Process for producing scrap materials with high purity level from inhomogeneous input material

Abstract

To provide a process for producing recycled scrap.SOLUTION: A process for producing scrap comprising the steps of: a) preparing or providing an inhomogeneous, ferrous scrap composition; b) comminuting the inhomogeneous, ferrous scrap composition in a comminution unit in order to obtain a comminuted material; c) selecting organic and / or inorganic impurities from the comminuted material to obtain a pre-cleaned material; d) analysing the pre-cleaned material by using one or more first detection devices to detect a first item of material information and separating out, according to the first item of material information, constituents of the pre-cleaned material to obtain a purified material; and e) analysing the purified material with one or more second detection devices in order to detect at least one second item of material information; f) matching the detected second item of material information with a predefined material criterion associated with the second item of material information, and if the second item of material information fulfils the associated predefined material criterion, then, outputting the purified material.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a manufacturing process for recycled scrap, cycle scrap containing particularly high iron that can be manufactured by said process, a scrap recycling plant optimized for carrying out said process, and an improved grinding section used in said process and plant.

[0002] The subject matter of the present invention is defined in the appended claims.

Background Art

[0003] Valuable material scrap is obtained by turning used metal products into scrap. Among them, iron and steel scrap has long been regarded not only as waste but also as an important secondary raw material, and can be used in various applications to reduce the need for newly manufactured metal. Using scrap as a raw material can not only suppress the industry's dependence on rare raw materials but also reduce the amount of unnecessary waste. Since the production of metals and alloys generally requires a large amount of energy and resources through large-scale industrial production, a decrease in the demand for newly manufactured products also leads to the realization of a sustainable economy.

[0004] In particular, in the field of manufacturing products used for high-performance applications, particularly high requirements are imposed on iron-containing scrap. When using scrap instead of newly manufactured metal, these must surely have material properties that are at least approximately equivalent to those of newly recovered metal.

[0005] Therefore, basically, in many industrial applications, there is a high need for a pure scrap mixture, and a scrap mixture with a more advantageous filling density is ideal. However, it is well known that this is a very difficult goal because the raw materials for manufacturing such a scrap mixture are essentially heterogeneous. For example, when turning washing machines from two different manufacturers into scrap, the scrap may have different properties even though they are similar products.

[0006] The prior art discloses various methods for obtaining such pure scrap mixtures, but they are generally very complex methods. In these methods, basically, a process of manually sorting by workers is carried out to isolate particularly suitable fractions from the scrap mixture.

[0007] In large-scale industrial shredder plants, in order to actually produce a relatively pure scrap mixture, the operator repeatedly passes the processed scrap through the processing plant and the shredder, that is, the scrap is subjected to multiple grinding steps, and downstream sorting operations are carried out as necessary, often aiming to achieve a higher purity and / or favorable packing density of the material.

Summary of the Invention

Problems to be Solved by the Invention

[0008] Processes known from the prior art have the disadvantage that, for example, they are relatively time-consuming and / or costly because the material needs to be processed twice, which may lead to an increase in waste volume or at least a halving of the material throughput of the plant. Also, in these methods, during the second pass through the plant, the material may only reach the discharge point of the first pass, and there may be material remaining in the plant. For this reason, a certain amount of the fraction that has not even been subjected to the necessary second shredding step may be included in the material taken out from the outlet.

[0009] Furthermore, the prior art processes often have the disadvantage that there is relatively little data on the finished product. This becomes a problem because it is not sufficient to simply provide scrap of a specific quality for high-performance applications, and for example, from a legal liability perspective, it is often essential to be able to properly prove its quality.

[0010] In addition, in a process known from the prior art, for example, it is often difficult to actively control product quality during the operation of the process in order to adapt the process to customer requirements as quickly as possible. Therefore, in a process known from the prior art, for example, it is often impossible to continuously manufacture two different specification scrap products in continuous operation and / or without modifying the plant.

[0011] In addition, in the prior art, it is often impossible to manufacture a product with a high packing density advantageous for a certain application within the manufacturing time that enables efficient large-scale industrial production.

Means for Solving the Problems

[0012] The first object of the present invention is to disclose an improved process for recycled scrap that can eliminate or at least reduce the drawbacks in the prior art.

[0013] Therefore, the object of the present invention is to provide an improved manufacturing process for recycled scrap of high quality and high packing density that enables the production of particularly pure scrap products with a particularly advantageous packing density from a general scrap fraction, i.e., a raw material that is heterogeneous and particularly difficult to handle.

[0014] The object of the present invention is to disclose a manufacturing process for recycled scrap that enables the operation of a time- and cost-efficient process in large-scale industrial production, which can produce high-quality products corresponding thereto, ideally in only one pass, and can manufacture these high-quality scrap products in large quantities at low cost.

[0015] Compared with the prior art, the disclosed manufacturing process for recycled scrap should enable the realization of a considerably higher purity in an industrially appropriate amount, particularly higher than the purity achievable with the processes hitherto.

[0016] As a supplementary requirement, the manufacturing process of the explicit recycled scrap must be feasible using conventional scrap fractions as raw materials and, to the extent possible, equipment that can be used in conventional scrap processing plants.

[0017] A supplementary object of the present invention is to be able to automatically provide more comprehensive information about the physical properties of the scrap batch for each case produced by the manufacturing process of the explicit recycled scrap.

[0018] Furthermore, the manufacturing process of the explicit recycled scrap must be highly flexible and easily adaptable, and in particular, efficiently adaptable to changes in the quality required by the customer, ideally even during operation. In this regard, a supplementary object of the present invention is to be able to flexibly adapt the chemical composition and / or particle shape and / or packing density of the recycled material by the manufacturing process of the explicit recycled scrap.

[0019] Also, it is desirable that the manufacturing process of the explicit recycled scrap particularly reduces the manufacturing risk of defective scrap batches that cannot be used by the customer.

[0020] A further object of the present invention is to make the manufacturing process of the explicit recycled scrap operable with low emissions and particularly safely, reducing safety risks and pollution of people and the environment.

[0021] Furthermore, a secondary object of the present invention is to identify high-quality recycled scrap suitable for high-performance applications.

