Processing Experts. SR-Processing

Transcription

1 Processing Experts SR-Processing

2 03 THE COMPANY SICON is there for you! We listen to what you ve got to say and take our cue from you. We fit in with your requirements - not the other way around. In the animal kingdom there s a creature that fulfills all these criteria: the chameleon! But outside the kingdom world, it has to be SICON! We re a medium-sized international company that manufactures systems for recycling metals and plastics. Our know-how is especially concerned with shredding scrap materials (pre-shredders and main shredders), processing shredder residues and separating plastics by density. In doing so, we don t just supply standard solutions but special ones, too! What distinguishes us is our customers. We don t see our clients as buyers but rather as partners and view our work together as being a long-term cooperation during which we ll always be there to help you if you need us! We ve been concerning ourselves with scrap for over 15 years. We listen to our customers and are in a position to bundle the knowledge we ve learned from cooperations with many different users; we want you to benefit from the experience we ve gained from working with other scrap-processing companies. Our products are the result of watching and listening. Functionality and performance are top priorities for us. As an operator of our own recycling plant ( ), our processes haven t been developed on the drawing board but instead tested in reality during numerous campaigns and multi-shift continuous operation. Our services don t just focus on supplying machine technology; if you want, we ll also assist you with scheduling in existing buildings or facilities, provide support with approval processes and discussions with regulatory authorities, and help you to find customers for your metal or plastic products. Our machines and equipment haven t been designed around a core machine; instead, they are fully adapted to the individual cost-benefit ratio of each of our customers. We re versatile and take every scrap-processing step into consideration, from assembly services and scrap yard logistics, through shredding machine technology and processing all product flows, right up to generating defined metal and non-metal fractions. 02 Index of contents The company 02 Cable recycling 12 FinesTuning 04 Polyfloat 14 SICON SICON-e 16 SICON Sensor sorting 18 SICON SICON service 19

3 05 FinesTuning Fines from (A)SR processing (fines < approx. 12 mm) make up 20 40% of the total weight of shredder residues. They contain large quantities of recyclable metals but also significant amounts of recyclable non-metals. The revenue potential of (A)SR fines is often under-estimated. With FinesTuning, SICON has developed a system that reliably separates over 99% of separable NF metals contained in fines fractions. The multi-step magnetic separator system guarantees complete metal recovery; it consists of two magnetic drums with different magnetic field strengths and an overbelt multi-pole magnetic separator combined with a special eddy current separator with downstream sensor sorting. An efficient system which, through lucrative metal revenues and reduced disposal costs, amortizes itself within a short space of time. SICON realizes FinesTuning in new plants and also as a retrofit solution for integration into existing plants with throughputs of up to 30 t/h. That pays off! Schredderrückstände (TPY) Recovering tiny fragments of non-ferrous metals Monate On average, a new FinesTuning system pays itself off within 9 to 21 months. Each metal fragment separately. With FinesTuning, metal fragments as small as < 1 mm can be filtered out from fines and reliably separated. raw shredder sand Iron Metal-free shredder sand Zorba fines System for recycling fines from lightweight, heavy or (A)SR shredder fractions Multi-stage separator for comprehensive separation with significantly higher grades of purity of the separated metals Multi-pole overbelt magnetic separator to additionally refine the ferrous fraction in order to achieve a pure marketable FE fraction 04 Throughputs of between 2 and 30 t/h Compact, space-saving system Supplied as a turnkey solution Quick return on investment Optional extension to include additional metal-processing steps, e.g. separation of copper from the recovered Zorba fraction

