secondary X-Ray radiation hv’


March, 4th 2013

STEINERT – X-Ray Fluorescence

Singulated mixed ore X-Ray tubes excite material Detectors capture emitted

fluorescent X-rays

X-STREAM by


March, 4th 2013

STEINERT – Valve bars and air supply

• Ejection of detected material is done using pneumatic high speed valves arranged in

adjustable valve bars

• Typically direction of air jet: perpendicular to the material discharge trajectory

• Valve orifice distances:

• ¼” for fines material (6..20 mm)

• ½” standard valves

• Special valve bars for heavy material

•Typical air pressure: 5 to 10 bar

•Typical air consumption: 5 to 10 m³/min/m

• Required air quality acc DIN ISO 8573

Particle content (dust): Class 3

Pressure dew point (water): Class 4 (> 3° Celsius)

Class 3 (<= 3° Celsius)

Oil concentration (Oil): Class 2 (aniline point between 80°C and 100°C)


Eddy Current Separator

• Material size: 1 mm to 250 mm

• Size distribution: 1..3 to 1..5

for example 1 .. 5 mm, 5 ..15 mm, 15 .. 50 mm, 50 .. 200 mm

• Single layer on belt

• Typical capacities:

3 to 10 m³/h/m for smaller size material up to 10 mm

30 to 60 m³/h/m for larger material

March, 4th 2013

STEINERT – Eddy Current Separation and Sensor Sorting - Process Data

30

Sensor Sorting Systems

• Material size: 5 mm to 200 mm

• Size distribution: 1..3 to 1..5

for example 5 ..15 mm, 15 .. 50 mm, 50 .. 200 mm

• Single layer on belt

• Capacities up to 120 m³/h/m for larger material


March, 4th 2013 31

Application – End of Life Vehicles


End of Life Vehicle (ELV) Recycling

• US: 12 to 15 Mio ELV/year

• UK: 2 Mio ELV/year etc.

• with about 58 Mio cars build in 2000 world wide

ELV typical composition

60 to 70% steel and ferrous metals

8% light non-ferrous metals

2% non-wire Cu, brass, Zn

0,5% insulated copper wires

0,5% copper from motors

20 to 30kg copper per ELV

March, 4th 2013 32

Application – Car Shredder –Steel Product until 2009

Scrap

Suspension

Magnet

Shredder

Steel with copper

Auto

Shredder

Residue

Magnetic

Drum

To ASR plant – Non-Ferrous

Metal Recovery

Coarse

Fines


March, 4th 2013 33

Application – Car Shredder – Copper from Steel Product after 2009

Scrap

Suspension

Magnet

Shredder

Steel with copper

Auto

Shredder

Residue

Magnetic

Drum

To ASR plant – Non-Ferrous

Metal Recovery

120 t/h 1,2 t/h

Copper free

steel

X-Ray Sorting

System (XSS-F)

Copper

(Meatballs)

Coarse

Fines


March, 4th 2013 34

X-Ray Sorting System XSS-F

Sensor: X-ray Fluorescence

Function: Separation of meatballs

Application: Scrap

Copper-recycling etc.

Technology: X-ray tube emits photons towards the target

material

Primary photons from the X-ray tube have

enough energy to knock electrons out of the

innermost, K or L, orbitals

Electron is ejected out of the atomic shell

and creates a free spot

Atom becomes unstable

Electron from an outer shell fills free spot

Excess energy emitted in the form of

secondary X-ray


March, 4th 2013 35

Application – Car Shredder – Copper from Steel Product

Meatball Separation • about 120 t/h input capacity

• Separates all visible copper Steel after XSS-F

Copper & Meatballs


March, 4th 2013 36

Application – Car Shredder – Copper from Steel Product

Copper & Meatballs

~1% from steel scrap


March, 4th 2013 37

Application – Car Shredder – ASR until 2009

Eddy-Current

Separation

ZURIK

Stainless

steel, etc.

ASR ¾ to 2”

Mixed NF-

Metals

ZORBA


25 t/h

8-10 t/h

15 t/h

Induction-Sorting

System

Waste

2 - 3 t/h

March, 4th 2013 38

Application – Car Shredder – ASR after 2009

Eddy-Current

Separation

ZURIK

Stainless

steel, etc.