[0022] A further secondary object of the present invention is to identify an improved plant for scrap recycling and a new grinding section that are each optimized for use in the explicit process.

[0023] The inventors of the present invention have developed a novel and powerful process to achieve the above object, along with the associated plant. In short, the process of the present invention emphasizes a unique combination of sorting techniques using process analysis defined in the claims, and is based on comprehensively modifying existing process technologies.

Advantages of the Invention

[0024] According to the process of the present invention, for the first time based on the inventors' findings, it is possible to produce an industrially appropriate amount of high-quality scrap products in a time- and cost-efficient manner in a single pass. Even when using heterogeneous raw materials, i.e., common scrap fractions, it is possible to manufacture while achieving an iron content of over 97% and a favorable packing density, while almost completely removing organic impurities, which, based on the inventors' findings, was impossible in large-scale industrial processes in similar prior art, processes with at least equivalent throughput and / or reproducibility. Also, as a synergistic advantage, the material information obtained during the manufacturing process can be used for recording the characteristics of the material and can be proven for the manufactured scrap products with little effort.

[0025] In the experiments conducted by the inventors, recycled scrap products with an iron content of over 97% could be obtained on a large industrial scale. Furthermore, by using a suitable plant of the present invention, a recycled scrap product with a packing density of approximately 1.5 t / m 3 of substantially spherical particles could be obtained.

[0026] Therefore, the manufacturing process of recycled scrap defined in the claims, the scrap that can be manufactured using the manufacturing process, the plant for scrap recycling, and the pulverizing section can achieve the above object. Preferred embodiments of the present invention will be apparent from the dependent claims and the following description.

Modes for Carrying Out the Invention

[0027] The preferred embodiments of the present invention described below are particularly preferably combined with other preferred features. Therefore, it is highly preferable to combine a plurality of the following particularly preferred embodiments. Similarly, embodiments in which features preferred regardless of degree are combined with one or more other features preferred regardless of degree are preferred. The features of a preferred recycled scrap, a preferred plant for scrap recycling, and a preferred crushing section are clarified by the features of a preferred process.

[0028] The present invention relates to a) a step of manufacturing or supplying a heterogeneous iron-containing scrap mixture; b) a crushing step of crushing the heterogeneous iron-containing scrap mixture in a crushing section to obtain a crushed material; c) a sorting step of sorting organic and / or inorganic impurities from the crushed material to obtain a preliminarily purified material; d) an analysis and removal step of detecting at least one first material information by analyzing the preliminarily purified material with one or more first detection devices, and removing components of the preliminarily purified material based on the first material information to obtain a purified material; e) an analysis step of analyzing the purified material with one or more second detection devices to detect at least one second material information; f) a comparison step of comparing the detected second material information with a predetermined material standard assigned to the second material information, and when the second material information meets the assigned predetermined material standard, the purified material is taken out as recycled scrap, relating to a manufacturing process of recycled scrap.

[0029] The process of the present invention is basically also suitable for small-scale production. Therefore, it has been demonstrated that excellent scrap products can be produced, for example, even in a test-scale plant by the process of the present invention. However, at low throughput, the economic competition between the process of the present invention and more complex manual processing becomes even more intense. For example, it may be possible to provide pure scrap products by physicochemical separation of scrap mixtures on a laboratory scale. Since the process of the present invention exhibits great advantages in large-scale industrial processes, it is particularly preferred to be used in such processes. In the process of the present invention, it is highly preferred that the amount of recycled scrap discharged is 30,000 kg or more per hour, preferably 60,000 kg or more, and particularly preferably 75,000 kg or more. As is understood by those skilled in the art, in the implementation on a large industrial scale, especially in the implementation at the specifically indicated actual throughput, the demand for the process, the equipment used, and the raw materials becomes particularly high. This expands the scope of selection. For example, the demand for scrap raw materials for producing heterogeneous iron-containing scrap increases, and the heterogeneity of the raw materials often increases.

[0030] In step a) of the process of the present invention, a heterogeneous iron-containing scrap mixture is either supplied or directly produced in the process.

[0031] In actual production, for example, a plurality of iron-containing scrap fractions may be mixed. To perform this mixing, for example, various scrap fractions may be continuously fed into the grinding section in a considerable amount, or they may be fed into the supply port of the grinding section simultaneously so that these fractions reach the grinding section at the same time. This production method has actually been proven to be particularly efficient. Incorporating the mixing of a plurality of scrap fractions into the process is more advantageous because the mixing ratio can be adjusted to control the components of the mixture. Therefore, in the process of the present invention, the production of the heterogeneous iron-containing scrap mixture in step a) is preferably carried out by mixing a plurality of iron-containing scrap fractions to make scrap, and more preferably this mixing is substantially carried out in the grinding section.

[0032] The term "scrap fraction" is clear to those skilled in the art of metal processing. Also, those skilled in the art can easily distinguish different iron-containing scrap fractions. A scrap fraction is usually a collection of objects of the same attribute collected according to detailed selection criteria, and is collected and / or processed together.

[0033] Mixtures of various iron-containing scrap fractions may vary according to changes in legal regulations and industry-specific specifications. Those skilled in the art can always distinguish, for example, a scrap fraction consisting of so-called white goods (such as washing machines and ovens) from a scrap fraction consisting of, for example, pressed car bodies and factory-generated scrap from metal processing operations.

[0034] As understood by those skilled in the art, the iron-containing scrap fraction is a grading criterion for collecting ideal scrap of the same attribute. Although the scrap mixture is also heterogeneous in most cases, the scrap present in the said scrap fraction has a smaller deviation in material properties than the scrap of the secondary iron-containing scrap fraction and other similar scrap. In practice, the corresponding fraction is usually collected separately according to appropriate regulations and stored separately by users.

[0035] In the experiments conducted by the inventors, a heterogeneous iron-containing scrap mixture was produced using a wide range of common scrap fractions. Among these, certain scrap fractions are particularly advantageous because they are readily available and have a relatively high iron content. In a preferred process of the present invention, it is preferable to use one or more iron-containing scrap fractions selected from the group consisting of factory-generated scrap, white goods, composite materials, waste incineration scrap, pre-shredder materials, and used vehicle bodies. As is understood by those skilled in the art, the term "white goods" refers to household electrical appliances such as refrigerators, washing machines, dishwashers, stoves, etc., and is distinguished from electrical appliances such as televisions and mobile phones, which are called so-called "black goods". Pre-shredder materials are generated, for example, in disposal operations and sorting plants and often include, for example, bicycles, sunshades, and similar articles.

