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Performance Determination of Novel Design Eddy Current Separator for

Recycling of Non-Ferrous Metal Particles

Article in Journal of Magnetics · December 2016

DOI: 10.4283/JMAG.2016.21.4.635

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 ISSN (Print) 1226-1750
ISSN (Online) 2233-6656
Journal of Magnetics 21(4), 635-643 (2016) https://doi.org/10.4283/JMAG.2016.21.4.635

Performance Determination of Novel Design Eddy Current Separator

for Recycling of Non-Ferrous Metal Particles

Ahmet Fenercioglu1* and Hamit Barutcu2

Department of Mechatronics Engineering, Gaziosmanpasa University, 60250, Tokat, Turkey

(Received 20 July 2016, Received in final form 20 September 2016, Accepted 21 September 2016)

Improvements were made in the study for the design of the conventional Eddy Current Separator (ECS) used
for separating small sized non-ferrous particles in the waste. These improvements include decreasing the air
gap between the material and magnetic drum, making the drum position adjustable and placing the splitter
closer to the drum. Thus, small particles were separated with high efficiency. The magnetic drum was removed
from inside the ECS conveyor belt system as design change and was placed as a separate unit. Hence, the force
generated on the test material increased by about 5.5 times while the air gap between the non-ferrous materials
and drum decreased from 3 mm to 1 mm. The non-metal material in the waste is separated before the drum in
the novel design. Whereas non-ferrous metal particles are separated by falling into the splitter as a result of the
force generated as soon as the particles fall on the drum. Every material that passes through the drum can be
recycled as a result of moving the splitter closer to the contact point of the drum. In addition, the drum can also
be used for the efficient separation of large particles since its position can be adjusted according to the size of
the waste material. The performance of the novel design ECS was verified via analytical approaches, finite
element analysis (FEA) and experimental studies.
Keywords : eddy current separator, finite element analysis, non-ferrous metal recycling

1. Introduction gravity. The conventional working principle and industrial

application of the ECS have been shown in Fig. 1.
ECS are machines consisting of three separate units that Academic studies on ECS are quite limited even though
separate valuable non-ferrous metals such as copper, they have an important place in the field of recycling
aluminum from among wastes. These are the conveyor technologies. Majority of the recent studies published
belt, feeding unit and magnetic drum. The feeding unit is include ECS designs that can separate mostly small particles.
a vibratory system that enables the proper distribution of The literature [1] examined the separation success of
the waste material on the belt by placing them on the rotating ECS used to separate valuable metals at the
conveyor. The conveyor belt carries this material onto the particle size following the breaking down of electric-
magnetic drum. Whereas the magnetic drum is made up electronic products that have completed their service
of permanent magnet poles rotating at high speeds in a lives. Different ECS designs were examined for the
mechanical isolation sheet. An eddy current is induced in separation of non-metal valuable metals smaller than 5
the metal passing over the drum in accordance with the mm as well as copper cable parts. The 1st section of the
Faraday Law. A magnetic field is generated in the metal study focused on rotating ECS that is widely used in our
particle due to this current and thus a force is generated day. Whereas various experiments were carried out in the
when the particle enters the effect area of the varying 2nd section for the separation of electronic wastes via wet
magnetic field of the drum. The metal is thrown out with ECS technology. The experiments carried out to separate
the effect of this force and falls into the splitter cup. Non- the aluminum particles in electronic wastes were success-
metal materials fall into the other cup with the effect of ful [1]. Studies were carried out as part of literature [2] on
the modeling of the magnetic propulsion force of ECS. It
©The Korean Magnetics Society. All rights reserved. was put forth that the separation of various materials via
*Corresponding author: Tel: +90 530 348 6345 eddy current is not dependent only on the force that
Fax: +90 356 252 17 29, e-mail: ahmet.fenercioglu@gop.edu deflects the material thus calculating the gravity and

© 2016 Journal of Magnetics

− 636 − Performance Determination of Novel Design Eddy Current Separator… − Ahmet Fenercioglu and Hamit Barutcu

Fig. 1. (Color online) Conventional ECS (a) working principle (b) industrial application (K.W. Supply).

