A process for producing high-purity scrap material from heterogeneous input materials.

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 process for producing recycled scrap, particularly high-iron-content recycled scrap producible by said process, a scrap recycling plant optimized for carrying out said process, and an improved crushing unit 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 converting used metal products into scrap. Above all, 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 numerous applications to reduce the need for newly produced metal. The use of scrap as a raw material not only reduces the industry's dependence on rare raw materials but also reduces the amount of unnecessary waste. Large-scale industrial production of metals and alloys generally requires a large amount of energy and resources, so a reduction in the demand for newly produced metal also contributes 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 scrap is used instead of newly produced metal, it must reliably have at least approximately the same material properties as the newly recovered metal.

[0005] Therefore, basically, there is a high demand for pure scrap mixtures in many industrial applications, and a scrap mixture that further has an advantageous packing density is considered ideal. However, it is well known that this is a very difficult goal because the raw materials for producing such a scrap mixture are inherently heterogeneous. For example, when washing machines from two different manufacturers are converted into scrap, similar products may result in scrap having different properties.

[0006] Prior art discloses various methods for obtaining such pure scrap mixtures, but these are generally very complex. These methods essentially involve a manual sorting process by workers to isolate particularly suitable fractions from the scrap mixture.

[0007] In large-scale industrial shredder plants, in order to actually produce relatively pure scrap mixtures, operators often pass the processed scrap through the processing plant and shredder multiple times, that is, subjecting the scrap to multiple crushing processes and performing downstream sorting operations as needed, with the aim of achieving higher purity and / or a favorable packing density of the material. [Overview of the Initiative] [Problems that the invention aims to solve]

[0008] Processes known from prior art, for example, require processing the material twice, which is relatively time-consuming and / or costly, resulting in increased waste or at least a 50% reduction in the plant's material processing capacity. Furthermore, these methods can result in some material remaining in the plant during the second pass, having only reached the discharge point from the first pass. Consequently, a certain amount of fraction that has not undergone the necessary second shredding process may be present in the material removed from the outlet.

[0009] Furthermore, prior art processes often suffer from the drawback of having relatively little data available on the finished product. This becomes a problem because simply providing scrap of a specific quality for high-performance applications is insufficient; it is often essential to be able to properly demonstrate that quality, for example, from a legal liability standpoint.

[0010] Furthermore, in processes known from prior art, it is often difficult to actively control product quality during process operation, for example, in order to adapt the process to customer requirements as quickly as possible. Therefore, in processes known from prior art, it is often impossible to manufacture, for example, two scrap products with different specifications in succession and / or without modifying the plant.

[0011] Furthermore, with conventional technology, it is often impossible to manufacture products with a high filling density advantageous for a particular application within the manufacturing time required for efficient large-scale industrial production. [Means for solving the problem]

[0012] The first objective of the present invention is to demonstrate an improved recycling scrap process that can eliminate or at least reduce the shortcomings of the prior art.

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

[0014] The objective of this invention is to specify a recycled scrap manufacturing process that enables the production of correspondingly high-quality products, ideally in only one pass, and allows for the mass production of these high-quality scrap products at low cost, thereby enabling the operation of a time- and cost-efficient process in large-scale industrial manufacturing.

[0015] Compared to conventional technologies, the explicitly stated recycled scrap manufacturing process should enable the achievement of significantly higher purity in industrially appropriate quantities than was possible with previous processes.

[0016] As a supplementary requirement, the specified recycled scrap manufacturing process must be feasible using conventional scrap fractions as raw materials and utilizing, to the greatest extent possible, equipment available in conventional scrap processing plants.

[0017] A supplementary objective of the present invention is to enable the automatic provision of more comprehensive information about the physical properties of each scrap batch produced by the explicit recycled scrap manufacturing process.

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

[0019] Furthermore, explicit recycling scrap manufacturing processes are particularly desirable to reduce the risk of producing defective scrap batches that customers cannot use.

[0020] A further objective of the present invention is to enable the production process of explicit recycled scrap to operate with low emissions and in particular safety, thereby reducing safety risks and human and environmental pollution.

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

[0022] A further secondary objective of the present invention is to specify an improved scrap recycling plant and a novel crushing unit, each optimized for use in the specified processes.

[0023] The inventor of the present invention has developed a novel and powerful process for achieving the aforementioned object, as well as a corresponding plant. In summary, the process of the present invention emphasizes a unique combination of sorting technologies using process analysis as defined in the claims, and is based on a comprehensive modification of existing process technologies. [Effects of the Invention]

[0024] According to the process of the present invention, for the first time based on the inventor's findings, it becomes possible to produce industrially appropriate quantities of high-quality scrap products in a single pass with good time and cost efficiency. Even when using heterogeneous raw materials, that is, general scrap fractions, it is possible to produce scrap products with an iron content of 97% or more and advantageous packing density, while removing almost all organic impurities. According to the inventor's findings, this has not been achievable in large-scale industrial processes in the similar prior art, at least for processes having equivalent material throughput and / or reproducibility. In addition, as a synergistic advantage, the material information obtained in the production process can be used for recording material properties, and the produced scrap products can be certified with almost no effort.