[0036] In the process of the present invention, the actual scrap fraction mixture used in the production / heterogeneous iron-containing scrap mixture, i.e., the heterogeneous iron-containing scrap mixture with respect to the mixture of various different parts, is not finally determined. However, in the treatment of homogeneous raw materials, the demand is significantly reduced. Therefore, in the present invention, the iron-containing scrap mixture should be heterogeneous. This criterion can be easily determined by those skilled in the art in practice. As is understood by those skilled in the art, an iron-containing scrap mixture is considered heterogeneous when it is produced by mixing a plurality of iron-containing scrap fractions and / or when it includes fractions obtained by shredding different types of a plurality of articles selected from the group consisting of household electrical appliances corresponding to white goods, vehicle bodies, and waste generated in metal processing operations.

[0037] In step b) of the process of the present invention, the iron-containing scrap mixture is crushed. In the present invention, this crushing is carried out by a crushing unit. Therefore, step b) corresponds to, for example, the process of shredder treatment known to those skilled in the art from the prior art.

[0038] The available crushing units are various, such as scrap shears, Kondirator crushers, Zerdirator crushers, etc. However, in the processing of a large amount of materials, it has been proven that the use of a shredder or a Zerdirator crusher is particularly advantageous. In the present invention, a Zerdirator crusher means a crushing unit having a discharge area for the crushed material generally covered with an iron grid at the bottom of the crushing chamber. Also, the Zendirator crusher may further have an optional discharge area at the upper part of the crushing chamber. On the other hand, the term shredder means a crushing unit that does not have a discharge area for the crushed material at the bottom of the crushing chamber and generally has a discharge area for the crushed material covered with an iron grid at the upper part of the crushing chamber.

[0039] In the present invention, it is highly preferable that the crushing unit used is constructed with a movable substrate and / or a cover plate that enables the change of the discharge port capable of discharging particles from the crushing chamber.

[0040] Thereby, it is possible to reduce the discharged crushed particles and increase the average residence time of the particles in the crushing unit. Therefore, it is advantageous that the crushing strength can be controlled from the outside even during operation. By increasing the average residence time, the discharge area may be temporarily completely closed, and it is possible to improve the purification ability and / or reduce the particle size and increase the packing density according to requirements and demands. Therefore, in the process of the present invention, it is clearly preferable that the crushing chamber of the crushing unit has at least one discharge area for the crushed material, and a movable element, preferably a movable substrate and / or a cover plate, particularly preferably a hydraulically movable substrate and / or a cover plate, is installed in the discharge area, thereby enabling the change of the discharge port capable of discharging particles from the crushing chamber.

[0041] The inventor of the present invention has come to the conclusion that, in order to enable the above-described processing mode, it is most advantageous to attach the movable substrate and / or the cover plate, for example, inside or outside, preferably outside, the pulverizing chamber. The movable element is preferably movable remotely. From the above viewpoints, in step b) of the process of the present invention, it is basically preferable to control the average particle size of the pulverized material by controlling the residence time of the scrap mixture in the pulverizing section, particularly the average residence time, using a movable element installed in the discharge area.

[0042] When the pulverizing section is a shredder, it is preferable that at least one movable element, for example, a movable cover, is provided in the discharge area at the upper part of the pulverizing chamber. When the pulverizing section is a Zerdirator crusher, it is preferable that at least one movable element is provided in the discharge area at the bottom of the pulverizing chamber. However, as a preferred pulverizing section of the present invention, it is extremely preferable to use a pulverizing section in which at least one first movable element is provided in the discharge area at the upper part of the pulverizing chamber and a second movable element is provided in the discharge area at the bottom of the pulverizing chamber. In the pulverizing section, the residence time of the scrap mixture can be advantageously controlled using two different movable elements, but it can also be advantageously controlled by moving the movable element arranged in the lower discharge area to completely close the discharge area at the bottom of the pulverizing chamber. Thereby, the pulverizing section can be operated flexibly and advantageously as a Zerdirator crusher or a shredder. For example, a difficult-to-process scrap mixture may be pulverized in the shredder mode with the substrate closed. On the other hand, for example, in the case of a relatively easy-to-process scrap mixture containing particularly a metal plate, the substrate may be opened to set it in the Zerdirator crusher mode to increase the throughput.

[0043] The inventor of the present invention has found particularly appropriate operating parameters for the pulverizing section. According to this, in the process of the present invention, the hammer rotor of the pulverizing section is driven by an electric motor, and the output power of the electric motor is preferably greater than 2,000 kW, particularly preferably greater than 2,400 kW, and extremely preferably greater than 2,800 kW.

[0044] In particular, in the case of a high material throughput, a large amount of dust may be generated in step b). Especially in the case of a processing mode for controlling the discharge port capable of discharging particles from the grinding chamber, even in continuous operation, it is possible to achieve a particle size that is somewhat smaller than the particle size achievable by conventional methods. Therefore, in particular, the problem of dust has been pointed out in many cases in the process of the present invention. Based on experiments conducted by the inventors of the present invention, in order to avoid environmental pollution as much as possible, it is proposed to directly provide a dust removal unit in the grinding unit. Therefore, in the process of the present invention, it is preferable that the grinding unit includes a dust removal unit, preferably a dry dust removal unit, preferably a dry dust removal unit equipped with one or more activated carbon filters.

[0045] In step c), a first treatment stage is carried out to remove organic and / or inorganic impurities from the ground material obtained from the grinding unit. This sorting step can also be found in some prior art processes, but in many cases, the devices for carrying out the treatment are single and relatively simple.

[0046] By this sorting, advantageously, as many impurities visible to the naked eye in general are supplemented as possible. As is understood by those skilled in the art, step c) is not defined as sorting all impurities, but is at least a partial sorting. In the process of the present invention, the inorganic impurities are preferably metal impurities or mineral impurities, and more preferably metal impurities.

