Tag Archives: disposal

Environment Energy

Rotor Impact Mill turns previously unusable automotive shredder residue into a valuable resource

Recovering metals from fine shredder fractions: Non-ferrous metal fractions become usable thanks to enhanced processing.

Rotor Impact Mill turns previously unusable automotive shredder residue into a valuable resource

The BHS Rotor Impact Mill of type RPMV is shown in the center

Kajaanin Romu Oy operates one of Finland“s most advanced plants for recycling scrap in the town of Kajaani, located approximately 500 km northeast of Helsinki. The company recently commissioned a BHS-Sonthofen plant for processing automotive shredder residue (ASR) fine fractions of particle sizes between 0 and 30 mm. It separates the feed material abundant with valuable metals into „light“ and „heavy“ fractions in a single pass. This allows the plant operators to economically produce fractions that can be sold profitably. Moreover, the plant significantly reduces the cost of material disposal at landfills.

Experience with operating shredders in the context of recycling has proven time and again that heavy non-ferrous fractions of material left over after shredding and processing large automotive, electrical or electronic scrap components still hold value. A metric ton can contain up to 20 grams of gold and up to 300 grams of silver, as well as platinum and other precious and non-ferrous metals.

Operators report that they are able to earn about EUR 3,000 per metric ton just from selling the heavy fraction of non-ferrous metals. BHS has taken improved fine fraction processing even further by integrating secondary cleaning of metals into the processing stage. This allows Finnish operator Kajaanin Romu Oy to unlock the value of reusable materials present in the ASR fine fraction. The system delivers a throughput of around 10 metric tons per hour.

At the end of the process, even the non-ferrous metal fractions are cleanly separated in silos. This includes heavy ones such as copper, gold and silver as well as light fractions such as aluminum. Presently, the proportion of salable non-ferrous metals amounts to about five to seven percent of the processed volume.

BHS-Sonthofen ASR systems do not only process fine fractions from automotive shredders. They are also suitable for processing waste incineration plant slag and electronics scrap. This means that recycling companies can adapt their product portfolio to meet increasing requirements: The higher the proportion of electronic components and platinum in vehicles and electronic devices, the greater the volume of valuable substances that can be extracted for reuse.

The technology in detail

The plant installed at Kajaanin Romu is fed fine fractions with a particle size of under 30 mm from the automotive shredder. In other words, it processes fractions that could not be used prior to introducing this system. The Rotor Impact Mill of type RPMV 1513 – a system uniquely offered by BHS-Sonthofen – crushes the material and separates it. In doing so, it works selectively, finely crushing brittle materials such as mineral substances, glass and castings and separating composites. Elastic materials such as rubber, on the other hand, remain intact.

The metals can be reclaimed since the Rotor Impact Mill shapes the pliable metals into balls. This is necessary in order for non-ferrous metals to be cleanly separated from other materials in the downstream process. The material, which is often long and flat when inserted into the mill, has to be compact and as round as possible to enable separation of the non-ferrous metal pieces.

Following this step, the material passes through a hopper into a screening machine that separates it into three fractions of 0 to 3, 3 to 6, and 6 to 12 mm. Each of these is separated into „heavy“ and „light“ through density separation. The heavy material that contains the metallic components is further separated into magnetic and non-magnetic metallic fractions using magnetic separators.

In the final processing stage, non-ferrous metals are separated into heavy (e.g., copper, gold and silver) and light (e.g., aluminum) fractions.

Moreover, the plant also generates a light fraction that primarily consists of plastic parts. This fraction is suitable for thermal utilization and does not need to be disposed of at landfills.

About BHS-Sonthofen GmbH

BHS-Sonthofen GmbH is an owner-operated group of companies in the field of machinery and plant engineering based in Sonthofen, Germany. The company offers technical solutions for mechanical process technology, concentrating primarily on mixing, crushing, recycling and filtration. BHS-Sonthofen has a global presence, with more than 350 employees and several subsidiaries.

The Recycling Technology division offers a broad range of machines and plants for the recycling industry. The product portfolio comprises recycling machines for processing and pre-/post-shredding a diverse range of recyclable and waste materials using crushing and cutting technology. This includes scrap, shredder residual fractions, slag and incinerator bottom ash as well as tires, cables, refuse-derived fuels and domestic, commercial and industrial waste. Moreover, we plan and implement complete turnkey recycling plants for our customers.