centrifugal force on the material and analyzed the force the magnetic rotor speed is 25 Hz and the conveyor belt
generated on the particle on the drum [2]. Computer aided speed is 8 Hz [7]. Literature [8] focused on the analysis of
design, simulations, modeling and analyses of ECS were this new ECS via finite element method (FEM). The
carried via the effective use of computer technology thus forces induced by the magnetic drum on the material to
taking important steps for the development of the design be separated were determined according to different
[3]. Literature [4] put forth a new method that uses variables as a result of simulations carried out to verify
electromagnetic sensors for the separation of non-ferrous the performance of the splitter prior to design. Separation
waste metals via eddy current method and for defining the force increased with drum speed increase, air gap decrease,
metals. Non-ferrous metals were separated as copper, increase in the number of poles, increase of material size
bronze and stainless steel according to their types via this and selection of materials with high conductivity [8]. In
sensor on a prototype system [4]. Literature [5] carried [9] the separation performances of granule power cable
out a study in which the separation method for the small wastes with diameters of 1.5-2 mm and lengths of 4-5
metal particles via new dynamic ECS with permanent mm were examined experimentally. It was determined as
magnet was examined from inside the non-ferrous two a result of the experimental measurements carried out at
component mixture. This is also named as ECS with angular belt speed of 0.2 m/s, drum speed of 3,000 rpm that
drum. The effect of the drum angle on the separation separation success was 94.7 % for copper, 99.5 % for
process was examined by changing the drum angle on the aluminum and 97.8 % for the mixture with this new ECS
horizontal. Experiments carried out with copper, lead and [9].
aluminum were also successful [5]. In the literature [6]; Changes in ECS design have been made in this study
Kang and Schoenung carried out a study in which the which are different in comparison with those in the
main criterion for ECS separation was put forth as the relevant literature and the conventional system. The drum
ratio of ρ material density to σ electrical conductivity (σ/ was placed in front of the conveyor as a separate unit the
ρ). Materials with higher ratios can be separated more position of which can be adjusted. Thus, the gap between
easily [6]. Literature [7] presented a study in which vari- the material and the drum decreased since the belt was
ous experimental studies were carried out on the type removed. Non-metal materials fall first from the drum in
known as the most efficient ECS type in which the mag- this system and since these wastes do not pass beyond
netic drum rotates on the horizontal axis. It has been the drum, the splitter has been brought as close to the
emphasized that the speed of the magnetic rotor and the drum as its point of contact. Thus, separation efficiency
number of magnetic poles should be increased in order to was increased. The design was verified via analytical
increase magnetic flux frequency and that the separation approaches and FEA and the performance was determin-
force will reach its maximum value as a result of this ed as a result of the experimental studies carried out with
increase. In addition, it has also been stated that separa- the prototype. Hence, it was possible to separate granule
tion efficiency increases as a result of the adjustment of sized small particles.
the speed of material feeding and conveyor belt. It was
concluded as a result of the experiments carried out for 2. Material and Method
the separation of non-ferrous metal material from among
aluminum and plastic mixture waste at 5 mm dimension The operating principle of ECS is based on the force
and various weights that efficiency is above 95 % when produced by the magnetic force generated by the eddy
Journal of Magnetics, Vol. 21, No. 4, December 2016 − 637 −