[0025] In experiments conducted by the inventor, recycled scrap products with an iron content of 97% or more can be obtained on a large industrial scale. Furthermore, by using the preferred plant of the present invention, the packing density of substantially spherical particles is about 1.5t / m 3 recycled scrap products can be obtained.

[0026] Therefore, the aforementioned object can be achieved by the process for producing recycled scrap as defined in the claims, the scrap producible by said production process, the plant for scrap recycling, and the crushing unit. Preferred embodiments of the present invention are apparent from the dependent claims and the following description. Mode for Carrying Out the Invention

[0027] The preferred embodiments of the present invention described below are particularly preferable to be combined with other preferred features. Therefore, it is extremely preferable to combine several of the following particularly preferred embodiments. Similarly, embodiments that combine a feature that is preferable to a certain degree with one or more other features that are preferable to a certain degree are preferred. The features of a suitable recycled scrap, a suitable scrap recycling plant, and a suitable crushing section are evident from the features of a suitable process.

[0028] The present invention a) A process for manufacturing or supplying heterogeneous iron-containing scrap mixtures, b) A grinding step in which the heterogeneous iron-containing scrap mixture is ground in the grinding section to obtain the ground material, c) A sorting step of separating organic and / or inorganic impurities from the pulverized material to obtain a pre-purified material, d) An analysis and removal step in which at least one piece of first material information is detected by analyzing the pre-purified material with one or more first detection devices, and components of the pre-purified material are removed based on the first material information to obtain a purified material, e) An analysis step of analyzing the purified material using one or more second detection devices and detecting at least one piece of second material information, f) The present invention relates to a recycled scrap manufacturing process which includes a comparison step of the detected second material information with a predetermined material standard assigned to the second material information, wherein the refined material is extracted as recycled scrap when the second material information satisfies the predetermined material standard assigned to it.

[0029] The process of the present invention is also suitable for small-scale manufacturing. Therefore, it has been demonstrated that the process of the present invention can produce excellent scrap products even in, for example, test-scale plants. However, at low processing volumes, the economic competition between the process of the present invention and more complex manual processes intensifies. For example, pure scrap products can also be provided by physicochemical sorting of scrap mixtures on a laboratory scale. The process of the present invention is particularly preferable for use in large-scale industrial processes, as it offers significant advantages in such processes. In the process of the present invention, it is extremely preferable 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 those skilled in the art will recognize, in large-scale industrial implementations, especially in implementations at the specified actual processing volumes, the demand for the process, the equipment used, and the raw materials becomes particularly high. This broadens the range of choices, for example, increasing the demand for scrap raw materials that produce heterogeneous iron-containing scrap, and often leading to increased heterogeneity of the raw materials.

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

[0031] In actual manufacturing, for example, multiple iron-containing scrap fractions may be mixed. To perform this mixing, for example, a considerable amount of various scrap fractions may be successively introduced into the grinding section, or these fractions may be introduced simultaneously into the feed port of the grinding section so that they reach the grinding section at the same time. This manufacturing method has proven to be particularly efficient in practice. Incorporating the mixing of multiple scrap fractions into the process is advantageous because the mixing ratio can be adjusted to control the composition of the mixture. Therefore, in the process of the present invention, the production of a heterogeneous iron-containing scrap mixture in step a) is preferably carried out by mixing multiple iron-containing scrap fractions to produce scrap, and it is even more preferable that this mixing is carried out substantially in the grinding section.

[0032] The term scrap fraction is clear to those skilled in the field of metalworking. Furthermore, those skilled in the art can easily distinguish between different iron-containing scrap fractions. A scrap fraction is typically a collection of similar materials gathered according to detailed selection criteria, and then collected and / or processed together.

[0033] Mixtures of various iron-containing scrap fractions may vary in accordance with changes in legal regulations and industry-specific specifications. A person skilled in the art will always distinguish between scrap fractions consisting of, for example, so-called white goods (e.g., washing machines and ovens) and scrap fractions consisting of, for example, pressed car bodies or factory-generated scrap from metalworking operations.

[0034] As those skilled in the art will understand, iron-containing scrap fractions are an ideal grading standard for collecting scrap of similar properties. While scrap mixtures are generally heterogeneous in most cases, the scrap present in these fractions exhibits smaller deviations in material properties than scrap in secondary iron-containing scrap fractions or other similar scraps. In practice, these fractions are usually collected separately according to appropriate regulations and stored separately by the user.

[0035] In experiments conducted by the inventors, heterogeneous iron-containing scrap mixtures were produced using a wide range of common scrap fractions. Of these, certain scrap fractions are particularly advantageous because they are readily available and have a relatively high iron content. In the 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 material, and used vehicle bodies. As those skilled in the art will understand, the term white goods refers to household electrical appliances such as refrigerators, washing machines, dishwashers, and stoves, and is distinguished from so-called black goods, such as televisions and mobile phones. Pre-shredder material is generated, for example, in disposal operations or sorting plants, and often includes items such as bicycles, awnings, and similar items.

