Method for sorting steel-containing scrap

Abstract

The invention relates to a method for sorting steel-containing scrap, in particular scrap from end-of-life vehicles, comprising the steps of: - providing shredded steel-containing scrap filtered by means of a magnetic device (4), in particular from shredded end-of-life vehicles, said scrap containing a plurality of scrap constituents; - sorting the scrap constituents into at least two scrap fractions according to a minimum size of the scrap constituents; - outputting the scrap constituents according to their scrap fraction.

Description

[0001] 24-0776 DE

[0002] Method for sorting steel scrap

[0003] The invention relates to a method for sorting scrap metal comprising steel, in particular scrap metal from end-of-life vehicles.

[0004] Methods for producing scrap, particularly from end-of-life vehicles, and for sorting scrap components are generally known from the prior art. For example, such scrap, such as vehicle bodies from end-of-life vehicles and other products, is first shredded to break down the products for the recovery of scrap components. To separate scrap components from one another, especially ferrous components, particularly steel, from the other components, it is known to use a magnetic device that magnetically separates the scrap components by attracting only magnetic components to the magnetic device.

[0005] Since even during magnetic separation, scrap components that do not contain steel or are not steel can still adhere to, cling to, or rest on the steel-containing scrap components, purely magnetic separation of the scrap components is usually only suitable for producing scrap of scrap class E40. However, it is also known that scrap from scrap class E40 is not suitable for reuse in high-quality steel grades (e.g., flat steel) in larger quantities due to undesirable accompanying elements. Therefore, the proportion of these accompanying elements or the undesirable scrap components, such as copper, would have to be reduced from such scrap, for example, scrap class E40, before further use.For example, the aim is to increase the secondary raw material quota, especially for steel, in order to increase overall sustainability with regard to the recycling of scrap, particularly from end-of-life vehicles.

[0006] However, this is a very complex process that requires, for example, manual separation and sorting of the scrap components and may necessitate the use of sophisticated sensors capable of separating or distinguishing scrap components containing steel from those that do not. Since this procedure is too costly for the entire batch of scrap (24-0776 DE) or the throughput is correspondingly too low, such scrap processing is largely avoided.

[0007] This means, for example, that scrap obtained through purely magnetic separation, such as that in scrap class E40, cannot be used for the manufacture of motor vehicles, or can only be used to a limited extent for the production of certain vehicle parts. Since dedicated shredding campaigns for end-of-life vehicles are not usually conducted, the scrap, for example as mixed scrap, also contains other used appliances and the like. Such mixed scrap, or ballast of scrap class E40 obtained through magnetic separation, is therefore currently only typically reused for applications with lower purity requirements.

[0008] The invention is based on the objective of providing an improved method for sorting scrap containing steel, in which, in particular, the sorting or separation of scrap components containing steel from scrap components not containing steel is improved.

[0009] The problem is solved by a method according to claim 1. The dependent claims relate to possible embodiments.

[0010] As described, the invention relates to a method for sorting scrap containing steel, in particular scrap from end-of-life vehicles. As already described, a specific quantity or volume of scrap can be sorted to recover the scrap components that include steel. Specifically, all other unwanted scrap components, for example, copper, are to be sorted out so that they can potentially be used for other applications. The scrap can, in principle, be of any origin, for example, including consumer products, used appliances, and the like. Specifically, end-of-life vehicles can be present in the scrap, or end-of-life vehicles can form the basis for the production of the scrap that is to be sorted in the method described herein.

[0011] The invention specifically proposes that the method comprises the following steps: 24-0776 DE

[0012] Provision of scrap consisting of shredded and filtered steel using a magnetic device, in particular from shredded end-of-life vehicles, which scrap comprises several scrap components;

[0013] Sorting of the scrap components into at least two scrap fractions depending on a minimum size of the scrap components;

[0014] The output of scrap components depends on their scrap fraction.

