IWCC TECHNICAL SEMINAR. Solutions for classifying and separating copper from recyclable materials using magnetic and sensor sorting systems

IWCC TECHNICAL SEMINAR Solutions for classifying and separating copper from recyclable materials using magnetic and sensor sorting systems Stefan Würzner Engineering Manager & Application Specialist Santiago, Chile March, 4 th 2013

Welcome... 2

STEINERT Group 2011 Family owned Enterprise > 200 employees Factories in 4 countries Worldwide presence Steinert Elektromagnetbau, Germany Manufacturing Sales Service FOCUS RECYCLING Steinert US Steinert Japan Steinert Latinoamericana, Brasil Steinert Australia RTT Steinert, Germany Manufacturing Sales Service Sales Service Manufacturing Sales Service Manufacturing Sales Service Manufacturing Sales Service FOCUS RECYCLING FOCUS RECYCLING FOCUS MINING FOCUS MINING FOCUS RECYCLING March, 4th 2013 IWCC Technical Seminar, Santiago 3

STEINERT Group, Global Support: Through S & Joint Venture s (JV) JV - China JV South JV - India Africa 4

General Applications Recycling Scrap Mining Electro-technical Applications 5

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 Shredder scrap PCB-Recycling Refuse incineration slag Metallurgical slag Used foundry sand Degreasing baths etc. 6

STEINERT Separation Equipment for Dry Metal Recovery Suspension Magnets UME / AME Eddy Current Separator NES Magnetic Drums MTE / MTP Magnetic Head Pulleys BRE / BRP High Gradient Magnetic Separators HGS Sensor Sorting Systems ISS 3DS FSS NIR XSS / XRF 7

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 8

Eddy Current Separator ECS 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 9

Eddy Current Separator Working principle The Conductive Material A pole alternating rotating system is introduced metals pole made field system are induces of to expulsed permanent generates the eddy magnetic and currents magnets an forced alternating field out using is conductive incorporated of a magnetic their conveyor discharge metal field belt. pieces, trajectory. with close into the to the discharge induced magnetic drum point of field the of the belt being material. conveyor. opposite to the magnetic field of the pole system. N Alternating magnetic field Conveyor Belt Non ferrous metals Dicharge pulley High speed rotor with permanent magnets Non conductive material 10

Eddy Current Separator Separation possibilities 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 11

Sensor Sorting Systems - From Manual to Automated Material Sorting 21 st century Agricola 12

STEINERT Working principle Singularize Detect Eject 13

Sensor Sorting System Equipment layout feeder acceleration belt sensor air valves catcher hood with splitter 14

STEINERT Sensor portfolio Sensor Type 3D ISS KSS NIR XSS-T XSS-F Physical Material Properties Laser in combination with camera Surface shape, topological properties, particle presence Metal detectors Conductivity, Magnetic susceptibility CCD camera Reflection/absorption of visible light on the material surface, surface colour, brightness, light transmission NIR sensor Reflection/absorption of near infrared light on the material surface X-Ray transmission Absorption of x-ray energy in material, density and atomic density X-Ray Fluorescence Elemental composition, spectroscopy March, 4th 2013 IWCC Technical Seminar, Santiago 15

STEINERT Sensor portfolio Sensor Type 3D ISS FSS NIR XSS-T XSS-F Physical Material Properties Laser in combination with camera Surface shape, topological properties, particle presence Metal detectors Conductivity, Magnetic susceptibility CCD camera Reflection/absorption of visible light on the material surface, surface colour, brightness, light transmission NIR sensor Reflection/absorption of near infrared light on the material surface X-Ray transmission Absorption of x-ray energy in material, density and atomic density X-Ray Fluorescence Elemental composition, spectroscopy March, 4th 2013 IWCC Technical Seminar, Santiago 16

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 IWCC Technical Seminar, Santiago 17

STEINERT 3D Laser Scanning March, 4th 2013 IWCC Technical Seminar, Santiago 18

STEINERT Electro-Magnetic Sensor Emitter coil Detector coil pair Detects conductive or magnetic material Ferrous and non-ferrous metals as well as magnetite can be distinguished On-line measurement 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 March, 4th 2013 IWCC Technical Seminar, Santiago 20

