ScrapTuning®
The flexible and modular solution for a low-copper Shred
Every steelmaker and shredder operator is interested in producing low-copper shred with consistent quality and at affordable costs. With ScrapTuning®, SICON has developed a modular and flexible system that meets this requirement. The intelligent combination of various process steps — ranging from intensive mechanical cleaning of the shred through to automated, sensor-assisted sorting and final analysis — delivers the desired result: shred with a defined low copper content in the range of 0.10 to 0.15%, depending on the smelter’s specifications. At SICON, we call this “Crafted Scrap on Demand”. ScrapTuning® is designed so that individual modules can also be used as upgrades for existing plants. The SICON ScrapTuning® system starts with a poker separator, which separates long pieces, known as pokers, in a highly cost-efficient way. Furthermore, the SICON Poker Separator is part of the shredder safety system. In the event of an emergency, the total output is diverted from the ferrous downstream process, avoiding any further risk. The SICON MagStand is an innovative combination of two magnets operating in a cascade in overflow and underflow mode. An advanced internal magnet design, customized for the SICON application and equipped with VFD control of the magnetic power, intensifies the flipping action and therefore the cleaning of the shred. The SICON AirKnife separation system reliably separates debris and exposed harness copper. The AirKnife operates with lower energy consumption and maintenance costs than any Z-Box. Multiple adjustment options ensure precise separation, which is beneficial for the final separation steps. One version of SICON’s ScrapTuning® integrates the magnetic-ballistic separator PrimeScrap to separate a copper-rich fraction from low-copper shred. When using PrimeScrap, typically only approx. 25% of the throughput is supplied to a manual or automated sorting process. The system is always designed to allow the later integration of automated sorting and further sensor technology to produce crafted scrap.
SICON has these technologies available in-house. From the EcoSort® Classic CAI and EcoFlip CAI, which are AI-based optical sorters delivering outstanding sorting results, through to the integration of SICON’s high-end XRF technology, all technical options are available. Finally, the EcoScan® Online certifies the quality of the shred.
All modules of SICON’s ScrapTuning® can be integrated into existing downstream systems. An offline installation is also possible and can be particularly interesting for steel mills when it comes to improving the quality of the shred.
The SICON team provides individual advice and adapts the system to the specific local conditions and customer requirements.
Figure 1: ScrapTuning® with integration of the PrimeScrap
Figure 2: ScrapTuning® with automated sorting by EcoFlip
With ScrapTuning® SICON has developed the firsta process that delivers low-copper shredder scrapShred on an assured certified quality basis !
ScrapTuning® - Your benefits at a glance
- Reduction of manual sorting labor costs by up to 75%, with the potential to fully replace handpicking.
- Reduction of the residual copper content in Shred down to even 0,10%.
- Increase of the non-ferrous metal recovery rate
- Modular design enables step-by-step optimization of existing plants
- Ready for integration of advanced automated sorting technologies
- Throughputs possible from 20 to 300 mt/h
Application in steelmills
Steelmills usually have a variety of different suppliers and each shredder operator has a different ferrous downstream which ends up in a Shred of varying quality. SICON ScrapTuning® is available as an offline module with feeding system to purify externally supplied Shred and certify the chemical composition supplied Shred. The meltshop management knows in advance the chemistry and can optimize the use of Shred. This turns Shred into a high-quality product without any quality risk for steel production. ‘Crafted Scrap on Demand’ is the solution of SICON to maximize the use of Shred nit only in Electric Arc Furnaces but also in Smelters and even in Blast Furnaces.
Application in Shredding Plants
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