4 07 SICON-75 A good base to start with Reliable shredder residue processing starts with the SICON-75 system. A perfect match of equipment for ferrous metal separation, screening, classification, non-ferrous metal separation and FinesTuning makes the system exceedingly efficient. Based on the interaction of these units, SICON-75 ensures the complete separation of NF metals (Zorba) down to a fines fraction of less than 1mm. SICON-75 is a fully automated system that can be connected directly to a shredding plant or used as stand-alone unit. SICON also supplies individual upgrades for existing lines. If you want to improve the performance of your plant, please don t hesitate to get in touch with our experts. As with all other SICON solutions, SICON-75 has been designed as a modular system; we can also implement the unique advantages of our technical solutions in older systems. An eye for detail. With throughputs of up to 80 t/h, SICON-75 can detect and separate metal fragments upwards of < 1 mm in size. shredder residues ASR Fine iron Coarse iron Zorba Shredder residue processing in a single system (FE Metal separation, screening and classification, NF Metal separation, FinesTuning ) Large material feed bunker for uncoupling from the actual shredding process, eliminates peak loads and ensures uniform, optimum metal separation Multi-stage screening/classification with self-cleaning function of the drum screening machine and flip-flow screen 06 Optional scales for weighing input material flows and end-products Optional AIRSORT technology to optimize metal separation Intelligent process data logging software (weights, operating hours, problems, etc.) Throughputs of up to 80 t/h

5 09 SICON-100 More informationen on The first step towards advanced metal and ASR recovery SICON-100 enables you to recover NF metals more effectively from shredder residue. SICON-100 is the consistent extension of the Zorba fraction separation process implemented in the SICON-75 system. Stainless steel, copper strands, printed circuit boards and cables are comprehensively separated to produce a waste fraction that is entirely metal-free. Thanks to the SICON sensor technology in the SICON-100 system, highly individual lines can be tailormade to meet special customer requirements. Particularly versatile. The integration of VARISORT machines for sensor-sorting into SICON-100 enables stainless steel, cables and printed circuit boards to be separated from (A)SR, Zurik and Zorba fractions in a highly-efficient way. The shredder residue passes through the following stages in a fully automatic process: FE metal and non-ferrous metal separation (eddy current separation), FinesTuning, air separation, sensor-based sorting. As an optional extra, the shredder residue can be homogenized gently in the SICON-100plus system by the SICON (A)SR PTS crusher, which improves the metal recycling rate and cuts investment cost even further. At the same time, non-metals are recovered in a quality that allows them to be recycled. In this way, SICON-100plus goes beyond classical sensor-sorting and therefore allows you to achieve full (A)SR recovery. Whichever model you opt for, SICON-100 comes with units that are optimally tuned to one another. A system that fits your needs to a tee. It is not without reason that the machines, particularly the VARISORT induction separator, have established themselves as the best in their respective class. SICON-100 and SICON-100plus are also available as upgrades for existing plants. If you have metal losses in your waste or increasingly have to feed material repeatedly through your machines, then please get in touch with our experts. We also integrate our unique solutions into existing systems, thus significantly improving performance as far as throughput, metal recovery and product quality are concerned. (A)SR Shredder Residue Shredder fluff Iron Unshreddables Fine iron Zorba Shredder granulate Zurik Shredder residue are processed in a single system (FE metal separation, screening and classification, NF metal separation, FinesTuning, sensor-based sorting, air separation and preliminary crushing) Integration of SICON S+S VARISORT sorters (sensor-based sorting) for metal separation (optionally also for the removal of chlorine in cases where non-metals are also to be recycled) Pre-crushing by SICON (A)SR PTS crusher for gentle loosening 08 Optimum preparation for later sorting by the VARISORT induction separator Integration of AIRSORT sifters to separate light-weight materials Treatment and processing of non-metal fractions for the production of assured-quality substitute fuel or recycling plastics Optionally, additional processing of the Zurik fraction and separation into copper, aluminium and stainless steel