[0047] For example, although it is at least theoretically conceivable to manually perform the sorting in step c), such as by sorting with a conveyor belt, especially in the case of scrap processing on a large industrial scale as in this case, a great deal of labor is required, so at least in most industrially advanced countries, it is uneconomical. Therefore, in the process of the present invention, it is preferable to carry out the sorting in step c) using one or more sorting devices, preferably automatic sorting devices.

[0048] Among numerous sorting processes, the inventor of the present invention has found a sorting process particularly suitable for the process of the present invention. These suitable sorting processes include length sorting, air sorting, magnetic sorting, and screening sorting. These sorting methods and the devices used are generally known to those skilled in the art.

[0049] In order to optimize the quality of the resulting scrap products, the inventor of the present invention proposes to combine multiple of these working steps. Therefore, in the process of the present invention, the sorting of organic and / or metallic impurities in step c) preferably includes two or more, preferably three or more, particularly preferably four or more different working steps selected from the group consisting of length sorting, air sorting, magnetic sorting, and screening sorting.

[0050] In the experiments conducted so far, the inventor of the present invention has focused on achieving the highest possible product quality of recycled scrap regardless of cost - efficiency issues and has found a configuration particularly suitable for the process and plant of the present invention. According to the inventor's opinion, in the process of the present invention, the sorting of organic and / or metallic impurities includes length sorting, preferably air sorting using an air shifter including multiple cascades, magnetic sorting, and screening sorting, and it is preferably carried out in this order. In magnetic sorting, it is preferably to use two or more, preferably electromagnetic magnetic separators, and it is particularly preferable that the magnetic field strength of the electromagnetic magnet is adjustable.

[0051] A unique feature of the process of the present invention is that the preliminarily refined material obtained in step c), that is, the pulverized material with at least partially removed organic and / or inorganic impurities, is analyzed using a first detection device in step d).

[0052] Detect at least one material information, preferably two or more material informations. That is, after preliminary purification, automatically inspect the preliminarily purified material. In most cases, the first material information measured in this way is selected to correlate with the chemical composition and / or particle shape and / or particle size of the preliminarily purified material. The said material information may be, for example, spectroscopic measurement values obtained from the preliminarily purified material, or optical images.

[0053] Subsequently, according to the material information detected in step d), remove the components of the preliminarily purified material. That is, for example, if the first material information does not meet a predetermined standard or specification regarding, for example, chemical composition or shape, remove the fraction contained in the purified material based on the material information. Step d) of the process of the present invention means the whole removal assisted by a detection device. As the detection device, a detection device known to those skilled in the art, particularly spectroscopic and optical detection devices, may be optionally used.

[0054] As a result of the previous screening, the number of destructive particles to be removed is usually relatively small, so at least theoretically, it seems easy to manually perform the removal in step d). In this case, if the first material information is displayed to the operator on, for example, a monitor or other interface, the operator can easily obtain information about the fraction to be removed in the preliminarily purified material. However, from the perspective of the achievable material throughput and, in particular, the accuracy of screening, it is clearly preferable to perform the screening automatically. The inventor has succeeded in finding, in his own plant, a particularly high-performance device connected to the first detection device, for example, through a data processing device or a network. The process of the present invention preferably performs the screening in step d) using an automatic device, preferably a rod-shaped compressed air gun or a robot arm equipped with, for example, a plurality of compressed air nozzles, and particularly preferably using a robot arm.

[0055] In the process of the present invention, the material thus purified passes through a further detection device that detects at least one second material information, preferably two or more pieces of material information. In the present invention, this second material information is compared with the corresponding material information or the material criteria assigned to each piece of material information. That is, for example, the value measured spectroscopically is compared with a threshold value, or the particle shape measured optically is compared with a prototype of an acceptable particle shape.

[0056] In the process of the present invention, only when the second material information meets the predetermined material criteria assigned thereto, the purified material is discharged as recycled scrap, that is, as a product that can be transported, for example, by a conveyor belt to appropriate storage facilities. In other cases, the purified material is, for example, discarded, transported to a downstream plant for post-treatment, or reprocessed by the process of the present invention, with the latter being basically preferred. From the perspective of efficiency, it is more advantageous to process the recycle rate in process c) or process d) without returning it to the grinding section. Therefore, in the process of the present invention, it is preferable to reprocess the purified material in which at least one second material information does not meet the predetermined material criteria in process b), process c), or process d).

[0057] The comparison is preferably performed by a data processing device, for example, a computer. Therefore, in the process of the present invention, it is preferable to transmit the predetermined material criteria by the data processing device and / or perform a search from the storage unit.

[0058] In the process of the present invention, it is preferable that the purified material is discharged as recycled scrap when all the second material information meets the predetermined material criteria assigned thereto.

[0059] The analysis of process d) and process e) has many similarities.

[0060] As an efficient processing mode in a suitable continuous or semi - continuous process, it is desirable that the detection device also operates continuously. In the process of the present invention, it is preferable to continuously perform the analysis of step d) and / or step e), preferably the analysis of step d) and step e), especially in an in - line manner.

[0061] In order to realize the most optimal material properties as much as possible, especially for simultaneously optimizing the iron content, the content of organic impurities and / or the particle shape, it has been proven particularly advantageous that the first detection device and / or the second detection device independently detect a plurality of material information respectively. Therefore, in the process of the present invention, it is preferable to detect at least two, preferably at least three, pieces of first material information in step d) and / or to detect at least two, preferably at least three, pieces of second material information in step e). Also, in the process of the present invention, it is also preferable that at least one piece of first material information and / or at least one piece of second material information, preferably all the material information, is analyzed for the chemical composition and / or particle shape and / or mechanical physical properties of the material, preferably in correlation with the chemical composition.

[0062] For this purpose, in most of the processes of the present invention, it is preferable that at least one of the first material information and at least one of the second material information are correlated with the particle physical properties of the same material.