[0036] In the process of the present invention, the actual mixture of scrap fractions used in production / heterogeneous iron-containing scrap mixture, i.e., heterogeneous iron-containing scrap mixture with respect to a mixture of various different parts, is not ultimately determined. However, since the demand for processing homogeneous raw materials is significantly lower, the iron-containing scrap mixture should be heterogeneous in the present invention. This criterion can be readily determined by those skilled in the art in practice. As those skilled in the art will understand, an iron-containing scrap mixture is considered heterogeneous if it is produced by mixing multiple iron-containing scrap fractions and / or if it contains fractions obtained by scrapping multiple different types of articles selected from the group consisting of household electrical appliances, car bodies, and waste generated in metalworking 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 performed by a crushing unit. Therefore, step b) corresponds to, for example, the shredding process known to those skilled in the art from the prior art.

[0038] Various types of crushing units can be used, such as scrap shears, Kondirator crushers, and Zerdirator crushers, but the use of a shredder or Zerdirator crusher has proven particularly advantageous for processing large quantities of material. In this invention, a Zerdirator crusher means a crushing unit that has a crushed material discharge area at the bottom of the crushing chamber, generally covered with an iron grate. A Zendirator crusher may also have an optional discharge area at the top of the crushing chamber. In contrast, the term shredder means a crushing unit that does not have a crushed material discharge area at the bottom of the crushing chamber, but has a crushed material discharge area at the top of the crushing chamber, generally covered with an iron grate.

[0039] In the present invention, it is highly preferable that the grinding section used is constructed together with a movable substrate and / or cover plate that allows for the modification of the discharge port from which particles can be discharged from the grinding chamber.

[0040] This makes it possible to reduce the amount of crushed particles discharged and increase the average residence time of particles within the crushing section. Therefore, it is advantageous that the crushing intensity 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 refining capacity and / or reduce the particle size and increase the packing density as required or in demand. Accordingly, it is clearly preferable that in the process of the present invention, the crushing chamber of the crushing section has at least one discharge area for the crushed material, and that a movable element, preferably a movable substrate and / or cover plate, and particularly preferably a hydraulically movable substrate and / or cover plate, is installed in the discharge area, thereby changing the discharge port from which particles can be discharged from the crushing chamber.

[0041] The inventors of the present invention have concluded that, in order to realize the processing mode described above, it is most advantageous to mount the movable substrate and / or cover plate, for example, inside or outside the grinding chamber, preferably outside. The movable element is preferably remotely movable. From the above viewpoint, in step b) of the process of the present invention, it is basically preferable to control the average particle size of the ground material by controlling the residence time of the scrap mixture in the grinding section, in particular the average residence time, using a movable element installed in the discharge area.

[0042] If the grinding unit is a shredder, it is preferable that at least one movable element, such as a movable lid, is provided in the discharge area at the top of the grinding chamber. If the grinding unit is a zerdirator grinder, it is preferable that at least one movable element is provided in the discharge area at the bottom of the grinding chamber. However, as a preferred grinding unit of the present invention, it is extremely preferable to use a grinding unit in which at least one first movable element is provided in the discharge area at the top of the grinding chamber and a second movable element is provided in the discharge area at the bottom of the grinding chamber. In the grinding unit, the residence time of the scrap mixture can be advantageously controlled even if two different movable elements are used, but it can also be advantageously controlled by moving the movable element located in the lower discharge area to completely close the discharge area at the bottom of the grinding chamber. This makes it advantageous that the grinding unit can be flexibly operated as both a zerdirator grinder and a shredder. For example, scrap mixtures that are difficult to process may be ground in shredder mode with the substrate closed. On the other hand, for example, in the case of relatively easy-to-process scrap mixtures, especially those containing metal plates, the substrate may be opened to increase the processing capacity in zerdirator grinder mode.

[0043] The inventors of the present invention have found particularly suitable operating parameters for the grinding section. According to these parameters, in the process of the present invention, the hammer rotor of the grinding 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 most preferably greater than 2,800 kW.

[0044] In particular, in the case of high material processing volumes, a large amount of dust may be generated in step b). Especially in processing modes that control the discharge port that can discharge particles from the grinding chamber, it is possible to achieve a particle size that is somewhat smaller than the particle size that can be achieved by conventional methods, even with continuous operation. For this reason, dust is a problem that 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, it is proposed to directly provide a dust removal unit in the grinding unit in order to avoid environmental pollution as much as possible. Accordingly, 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, and preferably a dry dust removal unit equipped with one or more activated carbon filters.

[0045] In step c), a first processing step is performed to remove organic and / or inorganic impurities from the pulverized material obtained from the pulverization section. This sorting step is also seen in some processes of the prior art, but in many cases the processing apparatus is single and relatively simple.

[0046] This sorting process is advantageous in that it captures as many impurities as possible that are generally visible to the naked eye. As those skilled in the art will understand, step c) is not defined as sorting all impurities, but rather as sorting at least partially. In the process of the present invention, the inorganic impurities are preferably metallic or mineral impurities, and more preferably metallic impurities.