6 11 SICON-120 More informationen on Perfection in the (A)SR treatment process becomes an industrial standard A perfectly-engineered system. Building on the efficient SICON-100 system, SICON-120 even exceeds optimum metal recycling by producing fractions sorted by material. SICON-120 is a system made for the future, which already incorporates future changes in the composition of shredder residue caused by further advances in electrification. Where sensor-based processing systems normally reach their limits when it comes to ensuring a complete metal recovery (> 99% of the input flow), SICON-120 brings its inherent advantages into play. Instead of producing a Zurik fraction, metals (aluminum, copper, stainless steel) of the highest purity and high market value are yielded. An additional side-effect of this is that non-metals are also recovered in a quality that enables them to be re-used (e.g. plastics recycling). SICON-120 is a modular system capable of meeting all requirements including the shredder plant owner s wish to extend his line step-by-step in the future. Insulated and still separated. Not only copper but also recyclable plastics are obtained after processing materials with SICON-120. Even insulated copper components are detected reliably by the system. (A)SR Shredder Residue Aluminium Shredder granulate Shredder fluff Stainless steel Shredder sand Iron Unshreddables Fine iron Zorba Copper Fine Zorba Modular system with SICON PTS homogenization crusher and separation into fines (shredder sand), fibers (shredder fluff), plastics (shredder granulate and metals) Systematic refining of all three coarse fractions to achieve defined product qualities 10 Metals are separated into copper, aluminum and stainless steel and are recovered in high metallurgical grades Throughputs of up to 80 t/h Unique SICON support is also available with SICON-120 to ensure the sale of metal as well as non-metal fractions

7 13 Processing cables More informationen on Copper recovery at its best Many systems for processing shredder residues generate a Zurik fraction which contains between 30 and 80% metal. The metal content is mixed because major constituents include stainless steel as well as copper and aluminum cables. The solution implemented in the SICON-120 system that separates all cable residues, even the finest copper strands, can also be implemented offline as a standalone unit. Consequently, in addition to conventional sensor-based separation, SICON achieves a very efficient separation process which ultimately yields high-grade copper and aluminum granulate. The system is also available to shredder operators who relied on system solutions in the past that were less efficient than SICON solutions. The SICON team is also happy to integrate advanced SICON processing solutions into existing plants. Optimum processing of cable fractions. A particularly efficient form of separation which generates high-grade copper and aluminium granulate as end-products. cables or cable-rich fraction Aluminium or cable-rich residual fraction Copper Gentle and effective crushing in the SICON PTS-(A)SR crusher which has a low energy requirement Granulators of extremely rugged design with intensive wear protection for long service life at low operating cost Reliable separation of foreign material prior to granulation; this prevents any risk of damage to the crushing tools Effective and complete separation of stainless steel Throughputs of between 500 and 5,000 kg/h 12 Separation into pure copper and aluminum granulate

8 15 More informationen on Polyfloat Maximum precision With Polyfloat, SICON is defining new standards in the separation of plastics. 99.4% is the new benchmark for product purity that our thoroughly innovative and yet mature system can produce. Perfectly-matched processes within the system make it suitable for recycling PE/PP, ABS/PS and other plastics, even ASR and WEEE plastics. Preventing the formation of harmful air bubbles, the unique lamellar separation system ensures that Polyfloat is the best investment for higher product purity and better marketing opportunities. Plastics separation with a purity of 99.4%. Each type of plastic is separated according to individual density settings. raw granulate PE PP PVC Water Infeed Media Infeed Material Infeed Material Drying Separation Tank Media Preparation Tank Mashing Tank Light Fraction Maximum efficiency, fully-automated plastics separation technology (> 99.4% product purity) in a single system with shredder, metal separation and cleaning process Integrated lamellar separation system (prevents formation of air bubbles) Heavy Fraction 14 Recycling of PE/PP, ABS/PS and other plastic materials as well as WEEE (specific density of 0.9 to 1.4 g/cm3) also suitable for black plastic materials Easy integration into existing plants Wastewater-free process Throughputs of up to 12 t/h Quick return on investment PO Compound

9 17 SICON-e Stripped to the core The amounts of electrical and electronic scrap are growing all the time. Many different materials are involved and most are disposed of as waste. However, as separate collection and sorting are becoming more common, a lot of them can now be recycled. SICON-e provides a reliable method for recycling electronic scrap in a modularly designed system that grows with your needs. SICON-e not only separates metals such as stainless steel, copper, aluminium and printed circuit boards but also recovers plastics for recycling. The Polyfloat process enables SICON-e to obtain product purity levels of over 99% with plastic materials, regardless of the color of the plastic. electronic waste Shredding Metal Separation Granulating Screening Circuit Board Separation Wood Removal Air Classifying ICW-Separation PE/PP-Separation Brominated Plastic Removal ABS-Separation Cables Plastic Copper Printed circuit boards PS-Separation Rubber-Separation 16 Produces polyolefin and styrene fractions in a single system with maximum purity and yield rates Fully-automated system with intelligent and more reliable sensor and control technologies Also separates into PVC and non-pvc fractions for special recycling solutions Integrated process water and media purification Total recovery of all metals

