Shredder Residue Metal Recovery Line
The Shredder Residue Metal Recovery Line separates high-value ferrous, non-ferrous, stainless steel, and precious metals from the tailings stream left behind after primary shredding and pre-sorting. The system serves end-of-life vehicle (ELV) processors, scrap metal recyclers, and slag reclamation facilities that need to upgrade mixed residual output into salable metal concentrates.
The combines multi-stage magnetic separation, eccentric eddy current separation, and advanced sensor-based sorting (induction, LIBS, X-ray transmission, and optical) into one integrated recovery flow. This layered approach lifts recovery yield on fine and mid-fraction material that primary lines routinely miss, converting landfill-bound tailings into copper, aluminum, brass, stainless steel, and alloy-graded concentrates ready for smelting.
The line is engineered around each customer's input composition, throughput target, and output purity requirement. Typical configurations range from 4 t/h for boutique high-purity operations up to 20+ t/h for large-scale ELV and scrap tailings processors, with sensor sorting stages added or removed to match the product mix.
Applications
The targets residual scrap streams that still contain economically recoverable metal fractions after primary shredding or coarse sorting.
- End-of-Life Vehicle (ELV) Tailings Recovery: recovers zorba fractions, twitch fractions, and residual precious metals from car shredder output
- Scrap Yard Tailings Upgrading: extracts fine copper wire, aluminum shreds, and stainless steel from mixed non-ferrous residue
- Non-Ferrous Metal Concentrate Production: delivers alloy-graded aluminum, copper, brass, and zinc fractions for smelter feedstock
- Slag and Bottom Ash Metal Recovery: recovers metals from IBA (incinerator bottom ash) and other post-combustion residues
- Waste Electrical and Electronic Equipment (WEEE) Fine Sorting: separates copper, aluminum, and precious metal fractions from shredded e-waste tailings
- Aluminum Alloy Sorting Facilities: uses LIBS and X-ray transmission to distinguish cast, wrought, and specific alloy grades
- Stainless Steel Recovery: isolates 300-series and 400-series stainless from mixed non-ferrous streams
Theory and Method
Metal recovery from shredder residue depends on the fact that each valuable component in the mixed feed has a different combination of magnetic susceptibility, electrical conductivity, atomic density, elemental composition, and surface appearance. The line applies these principles in sequence, with each stage targeting one property and passing its reject stream to the next.
Ferrous removal comes first. A permanent overband magnet lifts ferromagnetic pieces off the conveyor before any downstream sensor sorting, and a magnetic drum separator polishes fine iron from the ferrous concentrate. The non-magnetic stream then enters an eccentric eddy current separator, which generates a high-frequency alternating magnetic field. Conductive non-ferrous metals develop induced eddy currents that produce a repulsive Lorentz force, throwing them off the belt trajectory while non-conductive material falls straight down.
Sensor-based sorting refines the concentrate further. An induction metal sorter uses electromagnetic sensing to catch conductive fragments the eddy current separator missed, targeting stainless steel and the smallest metal particles. LIBS (Laser-Induced Breakdown Spectroscopy) identifies aluminum alloy grades by vaporizing a microscopic amount of material and reading the emission spectrum, enabling cast-vs-wrought and series-specific separation. X-ray transmission (XRT) distinguishes particles by atomic density regardless of surface color or coating, recovering heavy metals (copper from aluminum, lead-bearing fractions, stainless steel). Finally, an AI-powered optical color sorter handles color and shape discrimination for final purity upgrade, such as copper-brass separation and residual contaminant removal. All ejection is performed by high-speed compressed-air valve arrays driven by real-time signal processing.
Key Features
The line integrates all recovery stages under a single PLC control system, with each sorting module tuned to the specific fraction it handles.
Apron Feeder
The heavy-duty apron feeder receives raw tailings material from a wheel loader or storage bunker and meters it onto the line at a controlled rate. Its self-scraping chain-plate design handles wet, oversized, and awkwardly shaped input without bridging or manual intervention.
