processing experts - sicon

SR-Processing

Processing Experts

02

SICON – Exceptionally flexible Extrem adaptable! 360°-View!SICON is an internationally active, medium-sized company that specializes in designing and building systems for recycling metals and plastics. Our core area of competence includes in particular the comminution of scrap (pre-shredders and main shredders), as well as the preparation of shredder residues and the density-based separation of plastics.

We have been dealing with scrap for more than 15 years. We listen and are able to combine our experience gained while working together with many operators. In this context, we want to share with you the experiences made by other scrap processors. Our products are the result of listening and observing. We also attach great importance to functionality and perfor-mance.

As an operator of our own processing sys-tem (1999-2013), our processes were not developed on a drawing board but rather through actual operation; and that with countless cycles and multi-shift con-tinuous operation.

Our range of services encompasses not only the delivery of machinery, but also upon request the planning in an existing building or premises, support during the licensing process and talks with regulatory authorities as well as assistance in canvassing customers for your metal or plastic products.

Our machines and systems were not designed or built around one core machine but are adapted specifically to our customer‘s individual cost/performance ratio. We are flexible and maintain a complete overview of all scrap processing steps, from dismantling services and scrapyard logistics through to machine technology of the comminution process (pre- and main shredders) as well as the processing of all product streams to generate defined metal and non-metal fractions.

COMPANY

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The company...............................................02

FinesTuning®...............................................04

SICON-75®...................................................06

SICON-100®.................................................08

SICON-120®.................................................10

Cable recycling............................................12

Polyfloat®....................................................14

SICON-e......................................................16

Sensor sorting............................................18

SICON service.............................................19

Contents

04

FinesTuning®

Recovering tiny fragments of non-ferrous metals

Fines from (A)SR processing (fines < approx. 12 mm) make up 20–40% of the total weight of shredder residues. They contain large quantities of recyclable metals but also significant amounts of recyclable non-metals. The revenue poten-tial of (A)SR fines is often under-estimated. With FinesTuning®, SICON has developed a system that reliably separates over 99% of separable NF metals contained in fines fractions. The multi-step magnetic separator system guarantees complete metal recovery; it consists of two magnetic drums with different magnetic field strengths and an overbelt multi-pole magnetic separator combined with a special eddy current separator with downstream sensor sorting. An efficient system which, through lucrative metal revenues and reduced disposal costs, amortizes itself within a short space of time.

SICON realizes FinesTuning® in new plants and also as a retrofit solution for integration into existing plants with throughputs of up to 30 t/h.

That pays off!

On average, a new FinesTuning® system pays itself off within 9 to 21 months.

Monate

Sch

redd

errü

ckst

ände

(TPY

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25.000

20.000

15.000

10.000

0 2 4 6 8 10 12 14 16 18 20 22 24

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Shre

dder

resi

due

(TPY

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Advantages at a glance

� System for recycling fines from lightweight, heavy or (A)SR shredder fractions

� Multi-stage separator for comprehensive separation with significantly higher grades of purity of the separated metals

� Multi-pole overbelt magnetic separator to additionally refine the ferrous fraction in order to achieve a pure marketable FE fraction

� Throughputs of between 2 and 30 t/h

� Compact, space-saving system

� Supplied as a turnkey solution

� Quick return on investment

Each metal fragment separately.

With FinesTuning®, metal fragments as small as < 1 mm can be filtered out from fines and reliably separated.

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Input materialRaw shredder sand

Output materialIron

Output materialShredder sand

Output materialZorba, fines

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SICON-75®

A good base to start with

Reliable shredder residue processing starts with the SICON-75® system. A perfect match of equipment for ferrous metal separation, screening, classification, non-ferrous metal separation and FinesTuning® makes the system exceedingly efficient. Based on the interaction of these units, SICON-75® ensures the complete separation of NF metals (Zorba) down to a fines fraction of less than 1mm. SICON-75® is a fully automated system that can be connec-ted directly to a shredding plant or used as stand-alone unit. SICON also supplies individual upgrades for existing lines. If you want to improve the performance of your plant, please don’t hesitate to get in touch with our experts. As with all other SICON solutions, SICON-75® has been designed as a modular system; we can also implement the unique advantages of our technical solutions in older systems.

