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GUIDE FOR SORTING AND UPGRADING OF NON FERROUS METALS

NON FERROUS METALS

A global leader in sensor-based sorting

ADD VALUE BY SEPARATION

Unsorted material of a non ferrous fraction

0302

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

Electronic products are now widespread in all areas of life

and create an enormous demand for non ferrous metals:

the worldwide demand for copper for onboard electrical

systems in cars alone amounts to 1.5 million tonnes/

year which corresponds to approx. 10 % of the worldwide

copper mine production.1

To meet this demand, the recycling of non ferrous metals

from shredded end-of-life equipment such as cars or

domestic appliances is steadily increasing in importance –

many raw materials such as copper or aluminium can be

recovered in this manner. However, for this to be possible,

these fractions must be capable of being extracted from

the mixture to a high degree of purity. This adds value to

non ferrous mixtures.

THE INVESTMENT IN A

MODERN RECYCLING PROCESS

IS WORTHWHILE:

The demand and price of resources

is constantly increasing

Legislation creates reliable conditions

The amount of recycled resources used in

production in general is rapidly increasing

Total recycling 85 % 95 %quota

Rate of material 80% 85%utilisation

since 2006

from2015

EU RECYCLING QUOTAS FOR END-OF-LIFE VEHICLES

RESOURCE PRICE TRENDNICKEL1

RESOURCE PRICE TRENDCOPPER

Source: ELV Directive (2000/53/EC) / Federal Ministry for the Environment, Nature Conservation and Nuclear Safety

2,000 $/t

3,000 $/t

4,000 $/t

5,000 $/t

6,000 $/t

7,000 $/t

8,000 $/t

11,000 $/t

10,000 $/t

9,000 $/t

2006

2007

2008

2009

2010

2011

30,000 $/t

25,000 $/t

20,000 $/t

15,000 $/t

10,000 $/t

2008

2009

2009

2010

2010

2011

2011

1 Nickel is one of the most important alloy elements for stainless steel and has a significant impact on its price. Source: London Metal Exchange, www.lme.com

Source: London Metal Exchange, www.lme.com

1 Source: Wuppertal Institut für Klima, Umwelt, Energie GmbH Wuppertal, June 2008

TITECH combisense [belt]

COMMONLY USED SORTING METHODS

Manual sorting of autoshredder fractions is a

cost-intensive process in industrial countries with

a natural lower limit in terms of material recovery:

smaller metal parts under 20 mm and wires cannot be

sorted or only with a large amount of time and effort.

Optically indistinguishable metals cannot be sorted and

are therefore lost.

are used to separate metals

with different densities, e.g. to separate aluminium

from other non ferrous metals. This process requires

large amounts of water and other additives, the

processing and disposal of which represent an

additional burden to the environment.

Sensor-based sorting can be used for a large

variety of applications because different sensors can

perform different sorting tasks. They extend the range

of possible options. The low-maintenance sorting

technology combines superior precision with high

throughputs and high availability.

MORE THAN JUST IRON

An average end-of-life vehicle

weighing a ton contains not

only steel but 79 kg of valuable

non ferrous metals such as

copper, brass, aluminium and

zinc. Nowadays a large share

of the overall resources used

in production is obtained from

recycling these metal components

– and this trend is rising.

0504

Source: University Brighton, Waste and Energy Research Group, 2004, modified

Source: German Federal Ministry for Economy and Technology

Average component parts

Non ferrous metals_7.9 %

Plastics_8.5 %

10.4 %_Other

Rubber_1.7 %2.9 %_Glass

Iron metals_68.6 %

EXAMPLE OF MATERIAL COMPOSITION OF END-OF-LIFE VEHICLES

USAGE OF RECYCLED MATERIAL IN OVERALL PRODUCTION

100%

0%

Primary raw material Recycled metals

Alu

min

ium

61%

Cop

per

53%

Zin

c

28%

Ste

el

45%

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

07

Modern sorting plants are required to recover as much

high quality resources as possible and also keep the

disposal costs low.

1. When sorting non ferrous metals, the composition

of the

challenge for the sorting process. These shares of

recyclable material, the bulk weight and impurities

must be analysed precisely and the clearly

planning – particularly in relation to the technology

to be used.

2. grain size.

on the subsequent sorting steps and processing

procedures.

3. For maximum resource yield, it is important that all

machines can process a .

4. of the

sorting – so called batch options).

of up to 99.9 % can be achieved. After all, only high

quality has the best chances on the market.