ASR ¾ to 2”

Copper,

brass

Zinc

Aluminium X-ray Sorting

System (XSS-T)

Combined

Sorting System

ZORBA


25 t/h

8-10 t/h

15 t/h

Induction-Sorting

System

Waste

Combined

Sorting System Copper wire

5 - 7 t/h

2 - 3 t/h

3 - 5 t/h

0,5 t/h

Waste

25 %

75 %

March, 4th 2013 39


Eddy-Current

Separation

ZURIK

Stainless

steel, etc.

ASR ¾ to 2”

Copper,

brass

Zinc


System (XSS-T)

Combined

Sorting System

ZORBA


25 t/h

8-10 t/h

15 t/h

Induction-Sorting

System

Waste

Combined


5 - 7 t/h

2 - 3 t/h

3 - 5 t/h

0,5 t/h

Waste

25 %

75 %

March, 4th 2013 40

Combined Sorting System – Yellow-Sort (3D / Colour / Induction)

Sensor: Laser, Camera and Induction Variable combination

Function: Separation of wire, printed

circuit boards

Application: Scrap

Electronic scrap

Mining

Wire-recycling etc.

Technology: Shape and size detection by laser

Colour detection by camera

Metal detection by induction-sensor

Computer determines target!


March, 4th 2013 41

Application – Car Shredder – Insulated Copper Wire


Shredder Residue • 30 t/h ASR

• 8-10 t/h NF-Metals

• 500 kg/h ICW

• 1,20 USD/lbs

March, 4th 2013 42

Application – Car Shredder – Insulated Copper Wire


March, 4th 2013 43


Eddy-Current

Separation

ZURIK

Stainless

steel, etc.

ASR ¾ to 2”

Copper,

brass

Zinc


System (XSS-T)

Combined

Sorting System

ZORBA


25 t/h

8-10 t/h

15 t/h

Induction-Sorting

System

Waste

Combined


5 - 7 t/h

2 - 3 t/h

3 - 5 t/h

0,5 t/h

Waste

25 %

75 %

March, 4th 2013 44

X-Ray Sorting System XSS-T

Sensor: X-ray Transmission Determination of material density

Function: Separation of light/heavy

metals, aluminium-alloy, minerals

Application: Scrap

Slag etc.

Technology: X-rays transmitted through material

Sensor determines intensity of received

radiation

Computer determines difference between

incidental and transmitted radiation


March, 4th 2013 45

Application – Car Shredder – Coarse Copper from Mixed NF-Metals

Mixed NF-

Metals Al/Zn

Copper

/Brass

Brass Copper IWCC Technical Seminar, Santiago

X-ray Sorting

System (XSS-T)

Combined

Sorting System

March, 4th 2013 46

Application – Car Shredder – Fines Copper from Auto Shredder Residue

Eddy-Current

Separation

Induction-Sorting

System

Stainless

steel

Waste

ASR < ¾”

Copper,

brass

Zinc


System (XSS-T)

ZORBA

UniSort

Flake Sorter


March, 4th 2013 47

UniSort® Systems – Flake Sorter (Colour)

Sensor: Camera (Colour)

Function: Separation of coloured

metals, printed circuit boards

Application: Non-ferrous heavy fine fraction

Electronic scrap etc.

Technology: Special designed high speed belt

Colour detection by camera

Special designed software evaluates target

Separation by air-jets


March, 4th 2013 48

Application – Car Shredder – Fine Copper from Mixed NF-Metals

Sorting result: 1st test run


Application – Recycling of Printed Circuit Boards – E-Scrap

March, 4th 2013 49

Steel

Screen

Manual Sorting

Crusher

Suspension Magnet

PCB

Mixed NF-

Metals

Copper

transformer,

windings

Steel

Fines

Coarse

Magnetic

Drum

Eddy-Current

Separation

Combined

Sorting System

Plastics

Further Treatment

Copper

Plastics Other raw

materials


Application – Recycling of E-Scrap – PCB’s and ICW


March, 4th 2013 51

STEINERT – Impulse for optimization and development

Key factors for efficiency:

Recovery

Purity

Availability

Maintenance

To be economic and efficient,

is particularly a question of

technology!


Thank you for your attention ...

Stefan Wurzner

Tel.: +55 31 3372 7560

[email protected]

March, 4th 2013

STEINERT Latinoamericana Ltda. R. Marechal Foch, 41 – SL 303

Grajaú - Belo Horizonte/MG

Tel.: +55 (31) 3372 7560

Email: [email protected]

Web: www.steinert.com.br


Solutions for classifying and separating copper from ... - Wurzner.pdf · Solutions for classifying...

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Transcript of Solutions for classifying and separating copper from ... - Wurzner.pdf · Solutions for classifying...