Advanced Industrial Technologies for Aluminium Scrap Sorting

Transcription

1 Advanced Industrial Technologies for Aluminium Scrap Sorting A.J. G, G C M.A. G, T. Erdmann, TiTech GmbH 1

2 2007 Global Al Flows in million tonnes Remelted Al >42 incl. old scrap? Melt loss 1.6 Scrap recovered as melt 96% Casting Scrap: traded 1.6 home? Manufacturing Fab Traded new new Old scrap 10 Burned or landfilled 4.2 Old Al scrap collected 62.5% Under Investig. 1.8 Source: IAI

3 Packaging cans bottles bags Reverse vending UBC 3x04, 5182 UBC Shredder Decoater Remelter Old Scrap MSW collected recyclables MSW MRF Al UBC 3x04, 5182 Rigid foil 1100 Household Foil 8011 MSW nondiverted waste Dirty MRF RDF plant Mixed Metal UBC 3x04, 5182 rigid foil 1100 Consumer durables 6061, 38x Steel Shredder NMM shred 60-70% Al ELV cars trucks buses Auto recycler Junk yard Hulks castings 38x, 319, 356, AM, AZ wheels A356, 6061, 5754 closures 6111, 5754 extrusions 6061, 6086 Heat exchangers 4143, 1100, 3003 CDW Construction clippings and demolition waste CDW MRF Mixed Metal siding 3105 doors & windows 6063, 6061 Hand sorted Al scrap Old cast: 38x, 319, 356 Old sheet: 3003, 3105 Old extrusions: 6061, 6063 WEEE Electronics Appliances Power tools WEEE MRF Mixed Metal Sheet housing 3XXX Extrusions 6061 Castings various WEEE Shredder NMM shred

4 Main markets for secondary Al and the most popular alloys for these markets Market Secondary alloy Compatible scrap sources Al packaging Building Al Automotive Al 3X04 can body sheet 3105 painted sheet 38X.X casting alloys Old cans, can manufacturing scrap Non-can wrought manufacturing scrap Al- and Mg-based scrap mix from 2 g/cc float fraction of a dense-media sink-float plant Old Al siding Al siding and extrusion construction scrap Mixed wrought manufacturing Al scrap with low copper content Old wrought scrap Some 38X alloys can accept a mixture of the most common old scrap varieties without dilution, providing the Mg concentration is controlled by chlorination 319.x casting Tighter concentration limits on 319 increase the dilution requirement and limit the types of old scrap that can be added to a 319 alloy batch Steel deoxidants 95% Al This specification can be met by many mixtures of old wrought alloy scrap 4

5 Secondary alloy markets Secondary alloy market for the four main secondary alloys far exceeds the global old scrap supply. These alloys can be batched using the scrap categories already on the market. Prompt new scrap is typically recycled to a more impurity tolerant alloy within the same alloy family. 5

6 Dismantling gives parts for re-use! 6

7 Shredding Is cost-efficient liberates mono-material particles increases the bulk density permits mechanized material handling and storage Fluff Foam Fiber Dust Foil 7

8 ELVs white goods Primary shredding plant mixed metal dealer scrap CDW MSW oversize 5,000-15,000 HP hammer mill drum magnet Oversize 5, 30 mm screens Cyclone & baghouse steel light SR Z-box elutriator <5 mm fines (nonmetal) Al + Mg concentrate >5<30 mm >30<100 mm Overbelt magnet Eddy current rotor circuit metal NMMC nonmagnetic metal concentrate Nonmetal lead, wire stainless steel Light SR Eddy current coil particle sorter circuit Stainless steel Nonmetal steel Nonmetal fines Steel 8

9 Nonmagnetic metal concentrate (NMMC) NA supply ~1,000 kt of NF metal/year, growing quickly 20-95% metal 60-70% Al in metal (~600 kt/year) 30-50% wrought in Al (~200 kt/year) 9