[0015] The first step of the process involves providing pre-sorted scrap metal containing steel. As described, this scrap can be obtained from end-of-life vehicles or any other products. The scrap is obtained by shredding, meaning the products are fed into a shredding machine and reduced in size. The resulting scrap is then separated using a magnetic device. This makes it possible to separate or remove ferrous or steel components from the entire scrap. Advantageously, the process utilizes pre-shredded and pre-sorted scrap, ensuring that other scrap components, such as plastics, are at least partially removed.

[0016] As described at the beginning, sorting solely using the magnetic device can lead to scrap components that, while not containing steel, are attached to, clinging to, or resting on other scrap components. During magnetic separation, these components are attracted to the magnetic device along with the scrap components that do contain steel. The present process aims to reduce these unwanted scrap components.

[0017] The provided scrap is sorted using the method described herein, in which the scrap components are sorted into at least two scrap fractions, namely depending on a minimum size of the scrap components. The minimum size can be defined largely arbitrarily and can ensure that scrap components below the minimum size are sorted into an undesired scrap fraction or a second or third scrap fraction, and scrap components above the minimum size are sorted into a second or third scrap fraction.

[0018] The minimum size is determined by sorting into a desired scrap fraction or a first scrap fraction. The scrap components are then output according to their scrap fraction. This means that the first scrap fraction can be used for a first application, the second scrap fraction for a second application, and so on.

[0019] The minimum size can refer to any dimensions of the components, in particular the largest dimension within each component. The minimum size can also refer, for example, to an average diameter or length, an average width, or an average height.

[0020] The invention is based in particular on the realization that it is not necessary to carry out manual sorting or to use complex sensors for sorting the scrap components into the different scrap fractions. Instead, it was recognized that the sorting of scrap components containing steel from those not containing steel can be carried out depending on the minimum size of the scrap components. This is primarily because scrap components containing steel form larger, cohesive pieces during the shredding process, i.e., during comminution. In contrast, scrap components not containing steel are shredded into comparatively smaller pieces.For example, screws, copper cables, wires, and the like are typically shredded into smaller pieces due to their differing mechanical properties; these pieces may even fall below the minimum size requirement. Scrap components containing steel, such as body parts, doors, flaps, and the like, form larger, cohesive pieces in the shredding process due to their mechanical properties, and these pieces exceed the minimum size requirement.

[0021] Thus, a relatively simple mechanical sorting process allows all scrap metal, or its components, to be sorted according to size. The second or third scrap fraction, containing components below the minimum size, represents those components that are separated from the rest of the scrap to make it higher-quality or purer. The components of the first scrap fraction, which are larger than the minimum size, therefore constitute the remaining scrap, which contains a comparatively high amount of steel (24-0776 DE) and is therefore purer than the second or third scrap fraction. This allows, in particular, the production of a higher-quality scrap fraction through sorting based on the minimum size, which can be used especially for the manufacture of motor vehicles.This allows, in particular, that lower-grade scrap, for example of scrap class E40, can be supplied to the process and, through sorting based on the minimum size, a scrap fraction consisting of unwanted components, the second or third scrap fraction described above, and a high-quality scrap fraction, namely the first scrap fraction described above, can be obtained.

[0022] In a further development of the process, it can be provided that the scrap is sorted into at least two scrap fractions by means of sieving, in particular mechanical sieving. The sieve has, for example, a mesh size corresponding to the minimum size. Scrap components smaller than the minimum size, such as screws, cable pieces, and the like, will therefore fall through or be moved through the sieve, while the higher-value scrap components larger than the minimum size can be retained by the sieve. This means that only the unwanted scrap components of the second and third scrap fractions can pass through the sieve, whereas the higher-value scrap components of the first scrap fraction, which are to be recovered, remain in the sieve. Sieving thus enables a comparatively simple sorting of the at least two scrap fractions.

[0023] In general, all scrap metal or scrap components can be sorted into more than two or three scrap fractions. For this purpose, various minimum sizes of the scrap components can be defined, and these can be separated from each other, for example, by sieving with different sieve sizes, particularly mesh widths.