[0047] For example, it is theoretically possible to perform the sorting in step c) manually, such as by using a conveyor belt. However, this would require a great deal of labor, especially in large-scale industrial scrap processing like the present invention, and is therefore uneconomical in most industrialized countries. Accordingly, in the process of the present invention, it is preferable to perform the sorting in step c) using one or more sorting devices, preferably automatic sorting devices.

[0048] The inventors of the present invention have identified, among numerous sorting processes, sorting processes particularly suitable for the process of the present invention. These suitable sorting processes include length sorting, air sorting, magnetic sorting, and sieving sorting. These sorting methods and the apparatus used are generally known to those skilled in the art.

[0049] To optimize the quality of the resulting scrap products, the inventors of the present invention propose combining multiple of these work processes. Accordingly, 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, and particularly preferably four or more, different work processes selected from the group consisting of length sorting, air sorting, magnetic sorting, and sieving sorting.

[0050] In previous experiments, the inventors of the present invention have found a configuration particularly suitable for the process and plant of the present invention, focusing on achieving the highest possible product quality of recycled scrap without considering cost-efficiency issues. In the inventors' opinion, the sorting of organic and / or metallic impurities in the process of the present invention preferably includes length sorting, preferably air sorting using an air sifter including multiple cascades, magnetic sorting, and sieving sorting, and is preferably carried out in this order. In magnetic sorting, it is preferable to use two or more magnetic separators, preferably electromagnets, and it is particularly preferable that the strength of the magnetic field of the electromagnets is adjustable.

[0051] A unique feature of the present invention's process is that the pre-purified material obtained in step c), i.e., the pulverized material from which organic and / or inorganic impurities have been at least partially removed, is analyzed in step d) using a first detection device.

[0052] At least one material information, preferably two or more, is detected. That is, the pre-purified material is automatically inspected after pre-purification. 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 pre-purified material. The material information may be, for example, spectroscopic measurements or optical images obtained from the pre-purified material.

[0053] Next, components of the pre-purified material are removed according to the material information detected in step d). That is, for example, if the first material information does not meet a predetermined standard or specification regarding, for example, chemical composition or shape, fractions contained in the purified material are removed based on the material information. Step d) of the process of the present invention refers to the entire removal process assisted by a detection device. As the detection device, any detection device known to those skilled in the art, particularly spectroscopic and optical detection devices, may be used.

[0054] As a result of the previous sorting, the number of destructive particles to be removed is usually relatively small, so at least theoretically, the removal in step d) seems easy to perform manually. In this case, if the first material information is displayed to the operator, for example, on a monitor or other interface, the operator can easily obtain information about the fractions to be removed in the pre-purified material. However, from the viewpoint of feasible material processing volume and especially sorting accuracy, it is clearly preferable to automate the sorting. The inventor has succeeded in finding a particularly high-performance device in his plant, for example, connected to the first detection device through a data processing device or network. The process of the present invention preferably performs the sorting in step d) using an automated device, preferably, for example, a rod-shaped compressed air gun with multiple compressed air nozzles or a robotic arm, and particularly preferably using a robotic arm.

[0055] In the process of the present invention, the purified material thus passes through a further detection device that detects at least one second material information, preferably two or more material information. In the present invention, this second material information is compared with the corresponding material information and the material standards assigned to each material information. That is, for example, values ​​measured by a spectroscopic formula are compared with a threshold, or the optically measured particle shape is compared with a template of an acceptable particle shape.

[0056] In the process of the present invention, the refined material is discharged as recycled scrap, i.e., as a product that can be transported, for example, to a suitable storage facility on a conveyor belt, only if the second material information meets the predetermined material standard to which it has been assigned. Otherwise, the refined material is either discarded, transported to a downstream plant for post-processing, or processed again by the process of the present invention, the latter of which is generally preferred. From the viewpoint of efficiency, it is advantageous to process the recycle rate in step c) or step d) without returning it to the crushing section. Therefore, in the process of the present invention, it is preferable to process the refined material in step b), step c), or step d) again if at least one piece of second material information does not meet the predetermined material standard.

[0057] The comparison is preferably performed using a data processing device, such as a computer. Therefore, in the process of the present invention, it is preferable to transmit and / or retrieve predetermined material criteria using a data processing device.

[0058] In the process of the present invention, it is preferable that the refined material is discharged as recycled scrap when all the second material information satisfies the predetermined material standards assigned to each of them.

[0059] The analysis of processes d) and e) shows many similarities.

[0060] For 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 perform the analysis of step d) and / or step e), preferably step d) and step e), continuously, particularly in line.

[0061] To achieve the most optimal material properties possible, particularly to simultaneously optimize iron content, organic impurity content, and / or particle shape, it has been proven to be especially advantageous for the first detection device and / or second detection device to independently detect multiple material information. Therefore, in the process of the present invention, it is preferable to detect at least two, preferably at least three, first material information in step d), and / or to detect at least two, preferably at least three second material information in step e). Furthermore, in the process of the present invention, it is also preferable that at least one first material information and / or at least one second material information, preferably all of the material information, correlate with the chemical composition and / or particle shape and / or mechanical properties of the analyzed material, preferably 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 correlates with the particle properties of the same material.