current induced in the conducting material. This principle

F = Ids × B (4)
is based on the Faraday, Ampere and Biot-Savart laws.
An electromotor force is generated in the conducting Here, I is the current that passes through the conductor.
material that is subject to the magnetic field of the rotat- This force makes the particle move and diverts it from its
ing drum which can be given as Eq. (1). The magnitude path. Literature [7] expressed the force generated by the
of this force is equal to the change of the magnetic flux variable magnetic field of the rotating magnetic drum in
with time. the ECS in a more simple manner via Eq. (5) and (6) [7].
dΦ 2 mσ
e = – ------- (1) F r = H f × -------- (5)
dt δs
The direction of the induced current is determined by np
the Lenz law. According to this law, the direction of the f = ------ (6)
2
current is opposite to the force that generates it. The
current induced in the particle subject to variable mag- Here, Fr represents the propulsion force, H represents
netic field according to the Faraday induction law has the magnetic field intensity, f represents the magnetic
been given in Eq. (2). The magnitude of the eddy current field frequency, n represents the speed of magnetic drum,
is determined by the change of magnetic flux density with p represents the number of magnetic poles, m represents
time. mass, σ represents conductivity, δ represents the form and
density factors of the material. The resultant force is
∂B related with material properties for different materials.
∇ × J = – ρ ------ (2) The ratio of conductivity to density (σ/ρ) determines the
∂t
magnitude of the force and the level of difficulty of the
Here, J denotes the current intensity (A/m2), B represents separation. Success of separation is greater in materials
the magnetic flux density (T) and ρ is the conductivity of for which this ratio is higher [7].
the material. The current induced in the material generates As can be seen from the equalities, there are many
a magnetic field in the conductor in accordance with parameters that affect the force. Some of these parameters
Ampere’s Law. This field interacts with the drum mag- are related with ECS design whereas the others are related
netic field thus generating a Lorentz force in the material with the material to be separated. The parameters related
as a propulsion force. The Lorentz force is a force that is with design are the magnetic flux density that circles the
acted on a point charge by electromagnetic fields. This material and the frequency of this flux. Whereas the
force is calculated in terms of electrical and magnetic variables that affect the magnetic flux density are the
fields via Eq. (3). magnetic field densities of the magnets and the air gap
between the material and the magnet. The variables that
F = q(E + v × B) (3)
affect the frequency are the number of poles of the
Here, F denotes the force, v represents the instantane- magnet and the speed of the drum. The parameters related
ous velocity of the particle and B is equal to the vector of with the material are specific resistivity, density and the
the magnetic field. These opposing magnetic fields gene- dimensions of the material. Separation force increases
rate the Lorentz force represented by Eq. (4) on a linear with increasing magnetic field density, number of poles
surface element (ds) of the conductor: and speed of the drum. Separation force increases with

Fig. 2. Working principle (a) conventional ECS (b) new design ECS.
− 638 − Performance Determination of Novel Design Eddy Current Separator… − Ahmet Fenercioglu and Hamit Barutcu

decreasing air gap distance and increasing specific re-

sistivity.
The novel design ECS is made up of 3 independent
units. These are the magnetic drum, the belt system and
the feeding unit. Magnetic drum is the most important
part that affects separation performance. It generates eddy
current and force on the material. The feeding unit loads
the waste material onto the conveyor belt. The conveyor
is a rolling belt with adjustable speed that carries the
wastes to the drum. In conventional ECS applications, the
magnetic drum is fixed inside the rolling belt. Whereas in
the new design ECS, the magnetic drum is placed in front
of the conveyor as a separate unit the position of which Fig. 4. (Color online) Magnetic drum 2d analysis model.
can be adjusted in two axes. The working principles of
the conventional and novel design ECS have been given
in Fig. 2.
The most important differences that affect performance
in the novel design ECS are the proximity of the splitter
to the drum, the narrowing of the gap between the drum
surface and the material and the adjustability of the drum
position. The prototype ECS was designed to separate
250 kg granule copper waste per hour. It has been shown
in Fig. 3.

2.1. Analysis and Experimental Setup

Theoretical approximations can be used depending on
some assumptions such as linearity, uniform field and
non-saturated core etc. in magnetic problems. Thus, analy- Fig. 5. (Color online) Measuring the Fx force induced on
tical method is not sufficient by itself for magnetic design material.
procedures. FEM analysis is a reliable verification tool.
The analysis was made via ANSYS MaxwellTM 2D transi- material was force stopped using the dynamometer with
ent platform to verify design. Test material was placed on rope and at that moment Fx force was measured according
the magnetic drum with air gap. The magnetic drum was to drum speed and air gap distance.
rotated 20 degrees from N to S poles since the remaining Efficiency experiments were made for the separation of
rotation pattern is the same. Force data was obtained in granule cables waste which has been given in Fig. 6.
this interval according to speed and air gap variations. Granule power cable sizes are about 1.5 mm diameter and
Analysis model is shown in Fig. 4. 4-5 mm length resembling rice. Experiments were made
Experimental setup is given in Fig. 5. The force is for copper, aluminum and mixed waste. Granule power
measured using a dynamometer. Test material was roped cables were weighed before separation, after which PVC
and fixed on the magnetic drum. The movement of the was mixed with cable granules and separated via novel

Fig. 3. (Color online) Prototype ECS.