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

TITECH x-tract [XRT]

SENSOR-BASEDSORTING

QUALITY WITH HIGH THROUGHPUT: FOUR DECISIVE FACTORS

06

Heavy metal,aluminiumcompound

TITECH combisenseand/or

TITECH x-tract [XRF]

TITECH x-tract [XRT]

Heavy metal

Ferrous- aluminiumcompound

Aluminium

Copper** Brass** Grey metals/zinc**

Printed circuitboards**

Zorbafrom shredder

process*

Batch operation

Finished aluminium

product

ResiduesManualcontrol

Magnet

EXTENSIONSHREDDER PROCESS

09

The main content of recyclable metals in end-of-life

cars are iron and iron-based metals. Non ferrous

metals (7.9 % on average) are normally separated by

using an eddy current separator and sold as a mixed

technology, it now pays for the shredder operator to

create individual fractions out of this mixed product

which yield much higher values on the market.

OPPORTUNITIES FOR SHREDDER OPERATORS

08

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

Tabelle:

Zusammensetzung

COMPOSITION COPPER PRODUCT (SORTED), GRAIN SIZE 10-30 MM

EXAMPLE OF COMPOSITION OF ZORBA (UNSORTED), GRAIN SIZE OF 10-30 MM

Copper_92.4 %

1.1 %_Other1.3 %_Non metals

60.2 %_ Aluminium cast

Brass_5.2 %

Source: TITECH

following sorting with TITECH combisense, manual counting / manual analysis

Source: TITECH

** optional manual check

12.3 %_Aluminium wrought

2.1 %_Residue

9.1 %_ Copper

7.3 %_Brass

9.0 %_Other Heavy Metals

Copper / Product / TITECH combisense

11

OPPORTUNITIES FOR HEAVY MEDIA OPERATORS

10

Brass / Product / TITECH combisense

with different densities – the valuable heavy metal mix

of copper, brass, stainless steel and zinc presents an

unsolvable problem for it. Apart from the aluminium

which is generally handed over to processing contractors

in low-wage countries who employ manual sorters and

Using TITECH sorting technology, the dense media

products. The added value thus obtained means that

the investment in the technology pays off in a short

time. After wet processing, the aluminium product still

contains impurities and its concentration can be further

improved using TITECH technology then sold on for a

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

* e.g. non ferrous metals (Zorba) from shredder, e-scrap, ash or waste processing plant** e.g. 304 and 316 alloys

Density level 1

Den

se M

edia

Sep

erat

ion

Density level 2

Residues/lightmaterials

TITECHfinder

TITECHautosort

TITECH combisenseand/or

TITECH x-tract [XRF]

Residues

Aluminium

Metals

Copper Brass ZincStainless steel**

Input: E.g. mixed metals*

Aluminium

batch operation

Heavy metalsmix

Printed circuitboards and copper wires

HEAVY MEDIA OPERATORSSIMPLIFIED FLOWCHART

MATERIALZUSAMMENSETZUNG VON ALTFAHRZEUGEN

Recycling of aluminium scrap is an extremely attractive

proposition – up to 95 % of the energy costs can be

saved when compared to the laborious extraction of the

more costly primary resource. At the same time, the

demand for aluminium is steadily increasing – e.g. due

to lightweight construction in car manufacturing.

To obtain useful aluminium, pure aluminium must be

added to the secondary resource, which still contains

small amounts of other metals which have not been

.

The TITECH x-tract [XRT] removes these impurities to

such a degree of precision that fewer primary resources

(aluminium) need to be added.

By the option to create a recycled product with a

gain new and cheaper sources of material.

TITECHx-tract [XRT]

Eddy currentseparator

Zorba

Zorba**

Residues

Residues***

Aluminium

Manualcontrol

Input Aluminium-Preconcentrate

from preprocess*

Screen

0–10 mm 10–40 mm 40–100 mm

Magnet Ferrous

Light fraction

Ferrous

Eddy currentseparator

Magnet

Residues

Windsifter

finishedaluminium

product

Heavy metal,cast

aluminium

TITECHx-tract [XRT]

Eddy currentseparator

Zorba

Residues

Residues

Aluminium

finishedaluminium

product

Heavy metal,cast

aluminium

Manualcontrol

12 09

Messing / Output / TITECH combisense

ALUMINIUM SMELTERSIMPLIFIED FLOWCHART

Input material: aluminium wrought material like window profiles, etc, results without burn-off and loss