[0063] In the opinion of the inventors of the present invention, spatial and / or temporal decomposition for detection is particularly advantageous, depending on the configuration of other plants and whether the plants are operating continuously. Such decomposition is particularly advantageous in step d) because it allows for the precise removal of impurities and minimizes material waste. Such decomposition is also advantageous in step e) because the deviation from the material standard may be, for example, partial, and at least the purified fraction of the material may be discharged as recycled scrap. In the continuous or semi-continuous operation of the process, temporal decomposition can further correlate the material information with the respective fractions of recycled scrap discharged. 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, by spatial and / or temporal decomposition, and as a result obtain spatial and / or temporally decomposed profile information in each case. Similarly, in the process of the present invention, it is preferable to perform the analysis of steps d) and / or e), preferably steps d) and e), using a measurement method that decomposes spatially and temporally.

[0064] Furthermore, this preferred processing mode synergistically enables the simultaneous use of measured material information, particularly secondary material information, in the specifications, certificates, and certifications of the recycled scrap. This makes it possible to use the recycled scrap in applications where there are high demands for scrap products, especially for safety reasons.

[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, and more preferably to correlate these material information with at least one operational information, preferably one temporal information, so that each material information is assigned to the discharged recycled scrap. It is preferable to attach each material information to each fraction of the discharged recycled scrap using a certificate, preferably an electronic certificate.

[0066] Through experimentation, the inventors of the present invention were able to find particularly suitable detection methods and associated detection devices. These methods yield excellent purity, and it has been proven that using multiple methods for measurement in each case is particularly effective. In the process of the present invention, it is preferable to perform the analysis of steps d) and / or e), preferably steps d) and e), 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, and especially near-infrared absorption spectroscopy. X-ray fluorescence analysis is used, for example, to measure elemental content, and infrared / near-infrared absorption spectroscopy is used, for example, to measure organic content.

[0067] Basically, the same type of detection device can be used in steps d) and e), thereby enabling the detection of the same type of measured values ​​as first and second material information, or the acquisition of first and second material information in the same data format, such as an image. However, the inventors of the present invention have found that using different detection methods is particularly effective when used to detect material information correlated with the same material or particle properties. This makes it possible to minimize measurement errors and synergistically improve the accuracy of the process by compensating for the shortcomings of different methods. Therefore, in the process of the present invention, it is preferable to detect first and second material information using different detection methods, and preferably correlate first and second material information with the same material or particle properties.

[0068] As mentioned above, a major advantage of the process of the present invention is that it can obtain excellent results even in continuous operation, and thus realize a processing mode that is particularly time and cost efficient. Therefore, the process of the present invention is very preferably a continuous or semi-continuous process, and it is even more preferable that the crushed material and / or pre-refined material and / or refined material, preferably at least a portion of all of these materials, is transported using a conveyor belt and / or vibrating conveyor.

[0069] The process of the present invention advantageously enables the production of large quantities of recycled scrap exhibiting particularly favorable iron content, shape factor, and / or packing density with high reproducibility. Therefore, it is particularly advantageous to carry out the process of the present invention in a manner that achieves the corresponding parameters, thereby demonstrably providing advantages over 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, the average shape factor of the length ÷ width of the recycled scrap is preferably in the range of 1 to 5, preferably 1 to 2.5, and more preferably 1 to 1.25, and it is extremely preferable that the particles of the recycled scrap are substantially spherical.

[0073] In the process of the present invention, the packing density of recycled scrap is 1.0 t / m³. 3 Preferably 1.2 t / m 3 The above is particularly preferably 1.5 t / m 3 It is especially preferable that the above conditions are met.

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

[0075] The inventors of this invention have found particularly advantageous developments through the interaction of the invented process with the configuration of the process, starting from the invented process itself. Here, three so-called feedback mechanisms for controlling and optimizing the process are described.

[0076] The first two feedbacks utilize material information detected during scrap processing in the process of the present invention. Furthermore, 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 so-called first feedback, which controls the components of a heterogeneous iron-containing scrap mixture according to first material information and / or second material information, preferably first and second material information, and particularly preferably by changing the mass ratio of multiple iron-containing scrap fractions in the iron-containing scrap mixture.

[0078] This processing mode allows for proactive response to deviations in scrap characteristics, particularly chemical composition, and enables proactive control of raw material selection in the upstream part of the process. This is preferably done using a data processing device, preferably a neural network or equivalent artificial intelligence, preferably a data processing device utilizing a neural network. Furthermore, the data processing device used is preferably trained to change the mass ratio of multiple iron-containing scrap fractions in the production of heterogeneous iron-containing scrap mixtures as an appropriate correction method for the measured deviation when the deviation of material information from a corresponding predetermined target value, particularly a material standard, is recorded. Since the first material information is detected earlier in the process, it can be advantageous to perform this first feedback based on the first material information for a faster response.