[0063] According to the inventor's opinion of the present invention, it is particularly advantageous to perform detection by spatially and / or temporally decomposing, which is particularly dependent on the configuration of other plants and whether the plant is operating continuously or not. Such decomposition enables accurate removal of impurities and minimizes material waste, which is particularly advantageous in step d). Also, such decomposition is advantageous in step e) because deviations from the material standard may be partial, for example, and at least a fraction of the purified material can be discharged as recycled scrap. In the continuous or semi-continuous operation of the process, the material information can be further correlated with the fraction of the recycled scrap discharged respectively by temporal decomposition. Therefore, in the process of the present invention, it is preferable to detect at least one first material information and / or at least one second material information, preferably all material information, spatially and / or temporally, preferably spatially and temporally decomposed, and as a result, obtain spatially and / or temporally decomposed profile information in each case. Therefore, similarly, in the process of the present invention, it is preferable to perform the analysis of step d) and / or step e), preferably step d) and step e), using a measurement method that decomposes spatially and temporally.

[0064] Furthermore, this preferred processing mode enables the multiplicative use of the measured material information, particularly the second material information, simultaneously in the specifications, certificates, and certifications of the recycled scrap discharged. This makes it possible to use the recycled scrap in applications with high requirements for scrap products, particularly for reasons related to safety.

[0065] In the process of the present invention, it is preferable to store at least one first material information and / or at least one second material information, preferably at least one second material information, in the storage unit of the data processing device. More preferably, these material information are correlated with at least one operation information, preferably one time information, so that each material information is assigned to the discharged recycled scrap. Each material information is preferably assigned to the fraction of the discharged recycled scrap using a certificate, preferably an electronic certificate.

[0066] Through experiments, the inventors of the present invention have been able to find particularly suitable detection methods / associated detection devices. These methods bring excellent purity, and it has been proven that it is particularly effective to use multiple methods for the measurement in each case. In the process of the present invention, the analysis of step d) and / or step e), preferably step d) and step e), is preferably carried out using one or more, preferably two or more, different methods selected from the group consisting of X-ray fluorescence analysis, optical image recognition, preferably optical image recognition using artificial intelligence, infrared absorption spectroscopy, particularly near-infrared absorption spectroscopy. X-ray fluorescence analysis is used, for example, for measuring the elemental content, and infrared / near-infrared absorption spectroscopy is used, for example, for measuring the organic content.

[0067] Basically, the same type of detection device can be used in steps d) and e), whereby measurement values of the same type can be detected as the first and second material information, or the first and second material information can be obtained in the same data format such as an image. However, the inventors of the present invention have found that it is effective to use different detection methods, particularly when used for detecting material information correlated with the same material or particle physical properties. This makes it possible to minimize measurement errors and complement the disadvantages between different methods multiplicatively to improve the accuracy of the process. Therefore, in the process of the present invention, it is preferable to detect the first and second material information using different detection methods, and preferably to correlate the first and second material information with the same material or particle physical properties.

[0068] As described above, it is considered that a great advantage of the process of the present invention is that excellent results can be obtained even in continuous operation, and thus a processing mode with particularly high time and cost efficiency can be realized. Therefore, the process of the present invention is very preferably a continuous or semi-continuous process, and it is more preferable to convey at least a part of the crushed material and / or pre-purified material and / or purified material, preferably all of these materials, using a conveyor belt and / or a vibrating conveyor.

[0069] The process of the present invention advantageously enables obtaining a large amount of recycled scrap that reproducibly exhibits a particularly advantageous iron content, shape factor, and / or packing density. Therefore, in the process of the present invention, it is particularly advantageous to perform so as to achieve the corresponding parameters, whereby the advantages become apparent compared to the prior art.

[0070] In the process of the present invention, it is preferable that the maximum particle size of the recycled scrap is 100 mm or less, preferably 80 mm or less, and particularly preferably 60 mm or less.

[0071] In the process of the present invention, it is preferable that the average particle size of the recycled scrap is in the range of 60 to 250 mm, preferably 80 to 200 mm, and particularly preferably 100 to 150 mm.

[0072] In the process of the present invention, it is preferable that the average shape factor of the length÷width of the recycled scrap is in the range of 1 to 5, preferably 1 to 2.5, and more preferably 1 to 1.25, and it is very preferable that the particles of the recycled scrap are substantially spherical.

[0073] In the process of the present invention, the packing density of the recycled scrap is 1.0 t / m 3 or more, preferably 1.2 t / m 3 or more, and particularly preferably 1.5 t / m 3 or more.

[0074] Furthermore, in the process of the present invention, it is preferable that the iron content rate of the recycled scrap is 97% or more, preferably 98% or more, more preferably 99% or more based on the mass of the recycled scrap.

[0075] Starting from the process invented by the inventor of the present invention, the inventor has found particularly advantageous developments due to the interaction with the configuration in the process of the present invention. Here, three so-called feedbacks for controlling and optimizing the process will be described.

[0076] For the first two feedbacks, the material information detected during the scrap processing in the process of the present invention is used. Also, each step of the process of the present invention is controlled according to the recorded material information.

[0077] The process of the present invention preferably includes a so-called first feedback that controls the components of a heterogeneous iron-containing scrap mixture according to the first material information and / or the second material information, preferably the first and second material information, and particularly preferably changes and controls the mass ratio of a plurality of iron-containing scrap fractions in the iron-containing scrap mixture.

[0078] By this processing mode, it is possible to actively respond to the characteristics of the scrap, particularly the deviation of the chemical composition, and actively control the selection of raw materials in the upstream part of the process. This is preferably carried out using a data processing device, preferably a neutral network or an equivalent artificial intelligence, preferably a data processing device using a neutral network. Also, the data processing device used is preferably a device trained to change the mass ratio of a plurality of iron-containing scrap fractions in the production of a heterogeneous iron-containing scrap mixture as an appropriate correction method for the measured deviation when the deviation of the material information from the corresponding predetermined target value, particularly the material standard, is recorded. Since the first material information is detected earlier in the process, it may be advantageous to perform this first feedback based on the first material information for earlier response.