Journal of Magnetics, Vol. 21, No. 4, December 2016 − 639 −

Fig. 6. (Color online) Granule cable waste (a) mixture cable waste with pvc (b) granule cable.

ECS. Following the separation, cable granules were re- ECS.

weighed and compared with the weight before separation. Here, la represents the distance between the splitter and
Therefore efficiency was calculated experimentally. PVC the center of the drum in conventional ECS, whereas lb
waste was not included in the calculation since all PVC represents the same distance for the novel ECS and lb < la.
particles in the waste fell into the other cup due to the Non-ferrous metals in the waste can be separated by
effect of gravity. falling onto the splitter due to the effect of the force gene-
rated by the eddy current. In conventional ECS, the force
3. Results and Discussion generated is not sufficient to enable the small particles to
cover this distance since the splitter is further away. The
Novel ECS performance results were obtained from magnetic drum position is adjustable in the new ECS and
FEA and experiments. Effects on performance were ex- it has been placed as an independent unit in front of the
amined in accordance with proximity of the splitter, de- conveyor. Non-ferrous wastes fall down into a container
creasing the air gap, adjustable drum position, number of before the drum. Hence, the distance that the material
magnet poles, drum speed, magnet volume and material covers has been minimized by placing the splitter in
type. contact with the drum. The material is diverted from its
path via a small force generated on the non-ferrous metals
3.1. Effects of the proximity of the splitter to the drum that fall onto the drum and hence they drop down onto the
In conventional ECS, materials are separated after splitter after which they are separated. Thus, it is possible
passing through the drum. In this case, non-metal wastes to separate small sized metals that can pass through the
fall down after the drum. A gap has to be left between the drum.
splitter and the drum in order to ensure that this falling
action takes place. Efficiency decreases in the separation 3.2. Effects of moving the material closer to the drum
of small particles since this gap increases the path of the (decreasing the air gap)
material. Whereas there is no need for such a gap after the The drum is located inside the conveyor in conventional
drum since non-conductive waste materials fallen down ECS. These two moving systems may operate at different
before the drum. Hence, the splitter has been placed close speeds and in different directions inside the same mech-
to the drum so as to contact it. Figure 7 compares the anical structure. In this case, the distance between the
position of the splitter in conventional and novel design drum surface and the material increases since the mag-

Fig. 7. Distance between splitter and drum (a) conventional ECS (b) new design ECS.
− 640 − Performance Determination of Novel Design Eddy Current Separator… − Ahmet Fenercioglu and Hamit Barutcu

air gap on the force has been given in Fig. 9.