- Function: primary bunker discharge and metering feed
- Design: heavy-gauge steel chain plates with self-cleaning scraper
- Feed handling: not limited by particle size, density, or moisture
Chain Apron Conveyor
The heavy-duty chain apron conveyor connects the process stages and handles the highest-abrasion transfers where belt conveyors would be damaged. Wide, overlapping steel apron plates ride on a chain drive with high torque and low maintenance requirements.
- Function: high-abrasion inter-stage transfer
- Design: hinged steel apron plates on driven chain
- Advantages: high torque, low noise, high durability, wide feed range
Permanent Overband Magnet (Self-Cleaning)
The self-cleaning permanent overband magnet suspends above the conveyor belt and removes ferrous metals from the material stream continuously. Rare-earth NdFeB magnets deliver strong, stable field intensity without coil power or cooling, and a dedicated self-cleaning belt discharges captured iron to a side chute so operators never need to shut down for magnet cleaning.
- Function: continuous ferrous removal from mixed stream
- Magnet type: high-performance NdFeB (rare earth), no external excitation power required
- Structure: double-pole magnetic circuit, waist drum-shaped frame with automatic belt tracking
- Sealing: fully sealed bearings adapt to dusty, wet, or corrosive environments
- Operation: self-cleaning belt for continuous, unattended iron discharge
Permanent Overband Magnet Specifications:
| Model | Suitable Belt Width (mm) | Material Thickness (mm) | Suspended Height (mm) | Magnet Intensity | Power (kW) | Belt Speed | Overall Dimensions L×W×H (mm) | Ring Center Distance (mm) | Weight (kg) |
|---|---|---|---|---|---|---|---|---|---|
| TT-POM-5 | 500 | 80 | 150 | 63 mT | 1.5 | ≤2.5 m/s | 1650 × 835 × 940 | 1100 × 635 | 580 |
| TT-POM-6 | 600 | 125 | 200 | 1.5 | 1700 × 835 × 940 | 1150 × 735 | 700 | ||
| TT-POM-6.5 | 650 | 150 | 200 | 1.5 | 1750 × 985 × 940 | 1200 × 785 | 700 | ||
| TT-POM-8 | 800 | 200 | 250 | 70 mT | 2.2 | 1900 × 1140 × 960 | 1350 × 935 | 820 | |
| TT-POM-10 | 1000 | 250 | 300 | 3.0 | 2140 × 1350 × 1010 | 1590 × 1135 | 1220 | ||
| TT-POM-12 | 1200 | 300 | 350 | 4.0 | 2340 × 1550 × 1060 | 1790 × 1335 | 1420 | ||
| TT-POM-14 | 1400 | 350 | 400 | 5.5 | 2540 × 1750 × 1060 | 1990 × 1535 | 1730 | ||
| TT-POM-16 | 1600 | 400 | 450 | 7.5 | 3040 × 1550 × 860 | 2190 × 1335 | 2140 |
Magnetic Drum Separator
The top-feed magnetic drum separator is a semi-enclosed, vibratory-fed magnetic drum for high-throughput fine ferrous recovery. Adjustable magnetic field strength allows tuning to the specific fraction being processed.
- Magnetic field strength: 1,800 to 8,000 Gauss (selectable)
- Operation: continuous, high recovery rate
- Design: simple structure, reliable operation, straightforward maintenance
Magnetic Drum Separator Specifications:
| Model | Drum Length (mm) | Drum Diameter (mm) | Magnet Intensity (Gs) | Driving Power (kW) | Vibrating Motor Power (kW) |
|---|---|---|---|---|---|
| TT-MDS-32/50 | 500 | Ø320 | 1,800 to 8,000 | 1.1 | 0.4 |
| TT-MDS-32/60 | 600 | ||||
| TT-MDS-32/80 | 800 | 1.5 | 0.8 | ||
| TT-MDS-32/100 | 1000 | ||||
| TT-MDS-32/120 | 1200 | 1.1 | |||
| TT-MDS-32/140 | 1400 | 1.5 |
Eccentric Eddy Current Separator
The eccentric eddy current separator recovers non-ferrous metals (copper, aluminum, brass, zinc) from the non-magnetic stream. An eccentric rotor design places the magnetic pole close to the belt surface, giving a wider throw angle for small particles than a concentric rotor design, and a vibrating feeder plus adjustable baffle allows fine-tuning to the fraction being processed.
