Dry Air Separation for Copper Recovery from Shredder Residue

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Solution Overview

Problem

Current methods for recycling non-ferrous metals, such as copper wire, from waste streams are labor-intensive and costly, often requiring manual sorting and wet processes that generate waste and are not economically sustainable, especially for materials like copper wiring in automobile shredder residue and electronic waste.

Innovation Solution

A dry processing system utilizing air separators and vacuum pressure separators to separate and concentrate non-ferrous metals, including copper wire, by segregating materials into different size fractions and using magnetic and electrostatic separation techniques to achieve high concentrations of metals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual sorting is used to recover copper wire and non-ferrous metals, then labor flexibility is maintained, but labor costs become prohibitively high and economic sustainability is compromised

Engineering Contradiction:

Improveeconomic sustainabilityVSAvoidautomation level

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The patent replaces manual mechanical sorting with automated detection systems including X-ray fluorescence (XRF) sensors, optical sensors, and metal detectors that automatically identify and sort non-ferrous metals and copper wire from shredded materials, eliminating the need for manual labor while maintaining high recovery efficiency

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent employs pneumatic delivery systems and air streams to transport sorted materials through the processing line and deliver separated non-ferrous metals to collection bins, replacing manual material handling with automated pneumatic conveyance

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Measurement precision

If wet processes are used to separate and recover metals from waste streams, then separation effectiveness is improved, but water consumption increases and waste sludge is generated

Engineering Contradiction:

Improveseparation effectivenessVSAvoidwaste sludge

Core Design Contradiction:

Measurement precisionVSLoss of substance

Solution Approach 1:

The patent replaces wet chemical and hydraulic separation processes with dry mechanical separation systems including screens, eddy current separators, and magnetic separators that achieve effective metal recovery without water consumption or sludge generation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the separation parameter from wet chemical properties to dry physical properties such as density, magnetic susceptibility, and electrical conductivity, enabling effective separation without water or chemical agents

Inventive Principle:

Principle #35Parameter changes

3Productivity

If traditional recycling processes are used for automobile shredder residue, then ferrous metals are recovered, but non-ferrous metals including copper wire remain in the residue and are disposed of in landfills

Engineering Contradiction:

Improvematerial recovery rateVSAvoidnon-ferrous metal content

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent employs X-ray fluorescence (XRF) sensors and optical detectors that provide real-time feedback on the composition of shredded materials, enabling the control system to adjust separation parameters and maximize recovery of non-ferrous metals while minimizing contamination in the residue stream

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary detection and sorting of non-ferrous metals before final residue disposal, using metal detectors and sensors to identify and separate valuable materials from the waste stream, ensuring high recovery rates before the remaining residue is sent to landfill

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables cost-effective and efficient recovery of non-ferrous metals with high concentrations, reducing landfill waste and operational costs by automating the sorting process and minimizing water usage.

Implementation Method 1

processing the received waste stream with a closed-loop air separator to separate the waste stream into a light fraction waste stream and a heavy fraction waste stream

Methodology Applied

Scientific EffectDensity separation: Density Gradient

Implementation Method 2

processing the heavy fraction waste stream in a vacuum pressure separator to increase the concentration of non-ferrous metals in the heavy fraction waste stream

Methodology Applied

Scientific EffectVacuum pressure separation: Pressure Gradient

Data Source

PatentUS9764361B2Processing a waste stream by separating and recovering wire and other metal from processed recycled materials

Publication Date: 2017.09.19 TAV HLDG

AI summary

Processing waste materials to recover valuable metals, such as copper, from the materials. Waste materials are further refined to concentrate the metallic material after the waste materials are initially processed. Processes include employing air separation and screening. Processes also include employing a dynamic sensor and a vacuum pressure separator to separate metals from other materials. A central processing facility may process metal concentrate from multiple concentration facilities.