[0079] The process of the present invention preferably includes so-called second feedback, which controls the grinding in step b) according to first material information and / or second material information, preferably first and second material information, and preferably by changing one or more operating parameters of the grinding unit selected from the group consisting of the size of the grinding chamber, the size of the discharge port that can be discharged in the discharge area, and the speed of the hammer rotor. The basic concept is the same as the first feedback, but 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 unit are controlled. In controlling the operating parameters of the grinding unit, the size of the particle discharge port is a suitable operating variable. Using this feedback is particularly effective when using the grinding unit of the present invention in the process of the present invention. In the control of step b), it is also preferable to use a data processing device, preferably a neural network or equivalent artificial intelligence, preferably a data processing device utilizing a neural network, which is trained to change the operating parameters of the grinding unit as an appropriate correction method for the measured deviation when a corresponding predetermined target value, particularly the deviation of the material information from the material standard, is recorded.

[0080] The final third feedback uses material information, but not material information detected during the additional processing stage, rather than during the process of the present invention. This detection is performed in essentially the same way as the detection of the first and second material information described above. This material information is detected from products obtained through recycling scrap processing, such as mixtures or converted products, and relates, for example, to material composition and strength. At least one piece of third material information is periodically provided to the operators of the process of the present invention from an external source, such as a customer who has received cooled scrap for converters.

[0081] The process of the present invention preferably includes so-called third feedback, which detects at least one third material information during the additional processing of recycled scrap and controls the components of the heterogeneous iron-containing scrap mixture, preferably the mass ratio of iron-containing scrap fractions in the heterogeneous iron-containing scrap mixture, preferably as described above, and / or the grinding in step b), preferably as described above, and / or the sorting in step c), according to the at least one third material information. 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 feedback, and particularly preferably includes first, second, and third feedback.

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

[0084] Furthermore, the present invention is A grinding unit for grinding a heterogeneous iron-containing scrap mixture, preferably the grinding unit of the present invention, A sorting means for separating organic matter and / or metallic impurities from crushed material, One or more first detection devices analyze the material obtained after sorting and detect first material information, An automatic removal means for automatically removing fractions from the material obtained after sorting according to the aforementioned first material information, One or more second detection devices analyze the material obtained after removal and detect second material information, The present invention relates to a scrap recycling plant preferably used in the process of the present invention, which includes a data processing device adapted to compare the second material information with a predetermined assigned material standard, and to discharge the material refined by the device as recycled scrap if the second material information satisfies the predetermined assigned material standard.

[0085] The plant of the present invention is advantageous because it is suitable for carrying out the process of the present invention. The plant of the present invention is particularly preferably to include additional components necessary for carrying out the process of the present invention in a preferred embodiment, in particular specific grinding units, sorting devices, detection devices, and data processing devices adapted to realize the first, second, and / or third feedback described above.

[0086] Finally, the present invention is A grinding chamber having at least one discharge area for the ground material, The present invention relates to a grinding unit for use in a process or plant of the present invention, which includes at least one hammer rotor installed in a grinding chamber and a movable element designed to control the outlet for the ground material from the grinding chamber that can be discharged in a discharge area. The grinding unit also preferably includes a movable substrate and / or cover plate, particularly preferably a hydraulically movable substrate and / or cover plate, which can change the outlet for the ground particles from the grinding chamber that can be discharged in a discharge area.

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

[0088] The grinding unit of this invention is optimized for use in the process of the present invention and is particularly preferred because it allows for the control of step b) as described above and the implementation of the second feedback mechanism to be particularly easy. Compared to the prior art, the grinding unit of the present invention can change the average residence time of particles in the grinding chamber even during operation, making it possible to change, for example, the particle size or the degree of purification of the processed scrap.

[0089] The grinding unit of the present invention is particularly preferable in which the grinding unit at the top of the grinding chamber has a first discharge area having a first movable element designed to control the discharge port of the ground material from the grinding chamber, which can be discharged in a first discharge area, and the grinding unit at the bottom of the grinding chamber has a second discharge area having a second movable element designed to control the discharge port of the ground material from the grinding chamber, which can be discharged in a second discharge area. This grinding unit of the present invention is particularly preferable because, for the first time from the inventor's knowledge, it is possible to realize a grinding unit that can be flexibly switched, that is, for example, to switch between a shredder and a zerdirator grinder even while in operation. For this reason, the grinding unit of the present invention is particularly preferable in which it 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, which combines one or more of the aforementioned preferred process features, it is extremely preferable that the grinding section includes a soundproof enclosure.

[0091] In the process of the present invention, which combines one or more of the aforementioned preferred process features, it is extremely preferable that the crushing section is fixed in the ground by a foundation.

[0092] In the process of the present invention, which combines one or more of the aforementioned preferred process features, it is extremely preferable to weigh the scrap mixture and / or the crushed material and / or the pre-refined material and / or the refined material.

[0093] In the process of the present invention, which combines one or more of the aforementioned preferred process features, it is extremely preferable to control the process by a control unit.

