According to the state of the art, most of the mixed copper and copper alloy scrap and residues are processed in a copper smelter. Despite the environmental and economic advantages relative to primary production, the recycling of copper and its alloying elements (zinc, tin, lead, nickel, etc.) requires significantly more energy and cost than remelting unmixed or pure scrap fractions such as separate collected material or production scrap. To date, however, less attention has been given to the mechanical purification of mixed scrap. Therefore, sorting by alloy-specific components (SBASC) using an industrial X-ray fluorescence (XRF) sorting system was tested on the coarse metallic fraction (10-32 mm) of mixed foundry residues. The findings show that XRF-SBASC can recover higher-grade copper concentrates (reaching 98.3% Cu), leaded brass and complex alloys, such as aluminium bronze and red brass with high purities, for the use in the production of new materials. XRF-SBASC can therefore contribute to a more resource efficient metal recycling, mainly by reducing the energy consumption and loss levels in copper metallurgy.
Keywords: Copper; X-ray fluorescence sorting systems; copper alloys; foundry residues; non-ferrous metal recycling; resource efficient recycling; scrap; sorting by alloy specific components.