[0024] In one embodiment of the method, at least a first minimum size for sorting a first scrap fraction may be at least 150 mm, in particular 200 mm to 300 mm. The minimum size can be adjusted largely arbitrarily, depending on how the shredding process is carried out, for example, the size of the scrap components to be recovered by the method, such as those considered high-quality (see DE 24-0776). In principle, it is possible to adjust all minimum sizes described herein, whereby increasing the minimum size for a specific scrap fraction allows for the recovery of a higher steel content or purer scrap, while reducing the minimum size potentially allows for the inclusion of more undesirable scrap components.Due to the initial minimum size, the first scrap fraction can be selected in such a way that, due to its mechanical properties, especially steel or sheet steel, it leaves the shredding process with a larger piece size or grain size and thus exceeds the minimum size and can therefore be sorted out and retained.

[0025] In a further embodiment of the method, at least a second minimum size for sorting a second scrap fraction can be at least 50 mm, in particular 100 mm to 150 mm. Sorting into the different scrap fractions allows for classification based on the minimum size, i.e., based on the size of the scrap components. For example, the individual sorting steps or screening processes can be carried out sequentially. This allows the individual scrap fractions to be separated from each other according to their size, thus improving the reuse of steel scrap.

[0026] This allows, in particular, the direct use of the first scrap fraction, which, for example, can make up 80% of the total scrap by mass. The subsequent scrap fractions, in contrast, can have significantly lower mass proportions; for example, the second scrap fraction might only comprise 15% by mass. The first scrap fraction can be used directly, for example, in automotive manufacturing. The second scrap fraction can be further sorted or upgraded through additional processes. Since its mass proportion is significantly lower, the effort required for manual sorting, for example, is considerably less.

[0027] Furthermore, the process may stipulate that at least a third minimum size for sorting a third scrap fraction is at least 20 mm, in particular 30 mm to 50 mm. This third scrap fraction thus comprises the scrap components with the smallest piece sizes or grain sizes. As described, depending on the third minimum size, it can be determined how many scrap components are to be sorted out or how many scrap components are to be admitted to the corresponding higher-value scrap fraction. In principle, any minimum size between 20 mm and 50 mm can be specified, for example, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, or 50 mm.It is also possible to sort exclusively based on the first minimum size and the second minimum size, the first minimum size and the third minimum size, or exclusively based on the second minimum size and the third minimum size.

[0028] As described at the outset, the scrap to be sorted in the process described herein is typically scrap obtained by shredding and magnetic separation using a magnetic device. In one embodiment of the process, this process step can be carried out within the process described herein. This means that, in one embodiment, providing the scrap includes shredding at least one end-of-life vehicle and / or magnetic separation of the shredded vehicle. Therefore, within the process, the scrap can be obtained directly, or products, i.e., end-of-life vehicles, waste electrical and electronic equipment (WEEE), and the like, can be processed into the scrap to be provided to the process. For this purpose, at least one product, for example, an end-of-life vehicle, can be shredded. Subsequently, it is possible to separate the shredded vehicle by means of magnetic separation, i.e.,In particular, it can be separated using a magnetic device. The scrap obtained in this way is then separated into at least two scrap fractions based on the minimum size, as described above.

[0029] As previously described, this is achieved, for example, using a sieve. In particular, several sieves can be provided for multiple minimum sizes. In one embodiment of the method, at least one sieve can be combined with a magnetic separating element. The magnetic separating element is, for example, part of the magnetic device and is configured to generate a magnetic field to magnetically attract scrap components containing steel. As already described, the sieve retains scrap components that exceed the minimum size defined by the sieve. In other words, the magnetic separation of the scrap components containing steel from those that do not can first be carried out magnetically, and then, by using the sieve, only those scrap components larger than the minimum size can be retained in the sieve.