[0094] In the process of the present invention, which combines one or more of the aforementioned preferred process features, it is extremely preferable that an audible or visual alarm is issued in the event of an abnormality.

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

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

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

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

[0099] A plant of the present invention that combines one or more of the aforementioned preferred plant features is very preferably equipped with a signaling device and / or a warning device.

[0100] A plant of the present invention that combines one or more of the aforementioned preferred plant features is very preferably equipped with an emergency switch for shutting down the plant.

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

[0102] The plant of the present invention, which combines one or more of the aforementioned preferred plant features, most preferably includes a control unit for controlling the plant.

[0103] The plant of the present invention, which combines one or more of the aforementioned preferred plant features, is most preferably greater than 5m in total length, preferably greater than 10m, and more preferably greater than 15m.

[0104] The grinding section of the present invention, which combines one or more of the aforementioned preferred features of the grinding section, is very preferably equipped with a base, preferably a concrete base.

[0105] The grinding unit of the present invention, which combines one or more of the aforementioned preferred features of the grinding unit, most preferably includes a steel hammer.

[0106] The grinding unit of the present invention, which combines one or more of the aforementioned preferred features of a grinding unit, is very preferably equipped with an operating means.

[0107] The grinding unit of the present invention, which combines one or more of the aforementioned preferred grinding unit features, is most preferably greater than 100 kg and more preferably greater than 200 kg.

[0108] The grinding section of the present invention, which combines one or more of the aforementioned preferred grinding section features, is very preferably made of more than 75% steel by weight.

[0109] The following describes preferred embodiments of the process of the present invention and the plant used therefor, which the inventors of the present invention have found to be particularly advantageous. These preferred embodiments have a packing density of approximately 1.5 t / m³ of particles that are almost free of organic matter, have an iron content of 97%, are substantially spherical, i.e., have a shape factor of approximately 1 and a maximum particle diameter of approximately 80 mm. 3 This was discovered through comprehensive optimization that enables the large-scale industrial production of recycled scrap.

[0110] The processed materials are transported on a conveyor belt, allowing the process to operate as a continuous process.

[0111] The raw material produced is a heterogeneous mixture of iron-containing scrap. It is manufactured by mixing multiple iron-containing scrap fractions, such as white goods, factory-generated scrap, pre-shredder materials, and pressed used car bodies, at the feed port of the crushing section.

[0112] A heterogeneous mixture of iron-containing scrap is crushed in the crushing unit of the present invention shown in Figure 1. This crushing unit is equipped with a hydraulically movable substrate and cover plate, which can be used to change the discharge port of the crushed material from the crushing chamber. This allows control of the average residence time of particles in the crushing chamber and the average particle size of the crushed material. A movable substrate installed at the bottom of the crushing chamber closes the lower discharge area, allowing discharge only from the upper discharge area of ​​the crushing chamber. Therefore, the crushing unit of the present invention can operate as both a shredder and a zerdirator. In the experiments conducted, the crushing unit normally operates as a shredder.

[0113] The grinding section further includes a dry dust removal section containing multiple activated carbon filters.

[0114] The shredded material is passed through a sorting mechanism to separate organic and inorganic impurities from the pulverized material, thereby obtaining pre-purified material.

[0115] The sorting mechanism includes a series-arranged, general-purpose length sorter, a wind shifter with a three-stage cascade, two magnetic sorters with adjustable magnetic electromagnets, and sieves.

[0116] The material stream is analyzed by two primary detection devices. A camera detects information regarding the shape and size of fractions in the pre-purified material, and a continuous-operation near-infrared spectrometer measures material information that correlates with the chemical composition of the analyzed material. This spatially and temporally resolved material information is sent, under computer control, to a robotic sorting system that removes impurities / fractions identified as not meeting predetermined requirements based on the provided data, with sensor assistance.

[0117] Subsequently, the purified material is placed on a conveyor belt and passes through a region for further re-analysis. The detection equipment available here includes a continuous-operation near-infrared spectrometer as well as an X-ray fluorescence spectrometer, the latter providing supplementary information about the chemical composition (for example, re-verification of particle dimensions using a camera is not performed in this process, but may be performed). The information thus recorded is compared with assigned predetermined material criteria, in this embodiment selected organic and metallic impurities, particularly the presence or absence of copper, using a data processing device.

[0118] If all material standards are met, the finished material is discharged as recycled scrap and sent to storage via 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 linked to the corresponding batch using an electronic certificate. This electronic certificate can also be used by the customer later to authenticate scrap products for specific applications.

[0120] The plant in question is equipped with computer control means capable of performing process control according to different feedback, namely, detected material properties. In this embodiment, the operating parameters of the crushing section, more precisely the output in the discharge area and the adjustment of the movable substrate, were controlled according to first material information detected by a camera. The composition of the heterogeneous iron-containing scrap mixture was modified according to near-infrared / fluorescent X-ray measurements. In the current stage of development, this adaptation is carried out by visual instruction means for the excavator operator, which displays instructions on a screen indicating the amount of scrap fraction to be fed. However, an automated feeding system is required as a countermeasure.