The FEA solutions are given in Fig. 9. The resultant
force that is generated on the copper material with dimen-
sions of 30×1×10 mm when the drum is rotated at a speed
of 2,000 rpm. Whereas the average value of the force (Fx)
Fig. 8. Airgap between drum and material (a) conventional is about 166 mN when the air gap is 3 mm, it becomes
ECS (b) new design ECS. 913 mN when the air gap is 0.5 mm. Figure 9 indicates
the force measured on the material during the experiments
carried out under the same analysis conditions according
netic drum is located inside the rotating cylinder. There is to the air gap. Here, the drum speed has been adjusted as
a belt between the magnetic pole and the material. Thus, 2,000 rpm and same copper material has been used for
magnetic reluctance increases due to increasing air gap this experiment. The air gap was increased by 0.5 mm
distance. Therefore, the magnetic field effect of the magnet during the experiment and the effect of the air gap on the
on the material decreases. The belt is removed in the new force was tested up to 3 mm.
design since the drum is used as a separate unit and the
material is brought very close to the drum surface. The 3.3. Effects of the position of the adjustable drum
drum is covered with a thin film layer that does not The drum rotates at a fixed position inside the conveyor
contact the drum in order to isolate the drum movement belt in conventional ECS. Whereas the position of the
and its wind. The material falls directly onto this surface drum can change in the X and Y axes in new design ECS.
and the maximum air gap is 1 mm. The air gaps between Figure 10 shows the position of the drum.
the material and the drum for conventional and novel The effects of the changes in the x and y axis positions
design ECS are shown in Fig. 8. on efficiency acquired as a result of the experiments
Here, the air gap of ECS is shown by lg1, whereas the carried out for the waste granule material from aluminum
air gap of the novel design ECS is lg2 and lg1 > lg2. As is and copper power cable scraps have been given in Fig.
given in Eq. (7), air gap reluctance (R) depends on the 11.
length of the air gap (lg), magnetic permeability of the air The effects given here are those that are due to the
(m0) and the flux path cross-section (A0). different design of ECS. Experiments have been carried
out to determine the effect of the drum position on perfor-
lg
R = --------
- (7) mance. The drum speed was kept constant at 2,000 rpm,
μ0A
belt speed at 0.3 m/s during the experiments. The amount
Reluctance (magnetic resistance) increases with increas- of material separated for the 0, 1 and 2 cm positions of
ing air gap lg and magnetic flux (φ) decreases. This has the drum on the X axis has been determined when the
been expressed by the Maxwell equations given in Eq. drum was at −2 cm on the Y axis. The results have been
(8). given in Fig. 11(a). The drum was kept at X=0 position
during the other experiment. Separation process was
Hdl = φR (8)
carried out for the −2, −3 and −4 cm positions of the
Accordingly, force decreases. In addition, the effect of drum on the Y axis and efficiencies were examined. The
acquired results have been given in Fig. 11(b). High
efficiency is obtained here for small materials at positions

Fig. 9. (Color online) Effect of air gap on the resultant force Fig. 10. X=0, Y=0 position of the drum in the novel design
for the test copper material, analysis and experiments results. ECS.
Journal of Magnetics, Vol. 21, No. 4, December 2016 − 641 −

Fig. 11. (Color online) Effect of drum position on efficiency (a) x axis, (b) y axis.

of the drum which are closest to the outlet of the con-

veyor to where the material drops. Non-metal wastes such
as PVC etc. can drop down from the narrow gap between
the drum and the conveyor especially for shredded wastes
since the material is in granule form. In this position, the
kinetic energy that forms in the material is lower since the
metal material falls from a closer distance and thus it can
easily divert the material from its path. If the size of the
material to be separated changes, it will also be possible
to separate wastes with different dimensions by adjusting
Fig. 12. (Color online) Analysis and experiment results of
the position of the drum. The gap should be widened
effect of drum speed on force.
especially to be able to separate larger materials and to
ensure that the other wastes fall down the gap between
the drum and the conveyor. However, it has been deter- the material. A copper material with a height of 1 mm,
mined as a result of the experiments carried out that width of 10 mm, length of 30 mm was placed during the
separation efficiency decreases as the small materials get analyses on the magnetic drum that was designed with 36
farther away from the conveyor outlet. poles. The FEA solutions of the resultant force generated
on the material for the drum speed interval of 500-2,000
3.4. Effects of the number of poles of the drum and rpm have been given in Fig. 12. Whereas Fig. 12 shows
speed the experimental study results that indicate the effect of
The expression given in Eq. (5) and (6) according to the the drum speed on the force generated on the material.
Faraday Law show the effect of frequency on eddy current. The air gap was kept constant at 0.5 mm during this
The rate of change of the magnetic field affects the eddy experiment. The material used was copper with the same
current and the amplitude of the force. There are 2 factors dimensions. The forces generated on the material have
that affect frequency. These are the drum speed and the been given for the values of the drum speed that vary
number of poles. There are 36 magnet poles in the proto- between the 500-2,000 rpm interval.
type ECS. The frequency of the magnetic field and the
generated eddy current for a speed of 2,000 rpm is calcu- 3.5. Effects of magnet volume
lated via Eq. (6) as 600 Hz. According to the experi- Magnetic drum consists of N35 neodymium magnet
mental studies and analyses carried out to separate shredd- poles. Analyses were carried out by varying the magnet
ed power cable wastes, the effect of drum speed on force height while keeping all other parameters constant in
and separation efficiency has been verified [9]. The air order to examine the effect of magnet dimensions on
gap was kept constant at 0, 5 mm in order to examine the force. Accordingly, drum rate and air gap were selected as
effect of drum speed on the forces that are generated on 2,000 rpm and 0.5 mm respectively. Copper with dimen-
− 642 − Performance Determination of Novel Design Eddy Current Separator… − Ahmet Fenercioglu and Hamit Barutcu