[0030] A screening device can be used to sieve the scrap components and sort them into individual scrap fractions. The screening device can, for example, be part of a system for sorting steel scrap. The screening device can include at least one screen. In particular, the screening device can also include several screens arranged one behind the other in the direction of material flow. The screens of the screening device have, in particular, different screen sizes or mesh sizes so that all the scrap can be screened in the direction of material flow. The resulting scrap fractions can then be fed into various further processes. Specifically, it can be provided that the first scrap fraction, for example, with particle sizes or grain sizes above the first or second minimum size, i.e., larger than 150 mm, can be fed directly into a further manufacturing process.

[0031] At least one scrap fraction can be post-treated to increase its steel content. As previously described, this post-treatment can be carried out using manual sorting and / or at least one sensor system. Specifically, the second and / or third scrap fraction, i.e., those with particle sizes or grain sizes smaller than 150 mm, particularly smaller than 80 mm (e.g., 50 mm), can be post-treated. The third scrap fraction represents a significantly smaller mass fraction than the other scrap fractions, for example, around 5%. This means that the effort required for manual or sensor-based sorting is considerably less than if all the scrap were sorted in this way. Furthermore, it is also possible to feed the third scrap fraction into another process, for example, where its high proportion of accompanying elements or alloying elements can be utilized.For example, depending on the process, copper or aluminum can be further recycled in such a different process.

[0032] Overall, it turns out that sorting based on the minimum size can significantly increase the total throughput of the plant, since, for example, less than 20% of the total scrap requires further treatment (e.g., 24-0776 DE), or 15% can be retreated (i.e., the second scrap fraction), and the remaining 5% of the third scrap fraction can be reused or disposed of.

[0033] In addition to the method for sorting scrap containing steel, the invention relates to a method for manufacturing a motor vehicle, wherein at least a part of the motor vehicle, in particular a body section, for example an outer skin section, and / or a door section and / or a flap section, is manufactured from a material obtained by the method described above. In particular, the first scrap fraction obtained as described above can be used to manufacture at least one part of the motor vehicle. This makes it possible to return the recovered scrap to the automotive sector.

[0034] In particular, it is also possible for the material obtained from the previously described process to be used as an additive or aggregate. For example, at least one part of the motor vehicle can be manufactured only partially from the material obtained using the described process. For instance, a defined percentage, say 30%, of such a part can be manufactured with material sorted from steel scrap, for example, as the first scrap fraction.

[0035] Furthermore, the invention relates to a plant for processing steel scrap, in particular scrap from end-of-life vehicles, wherein the plant is configured to carry out the previously described method for manufacturing a motor vehicle and / or for carrying out the previously described method for sorting steel scrap. The plant can have at least one screening device configured to sort the scrap components as described above and to classify them accordingly into at least two scrap fractions. Alternatively or additionally, the plant can be configured to use scrap provided in this way, i.e., the scrap fractions sorted according to the previously described method, for manufacturing parts of motor vehicles. The plant can determine the proportion of the first scrap fraction obtained by the previously described method. It is also possible that at least one 24-0776 DE

[0036] Part of the motor vehicle is manufactured entirely from the first scrap fraction described above.

[0037] All advantages, details, designs and / or features described in relation to the process for sorting steel scrap are fully transferable to the process for manufacturing a motor vehicle and the plant for processing steel scrap, and vice versa.

[0038] The invention is explained with reference to exemplary embodiments and the figures. The figures are schematic representations and show:

[0039] Fig. 1 shows a schematic representation of a plant for processing steel-containing scrap according to an exemplary embodiment; and

[0040] Fig. 2 shows a schematic representation of a method for sorting steel scrap according to an exemplary embodiment.

[0041] Fig. 1 schematically shows a plant 1 designed for processing scrap containing steel, for example, scrap from end-of-life vehicles and / or equipment. In principle, plant 1 can be designed to process any scrap containing steel, regardless of the source material. Plant 1 can optionally be configured for sorting the scrap and / or for manufacturing a product, in particular a motor vehicle part, from a scrap fraction obtained by sorting the scrap.

