EQUIPMENT SPOTLIGHT | SEPTEMBER 2024 Size Reduction

by maryt@americanrecycler.com

Global e-waste generation is estimated to reach 74.7 million metric tons by 2030. One of the first and key elements for the separation of recycled materials is size reduction. Most of the materials to be recycled are comingled with other types of commodities that usually prevent the materials from being readily sorted and recycled in order for them to be converted into a new finished good. Size reduction assists with the proper liberation of comingled materials and allows for separation technologies to properly segregate the materials into individual constituents. Regardless of the separation technology employed (magnetic technology, dry or wet density separation technologies); liberation and proper size distribution should result in the proper recovery of recycled goods. Size reduction technologies play a critical role to achieve high purity and recovery of products.

Eldan Recycling A/S

The ELDAN Heavy Duty Granulator (HDG) is modified for recycling tough material, including electrical waste such as ASCR cables, low-grade cables with some impurities – as well as nonferrous metals, refrigerators, industrial waste and more. The product’s new knife system with integrated rotary knives/knife holders with a rotor provides a solid foundation for the resistance required when processing heavy objects. The knives are straight, can be used on all four sides and grind materials easily. Friction clutches protect the machine from material overload and the belt drive involved ensures a simple transmission. The HDG also processes RDF well and can produce 20 mm material size. The HDG also performs well as a pre-chopper for these materials and other Cu or Al cables and can include various screen hole sizes̶down to 12mm and upwards, according to customer requirements. 

A summary of HDG features includes: adjustable knife clearance, which optimizes the cutting function; product knives that can be reground multiple times on a “flat-bed” grinder, ensuring long life and low operation costs; the HDG design allows for the quick and easy change of knives and screens; the rotor is manufactured and designed for minimum wear with hard-face welding; screens provide different hole sizes for flexible production; five pieces of screens per set are included and interchangeable, depending on wear and exchangeable wear parts “provide operators with a virtually indestructible machine,” remarked Carsten Nielsen, product manager. 

Orbcon/Prall-Tec offers multiple types of size reduction technologies based on the application involved – electronics recycling, C&D recycling, glass, incinerator bottom ash, auto shred residue and metals in general. “Our product line includes impact crushers, fine grinding mills, hammermills, dual shaft shredders and balling mills. Throughputs of our products extend from 4tph up to 200tph for impact crushers that process aggregate materials,” explained Adam Floyd, process and business development director.

Floyd mentioned that in order to achieve the highest efficiency on metal recovery, it is increasingly important to employ size reduction steps to properly sort comingled materials. “For example, our PTV Balling Mill is a versatile shredding step currently utilized by auto shredder operators to process their fine ASR with the goal of further recovering valuable metals that may otherwise end up as waste. The PTV not only liberates comingled insulation from the copper wires, it changes the shape of fine copper strands to a round and denser particle. This is a crucial step in recovering copper strand in the sorting steps that follow. Also, the versatility of the PTV allows users to also process some low grade byproducts – such as handpicked shredder wire or electronic wire commingled with plastics, via a balling mill. Similarly, the PTV allows users to further increase the quality of such products into furnace-ready commodities.”

Orbcon

“Of course, our customers prefer high throughput, low operating cost systems. Whether they are processing electronic waste/scrap, auto shredder residue or aggregate materials, it is fundamentally important that processing is high capacity and high efficiency, but with low operating costs. In order to deliver all of these aspects, most of our units operate in dual rotational directions, further extending the life of the consumable wear parts to almost double,” concluded Floyd.

Schutte Hammermill is “renowned for providing high quality size reduction equipment solutions. Our RAS/DataKiller Pro is the state-of-the-art solution designed to meet the rigorous demands involved, via exceptional throughput – capable of efficient, fast processing of large electronic scrap volumes to below 2mm. This high capacity efficiency ensures that recycling facilities can keep up with the increasing influx of e-waste,” stated Bill Castine, general manager.

According to Castine, the RAS/DataKiller Pro is a multi-stage shredder-mill combo, constructed from high-quality materials to ensure long-lasting performance, even under the most demanding conditions. “This durability typically results in lower maintenance costs and reduced downtime. The machine also delivers precise, consistent size reduction, which is crucial for downstream separation processes and enhances recovery rates of valuable metals and other materials. Through advanced technology, the RAS/DataKiller Pro helps reduce the environmental impact of e-waste while ensuring that sensitive or hazardous materials are safely handled and valuable resources are recovered, which aids sustainability. Combining high efficiency, robust construction and precision makes the RAS/DataKiller Pro an invaluable asset for recycling facilities facing the growing e-waste problem while striving for environmental sustainability.”

Schutte Hammermill

Castine noted that such challenges, as electronic devices are becoming obsolete faster, also causes an increase in electronics disposal. This trend necessitates advanced recycling solutions that can handle the intricate mix of metals, plastics and hazardous materials found in e-waste. Schutte Hammermill, established in 1928, with a reputation for manufacturing robust and reliable size reduction equipment, will continue to provide solutions to a diverse field of industries.