For further information, please visit: www.bhs-sonthofen.de

BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
Phone: +49 8321 6099-231
E-Mail: press@bhs-sonthofen.de
Url: http://www.bhs-sonthofen.de

VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

Science Research Technology

SIMPEX HYDRAULIK: Automatic ladle milling unit saves time and money

SIMPEX HYDRAULIK: Automatic ladle milling unit saves time and money

The milling unit is placed inside the casting ladle and fixed by three hydraulically actuated clamps

Relining of monolithically lined casting ladles in steel plants: Precise control instead of uncontrolled wrecking

The new vertical ladle milling unit MLC 2011, developed by SIMPEX HYDRAULIK, simplifies the relining of monolithically lined casting ladles, while cutting refractory and waste disposal costs. The automatic process reduces personnel requirements to a minimum.

The mobile vertical ladle milling unit MLC 2011 contains a precisely controllable milling head for the removal of fused refractory material and baked-on slag from the existing monolithic lining on the inside wall of the casting ladle. This is an optimal preparation for the application of the new layer of refractory material.

Before the ladle can be relined, the inside wall must be „white“ in order for the new refractory concrete to properly bond with the remaining refractory layer. This means that there must not be any fused areas or areas with baked-on slag left. At the same time, it is to be avoided that any material still in good condition will be removed.

The new ladle milling unit operates with a precisely controllable milling head. The thickness of the layer to be removed is set according to the degree of fusion. While ladle wrecking by means of manually operated wrecking machines or caterpillars with hydraulic hammers is extremely difficult to control, the new machine removes the worn refractory layer in a perfectly controlled and uniform way.

The entire process takes place automatically. This dramatically reduces the time requirement compared to the previously common manual practice. The operation takes approximately one hour. When the milling has been completed, the inside walls are visually inspected. If necessary, another layer is removed or certain areas are specifically reworked with the milling head operated manually. The system is also suitable for spot repairs in cases where it is not necessary to mill the complete inside wall of the ladle.

The amount of wrecked material is dramatically reduced because the system does not remove more material than necessary. This cuts not only the transportation and disposal costs for the waste material, but also the consumption of refractory concrete. As the material consists of aluminium oxide (AI2O3), it may for example be used as slag forming agents, resulting in a closed and thus eco-friendly system.

Additionally, the ladle milling unit extends the life of the permanent lining. As the ladle is in the upright position during milling, it sits solidly in the ladle cone. Therefore it is subjected only to pressure load. Moreover, there are no impact effects acting on the monolithic or the permanent lining, as would occur during manual wrecking with the ladle in a tilted position. Thus, the ladle milling unit avoids the occurrence of cracks and brittleness.

SIMPEX HYDRAULIK has developed the ladle milling unit in cooperation with Hackenberg Ingenieurgesellschaft. The design phase has been completed. The first prototype will be built shortly.

According to Andreas Berendt, Managing Director of SIMPEX HYDRAULIK GmbH, the system will provide numerous benefits: „The milling unit saves not only material and disposal costs. It also eliminates a great deal of the strenuous and hazardous work taking place in a steel plant.“

The first unit has been designed for casting ladles with filling weights between 80 and 160 t. It consists of the milling equipment proper, a holding frame and a container, which accommodates the hydraulic unit including the tank and the controls.

The equipment is easy to use: A bay crane, which is typically available in any steel plant, lifts the milling unit into the ladle. Three hydraulic cylinders ensure that the unit is perfectly centred and fixed inside the ladle. Here a key advantage of this milling unit becomes obvious: The milling head is always accurately positioned relative to the ladle and it can be moved to any position of the lining – either automatically or manually by remote control.

Milling is performed automatically. It takes approximately one hour to be completed. Afterwards, the milling unit will be lifted into the provided holding frame or into the next ladle to be milled.


SIMPEX HYDRAULIK has a more than 35-year track record of brand- and manufacturer-independent expertise and quality in the fields of hydraulics, pneumatics and centralised lubrication technology. Having emerged from the trade in hydraulic components, today the company is engaged in the development, manufacturing and commissioning of hydraulic plants and plant units, test stands and components for sensor and servo-technology.

In the field of centralised lubrication technology, the company’s activities in revamps of existing plants and in the construction of new plants are as much sought-after as its maintenance services.

Another core competency of this group of medium-sized companies is the repair and overhaul of hydraulic components of all kinds, independent of brands and manufacturers.

The enterprises SIMPEX HYDRAULIK GmbH in Brandenburg, Eisenhüttenstadt, Gera and Neuss (all Germany) are companies of HYDRAULIK UNION.

Andreas Berendt
Siemensstraße 39
07546 Gera

Regina Reinhardt
Süsterfeldstraße 83
52072 Aachen