10 Sink-float dense-media plant NMMC = nonmagnetic metal concentrate Process water treatment HP hammer mill Oversize NMMC from SDF 100 mm 3 mm screens Overbelt magnet NMMC from SLF dense Dewatered sludge float Al +Mg mix Eddy current rotor circuit Nonmetal Fe attach. 2.0 g/cc magnetite slurry headpulley magnet 3.5 g/cc ferrosilicon slurry Dense metal mix Al alloy mix >9 mm float Eddy current rotor and shape sort circuit Insul. Wire 1.0 g/cc wash 9 mm screen Jig Nonmetal rock dense <9 mm metal mix Al +Mg grain light Eddy current rotor circuit Nonmetal grain steel steel fines Nonmetal fines & dust 3 mm screen Overbelt magnet Cyclone separator & baghouse light foam paper foil textile 10

11 Al mix from dense-media float fraction 11

12 Scrap sorting plant (current technology) Dense metal mix (dense media sink) Dense metal mix (dry sort) Al + Mg (light media float) Al Mg Cu red brass yellow brass Zn stainless steel lead wire nonmetal steel 12

13 Al Recycling System Needs and Opportunities There is a need to improve Al scrap collection through improved diversion from landfills and incinerators, and better separation from steel, nonmetals and fines residues. There is a need to keep Mg scrap out of Al recycling system There is no need for closed loop recycling (back to the same alloy) There is no recycling system need to further upgrade scrap to use it in other alloys. There is no system need to develop new secondary alloys, or use post-consumer scrap in prime alloys. There are financial opportunities in buying lower grade mixed scrap and upgrading it to your own alloy specifications. 13

14 Status of metal scrap particle separation Desired separation Metal - nonmetal Steel from nonmetal+nonmagnetic metal Nonmagnetic metal from nonmetal Metal from nonmetal fines (<9 mm) Separation method Drum magnet, overbelt magnet Screen, air elutriator, eddy current rotor, eddy current coil sensor Jig, eddy current rotor Nonmetal or other metal contaminants from Al Magnetic headpulley, eddy current rotor, hand sort Al - other metal Light from dense NF metals Al from Mg Al-Al Al with attachments from liberated Al Alloy grouping and Al by alloy Particle-by-particle target alloy batching Average particle stream elemental composition measurement Sink- float (wet or dry), eddy current rotor, hand sort, colour sensor, XRT sensor Hand sort, XRT sensor LIBS sensor, XRF sensor LIBS sensor, XRF sensor LIBS sensor, XRF sensor, PGNAA sensor 14

15 Chute type particle sorter 1 2 Small particle sorting 3-20 mm 1 Unsorted particle feed 2 Scanning and processing 3 Diversion 3 15

16 Belt type particle sorter Larger particle sorting mm 1 Unsorted particle feed 2 Scanning and processing 3 Diversion 16

17 Eddy-current coil sensor sorter Find metal in residue and/or Mixed feed ECC sensor Sorted Products separate stainless steel Conveyor Air jet ejection 17

18 Combined color/nir and ECC sensor sorter Separate Cu, brass, Zn, stainless steel, nonmetal or Mixed feed Illumination Color sensor Sorted Products Al, Mg and nonmetal or Insulated wire from non-metal Conveyor ECC sensor Air jet ejection International Aluminium Recycling Workshop, Trondheim, Norway June

19 Dual energy x-ray transmission sensor sorter Identify contaminants, attachments, separate : Mixed feed X-ray illumination Sorted Products products light metals from dense metals Al from Mg? Al(Mg, Si) from Al(Cu,Zn)? Conveyor DE x-ray array sensor Air jet ejection 19

20 DE-XRT identification of Al and Mg International Aluminium Recycling Workshop, Trondheim, Norway June

21 Elemental concentration sensor sorters Mixed feed X-Ray Illumination XRF array sensor Sorted Products XRF sensor Alloy sort based on analysis of dense elements Conveyor Air jet ejection LIBS sensor Alloy sort based on analysis of all elements, light and dense Mixed LASER OE feed Illumination Spectrometer XYZ 3D Camera scanner Conveyor Sorted Products Air jet ejection 21