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� Shredder residue processing in a single system (FE Metal separation, screening and classification, NF Metal separation, FinesTuning®)

� Large material feed bunker for uncoupling from the actual shredding process, eliminates peak loads and ensures uniform, optimum metal separation

� Multi-stage screening/classification with self-cleaning function of the drum screening machine and flip-flow screen

� Optional scales for weighing input material flows and end-products

� Optional AIRSORT® technology to optimize metal separation

� Intelligent process data logging software (weights, operating hours, problems, etc.)

An eye for detail

With throughputs of up to 80 t/h, SICON-75® can detect and separate metal fragments upwards of < 1 mm in size.

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Input materialShredder residues ASR

Output materialFine iron

Output materialCoarse iron

Output materialmetal free

fraction

Output materialZorba

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SICON-100®

The first step towards advanced metal and ASR recovery

SICON-100® enables you to recover NF metals more effectively from shredder residue. SICON-100® is the consistent extension of the Zorba fraction separation process implemented in the SICON-75® system. Stainless steel, copper strands, printed circuit boards and cables are comprehensively separated to produce a waste fraction that is entirely metal-free. Thanks to the SICON sensor technology in the SICON-100® system, highly individual lines can be tailormade to meet special customer requirements.

The shredder residue passes through the following stages in a fully automatic process: FE metal and non-ferrous me-tal separation (eddy current separation), FinesTuning®, air separation, sensor-based sorting. As an optional extra, the shredder residue can be homogenized gently in the SICON-100plus® system by the SICON (A)SR PTS crusher, which improves the metal recycling rate and cuts investment cost even further. At the same time, non-metals are recovered in a quality that allows them to be recycled. In this way, SICON-100plus® goes beyond classical sensor-sorting and therefore allows you to achieve full (A)SR recovery.

Whichever model you opt for, SICON-100® comes with units that are optimally tuned to one another. A system that fits your needs to a tee. It is not without reason that the machines, particularly the VARISORT® induction separator, have established themselves as the best in their respective class.

SICON-100 and SICON-100plus® are also available as upgrades for existing plants. If you have metal losses in your waste or increasingly have to feed material repeatedly through your machines, then please get in touch with our ex-perts. We also integrate our unique solutions into existing systems, thus significantly improving performance as far as throughput, metal recovery and product quality are concerned.

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Shredder fluff

Iron

Unshreddables

Fine Iron Zorba

Zurik

Shredder granulate


� Shredder residue are processed in a single system (FE metal separation, screening and classification, NF metal separation, FinesTuning®, sensor-based sorting, air separation and preliminary crushing)

� Integration of SICON S+S VARISORT® sorters (sensor-based sorting) for metal separation (optionally also for the removal of chlorine in cases where non-metals are also to be recycled)

� Pre-crushing by SICON (A)SR PTS crusher for gentle loosening

� Optimum preparation for later sorting by the VARISORT® induction separator

� Integration of AIRSORT® sifters to separate light-weight materials

� Treatment and processing of non-metal fractions for the production of assured-quality substitute fuel or recycling plastics

� Optionally, additional processing of the Zurik fraction and separation into copper, aluminium and stainless steel

Particularly versatile

The integration of VARISORT machines for sensor-sorting into SICON-100® enables stainless steel, cables and printed circuit boards to be separated from (A)SR, Zurik and Zorba fractions in a highly-efficient way.

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Input material(A)SR Shredder Residue

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SICON-120®

Perfection in the (A)SR treatment process becomes an industrial standard

A perfectly-engineered system. Building on the efficient SICON-100® system, SICON-120® even exceeds optimum metal recycling by producing fractions sorted by material. SICON-120® is a system made for the future, which already incorporates future changes in the composition of shredder residue caused by further advances in electrification. Where sensor-based processing systems normally reach their limits when it comes to ensuring a complete metal re-covery (> 99% of the input flow), SICON-120® brings its inherent advantages into play. Instead of producing a Zurik fraction, metals (aluminum, copper, stainless steel) of the highest purity and high market value are yielded. An addi-tional side-effect of this is that non-metals are also recovered in a quality that enables them to be re-used (e.g. plastics recycling). SICON-120® is a modular system capable of meeting all requirements – including the shredder plant


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Complete selection - effective recovery

Not only copper but also recyclable plastics are obtained after processing materials with SICON-120®. Even insulated copper components are detected reliably by the system.

