Table of Contents. 1 Scope

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1 The manager of DMMG/AT is responsible of content and document compliance. 1 Scope Disposal and Recycling of 3-phase squirrel cage AC-motors in frame sizes from 56 to 450 manufactured by ABB Discrete Automation & Motion Low Voltage Motors Table of Contents 1 Scope General Dismantling of the motor Separation into Different Kinds of Material Waste and Land Fill Final comments... 5 Type des. Part no. Prep. DMLM/ATP / Per Nordström Doc. kind No. of p. Appr. / Åke Andersson Title Recycling low voltage motors 6 Resp. dept DMLM/ATP Approved 3GZW en A 1 FILE: 3gzw docx; SAVEDATE: :57; TEMPLATE: TECHN_DOC_STAND_P.dot C; SKELETON:

2 2 General Your electrical motor contains valuable and scarce materials. It is of great importance that it gets recycled! Normally the local scrap dealer knows how to take care of it in an eco-efficient way. ABB Discrete Automation & Motion, Low Voltage Motors, works according to the Environmental Management System ISO This means that are an organization that works with environmental matters in a serious and systematic way. To improve the environmental aspects of the products, they are developed in collaboration with the Environmental Coordinator. As a result of this collaboration, nonhazardous material types and processes are chosen for these products. It is also combined with a total overview by issuing Life Cycle Assessment where the products are studied in all aspects of their life cycle. The life cycle assessment is divided into 3 phases: The Production Phase, where the environmental aspects of the Production of the product are analyzed. The Use Phase, where the environmental aspects during the use of the product at the client s are studied and analyzed. The Disposal Phase, where the environmental aspects at the end of life are studied. This concerns disposal and recycling of material included in the product. This instruction concerns the disposal and recycling of 3-phase squirrel cage AC-motors size manufactured by ABB Discrete Automation & Motion Low Voltage Motors. Due to different conditions for recycling in different parts of the world, the methods below are described in a general way. 3 Dismantling of the motor The possible use of recycled materials are very much dependent on how degraded by alloys it is. In order to get as pure materials as possible at the recycling, the motor has to be dismantled. The objective of the dismantling is to, as far as possible, get pieces of only one material. If two materials cannot be dismantled from each other they have to be fragmentized in order to be recycled. This means that the mixed material is cut into small pieces. Thereafter it is separated by magnetic methods. This consumes a lot of energy about kwh/ton causing a large environmental impact during its generation. The economic value of the material increases with its purity. Copper mixed with steel is worth somewhere around 3% of the normal prize for recycled copper. This means that there are strong economic incentives for dismantling the motor before recycling the material. 3GZW en A 2

3 4 Separation into Different Kinds of Material The motor may be separated into components according to the drawing below No. Component Material Comment 1, 2 End-shields Aluminium or cast-iron 3, 4 Bearings Bearing covers Rubber V-rings Steel Rubber Landfill 5 Cover Terminal box Terminal block Terminal fittings Aluminium alloy, cast-iron or steel Aluminium alloy or cast-iron Plastic, metal Landfill 6 Plastic fan cover Metal fan cover Plastic 7 Screws, endshields 8 Screws, fan cover 9 Key 10 Bushing, fan cover Rubber Landfill 11 Drainage plug Plastic Landfill Energy recycling 12 Plastic fan Aluminium fan Plastic Aluminium alloy 13 Rotor core Pure aluminium and electrical steel or pure electrical steel only 14 Shaft Steel 15 Housing Aluminium alloy or cast-iron 16 Stator core Electrical steel 17 Winding Copper and plastic 18 Slot insulation Plastic Landfill Energy recycling When aluminium, difficult to separate 3GZW en A 3

4 The components are separated into groups as follow: Steel Components made of normal steel are 100% recyclable and may have an important value as metallic scrap if it is not mixed with other metals or landfill waste. Electrical Steel (Non Oriented) Stator core. First the stator has to be separated from the housing. If the housing is made of Aluminum it is most easily sawed. If the housing is made of cast iron it is easier to press the stator out. The stator coils run through the slots of the stator core. Due to an impregnation resin the coils are very rigid. However there is a plastic insulation between the coil and the steel core that hinders the coil from sticking directly to the steel. To separate the coils from the steel core, first remove one end of the winding. This might be done by the use of a pneumatic saw or by using other cutting tools. Then the rest of the winding can be slid out of the steel core with some force. The electrical steel should be recycled in a special fraction. It is not recommended that the complete stator is sent for fragmentation, as the value of the components in this case will be very low. It also needs a lot of energy. Mixed Metallic Material External fans and Tachometer generators etc. These components often contain steel integrated with copper and plastic material. In general it is sent for fragmentation. It may be possible to save some energy and money it these components first are disassembled. Rotor core. When manufacturing the rotor Aluminum is melted into the slots of the rotor laminations. Thereby it gets difficult to separate the two materials. The rotor core should be put in the mixed metallic fraction. Depending on the ratio Aluminum the rotor core can either be melted down in steel alloys containing Aluminum or in Aluminum alloys containing iron. When synchronous reluctance motor, rotor core contents only pure electrical steel and no aluminium. Cast Bearing end shields, cover, housing etc. These components are disassembled by undoing bolts and then recycled. Aluminium Alloy For environmental reasons this is very important to separate, as new aluminium needs a large amount of energy in order to be manufactured. Bearing end shields, cover housing, fan etc. These components are disassembled by undoing bolts and then recycled. The housing can be removed by sawing and then making it crack. Metals Integrated with Plastics Terminal block. The two materials cannot be easily separated and has to go to landfill 3GZW en A 4

5 Copper This is the most important material to separate. Copper is a material of limited access in the nature. It needs a lot of energy and processes in order to be produced and has a very high value. As an indication it may be mentioned that the price paid for clean copper scrap is times higher than for normal carbon steel. However copper mostly is integrated in the actual components and needs some effort in order to be separated. There exist some special tools for making this separation simpler but normally it may be used wedges, large hammers, gas burners and manpower to do this. The method varies from country to country. Stator coils. The stator coils run through the slots of the stator core. Due to an impregnation resin the coils are very rigid. However there is a plastic insulation between the coil and the steel core that prevents the coil from direct contact to the steel. To separate the coils from the steel core, first remove one end of the winding. This might be done by the use of a pneumatic saw or by using other cutting tools. Then the rest of the winding can be slid out of the steel core with some force. It is not recommended that the complete stator is sent for fragmentation, as the value of the components in this case will be very low. It also needs a lot of energy. 5 Waste and Land Fill All insulation material is to be considered as not hazardous waste. It may be used as land fill or be sent to power plants to be burned. However these power plants must be adapted for this kind of fuel and have the proper types of filters etc. in order to protect the environment from the gases and dust produced. 6 Final comments If there are any questions about environmental matters not considered in this instruction may be answered by the LSO, Local Sustainability Officer. 3GZW en A 5

6 REVISION Rev. ind. Page (P) Chapt. (C) Description Date Dept./Init. A Released DMMG/ATP 3GZW en A 6