[0079] The process of the present invention controls the grinding in step b) according to the first material information and / or the second material information, preferably the first and second material information, and preferably by changing one or more operating parameters of the grinding section selected from the group consisting of the size of the grinding chamber, the size of the discharge opening that can be discharged in the discharge area, and the speed of the hammer rotor, so-called second feedback is preferably included. Although the basic idea is the same as that of the first feedback, in the second feedback, instead of controlling the components of the heterogeneous iron-containing scrap mixture according to the detected material information, the operating parameters of the grinding section are controlled. In the control of the operating parameters of the grinding section, the size of the particle discharge port is a suitable operating variable. It is particularly effective to use this feedback when using the grinding section of the present invention in the process of the present invention. In the control of step b), a data processing device is also used, preferably a neutral network or an equivalent artificial intelligence, preferably a data processing device using a neutral network, and when a corresponding predetermined target value, especially the deviation of the material information from the material standard, is recorded, it is preferable to use a device trained to change the operating parameters of the grinding section as an appropriate correction method for the measured deviation to correspond.

[0080] The last third feedback uses material information, but the material information detected in the process of additional processing rather than the process of the present invention. This detection is basically carried out in the same manner as the detection of the first and second material information described above. This material information is detected from products such as mixtures and conversion products obtained by the recycling scrap process, for example, regarding material components and strength. At least one third material information is periodically provided to the operator of the process of the present invention from an external source, for example, a customer who has received converter cooling scrap.

[0081] The process of the present invention detects at least one third material information during the additional processing of recycled scrap, preferably making the composition of the heterogeneous iron-containing scrap mixture, preferably the mass ratio of the iron-containing scrap fraction in the heterogeneous iron-containing scrap mixture, suitable as described above, and / or preferably making the grinding in step b) suitable as described above, and / or controlling the sorting in step c) according to the at least one third material information, including a so-called third feedback. Here, the use of a neural network or equivalent artificial intelligence, preferably a neural network, is advantageous.

[0082] The process of the present invention preferably includes first and second feedbacks, and particularly preferably includes first, second, and third feedbacks.

[0083] Furthermore, the present invention relates to recycled scrap that is produced or can be produced by the process of the present invention and has an iron content of 97% by weight or more, preferably 98% by weight or more, particularly preferably 99% by weight or more based on the mass of the recycled scrap. Such recycled scrap of the present invention is also suitable for demanding applications and is particularly advantageous because its quality is almost indistinguishable from newly produced metal.

[0084] Furthermore, the present invention at least one grinding unit for grinding the heterogeneous iron-containing scrap mixture, preferably the grinding unit of the present invention, sorting means for sorting organic substances and / or metal impurities from the ground material, one or more first detection devices for analyzing the material obtained after sorting and detecting first material information, automatic removal means for automatically removing fractions from the material obtained after sorting according to the first material information, one or more second detection devices for analyzing the material obtained after removal and detecting second material information, A data processing device adapted to compare the second material information with a predetermined material standard and, when the second material information meets the assigned predetermined material standard, to discharge the material purified by the apparatus as recycled scrap, and preferably a scrap recycling plant for use in the process of the present invention.

[0085] The plant of the present invention is advantageous because it is suitable for implementing the process of the present invention. The plant of the present invention particularly preferably includes additional components necessary for implementing the process of the present invention in a preferred embodiment, in particular a specific grinding section, a sorting device, a detection device, and a data processing device adapted to realize the aforementioned first, second, and / or third feedback.

[0086] Finally, the present invention A grinding chamber having at least one discharge area for the ground material, And at least one hammer-equipped rotor installed in the grinding chamber, and including a movable element designed to control the discharge port of the ground material from the grinding chamber that can be discharged in the discharge area, preferably related to a grinding section used in the process of the present invention or the plant of the present invention. Further, this grinding section preferably includes a movable substrate and / or a cover plate that can change the discharge port of the ground particles from the grinding chamber that can be discharged in the discharge area, particularly preferably a hydraulically movable substrate and / or a cover plate.

[0087] As understood by those skilled in the art, the grinding chamber generally includes an inlet opening for introducing the scrap mixture to be processed into the grinding chamber separately from the discharge area of the ground material in the present invention.

[0088] This grinding section of the present invention is optimized for use in the process of the present invention, and is particularly preferably because it can control the steps of step b) as described above and can particularly easily realize the second feedback. Compared with the prior art, the grinding section of the present invention can change the average residence time of the particles in the grinding chamber even during operation, for example, change the particle size and the degree of purification of the processed scrap.

[0089] The grinding section of the present invention comprises a first discharge area in the upper part of the grinding chamber, the grinding section in the first discharge area having a first movable element designed to control the discharge opening of the ground material from the grinding chamber that can be discharged in the first discharge area, and a second discharge area in the bottom part of the grinding chamber, the grinding section in the second discharge area having a second movable element designed to control the discharge opening of the ground material from the grinding chamber that can be discharged in the second discharge area. This is particularly preferred. With this grinding section of the present invention, for the first time based on the inventor's findings, it is particularly preferred because a grinding section that can be switched flexibly, i.e., for example, between a shredder and a Zerdirator grinder even during operation, can be realized. Therefore, it is particularly preferred that the grinding section of the present invention can operate as both a shredder and a Zerdirator grinder by moving one or more elements in the discharge area of the grinding chamber.

[0090] In the process of the present invention combining one or more of the above-described preferred process features, it is highly preferred that the grinding section includes a soundproof enclosure.

[0091] In the process of the present invention combining one or more of the above-described preferred process features, it is highly preferred that the grinding section is fixed in the ground by a foundation.

[0092] In the process of the present invention combining one or more of the above-described preferred process features, it is highly preferred to weigh the weight of the scrap mixture and / or the ground material and / or the pre-purified material and / or the purified material.

[0093] In the process of the present invention combining one or more of the above-described preferred process features, it is highly preferred to control the process by a control unit.

[0094] In the process of the present invention combining one or more of the above-described preferred process features, it is highly preferred that an audible or visual alarm is issued in case of an abnormality.

[0095] In the process of the present invention that combines one or more of the features of the aforementioned preferred process, it is extremely preferable that the pulverizing section is made of steel in a range exceeding 75% by weight.

[0096] In the process of the present invention that combines one or more of the features of the aforementioned preferred process, it is extremely preferable to store the discharged recycled scrap in a storage.