STEINERT Colour Sorting Measures reflected light from material surface On-line measurement 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 IWCC Technical Seminar, Santiago 22

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 IWCC Technical Seminar, Santiago 23

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 IWCC Technical Seminar, Santiago 25

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 On-line measurement March, 4th 2013 IWCC Technical Seminar, Santiago 26

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 IWCC Technical Seminar, Santiago 27

STEINERT X-Ray Fluorescence X-STREAM by Singulated mixed ore X-Ray tubes excite material Detectors capture emitted fluorescent X-rays March, 4th 2013 IWCC Technical Seminar, Santiago 28

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) March, 4th 2013 IWCC Technical Seminar, Santiago 29

STEINERT Eddy Current Separation and Sensor Sorting - Process Data 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 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 IWCC Technical Seminar, Santiago 30

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 20 to 30kg copper per ELV 0,5% copper from motors 31

Application Car Shredder Steel Product until 2009 Shredder Magnetic Drum Scrap Suspension Magnet Steel with copper Auto Shredder Residue Coarse Fines To ASR plant Non-Ferrous Metal Recovery 32

Application Car Shredder Copper from Steel Product after 2009 Shredder Magnetic Drum X-Ray Sorting System (XSS-F) Scrap Suspension Magnet Steel with copper 120 t/h 1,2 t/h Copper (Meatballs) Auto Shredder Residue Copper free steel Coarse Fines To ASR plant Non-Ferrous Metal Recovery 33

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 34

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 35

Application Car Shredder Copper from Steel Product Copper & Meatballs ~1% from steel scrap 36

Application Car Shredder ASR until 2009 ASR ¾ to 2 25 t/h Eddy-Current Separation ZORBA 8-10 t/h Mixed NF- Metals 15 t/h Induction-Sorting System 2-3 t/h ZURIK Stainless steel, etc. Waste 37

Application Car Shredder ASR after 2009 Eddy-Current Separation ASR ¾ to 2 25 t/h ZORBA 8-10 t/h Induction-Sorting System Combined Sorting System 15 t/h 5-7 t/h 3-5 t/h 2-3 t/h ZURIK Stainless steel, etc. 0,5 t/h Copper wire X-ray Sorting System (XSS-T) Combined Sorting System 25 % 75 % Aluminium Zinc Waste Waste Copper, brass 38

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! 40

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 41

Application Car Shredder Insulated Copper Wire 42

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 44

Application Car Shredder Coarse Copper from Mixed NF-Metals Mixed NF- Metals X-ray Sorting System (XSS-T) Al/Zn Copper /Brass Combined Sorting System Brass Copper 45

Application Car Shredder Fines Copper from Auto Shredder Residue ASR < ¾ Eddy-Current Separation ZORBA Induction-Sorting System Stainless steel X-ray Sorting System (XSS-T) Aluminium UniSort Flake Sorter Zinc Waste Copper, brass 46

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 47

Application Car Shredder Fine Copper from Mixed NF-Metals Sorting result: 1 st test run 48

Application Recycling of Printed Circuit Boards E-Scrap Manual Sorting Suspension Magnet Crusher Steel Copper transformer, windings Fines Screen Coarse Further Treatment PCB Combined Sorting System Copper Steel Magnetic Drum Plastics Other raw materials Mixed NF- Metals Eddy-Current Separation Plastics 49

Application Recycling of E-Scrap PCB s and ICW 50

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! 51

Thank you for your attention... STEINERT Latinoamericana Ltda. R. Marechal Foch, 41 SL 303 Grajaú - Belo Horizonte/MG Tel.: +55 (31) 3372 7560 Email: steinert@steinert.com.br Web: www.steinert.com.br Stefan Wurzner Tel.: +55 31 3372 7560 stefan@steinert.com.br March, 4th 2013 IWCC Technical Seminar, Santiago 52