22 TiTech LIBS sensor Al alloy sorter specifications Conveyor belt width 60 cm Conveyor belt speed 3 m/s Particle chemical analyses 40 /s 14 alloying elements analyzed Al, Mg, Si, Cu, Zn, Mn, Fe, Cr, Sr, Ti, Zr, Ce, La, Nd Particle size >1 < 15 cm Particle weight >1 <250 g Throughput for 50 g particles 7.2 t/h for 20 h/d, 5 d/w operation 36,000 t/y Output streams 4 22

23 Alloy Sorter feed end

24 LIBS Sensor

25 Typical Al wrought scrap illuminated by laser line

26 Splitter Box

27 Blowbar, splitters and four output bins

28 Particle tracking and targeting reproducibility 3 m/s, 40 Hz 28

29 Individual Mn and Mg LIBS measurements on particles moving at 3 m/s Mn spectral signal (counts) Thousands 140 Mn Mg spectral signal (counts) Thousands 1,200 Mg 1, Mn Wt% -200 Mg wt% International Aluminium Recycling Workshop, Trondheim, Norway June

30 LIBS sensor virtual sort of Al sheet alloys and a Mg-based alloys Parent metal identification based on single-laser-bursts on clean particles moving at 3 m/s Recovery wt% Metal Output bins Sorted Al 1095 Al 7075 Mg Al % 0% 0% Al % 99% 0% Mg 0% 0% 99% 30

31 Average spectral line count ratio (/Al) LIBS sensor signal for wrought Al alloys Zn Mn Cu Si Fe Mg Aluminium sheet alloy 31

32 Virtual sort results on wrought Al alloys based on single laser burst LIBS measurements on moving samples Recovery wt% Alloy Alloy output bins Sorted B % 10% 0% 0% 0% 0% % 83% 0% 0% 0% 0% % 3% 83% 0% 0% 0% % 0% 0% 83% 57% 0% % 0% 3% 67% 83% 0% 3105B 0% 0% 0% 0% 0% 87% Output Bin Composition wt% Bin Al Si Fe Cu Mn Mg Zn B

33 Competition: Sorting table vs Sorting circuit 33

34 New recycling processes enabled by sensor-based sorters Stainless steel recovery from shredder non-metallic residue Dry sorting of shredded non-magnetic mixed metals Light metal alloy batching/sorting 34

35 Shredded metal concentrate dry sorting plant NMMC = Nonmagnetic metal concentrate NMMC from SDF NMMC from SLF 3 mm screen contaminated HP hammer mill Oversize >3<9 mm Oversize 30 mm 9 mm fines screens >9<30 mm dense >30<100 mm Overbelt magnet Cyclone separator & baghouse light <3 mm fines Overbelt magnet steel DE x-ray sensor particle sorter circuit >9<100 mm metal mix Headpulley magnet Eddy current rotor circuit nonmetal magnetic Alalloy mix Mgalloy mix Dense metal mix Wire >3<9 mm metal mix Eddy current coil particle sorter circuit Stainles s steel Steel Nonmetal foam paper foil textile Nonmetal fines & dust 35

36 Light metal alloy batching/sorting plant Mg Mg + Al Al Contaminated DE x-ray sensor particle sorter circuit HP hammer mill Oversize >3<9 mm Oversize 30 mm 9 mm fines screens >9<30 mm <3 mm fines >30<100 mm Al-alloy mix Mg-alloy mix Clean LIBS sensor elemental composition particle sorter circuit >9<100 mm Mg / Mg+Al / Al Overbelt magnet Headpulley magnet Eddy current rotor circuit steel attached steel stainless steel Dense Metals Al alloy 1 Al alloy 2 Alalloy mix Mg alloy 1 Mg alloy 2 Mgalloy mix >3<9 mm Al mix >3<9 mm Mg mix Nonmetal steel Al fines Mg fines 36

37 Takeaway Dismantling enables remanufacturing and reuse Shredding liberates mono-material particles and enables material recycling Bulk material separations for separation of metal from non metal and metal shred by density are mature and low cost Sensor based industrial sorters are industrially proven robust Sensor based sorters are displacing manual sorting in EU and NA Sensor based sorters enable new scrap recycling processes LIBS elemental concentration sensor sorter is now industrially well proven and commercial model is under development. Sensor based sorters now need market pull from the recycling industry 37