[0042] Annex 1 includes a manufacturing device 2 to which a scrap fraction, in particular a first scrap fraction, can be supplied, from which at least one part of the motor vehicle, for example a body section and / or a door section and / or a flap section, can be extracted. The scrap fraction can, in particular, be supplied by a sorting device 3. For example, scrap is supplied to the sorting device 3 by a magnetic device 4, which in turn can receive shredded scrap from a shredding device 5. 24-0776 DE

[0043] In other words, the shredding process for old products, such as end-of-life vehicles, can take place in the shredding device 5. The resulting scrap, which contains steel, can be separated using the magnetic device 4. However, components such as screws, cables, and the like remain in the scrap. These components do not contain steel or only high-alloy steel, but adhere to or rest on the other scrap components that do contain steel. To remove these, the sorting device 3 is used to separate an initial scrap fraction from the total scrap obtained from the magnetic device 4. This initial scrap fraction can then be used in the manufacturing device 2 for production. As described, the sorting device 3 can also be supplied with already shredded and pre-sorted scrap, for example, from scrap class E40.The magnetic device 4 and the shredder 5 are therefore optional in system 1. If system 1 is only to be used for sorting, all devices except the sorting device 3 can be omitted. If system 1 is only to be used for production, the sorting device 3, the magnetic device 4, and the shredder 5 can be omitted. The first scrap fraction can be provided to the production device 2 already sorted by means of a sorting device 3.

[0044] The method for sorting steel scrap is subsequently explained by way of example with reference to blocks 6-9 in relation to Fig. 2. The described method can be carried out, in particular, on the system 1, for example on the sorting device 3, or the material can be supplied using the magnetic device 4 and shredder 5. An optional subsequent manufacturing process can be carried out, as already described, with the manufacturing device 2.

[0045] The process can start in Block 6, where scrap containing steel is provided. The scrap can be sourced from any supplier or, for example, shredded using a shredder 5 and pre-separated or pre-sorted with a magnetic device 4. Although the magnetic device 4 ensures that magnetic components, i.e., ferrous or steel-containing scrap components, can be separated from other scrap components, unwanted scrap components may still be present in the scrap provided in Block 6 due to adhesion, sticking, or similar factors. For example, scrap of scrap class E40 may be provided in Block 6.

[0046] The supplied scrap is then sorted in block 7. This is done, for example, in the sorting device 3 described above. The sorting device 3 can have at least one screen with a specific mesh size. More than one screen, for example, several screens, can be used. Based on the minimum size determined by the screen, the scrap components are sorted into at least two scrap fractions. For example, a first scrap fraction can include scrap components that exceed a minimum size, for example, larger than 100 mm, specifically larger than 150 mm up to 300 mm. Due to the specific behavior of steel scrap, such as body panels, during the shredding process, these components have a larger particle size compared to other scrap components.

[0047] Furthermore, it is possible, for example by using several sieves, to sort at least a second scrap fraction whose scrap components exceed a second minimum size, for example at least 50 mm, in particular 80 mm to 100 mm.

[0048] Optionally, a defined scrap fraction can be sorted that falls below a third minimum size, meaning that the scrap components of the third scrap fraction are at most 50 mm, specifically at most 30 mm, for example, smaller than 20 mm. Here, a dimension in one direction is sufficient; that is, scrap components are assigned to the first scrap fraction if they are larger than 100 mm in at least one direction.

[0049] In block 8, the different scrap fractions can then be output. Besides their piece size, the different scrap fractions also differ in their steel content, particularly in the proportion of differently alloyed steel and the level of contamination from non-steel components. As described, the third scrap fraction has the lowest steel content, as it consists, for example, exclusively of screws, bolts, cables, and similar items that break or snap during the shredding process. The second scrap fraction, in contrast, can have a higher steel content. The first scrap fraction represents the purest scrap fraction in terms of steel content, containing the highest percentage. In particular, it may be possible to directly feed the first scrap fraction into a recycling process for use in manufacturing.