Fig. 15. (Color online) Granule cable waste separation results.

Fig. 13. (Color online) Effects of magnet volume.
in the material with lower resistivity and higher conduc-
tivity is greater. Analysis and experimental results of Fx
sions of 5×1×10 mm was used as the material. Analyses force values are given in Table 1 for drum speed of 2,000
were carried out for cases when the magnet height was 5 rpm.
and 10 mm and the resultant force acting on the material As can be seen from Table 1, the force induced in the
was given in Fig. 13. copper material is greater in comparison with that in
Average value of resultant forces are 428.17 mN for 10 aluminum. However, this result is different in efficiency
mm and 258.84 mN for 5 mm magnet height. The effect experiments. The experimental measurements carried out
of this parameter was not examined experimentally. How- at belt speed of 0.2 m/s, drum speed of 3,000 rpm that
ever, it was determined analytically that the increase of separation success was 94.7 % for copper, 99.5 % for
magnet volume increases the induced current in the aluminum and 97.8 % for the mixture with this novel
material according to the Ampere’s Law given in Eq. (9). ECS [9]. The reason for this was explained by Kang and
Schoenung in [6]. It was put forth that the main criterion
Hdl = I (9)
for an ECS for separation is the ratio of the material
Here, the current and the resulting force increases since density ρ to the electrical conductivity σ (σ/ρ) [6].
the magnet height (l) is affected. Visual results that put Materials for which this ratio is greater can be separated
forth the flux lines and the distribution of magnetic flux more easily. The induced eddy current and force are
density in magnetic analyses have been given in Fig. 14. greater for copper since its conductivity is higher in
It is observed that flux lines circle the material and that comparison with aluminum. However, aluminum was
saturation occurs at the magnet corners [8].
Table 1. Analysis and experimental results of Fx force values
3.6. Effects of material type
50 × 30 × 1 mm Copper Aluminum
Eddy current is generated according to the resistivity of
Experiment results 4.938 N 3.235 N
the material. The induced current and force increases with
Analysis results 4.768 N 3.080 N
decreasing material resistivity. Hence, the force induced

Fig. 14. (Color online) (a) Flux lines, (b) flux density.
Journal of Magnetics, Vol. 21, No. 4, December 2016 − 643 −

separated more easily since its density was lower than aluminum wastes, 94.7 % of the copper wastes and 97.8
that of copper. Separation result is demonstrated in Fig. % of the mixed wastes were separated during the experi-
15 for mixture waste [9]. ments carried out with power cables in granule form [9].
In addition, the effects of drum speed, magnet volume,
4. Conclusion material type and width were also examined in order to
determine the performance of the new ECS. The induced
The separation of non-ferrous small sized particles via force increases with increasing drum speed, magnet height,
ECS is a significant problem. The objective of studies material conductivity and width. The acquired results
carried out until today on ECS are generally the separa- were predicted via analytical approaches and verified via
tion of small particles. Whereas in this study, design FEA solutions and experimental studies.
changes were made in conventional ECS in order to
separate small particles and it was called “novel design Acknowledgement
ECS”. Magnetic drum was removed from the conveyor
belt system and was placed in front of the conveyor as an This study was supported by TÜBİTAK (Scientific and
independent unit in this novel design. Thus, only non- Technological Research Council of Turkey) within the
ferrous materials can pass from the drum since the non- scope of the project numbered 213M551.
conducting materials in the waste to be separated fall
down first from the drum. Hence, the splitter can be References
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