- Rotor type: eccentric high-speed magnetic rotor
- Particle size range: ≥1 mm²
- Magnet material: NdFeB with anti-fall spray-plastic protection
- Recovery target: aluminum, copper, brass, zinc, and other non-ferrous metals
Eccentric Eddy Current Separator Specifications:
| Model | Feed Width (mm) | Feed Length (mm) | Particle Size | Capacity (m³/h) | Power (kW) | Weight (kg) | Length (mm) | Width (mm) | Height (mm) |
|---|---|---|---|---|---|---|---|---|---|
| TT-ECS-5 | 300 | 1500 | ≥1 mm² | 6 | 5.9 | 730 | 4600 | 1123 | 1200 |
| TT-ECS-6 | 400 | 10 | 895 | 1223 | |||||
| TT-ECS-8 | 600 | 20 | 1225 | 1623 | |||||
| TT-ECS-10 | 800 | 25 | 6.3 | 1555 | 1823 | ||||
| TT-ECS-12 | 1000 | 30 | 7.0 | 1875 | 2023 | ||||
| TT-ECS-14 | 1200 | 35 | 8.8 | 2275 | 2223 | ||||
| TT-ECS-16 | 1400 | 40 | 10 | 2850 | 2423 | ||||
| TT-ECS-20 | 1800 | 50 | 10.7 | 3650 | 5000 | 2823 | |||
| TT-ECS-22 | 2000 | 55 | 13 | 4500 | 5000 | 3023 |
Induction Metal Sorter (Sensor-Based)
The induction metal sorter identifies conductive particles (both ferrous and non-ferrous) on the conveyor using high-sensitivity electromagnetic (EM) sensors, then ejects them from the stream through an array of compressed-air valves. It is used to upgrade non-ferrous concentrate purity, recover stainless steel, and recover the smallest metal fragments that eddy current separators cannot reach.
- Sensor: high-sensitivity electromagnetic (EM) with image-processing algorithm
- Detectable metal size: 1 to 2 mm minimum
- Resolution options: 25 mm or 12.5 mm scan resolution
- Valve options: 48 to 240 valves (belt width dependent)
- Optional integration: EM + NIR sensor fusion for "poly" separation
Induction Metal Sorter Valve Configurations:
| Belt Width | 6-Valve Bank | 12-Valve Bank | 18-Valve Bank | 24-Valve Bank | 30-Valve Bank |
|---|---|---|---|---|---|
| Ts1500 / 6.25 mm | 48 valves | 96 valves | 144 valves | 192 valves | 240 valves |
| Ts400 / 6.25 mm | 96 valves | 192 valves | 288 valves | 384 valves | 480 valves |
| Ts200 / 6.25 mm | 96 valves | 192 valves | 288 valves | 384 valves | 480 valves |
LIBS Sorter (Laser-Induced Breakdown Spectroscopy)
The LIBS sorter identifies aluminum alloy grades and other non-ferrous metals by their elemental composition. A pulsed laser vaporizes a microscopic amount of material from each particle, and a spectrometer analyzes the emitted light to identify the alloy in real time. Particles are then ejected by compressed-air valves. LIBS enables cast-vs-wrought aluminum separation and alloy-specific sorting (5000-series from 6000-series, for example) that no other sensor technology can deliver.