[0050] The discharged scrap fractions can optionally be fed into a further process step in Block 9. For example, the first scrap fraction, as already described, can be fed into a manufacturing process in Block 9 for the production of at least one part for a motor vehicle. It is also possible for the first scrap fraction to be added, meaning that the part is not manufactured exclusively from the first scrap fraction.

[0051] Furthermore, in block 9, at least one scrap fraction can undergo further processing. For example, the second scrap fraction can be further sorted by manual sorting and / or sensor selection. Since this fraction constitutes only a small proportion of the total scrap, for example, 15%, the overall effort required for manual and / or sensor selection is significantly reduced compared to applying it to the entire scrap. Alternatively, the second scrap fraction can be fed into a different process with less stringent requirements.

[0052] The third scrap fraction can be directly fed into another process, for example, one in which the alloy material or accompanying material present can be recycled. Advantageously, the largest mass fraction, for example 80%, represented by the first scrap fraction, can thus be directly sorted from the total scrap. This eliminates the need for complex manual or sensor-based sorting; instead, the selection is based solely on minimum size, for example, through a relatively simple sieving process.

[0053] As described, Plant 1 can be used to carry out the processes described herein. As described, scrap metal comprising steel can be supplied to Plant 1. Alternatively, namely when the shredding device 5 and the magnetic device 4 of Plant 1 are not present, but Plant 1 receives scrap metal directly, for example of scrap class E40, the sorting device 3 can be used to sort this scrap metal. Likewise, the process described with reference to Fig. 2 can be carried out on Plant 1.

[0054] The advantages, details and features described in relation to the individual embodiments can be combined, interchanged and transferred to one another as desired.

[0055] 24-0776 DE

[0056] REFERENCE MARK LIST

[0057] 1 Annex

[0058] 2 Manufacturing device 3 Sorting device

[0059] 4 Magnetic device

[0060] 5 shredder device

[0061] 6-9 Block

Claims

24-0776 DE REQUIREMENTS 1. Method for sorting steel-containing scrap, in particular scrap from end-of-life vehicles, comprising the steps: Provision of scrap consisting of shredded and filtered steel by means of a magnetic device (4), in particular from shredded end-of-life vehicles, which scrap comprises several scrap components; Sorting of scrap components into at least two scrap fractions depending on a minimum size of the scrap components; The output of scrap components depends on their scrap fraction.

2. Method according to claim 1, characterized in that the scrap is sorted into at least two scrap fractions by means of sieving, in particular mechanical sieving.

3. Method according to claim 1 or 2, characterized in that at least one first minimum size for sorting a first scrap fraction is at least 100mm, in particular 150mm - 300mm.

4. Method according to one of the preceding claims, characterized in that at least a second minimum size for sorting a second scrap fraction is at least 50mm, in particular 80mm - 100mm.

5. Method according to one of the preceding claims, characterized in that at least a third minimum size for sorting a third scrap fraction is at least 20mm, in particular 30mm - 50mm.

6. Method according to one of the preceding claims, characterized in that the provision of the scrap comprises shredding at least one end-of-life vehicle and / or magnetic separation of the shredded end-of-life vehicle.

7. Method according to one of the preceding claims, characterized in that at least one sieve is combined with a magnetic separating element, 24-0776 DE in particular the magnetic separating element to which at least one sieve is connected.

8. Method according to one of the preceding claims, characterized in that at least one scrap fraction is post-treated to increase the steel content.

9. Method for manufacturing a motor vehicle, characterized in that at least a part of the motor vehicle, in particular a body section and / or a door section and / or a flap section, is manufactured from a material obtained by a method according to one of the preceding claims.

10. Plant (1) for processing scrap comprising steel, in particular scrap from end-of-life vehicles, characterized in that the plant is designed for carrying out a method according to one of the preceding claims.

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