[0097] In the process of the present invention that combines one or more of the features of the aforementioned preferred process, it is extremely preferable to load and transport the discharged recycled scrap onto a heavy goods vehicle, a freight train or a cargo ship, preferably a freight train or a cargo ship.

[0098] In the process of the present invention that combines one or more of the features of the aforementioned preferred process, it is extremely preferable that it can be interrupted by an emergency switch.

[0099] In the plant of the present invention that combines one or more of the features of the aforementioned preferred plant, it is extremely preferable to include a signaling device and / or a warning device.

[0100] In the plant of the present invention that combines one or more of the features of the aforementioned preferred plant, it is extremely preferable to include an emergency switch for stopping the plant.

[0101] In the plant of the present invention that combines one or more of the features of the aforementioned preferred plant, it is extremely preferable that the pulverizing section is made of steel in a range exceeding 75% by weight.

[0102] In the plant of the present invention that combines one or more of the features of the aforementioned preferred plant, it is extremely preferable to include a control unit for controlling the plant.

[0103] In the plant of the present invention that combines one or more of the features of the aforementioned preferred plant, it is extremely preferable that the overall length is greater than 5 m, preferably greater than 10 m or more, and more preferably greater than 15 m.

[0104] The crushing section of the present invention, which combines one or more of the above-mentioned preferable features of the crushing section, preferably has a foundation, more preferably a concrete foundation.

[0105] The crushing section of the present invention, which combines one or more of the above-mentioned preferable features of the crushing section, very preferably includes steel hammers.

[0106] The crushing section of the present invention, which combines one or more of the above-mentioned preferable features of the crushing section, very preferably includes operating means.

[0107] The crushing section of the present invention, which combines one or more of the above-mentioned preferable features of the crushing section, very preferably has a weight greater than 100 kg, more preferably greater than 200 kg.

[0108] The crushing section of the present invention, which combines one or more of the above-mentioned preferable features of the crushing section, very preferably consists of more than 75% by weight of steel.

[0109] Hereinafter, preferred embodiments of the process of the present invention and the plant of the present invention used therefor, which the inventors of the present invention have found to be particularly advantageous, will be described. These preferred embodiments have an iron content of 97% with little organic matter, a packing density of particles that are substantially spherical, i.e., a shape factor of about 1 and a maximum particle diameter of about 80 mm, of about 1.5 t / m 3 were found through an overall optimization that enables the production of recycled scrap on a large industrial scale.

[0110] The treated material is conveyed by a conveyor belt to make the process an ongoing process.

[0111] The raw material to be produced is a heterogeneous iron-containing scrap mixture. It is produced by mixing a plurality of iron-containing scrap fractions, i.e., white household appliances, factory-generated scrap, pre-shredder material, pressed used vehicle bodies, etc., at the supply port of the crushing section.

[0112] The heterogeneous iron-containing scrap mixture is crushed in the crushing section of the present invention shown in FIG. 1. This crushing section includes a hydraulically movable substrate and a cover plate, and the discharge port of the crushed material from the dischargeable crushing chamber may be changed using these. Thereby, the average residence time of the particles in the crushing chamber can be controlled, and the average particle size of the crushed material can be controlled. By means of the movable substrate installed at the bottom of the crushing chamber, the lower discharge region can be closed, and only the discharge region at the upper part of the crushing chamber can be made dischargeable. Therefore, the crushing section of the present invention can operate as a shredder or as a Zerdirator crusher. In the implementation experiment, the crushing section usually operates as a shredder.

[0113] The crushing section further has a dry dust removal section including a plurality of activated carbon filters.

[0114] The shredded material is passed through a sorting mechanism to sort out organic and inorganic impurities from the crushed material and obtain a preliminarily purified material.

[0115] The sorting mechanism includes, in series arrangement, a general length sorter, a wind shifter including a three-stage cascade, two magnetic separators using adjustable electromagnetic magnets for magnetic separation, and a sieve.

[0116] The material stream is analyzed by two first detection devices. Information regarding the shape and size of the fractions in the preliminarily purified material is detected by a camera, and measurements correlated with the chemical composition of the analyzed material are measured as material information by a continuously operating near-infrared spectrometer. These spatially and temporally resolved material information is sent, by computer control, to a robotic sorting device that removes impurities / fractions identified as not meeting predetermined requirements based on the provided data with sensor assistance.

[0117] Thereafter, the refined material is placed on a conveyor belt and further passes through an area where reanalysis is performed. The detection devices that can be used here include a fluorescence X-ray spectrometer in addition to a continuously operating near-infrared spectrometer, and the latter provides supplementary information regarding chemical components (for example, reconfirmation of the dimensions of particles using a camera is not carried out in this process but may be carried out). The information thus recorded is compared with the assigned predetermined material criteria, in this embodiment the selected organic and metallic impurities, especially the presence or absence of copper, using a data processing device.

[0118] When all the material criteria are met, the finished material is discharged as recycled scrap and sent to a storage facility on a conveyor belt.

[0119] The detected secondary material information is stored in a computer and associated with the manufacturing time / discharge time. This material information is associated with the corresponding batch using an electronic certificate. This electronic certificate can also be used by the customer later and can be used for the authentication of scrap products in specific applications.

[0120] The corresponding plant is equipped with computer control means capable of performing different feedback, that is, controlling the process according to the detected material physical properties. In this embodiment, the operating parameters of the pulverizing section, more precisely the output in the discharge area and the adjustment of the movable substrate, are controlled according to the primary material information detected by a camera. The components of the heterogeneous iron-containing scrap mixture are changed according to the near-infrared measurement values / fluorescence X-ray measurement values. At the current stage of development, this adaptation work is carried out by visual indication means for the operator, which display instructions to the operator of the excavator and indicate the amount of scrap fraction to be fed in. However, automatic feeding is required as a countermeasure.

[0121] The process and the plant receive third material information from the users of the recycled materials and are adapted to control the operating parameters of the grinding section and the components of the heterogeneous iron-containing scrap mixture based on this third material information. Since there are no actual users, currently this feedback can only be verified with assumed experimental data, but the plant is adapted as per the present invention.

