The Zig-Zag Air Separator is specifically engineered to deliver exceptional separation performance in battery recycling applications. Utilizing a multi-stage cross-flow separation system (8 to 15 stages), it efficiently separates light materials from heavier fractions. At lower air velocities, lighter materials are removed, while heavier materials require higher air flow rates for effective separation. The optimized Zig-Zag design and precision-engineered angles ensure superior separation of aluminum and copper from black mass. Integration with mechanical crushing systems significantly enhances overall recycling efficiency, streamlining the process and reducing the need for complex downstream treatments.
The Zig-Zag Air Separator features an advanced segmented channel geometry, designed to optimize material flow and enhance separation precision. Each segment guides particles through controlled airflow zones, promoting the progressive release of agglomerates and improving the separation of fine fractions. This channel design ensures uniform airflow distribution and minimizes material buildup. Through its multi-step separation process, the system effectively breaks down material agglomerates and improves material flow, boosting process efficiency. A specially designed ventilator rotor disk guarantees a consistent airflow, ensuring stable operation and high throughput even under varying process conditions. Optional airflow regulation enables operators to maintain consistent product quality by adapting to variations in feedstock characteristics. Additionally, integrated cleaning valves within the separator channel allow for quick and easy maintenance, minimizing downtime and maximizing operational reliability.
With its high efficiency, precision separation, and long-term operational reliability, the Zig-Zag Air Separator is the ideal solution for battery recycling operations seeking to optimize material recovery and promote a cleaner, more sustainable process.
Technical Specifications
The Zig-Zag Air Separation System separates light and heavy material fractions by means of a controlled upward airflow inside a multi-stage separation chamber.
The system is suitable for applications such as battery recycling, cable recycling, metal recovery, plastic separation, electronic waste processing and mineral classification.
| Model | Nominal Capacity | Feed Size | Stages | Airflow | Fan Power | Inst. Power | Feed Inlet | Heavy Out | Dimensions (W × L × H) |
|---|---|---|---|---|---|---|---|---|---|
| ZZ-100 | 100 kg/h | 0.2–15 mm | 8 | 750 m³/h | 2.2 kW | 3.5 kW | 150 × 150 mm | DN100 | 800 × 1,200 × 2,400 mm |
| ZZ-250 | 250 kg/h | 0.2–20 mm | 8–10 | 1,300 m³/h | 4 kW | 5.5 kW | 200 × 200 mm | DN125 | 1,000 × 1,500 × 2,900 mm |
| ZZ-500 | 500 kg/h | 0.2–25 mm | 10 | 2,500 m³/h | 7.5 kW | 10 kW | 300 × 250 mm | DN150 | 1,250 × 1,800 × 3,500 mm |
| ZZ-1000 | 1,000 kg/h | 0.2–30 mm | 10–12 | 4,800 m³/h | 15 kW | 19 kW | 450 × 300 mm | DN200 | 1,600 × 2,200 × 4,200 mm |
| ZZ-2000 | 2,000 kg/h | 0.2–40 mm | 12 | 8,500 m³/h | 22 kW | 28 kW | 650 × 400 mm | DN250 | 2,000 × 2,800 × 5,200 mm |
| ZZ-3000 | 3,000 kg/h | 0.2–50 mm | 12–14 | 12,500 m³/h | 37 kW | 45 kW | 800 × 500 mm | DN300 | 2,300 × 3,200 × 5,800 mm |
| ZZ-5000 | 5,000 kg/h | 0.2–60 mm | 14–15 | 21,500 m³/h | 75 kW | 89 kW | 1,100 × 650 mm | DN400 | 2,900 × 4,000 × 7,000 mm |
Standard Technical Features
- Adjustable airflow for different material densities
- Variable-frequency-controlled radial process fan
- Multi-stage Zig-Zag separation chamber
- Controlled material feeding system
- Separate light and heavy fraction outlets
- Inspection and cleaning doors
- Replaceable wear-resistant internal liners
- Dust-tight construction
- Connection points for cyclone and dust filtration systems
- PLC-based automatic control system
- Emergency stop and motor protection system
- Carbon steel or stainless-steel construction options
- Optional ATEX-compliant design
Available Inlet and Outlet Connections
- Material feed inlet
- Process air inlet
- Heavy fraction discharge
- Light fraction and air outlet
- Cyclone connection
- Dust collection connection
- Cleaning air connection
- Inspection and sampling points
- Differential pressure measurement points
- Electrical grounding connection
Material Requirements
| Parameter | Recommended Condition |
|---|---|
| Material condition | Dry and free-flowing |
| Recommended moisture | Below 2% |
| Maximum moisture | Approximately 3–4%, depending on material |
| Feed consistency | Uniform and continuously controlled |
| Oversized materials | Must be removed before feeding |
| Long wires and cables | Must be separated before the Zig-Zag unit |
| Operating temperature | Maximum 50°C unless otherwise specified |