[0121] The process and plant receive third-party material information from users of recycled materials and adapt to this information to control the operating parameters of the crushing section and the composition of the heterogeneous iron-containing scrap mixture. Currently, this feedback can only be verified with hypothetical experimental data because there are no actual users, but the plant adapts as per the present invention.

[0122] By continuously detecting material information, controlling processes based on this detection, and performing subsequent detections using the same detection method, a comprehensive dataset can be advantageously obtained. This allows for the training of neural networks to provide more accurate feedback and minimize the need for expert empirical knowledge.

[0123] The grinding unit of the present invention and its preferred embodiments will be described in more detail below with reference to the drawings. Figure 1 is a schematic cross-sectional view showing a preferred embodiment of the grinding unit of the present invention. [Brief explanation of the drawing]

[0124] [Figure 1] Figure 1 is an example of a schematic cross-sectional view of a suitable grinding section 10 of the present invention.

[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 crushing chamber 12 includes an inlet opening 22, and for example, the scrap mixture supplied by the conveyor belt 18a is fed into the crushing chamber 12 through the inlet opening 22. Furthermore, the crushing chamber 12 includes two discharge areas 14a and 14b.

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

[0127] In Figure 1, the mobility of the movable elements 20a and 20b is indicated by double-headed arrows. The discharge areas 14a and 14b are each covered with iron grates to prevent excessive particles from being released from the grinding chamber 12. Preferably, the iron grates in the discharge areas 14a and 14b may have an adjustable mesh size and / or be reversibly and nondestructively replaceable.

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

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

[0130] 10. Grinding section 12. Grinding Chamber 14a, 14b discharge area 16 rotors 18a~18c Conveyor belt 20a, 20b Movable elements 22 Entrance opening

Claims

1. a) A process for manufacturing or supplying heterogeneous iron-containing scrap mixtures, b) A grinding step in which the heterogeneous iron-containing scrap mixture is ground in the grinding section (10) to obtain ground material, c) A sorting step to obtain a pre-purified material by separating organic and / or inorganic impurities from the crushed material by two or more different work processes selected from the group consisting of length sorting, air sorting, magnetic sorting, and sieving sorting, d) Analysis of the pre-purified material by one or more first detection devices to detect at least one first material information, and an analysis and removal process by an automated device to obtain a purified material by removing components of the pre-purified material based on the first material information, e) An analysis step of analyzing the purified material using one or more second detection devices and detecting at least one piece of 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, If the second material information satisfies the assigned predetermined material criteria, the refined material is removed as recycled scrap. The aforementioned crushing unit (10) A grinding chamber (12) having at least one discharge area among the first discharge area (14a) and the second discharge area (14b) of the ground material, It includes at least one rotor (16) which is installed in the grinding chamber (12) and has a hammer, The grinding unit (10) includes a movable element designed to control the discharge area of ​​the ground material from the grinding chamber (12) that is available within the discharge area, A process for producing recycled scrap, wherein the crushing step in step b) is controlled by the first material information and / or the second material information.

2. Using spatial and / or temporal decomposition, spatial and / or temporally decomposed profile information is detected and analyzed, and / or, The process according to claim 1, wherein the analysis in step d) and / or step e) is performed by one or more different methods selected from the group consisting of X-ray fluorescence analysis, optical image recognition, and infrared absorption spectroscopy.

3. The process according to claim 1, wherein the components of the heterogeneous iron-containing scrap mixture are controlled by the first material information and / or the second material information.

4. The process according to claim 1, wherein in the additional processing of the recycled scrap, at least one third material information is detected, and based on the at least one third material information, the components of the heterogeneous iron-containing scrap mixture and / or the crushing step in step b) and / or the sorting step in step c) are controlled.

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

6. A pulverizing section (10) for pulverizing a heterogeneous mixture of iron-containing scrap, A sorting means for separating organic matter and / or metallic impurities from the pulverized material. One or more first detection devices analyze the material obtained after the aforementioned sorting and detect first material information, An 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 analyze the material obtained after the aforementioned removal and detect second material information, The system includes 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 recycled scrap if the second material information satisfies the assigned predetermined material standard. Used in the process described in claim 1, A scrap recycling plant.

7. A grinding unit (10) for grinding a material, Used in the process described in claim 1 or the plant described in claim 6, Grinding chamber (12) and Installed within the aforementioned crushing chamber (12), at least one rotor (16) equipped with a hammer, A first discharge area (14a) and a second discharge area (14b) for discharging the crushed material from the crushing chamber (12), and at least one of these discharge areas, The system comprises movable elements (20a, 20b) designed to control the discharge area of ​​the pulverized material from the pulverizing chamber (12) in at least one of the discharge areas, The first discharge area (14a) is located above the crushing chamber (12), The aforementioned movable elements (20a, 20b) A first movable element (20a) is designed to control the discharge area of ​​the pulverized material from the pulverizing chamber (12) that is available in the first discharge area (14a), The second movable element (20b) is located in the second discharge area (14b) at the bottom of the grinding chamber (12) and is designed to control the discharge of the ground material from the grinding chamber (12). Crushing section (10).

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