Inside the Next-Gen Metal Recovery Line: an honest look at the eddy current separator

If you work in scrap, WEEE, or MRF operations, you already know the drill: ferrous gets pulled by magnets; the real profit, however, often hides in non‑ferrous. That’s where the eddy current separator (ECS) earns its keep. I spent a day in Dafu Village, Qingyuan Town—Qingyuan District, Baoding, Hebei—where one plant builds these units, and, to be honest, the shop-floor pragmatism impressed me more than the glossy brochures.

Industry trends (and why they matter)

We’re seeing higher rotor speeds, thinner belts, and tighter enclosures for better throw trajectories—especially in e‑waste and auto-shred residue. Integration with optical sorters is rising, surprisingly even in medium-size plants. Most buyers ask for modular frames to swap rotors (concentric vs. eccentric) depending on the feed mix. And yes, aluminum recovery is up because secondary smelters pay for cleanliness.

How it fits in your line

Typical flow: pre-screen (20–80 mm window), ferrous removal, density/airknife (optional), then the eddy current separator. Common materials: copper/aluminum cables, aluminum profiles and dross, cast Cu/Al sand, printed-circuit-board ash, non‑ferrous glass cullet, e‑waste mix, and poly‑metallic fines. Methods are straightforward: controlled belt loading (≈30–60% coverage), consistent feed depth, and rotor speed tuned to particle size.

Testing and KPIs: separation efficiency on Al/Cu targets, product purity (residual Fe/NF), belt wear rate, and rotor temperature. Many customers say they benchmark with periodic Gauss checks and belt thickness logs—low-tech, but it works.

Product snapshot (Eddy Current Separator)

Working width	800 / 1000 / 1200 / 1500 mm
Rotor type	Eccentric high‑frequency, NdFeB magnets (grade N35–N52, real‑world use may vary)
Rotor speed	≈ 2,000–3,500 rpm (tunable to fraction size)
Drive power	Belt 2–4 kW; Rotor 7.5–18.5 kW (depends on width)
Throughput	Up to ≈ 3–12 t/h (feed-dependent, pre‑screen critical)
Separation window	Best at 10–120 mm fractions; fines need higher rpm
Belt	PU wear layer; life ≈ 8–18 months (duty-dependent)
Service life	Bearings ≈ 30,000 h with proper lubrication

Vendor comparison (my quick-take)

Criteria	OW Recycling (Hebei)	Vendor A	Vendor B
Rotor design	Eccentric, high pole-count	Concentric (basic)	Eccentric, mid pole-count
Customization	Strong (belts, chutes, guarding)	Limited options	Moderate
Support	Remote tuning; quick spares	Standard	Regional only
Value vs. price	High (my view)	Premium	Budget

Real-world use, feedback, and compliance

- Industries: MRFs, scrap yards, WEEE, glass plants, foundries, aluminum smelter in-feeds.
- Customer notes: “cleaner twitch, less copper in heavies,” and “belt swaps are faster than expected.”
- Certifications: CE (Machinery Directive 2006/42/EC), ISO 9001:2015 QMS (factory level), electrical per EN/IEC 60204‑1; RoHS documentation on request.
- Testing: field strength checks referencing IEC 60404 series; rotor balance per ISO 21940; lockout/tagout signage per ISO 13857 safety distances.

Case notes (short and sweet)

- Auto-shred residue, 20–80 mm: Al recovery ↑ to ≈ 92% with rotor at 3,200 rpm; purity ≈ 95% after a cleaning pass.
- E‑waste fines, 10–30 mm: Copper loss reduced ≈ 1.8% after chute re‑angle and belt tension tweak (small changes, big payoff).
- Glass cullet line: non‑ferrous contamination dropped from 350 ppm to ≈ 110 ppm, unlocking a better sales grade.

Customization checklist

Ask for: variable rotor inverter maps, wear liners (AR or UHMW), dust hoods, long/short splitter sets, and belt scrapers. For noisy plants, consider acoustic panels—operators will thank you.

Citations

1. Machinery Directive 2006/42/EC (CE).
2. EN/IEC 60204‑1: Safety of machinery—Electrical equipment.
3. IEC 60404 series: Magnetic materials—measurement methods.
4. ISO 21940: Mechanical vibration—Rotor balancing.
5. Directive 2012/19/EU (WEEE) and recycling best‑practice guidance.