- Function: alloy-specific non-ferrous sorting by elemental composition
- Typical application: cast/wrought aluminum separation, brass and copper alloy sorting
- Ejection: high-speed compressed-air valve array
X-Ray Transmission Sorter
The X-Ray Transmission (XRT) sorter distinguishes particles by atomic density rather than surface appearance. Material passes on a conveyor belt between an X-ray emitter above and a set of LDA dual-energy receivers below, which measure how much energy each particle absorbs. A self-learning classifier reads the signal and triggers a compressed-air jet valve at the belt head pulley to eject targeted particles. XRT uniquely separates heavy metals from light metals regardless of color, coating, or geometry, recovering small copper wire from aluminum shred, isolating lead-bearing fractions, and separating stainless steel from mixed non-ferrous streams.
- Detection method: dual-energy X-ray transmission with LDA receivers
- Classifier: self-learning system that continuously accumulates material characteristic samples
- Typical applications: zorba sorting (aluminum from copper, zinc, lead, magnesium), cast-vs-wrought aluminum separation, chlorinated/brominated flame-retardant plastic removal, reclaimed aluminum quality upgrade
- Ejection: compressed-air jet valve array
X-Ray Transmission Sorter Specifications:
| Model | Belt Width (mm) | Raw Material Size (mm) | Capacity (t/h) | Power (kW) | Weight (t) | Machine Size L×W×H (mm) |
|---|---|---|---|---|---|---|
| TT-XRT-1200 | 1200 | 10 to 100 | 4 to 6 | 6.6 | 3 | 6000 × 1490 × 1780 |
| TT-XRT-1800 | 1800 | 6 to 8 | 4 | 6000 × 2090 × 1780 | ||
| TT-XRT-2400 | 2400 | 8 to 10 | 5 | 6000 × 2690 × 1780 |
Optical Color Sorter (AI-Powered)
The AI-powered optical color sorter uses high-resolution cameras and machine-learning classifiers to identify materials by color, texture, and shape. It handles final upgrade steps such as separating copper from brass, sorting plastic flakes by color for downstream reuse, and removing residual contamination from cleaned metal fractions.
- Function: sorting by color, shape, and surface texture
- Detection: high-resolution RGB cameras with AI classification
- Typical application: copper/brass separation, colored plastic flake sorting, contaminant removal
Electrical Control System
The line runs under a single PLC control system with automatic overload reverse control, interlock logic, and an operator HMI. All motors, sensors, and pneumatic actuators are wired to the central cabinet for coordinated operation and remote diagnostics.
- Controller: PLC-based programmable control
- Protection: automatic overload reverse, safety interlocks across the full line
- Interface: HMI touchscreen with process-status visualization
Technical Specifications
This line up is engineered around the customer's input composition, throughput target, and output purity requirement. Sensor sorting stages can be added, removed, or reconfigured based on the target recovery mix.
| Parameter | Specification |
|---|---|
| Line Focus | Metal recovery and purity upgrade from shredder tailings |
| Typical Throughput Range | 4 to 20+ t/h (customer-specific) |
| Input Material | Shredder residue, ASR tailings, ELV fluff, mixed non-ferrous concentrate |
| Raw Material Size | 10 to 100 mm (typical XRT working range) |
| Ferrous Recovery Stages | Permanent overband magnet, magnetic drum separator |
| Non-Ferrous Recovery Stages | Eccentric eddy current separator, induction metal sorter |
| Sensor-Based Sorting | LIBS, X-ray transmission (dual-energy), optical color, induction |
| Target Recoverable Metals | Copper, aluminum (cast and wrought, alloy-graded), brass, zinc, stainless steel, magnesium, lead, precious metals |
| Control System | PLC with HMI touchscreen, full-line interlocks |
| Installation Options | Skid-mounted modules or civil-work integrated |
| Power Supply | 380 V / 50 Hz (customer voltage available on request) |
Each line is engineered to the customer's specific tailings composition and output purity targets. Contact the Torontech application engineering team for a site-specific process flow diagram and quotation.