METAL RECOVERY FROM FINE FRACTIONS

Pure metal concentrates with highest recovery rates

Innovative processing of your material

BHS offers an established and optimized process for metal recovery from fine fractions. This consists of pre-sorting and the key process step of shredding, which is performed by a rotor impact mill, easily accomplishing multiple challenging processing tasks at once. The process then moves on to the steps of sorting via screens, standard separation as well as magnetic and eddy current separation. Each plant is individually adapted to the customer’s requirements due to the large variance of the input material.

Recovery of valuable metals from waste

Fine fractions smaller than 25 mm from automotive shredder residue (ASR), waste electrical and electronic equipment (WEEE), and incinerator bottom ash (IBA) all contain numerous valuable metals, from copper and aluminum to gold and platinum. BHS-Sonthofen has dedicated itself to helping its customers recover these valuable metals as efficiently as possible. The result: the high recovery rates and high purity of the recovered metal concentrates speak for themselves.

Benefits at a glance:

  • Highest metal recovery rates
  • Highest purity of concentrates with reduced operating costs
  • Flexible process solution for a wide range of feed materials
  • Fast amortization of your investment


Pre-crushed input material up to a particle size of 25 mm is optimally processed. The goal is to produce the purest metal concentrates. The two most important process steps, crushing and sorting, are ideally matched to the respective feed material.

[1] Presorting
Screen and zigzag sifters sort out larger particles with a particle size above 25 mm. Continuous dedusting also minimizes wear on downstream components.

[2] Crushing
The BHS rotor impact mill (RPMX) forms the heart of our process: This unique high-performance crusher provides efficient and selective loading of the feed material. This is the crucial basis for reliable sorting. In the standard process, the material runs through the machine several times in a “cycle.” If desired, several rotor impact mills can be connected in series for a continuous process with increased throughput.

[3] Sorting (screens)
Screens separate the crushed and optimally pelletized material into predefined size fractions for efficient further refining to guarantee high purity and recovery rates. Different screen sections provide flexibility.

[4] Separation (separating tables)
Excellent upstream pelletizing is decisive in order to obtain pure metal concentrate (copper, aluminum, etc.). Further separation into light and heavy fractions takes place on the separating tables, with the width of the screen section determining the ideal separation efficiency. Optimized separation of the output material is achieved by various setting options of the process parameters and adjustments to the individual input material.

[5] Magnetic and eddy current separation
Magnetic technology separates the valuable metal-bearing fractions into a magnetic and a non-magnetic part. The latter then passes through eddy current separation to achieve pure metal concentrates. These are now highly pure and directly salable.

[6] Optional accessories
Depending on the material and customer requirements, individual extensions of the sorting technology (for example, sensor-based technology) are available.

Innovative processes for the processing of fine fractions containing metal

Feinaufbereitung_2022-05_DE.mp4

Innovative processes for the processing of fine fractions containing metal

Whether pre-shredded end-of-life vehicles (ASR), electrical and electronic waste (WEEE) or incinerator bottom ash (waste incineration plant), they all have one thing in common: they contain valuable metals that are always worth recovering. This makes processing residual and fine fractions smaller than 25 mm in particular extremely important. BHS offers an established and effective process to achieve this. This consists of pre-sorting and the key process step of shredding, which is performed by a rotor impact mill, which easily accomplishes multiple challenging processing tasks at once. The process then moves on to the steps of sorting via screens, standard separation as well as magnetic and eddy current separation. Each plant is individually adapted to the customer’s requirements due to the large variance of the input material.

Process design via tests in the test tenter

Process design via tests in the test tenter

Large-scale tests to determine the wear pattern: efficient production machines are created on the basis of testing. Key operating parameters need to be defined in advance before the tests are carried out. The variety of materials demands an innovative process that always ensures the highest yield of high-quality metals through continuous further development. The high variance of the input material requires each plant to be individually adapted to the customer’s needs. The experts at BHS-Sonthofen therefore adapt each system to the specific feed material and your requirements based on our standard process. Defined tasks and special tools ensure that the project is completed efficiently.

Our testing capabilities include large-scale tests of the standard process with original customer material on a production scale, the implementation of optional process steps, and individual tests of all shredding machines as well as the separation and sorting technology. In addition, we offer comprehensive, standardized test evaluations (grading curves, etc.) and use the test results for further process optimization. They also serve as a basis for detailed plant engineering and for an individual profitability calculation of the customer’s project.

Machine portfolio

Rotorshredder (RS)

The Rotorshredder (RS) can do it all! Optimally shreds, separates and disaggregates valuable and residual metaliferous waste materials.

Rotor impact mill (RPMV & RPMX)

Ball shaper operating based on unique crushing principle

Universal Shredder (NGU)

Continuous high-performance crusher for all cutting-related applications

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Brochure of the "Recycling Technology" business unit
"Fine treatment for optimal metal recovery" application flyer
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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.

IE expo China 2024

04/18/2024 -04/20/2024 | Shanghai (China)

IFAT 2024

05/13/2024 -05/17/2024 | Munich (Germany)
Visit us in hall B4 at booth 351/450.

E-Waste World | Metal Recycling | Battery Recycling - Conference & Expo 2024

06/26/2024 -06/27/2024 | Frankfurt am Main (Germanv)

ICBR 2024 - International Congress for Battery Recycling

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

IFAT India 2024

10/17/2024 -10/19/2024

Customized recovery | Recovery of metallic fines from ASR

February 2023

The recovery of metallic fines from ASR requires a customized approach. Auto shredder residue (ASR), fines from shredded electrical and electronic equipment and waste incinerator bottom ash all have one thing in common: They contain valuable metals that are worth recovering. Therefore, processing these fine materials is of high importance.

recycling today scrap recycling | Winter 2023 | Supplement to recycling today

BHS fine treatment process recovers valuable metals from residual materials

July 2022

There is currently no way around the issue of resource saving but how can valuable materials can be recycled in the best possible way? Metals in particular are considered important scarce raw materials whose recovery is essential for the sustainable use of resources. BHS-Sonthofen offers an effective solution for metalliferous residues with a size of up to 25 mm.

recovery 04-2022

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

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

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<p>Find your personal contact person on site. We are there for you worldwide.</p>