MELT ANALYSIS OF ALUMINIUM AFTER TITECH X-TRACT

Element Share

Al Aluminium > 98 %Si Silicon < 0.5 %Fe Iron < 0.4 %Cu Copper < 0.2 %Zn Zinc < 0.1 %

2002199819881978kg

160

140

120

100

80

60

40

20

0

40

38

28

14

35

35

105

30

2551

2010

50

43

50

1711

20

Car body/Chassis

Engine/Transmission

Car body

Equipment

INCREASING OF ALUMINIUM IN AUTOMOTIVE SECTOR

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

Source: TITECH Source: Wirtschaftsgesellschaft des KfZ-Gewerbes mbH

13

* e.g. non ferrous metals (Zorba) from shredder, e-scrap or waste processing plant

Aluminium / Product /TITECH x-tract [XRT]

OPPORTUNITIES FOR ALUMINIUM SMELTER

ww

w.n

eueko

ord

inate

n.d

e

TITECH combisense

THE IDEAL SOLUTION FOR EACH SORTING TASK

HIGH END SEPARATIONSORTING OF FINE METALS

15

Throughput per metre Production width1

Source: TITECH – Values and information obtained from customer applications in practise 1 highly dependent on grain, composition and bulk weight

14

Recovery of all metals and metal compoundsTargeted separation of stainless steelsRecovery of cables

Generation and refinement of metal mono fractions such as copper, brass and grey metals

Sorting/separation of aluminium, precious metals and heavy metals (copper, brass, zinc, etc.)

Sorting and recovery of wood, polymers and compounds

TITECH finder

TITECH combisense

TITECH x-tract

TITECH autosort

1–5 t/h/m

1–4 t/h/m

3–8 t/h/m

1–2 t/h/m

SORTING SOLUTIONS TITECH sorting machines in shredders

MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS MARKET IMPULSES // SORTING METHODS // SORTING PROCESS // SORTING SOLUTIONS

Copper / Product /TITECH combisense

Due to the growing demand of commodities in general

and the downsizing of electronic components it is quite

worth to focus more on the treatment of small grain sizes

below 10mm (0.4 inches).Therefore recyclers start to

extend processes with equipment to recover and upgrade

ferrous metals from:

ELV processes

Dense media separation

WEEE recycling plants

Wire recycling

Ashes

Depending on the upfront treatment and material

composition it is needed to design a process extension

based on costumer needs. TITECH is using belt and

copper, brass and aluminium. These machines are able

inches) and create high value products.

Copper granulate, recovered by the recycling of copper

containing wires, is already high-value resource. The

problem: not all impurities can be removed by common

technologies such as screening or densimetric tables. Non

copper materials like brass, lead or stainless steel can

remain in the product. With TITECH technology it’s now

automatically and upgrade copper granulate to a purity of

up to 99.9 percent.

Copper / Product /TITECH combisense

M011802-0

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We print on 100% recycled paper. TITECH’s innovations are helping to produce it.

Headquarter & NordicTOMRA Sorting AS* Drengsrudhagen 2PO box 2781372 Asker Norway Phone: +47 66 75 24 40 Fax: +47 66 79 91 11 info@tomrasorting.com

UK & IrelandTOMRA Sorting Ltd.The Springboard CentreMantle Lane, CoalvilleLeicestershire, LE67 3DWUnited KingdomPhone: +44 1530 839 531Fax: +44 1530 810 231info-uk@titech.com

USA & Canadian DistributorWendt Corporation 2080 Military RoadTonawanda, NY, 14150-6765 USAPhone: 716 837 2211Fax: 716 837 9309sales@wendtcorp.comWeb: www.wendtcorp.com

IndiaLeevams Incorporated465, G.I.D.C., MakarpuraVadodara – 390 010Gujarat (India)Phone: +91 265 2637545Fax: +91 265 3932464sales@leevams.inwww.leevams.in

WWW.TITECH.COM

*

2012/0

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You name it – we sort it!

TITECH is the recycling brand of TOMRA Sorting Solutions and is established in more than 40 global markets.

TITECH offers over 25 different sorting applications to separate a large variety of valuable fractions including

plastics, metals and paper from waste.

raw waste and metal material. We can develop and implement bespoke recycling solutions for your business.

Moreover, TITECH cooperates closely with leading plant builders.

TOMRA Sorting Solutions is a leading provider of sensor-based sorting systems. With more than 6,000 systems in

place across the recycling, food processing and mining industries, we have engineered groundbreaking detection

systems, sensor technology and computing solutions.