[0122] By continuously detecting the material information, controlling the process based on this detection, and then performing subsequent detections using the same detection means, a comprehensive data set can be advantageously obtained. Thereby, a neutral network can be trained to provide more accurate feedback and reduce the need for expert's empirical knowledge as much as possible.

[0123] Hereinafter, the grinding section of the present invention and its preferred embodiments will be described more specifically with reference to the drawings. FIG. 1 is a schematic cross-sectional view showing a preferred embodiment of the grinding section of the present invention.

Brief Description of the Drawings

[0124]

Figure 1

[0125] The grinding section 10 is particularly suitable for use in the process / plant of the present invention and includes a grinding chamber 12. The grinding chamber 12 includes an inlet opening 22. For example, the scrap mixture supplied by the conveyor belt 18a is introduced into the grinding chamber 12 through the inlet opening 22. Further, the grinding chamber 12 includes two discharge regions 14a, 14b.

[0126] The first discharge region 14a is installed at the upper part of the grinding chamber 12 and includes a first movable element 20a designed to limit the discharge opening of the ground material from the grinding chamber 12 that can be discharged in the first discharge region 14a. In this embodiment, the first movable element 20a is a hydraulically adjustable cover plate. The second discharge area 14b is installed at the bottom of the grinding chamber 12 and includes a second movable element 20b designed to limit the discharge opening of the ground material from the grinding chamber 12 that can be used in the second discharge area 14b. In this embodiment, the second movable element 20b is a hydraulically adjustable substrate, which is formed in a double-opening lid shape with two parts.

[0127] In FIG. 1, the movability of the movable elements 20a and 20b is indicated by double arrows. The discharge areas 14a and 14b are each covered with an iron grid so that no oversized particles come out of the grinding chamber 12. Preferably, the iron grids in the discharge areas 14a and 14b may have an adjustable mesh size and / or be replaceable reversibly and non-destructively.

[0128] In the grinding chamber 12, the scrap mixture is ground by the rotor 16 with hammers. After staying in the grinding chamber 12 for a certain period of time, the ground particles are discharged from the grinding section 10 through either of the discharge areas 14a and 14b, and may be sent for additional processing by, for example, conveyor belts 18a and 18b.

[0129] By controlling the movable elements 20a and 20b, the average residence time of the particles in the grinding chamber 12 can be controlled. Furthermore, the second discharge area 14b can be completely closed by the second movable element 20b, and the operation of the grinding section 10 can be switched from a Zerdirator grinder to a shredder.

Explanation of reference numerals

[0130] 10 Grinding section 12 Grinding chamber 14a, 14b Discharge area 16 Rotor 18a~18c Conveyor belt 20a, 20b Movable element 22 Inlet opening

Claims

1. a) producing or providing a heterogeneous mixture of iron-containing scrap; b) grinding the heterogeneous iron-containing scrap mixture in a grinding section (10) to obtain a ground material; c) separating organic and / or inorganic impurities from the ground material by two or more different operational steps selected from the group consisting of length separation, air separation, magnetic separation and sieving to obtain a pre-purified material; d) analyzing the pre-purified material with one or more first detection devices to detect at least one first ingredient information, and removing components of the pre-purified material based on the first ingredient information to obtain a purified material by an analysis and removal process using an automated device; e) analyzing the purified material with one or more second detection devices to detect at least one second material signature; f) comparing the detected second material information with a predetermined material standard assigned to the second material information; If the second material information satisfies the assigned predetermined material criteria, the refined material is removed as recycling scrap; The crushing unit (10), a grinding chamber (12) with at least one of a first discharge area (14a) and a second discharge area (14b) of the ground material; At least one rotor (16) equipped with a hammer is installed in the grinding chamber (12), the grinding section (10) comprises a movable element designed to control the discharge area of ​​the ground material from the grinding chamber (12) available in said discharge area, The process for producing recycled scrap, wherein the crushing process in step b) is controlled by the first material information and / or the second material information.

2. and / or - detecting and analysing spatially and / or temporally resolved profile information of the at least one first material information and / or the at least one second material information, respectively, using spatial and / or temporal resolution; and / or 2. The process according to claim 1, wherein the analysis in step d) and / or step e) is carried out by one or more different techniques selected from the group consisting of X-ray fluorescence analysis, optical image recognition, infrared absorption spectroscopy.

3. The process of claim 1 , wherein a composition of the heterogeneous iron-bearing scrap mixture is controlled by the first material information and / or the second material information.

4. 2. The process according to claim 1, further comprising detecting at least one third material information during the further processing of the recycled scrap and controlling the composition of the heterogeneous iron-containing scrap mixture and / or the crushing step in step b) and / or the sorting step in step c) on the basis of said at least one third material information.

5. The process of claim 1 , wherein the process is a continuous process.

6. At least one crushing section (10) for crushing a heterogeneous iron-containing scrap mixture; A sorting means for sorting organic and / or metallic impurities from the pulverized material; one or more first detection devices that analyze the material obtained after the sorting and detect first material information; an automatic removal means for automatically removing a fraction from the material obtained after the sorting according to the first material information; one or more second detection devices that analyze the material obtained after the removal and detect second material information; a data processing device adapted to compare the second material information with an assigned predetermined material standard, and to discharge the material refined by the device as recycling scrap if the second material information satisfies the assigned predetermined material standard; For use in the process according to claim 1 . Scrap recycling plant.

7. a grinding chamber (12) with at least one of a first discharge area (14a) and a second discharge area (14b) of the ground material; At least one rotor (16) equipped with a hammer is installed in the grinding chamber (12), The grinding section (10) comprises movable elements (20a, 20b) designed to control the discharge area of ​​ground material from the grinding chamber (12) available in the first discharge area (14a) and the second discharge area (14b), at the top of the grinding chamber (12), the grinding section (10) has the first discharge area (14a) and a first movable element (20a) designed to control the discharge area of ​​ground material from the grinding chamber (12) available in the first discharge area (14a), and at the bottom of the grinding chamber (12), the grinding section (10) has a second movable element (20b) designed to control the discharge area of ​​ground material from the grinding chamber (12) available in the second discharge area (14b). Use in the process according to claim 1 or in the plant according to claim 6. Grinding section (10).

Images