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Flexible drives for energy-efficient metal recycling

Case Study: The World’s First Sustainable Metal Recycling Plant

Flexible drives for energy-efficient metal recycling

The world's first sustainable metal recycling plant

Mitsubishi Electric supplies 3,000 HP frequency converters for a large shredder plant of the S. Norton Group in Manchester

The S. Norton Group has commissioned a brand new, state-of-the-art metal shredding plant in Manchester, UK, with an investment of 20 million pounds. The group collects, processes, and exports 1.5 million tons of recycled metals annually. For Manchester, the ZZ Power Zerdirator shredder was designed to achieve an annual output of 130 tons per hour, thanks to the latest drive solutions from Mitsubishi Electric.

Challenges for the large metal recycling plant of the S. Norton Group in Manchester

Plants can be equipped with low-maintenance frequency inverters on three-phase asynchronous motors, leading to savings in energy, wear, and maintenance costs.

High energy costs
The recycling business is highly energy-intensive. Shredders, conveyors, and exhaust air treatment systems are massive electrical power consumers.

Changing power requirements
The rotor of a shredder must constantly adapt to changing power requirements due to the varying composition of the material being fed into the machine.

High load peaks and grid asymmetries
When the shredder rotor is loaded with metal scrap to be processed, it is temporarily slowed down. To compensate for this and bring the motor back up to speed, it draws as much power as possible from the grid, leading to load peaks, grid asymmetries, and high energy costs.

Therefore, new approaches are needed. Together with LINDEMANN Metal Recycling Solutions and Mitsubishi Electric, a system was developed that significantly reduces energy consumption.

Our Solution: Precise Control of the Shredder Motor with Energy-Efficient Frequency Inverters

Flexible control through the TMdrive or the FR-A800/FR-F800 series allows for higher motor utilization without overload and operation of the plant within the optimal range.

Mitsubishi Electric offers innovative drive solutions that provide an efficient and cost-saving alternative for the metal recycling industry.

For the S. Norton Group in Manchester, UK, a state-of-the-art metal shredding plant was equipped with the Lindemann ZZ Power Zerdirator shredder, powered by energy-efficient frequency converters and medium voltage converters from the TMDrive series.

These technologies enable precise control of the main motor and optimize material throughput while reducing energy consumption.

Result: Maximizing Efficiency and Sustainability of the Recycling Plant

Mitsubishi Electric plays a crucial role in enhancing the efficiency and sustainability of the plant by providing energy-efficient drive solutions.

Rising energy prices not only burden operations but also challenge the overall profitability of the sector. With intelligent products and solutions for energy and cost savings, Mitsubishi Electric contributes to the future viability of metal recycling, which is itself a cornerstone of the sustainable circular economy.

Intelligent Load Management

The intelligent load management functions of the frequency converters reduce load peaks and prevent grid asymmetries. This ensures a stable power supply and protects the infrastructure of energy providers.

Reduced Energy Consumption

By using Mitsubishi Electric’s energy-efficient medium and low voltage frequency converters, the energy consumption of the shredder plant has been significantly reduced. This contributes to substantial cost savings and a reduction in operating expenses.

Reduction of Energy Costs with Consistent Performance

By limiting the current draw of the shredder motor during material processing, energy costs are reduced without compromising system performance. This ensures an optimal balance between energy usage and production efficiency.

Increased Motor Utilization and Life Time of Equipment

The frequency inverters enable precise control of the motors, allowing for higher motor utilization without overload. This leads to more efficient operation and extends the life time of plant components, reducing maintenance and replacement costs.

Predictive Maintenance and Improved Plant Availability

Software solutions such as the Recycling Asset Portal enable real-time monitoring and optimization of operating data. This facilitates predictive maintenance and increases plant availability, minimizing downtime and further boosting productivity.

Supporting Sustainability Goals

Mitsubishi Electric's energy-efficient solutions directly contribute to achieving sustainability goals by reducing the environmental impact of recycling processes while simultaneously increasing efficiency.
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