Aluminium

Stainless steel Zorba

Fine Zorba


� Modular system with SICON PTS homogenization crusher and separation into fines (shredder sand), fibers (shredder fluff), plastics (shredder granulate and metals)

� Systematic refining of all three coarse fractions to achieve defined product qualities

� Metals are separated into copper, aluminum and stainless steel and are recovered in high metallurgical grades

� Throughputs of up to 80 t/h

� Unique SICON support is also available with SICON-120® to ensure the sale of metal as well as non-metal fractions

Shredder granulate

Unshreddables

Copper

Shredder sand Fine iron

Iron

Shredder fluff

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Input material(A)SR Shredder Residue

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Processing cables

Copper recovery at its best

Many systems for processing shredder residues generate a Zurik fraction which contains between 30 and 80% metal. The metal content is mixed because major constituents include stainless steel as well as copper and aluminum cables. The solution implemented in the SICON-120® system that separates all cable residues, even the finest copper strands, can also be implemented offline as a standalone unit. Consequently, in addition to conventional sensor-based separation, SICON achieves a very efficient separation process which ultimately yields high-grade copper and alu-minum granulate. The system is also available to shredder operators who relied on system solutions in the past that were less efficient than SICON solutions. The SICON team is also happy to integrate advanced SICON processing solutions into existing plants.


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Optimum processing of cable fractions

A particularly efficient form of separation which generates high-grade copper and aluminium granulate as end-products.


� Gentle and effective crushing in the SICON PTS-(A)SR crusher which has a low energy requirement

� Reliable separation of foreign material prior to granulation; this prevents any risk of damage to the crushing tools

� Throughputs of between 500 and 5,000 kg/h

� Granulators of extremely rugged design with intensive wear protection for long service life at low operating cost

� Effective and complete separation of stainless steel

� Separation into pure copper and aluminum granulate

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Output materialAluminium

Output materialCopper

Input materialcables

Input materialcable-rich fraction Input material

cable-rich residual fraction

or or

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Polyfloat®

Maximum precision

With Polyfloat®, SICON is defining new standards in the separation of plastics. 99.4% is the new benchmark for product purity that our thoroughly innovative and yet mature system can produce. Perfectly-matched processes within the system make it suitable for recycling PE/PP, ABS/PS and other plastics, even ASR and WEEE plastics. Preventing the formation of harmful air bubbles, the unique lamellar separation system ensures that Polyfloat® is the best investment – for higher product purity and better marketing opportunities.

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� Maximum efficiency, fully-automated plastics separation technology (> 99.4% product purity) in a single system with shredder, metal separation and cleaning process

� Integrated lamellar separation system (prevents formation of air bubbles)

� Recycling of PE/PP, ABS/PS and other plastic materials as well as WEEE (specific density of 0.9 to 1.4 g/cm3) – also suitable for black plastic materials

� Easy integration into existing plants

� Wastewater-free process

� Throughputs of up to 12 t/h

� Quick return on investment

Plastics separation with a purity of 99.4%

Each type of plastic is separated according to individual density settings.

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Input materialRaw granulate

Output materialPE

Output materialPP

Output materialPVC

Output materialPO-Compound

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SICON-e

Stripped to the core

The amounts of electrical and electronic scrap are growing all the time. Many different materials are involved and most are disposed of as waste. However, as separate collection and sorting are becoming more common, a lot of them can now be recycled. SICON-e provides a reliable method for recycling electronic scrap in a modularly designed system that grows with your needs. SICON-e not only separates metals such as stainless steel, copper, aluminium and printed circuit boards but also recovers plastics for recycling. The Polyfloat® process enables SICON-e to obtain product purity levels of over 99% with plastic materials, regardless of the color of the plastic.

The SICON-e scrap processing

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Shredding

Screening

Air Classifying

Metal Separation

Circuit Board Separation

ICW-Separation

Brominated Plastic Removal

Granulating

Wood Removal

PE/PP-Separation

ABS-Separation

PS-Separation

Rubber-Separation

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� Produces polyolefin and styrene fractions in a single system with maximum purity and yield rates

� Also separates into PVC and non-PVC fractions for special recycling solutions

� Fully-automated system with intelligent and more reliable sensor and control technologies

� Integrated process water and media purification

� Total recovery of all metals

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Input materialPrinted circuit boards

Output materialCables

Output materialPlastic

Output materialCopper

Input materialElectronic waste

Highly effective recovering of e-waste

The innovative modular design system that flexibly fits to your requirements.

