Shredding, disaggregation and separation of reusable materials

Rotorshredder

RS

Rotorshredder

The Rotorshredder shreds, separates and isolates materials. The shredding tools exert a high intense stress on the feed materials through impact, shock and shearing forces. This results in selective crushing with the following characteristics:

Processing of copper armatures and electric motors

bhs_sonthofen_meatballs_2018_gb_1080p25.mp4

Processing of copper armatures and electric motors

Optimized recovery of copper from motor armatures and electric motors – also known as meatballs – at a customer facility in France thanks to selective shredding using the BHS rotor shredder of type RS 2018. The fed copper armatures and electric motors are first shredded and separated using the RS unit. They can then be separated into pure fractions (e.g., copper, iron, etc.).

Simple tools

  • Multiple hammers mounted one on top of each other on a vertical shaft
  • No need to adjust or sharpen tools due to optimized design

Flexibility

  • Disaggregation of a large number of input materials
  • Possible to influence the intensity and selectivity of feed material processing thanks to adjustable machine parameters
  • Sound investment for the future

Continuous operation

  • Facilitates efficient integration into an end-to-end process
  • Short retention time for feed material in the machine to avoid excessive transfer of heat into the shredded material (e.g., prevents plastics from melting)

Discharge of large parts

  • Separate discharge of large individual parts that cannot be shredded thanks to automatic slide feed

Low maintenance requirements

  • Excellent access to interior of machine through two large doors
  • Easy to replace screwed-on wear parts

Flywheel

  • Optional large flywheel available
  • Automatic handling of short-term mechanical or electrical load peaks
  • Avoids spikes in power use and large costs associated with this

Function

Functional description

The patented BHS rotor shredder consists of a cylindrical working chamber with a vertical, high-speed shaft. Mounted on this are pairs of working tools in a vertical floating arrangement. The tools are stabilized and horizontally aligned by centrifugal force. The flexible suspension of the tools on the shaft also serves to provide overload protection. As an option, the rotor shredder can be equipped with a flywheel as an energy storage system.

The cylinder features a double-wall construction. The inside wall consists of a solid split grate, the openings of which may vary based on the customer’s specific requirements. The input materials are fed into the working chamber from the top. Upon entering the crushing radius of the tools, they are subjected to very intense stress through a combination of impact, punching and shear forces. The selectively processed material then exits the working chamber through the split grate. Solid individual parts that cannot be shredded can exit the working chamber via a separate chute.

Separating out impurities

The EU directive on the recycling of electrical and electronic waste requires the reliable separation of specific components containing harmful substances. The BHS rotor shredder can remove components containing hazardous substances (e.g., batteries, capacitors and assembled PCBs) from the composite material without destroying them completely. These impurities can be consistently removed from the material flow after passing through the shredder.

Process steps

Shredding process illustrated based on the example of a washing machine

The degree of shredding and the intensity of the processing can be variably adjusted by changing the speed, tool or grate. The system is offered in three different sizes to accommodate different requirements, particularly with regard to throughput rates and the size of the feed material.

Stage 1

Stage 1

Rotorshredder is in an idle state.

Stage 2

Stage 2

In operation, the hammers are stabilized and horizontally aligned by centrifugal force.

Stage 3

Stage 3

The inserted feed material is vigorously shredded after entering the impact chamber.

Stage 4

Stage 4

It takes just a few seconds before the selectively processed material exits the working chamber through the split grate.

Grid segments

Patented grate opening

One special feature of the rotor shredder is its patented grate opening located in the large, double-walled doors. The inside of the doors consists of grid segments with openings through which the material to be shredded automatically exists the working chamber when the required particle size has been attained. Different grid segment types can be used depending on the input material and the specific requirements at hand.

Grate configuration with large bottom opening for the separation of entangled input material, for example.

Grate configured with small, lower openings for a high shredding performance when processing hard, brittle materials.

Plants and systems

Experts in plant engineering

Experts in plant engineering

We design and build turnkey systems and systems components designed to process recycled materials for use in a wide range of applications. Our experienced specialists are there to help you define processes that are precisely aligned with your on-site conditions. We furthermore offer testing services for your materials at our technical center in Sonthofen. The final solution delivers high throughput rates, low operating costs and end products that meet the needs of the market, thus making this a safe investment. Numerous references testify to our expertise.

Technical specifications

Performance data
TYPE
Working chamber (diameter)Working chamber (height)Feed opening inside diameter 1) (H x W)Driver power (max.)
RS 20182.000 mm1.800 mm600 x 1.200 mm
900 x 1.200 mm
110 - 400 kW
RS 32183.200 mm1.800 mm1.500 x 1.500 mm 
110 - 400 kW


1)  Not appropriate for the crushing of massive single parts of high strength. The maximum input size equals about two thirds of the feed opening.

Dimensions and weights
TYPE
A2)B2)CDEWeight3)
RS 20185.000 mm6.000 mm3.100 mm3.850 mm2.000 m30.600 kg
RS 32185.700 mm6.700 mm3.000 mm5.130 mm2.430 mm42.500 kg


2)  Different data may apply depending on the feed hopper that is used.
3)  Weight for standard model incl. inlet and outlet hopper.

All technical data shown here refer to the standard version. The technical data for customer-specific versions may vary from the information shown here. All technical data may change due to development. Subject to modification without notice.

Solutions

"Rotorshredder (RS)" product flyer
Brochure of the "Recycling Technology" business unit
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Tests give certainty

Which technical solution is the right one for your recycling process? Don’t leave anything to chance. Our team of specialists will test your material at our test center and develop a solution tailored to your specific needs.

ICBR 2024 - International Congress for Battery Recycling

09/10/2024 - 09/12/2024 | Basel (Switzerland)

IFAT India 2024

10/17/2024 - 10/19/2024 | Delhi (India)

Recycling company in United Kingdom processes ASR fractions and electronic scrap using the BHS Rotorshredder

February 2022

British recycling specialists Recycling Lives commissioned a recycling plant that was planned and implemented by BHS-Sonthofen. The plant is designed to handle a variety of materials such as automotive shredder residue (ASR), electric and electronic scrap (WEEE), as well as so-called "meatballs" (electric motors and motor armatures). The process developed together with the company is based on a profitablity analysis and ensures marketable end products.

EXTRUSION INTERNATIONAL 1-2022

June 2020
recycling today June 22, 2020

Economically efficient processing of automotive shredder residues

July 2020
For almost a year, a BHS-Sonthofen rotor impact mill has been in operation at Jansen Shredder Recycling BV in Moerdijk, the Netherlands, for the fine processing of automotive shredder residues (ASR). Thanks to years of experience in the processing of metal-bearing waste materials, the experts from Sonthofen found the optimal machine for processing abrasive materials. Wear costs at Jansen have significantly decreased since.
ALUMINIUM Journal 7-8 / 2020

Recycling of meatballs even more efficient

August 2019

BHS-Sonthofen has developed a new procedure for processing meatballs in order to increase the amount of copper recovered. Electric motors and motor armatures represent a small fraction of waste from incineration or large shredders, and it is difficult to cleanly separate them by type.

recovery 04-2019

ASR PROCESSING - A FINE POINT TO MAKE

November 2016

Recyclers and equipment makers can work together to maximise the efficient recovery of metals from shredding plant fines fractions.
Finnish scrap processing firm Kajaanin Romu Oy has recently begun operating an automated sorting plant downstream of its shredder designed to thoroughly capture the metallic portion of automotive shredder residue (ASR).

recycling today 11-12/2016

Satisfied customers worldwide