10 19 Sensor Sorting More informationen on SICON service As variable as you want VARISORT An overview of our services: With the VARISORT product family from the traditional Bavarian concern Sesotec, we offer our customers the optimum technical solution for sensor-based sorting of bulk goods containing different materials. Since the 70 s, our partner has concerned itself with sorting and detecting metals and foreign materials. A leading company in the field, the concern develops and manufactures products on its own premises to give you the edge in the recycling market: state-ofthe-art sensor technology tailormade exactly to your requirements. Regular service and maintenance contribute significantly towards extending the service life of a shredder. Our SICON service program offers customers tailored service packages. Categorized into three different profiles: standard, advanced and premium, you ll always find the range of services you re looking for to meet your individual requirements. From consulting and general maintenance through rotor overhauls up to damage assessment or even the complete replacement of rotor systems, we offer everything a plant operator needs in order to be able to operate smoothly at all times. Depending on the task at hand, different detection sensors in the VARISORT are used: Multi-channel metal sensor M Multi-channel metal sensor M+ CCD color camera system C Multi-spectral near-infrared system Dual-energy x-ray transmission system XT X-ray fluorescence system XF With Sesotec as a technology supplier, we can draw on decades of know-how to separate detected materials. An adapted feed system helps to optimally distribute and settle the material on the acceleration conveyor to enable material fragments to be accurately removed from the flow of bulk goods by blasts of compressed air. It doesn t matter whether the fragments are large or small: we ve got the solution you need. VARISORT BIG for really large chunks VARISORT WEEE specially designed for sorting electronic waste and scrap metal VARISORT COMPACT ideal for fine-grained fragments And that s not all: VARISORT also allows you to combine different sensors for even more sorting applications: Sorting cables Separating printed circuit boards Producing a mixed plastics fraction When are you going to challenge us with a sorting task? A comprehensively-equipped technical center is at your disposal for customer trials. We ll be happy to show you the machines you ll be using to separate your bulk materials in the future. 18 Rotor overhauls A general rotor overhaul can significantly improve your current operating costs and is considerably more cost-effective than purchasing a new rotor. Overhauling more than 100 rotors a year, the repair and maintenance of shredder rotors is our key business in services. As a system supplier, we offer everything from the actual processing right up to delivery. Maintenance and damage analysis Maintenance forms an integral part of profitable shredder plant operation. As a system developer, based on our 15 years of experience we offer an especially comprehensive maintenance service for each part of your system. On top of actual maintenance, you ll also receive a comprehensive objective report on the actual state of repair or your system. This report will not only describe how your system is currently running but will also include recommendations for short- or long-term measures which could help to make noticeable improvements. Development There are many aspects to system optimization. Whether you want to bring your existing plant up-to-date with the latest developments, integrate individual machines into a system or are looking for a completely new individual plant system SICON is the right partner for all of your queries regarding the development and optimization of shredder plants. Please do not hesitate to contact our engineering department in Hilchenbach, Germany. We ll be happy to help you. Consulting Constructing and optimizing systems is not the result of fast and spontaneous decisions. There is a strategy behind them. We would be happy to advise you on all your concerns regarding the optimization of your plant concept. Product sales Are you having problems selling your product or can only get rid it with additional disposal fees? With its extremely broad network of contacts, SICON can help you to find a consumer, or expand your existing system so that you can manufacture a product with a positive return. y

11 SICON Deutschland Vordere Insbach Hilchenbach, Germany Phone: +49 (2733) SICON Amerika Old Roswell Road, Suite 126 Alpharetta, GA 30009, USA Phone: +1 (678) sicon.eu