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Sensor-Sorting

As variable as you want – VARISORT®

With the VARISORT product family from the traditional Bavarian concern Sesotec, we offer our customers the opti-mum technical solution for sensor-based sorting of bulk goods containing different materials. Since the 70’s, our partner has concerned itself with sorting and detecting metals and foreign materials. A leading company in the field, the concern develops and manufactures products on its own premises to give you the edge in the recycling market: state-of-the-art sensor technology tailormade exactly to your requirements.

Depending on the task at hand, different detection sensors in the VARISORT are used:

� Multi-channel metal sensor M

� Multi-channel metal sensor M+

� CCD color camera system C

� Multi-spectral near-infrared system

� Dual-energy x-ray transmission system XT

� X-ray fluorescence system XF

With Sesotec as a technology supplier, we can draw on decades of know-how to separate detected materials. An adap-ted feed system helps to optimally distribute and settle the material on the acceleration conveyor to enable material fragments to be accurately removed from the flow of bulk goods by blasts of compressed air. It doesn’t matter whether the fragments are large or small: we’ve got the solution you need.

� VARISORT BIG – for really large chunks � VARISORT WEEE – specially designed for sorting electronic waste and scrap metal� VARISORT COMPACT – ideal for fine-grained fragments And that’s not all: VARISORT also allows you to combine different sensors for even more sorting applications:

� Sorting cables� Separating printed circuit boards� Producing a mixed plastics fractionn

When are you going to challenge us with a sorting task?

A comprehensively-equipped technical center is at your disposal for customer trials.We’ll be happy to show you the machines you’ll be using to separate your bulk materials in the future.

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SICON service

Overview of our services

Regular service and maintenance make a significant contribution to extending the service life of a shredder. With our SICON Services program we offer our customers tailored service packages. With three different profiles: Standard, Advanced and Premium, every party will find the range of features that suit their individual requirements. From consulting and general maintenance through to repairing or replacing rotors and damage assessment, we offer every-thing that plant operators need in order to be able to operate smoothly at all times.

Rotor repairsA general rotor repair can have a significant impact on the optimization of your current operating costs and can be considerably more cost-effective than purchasing a new rotor. Professional repair and maintenance of shredder rotors is one of our primary focal points and we have lots of experience repair-ing more than 100 rotors a year. As a system supplier, we offer everything from the actual processing through to delivery.

Maintenance and damage analysisMaintenance is an integral part of operating a profitable shredder plant. As a system developer, we offer an especially comprehensive maintenance service based on our 15 years of experience for every area of your system. Besides actual maintenance, you also receive a comprehensive objective report on the actual state of repair or your system. This report will not only describe how your system is cur-rently running but will also include any short or long-term measures for making any noticeable improvements.

DevelopmentSystem optimization has many aspects that have to be taken into account. Whether you want to bring your existing system up-to-date with the latest developments, integrate individual machines into one system or are looking for a completely new individual plant system – SICON is the right partner for all of your questions involving the development and optimization of shredder plants. Please do not hesi-tate to contact our engineering department in Hilchenbach, Germany. We would be happy to assist you.

ConsultingBuilding and improving sophisticated systems is not the result of fast and spontaneous decisions. There is a strategy behind them. We would be happy to advise you with regard to all your concerns with regard to optimizing your plant concept.

Product salesAre you having problems selling your product or can only get rid it with additional disposal fees? SICON with its extremely broad network of contacts will help you to find a consumer or expand your existing system so that you can produce a product with a positive return.

SICON DeutschlandVordere Insbach 2657271 Hilchenbach, GermanyPhone: +49 (2733) 811 76-0

sicon.eu

SICON Amerika11390 Old Roswell Road, Suite 126Alpharetta, GA 30009, USAPhone: +1 (678) 527 14-32

sicon-america.com

SICON – Exceptionally flexible Extrem adaptable! 360°-View!

processing experts - sicon

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