Ferrous Scrap Processing for Quality Differentiation
The Brazilian ferrous scrap market is dominated by mixed scrap traded as a tight-margin commodity.
Precision foundries and steelmakers with electric arc furnaces pay more for clean, classified scrap. High-purity scrap reduces melting losses, decreases slag and eliminates contaminants (copper, tin, zinc) that permanently compromise steel quality.
The opportunity lies in transforming mixed scrap into premium scrap through controlled shredding, particle size classification and magnetic refining.
5-Step Process
1. Reception and Sorting
Scrap from various sources (industries, demolition companies, scrap yards) goes through manual sorting for removal of non-processable materials and separation of high-value non-ferrous metals (copper, aluminum, brass).
2. Primary Shredding — D Line
Large scrap (appliance carcasses, structural steel, automotive scrap, drums) homogenized to 50-100 mm with up to 70% volume reduction.
Low-rotation shredding (20-40 RPM) standardizes size, liberates contaminants (plastics, rubber, wood) trapped in metal parts and minimizes fines. High-rotation shredders (hammermills) generate 30-40% fines; the D Line generates less than 10%.
3. Particle Size Classification — Disc Classifier
Rotating discs with adjustable spacing (20-80 mm) retain metal scrap at the upper exit while plastics, rubber, paper and glass fall between discs. Recovered contaminants can be sold for recycling or energy recovery.
4. Magnetic Refining
High-intensity permanent magnet separators remove residual ferrous metals and fines from the shredded stream. Non-ferrous conductive metals (copper, aluminum, zinc, brass, bronze) are recovered by eddy current separation, while non-magnetic stainless steel requires sensor-based or induction sorting depending on the configuration. Multi-stage configuration (medium intensity first pass, high on second).
The non-ferrous fraction is recovered and sold separately for recycling (aluminum scrap, copper, brass, bronze).
5. Baling and Commercialization
Premium scrap is pressed into bales and sold to foundries and steelmakers.
Quality and Price
Electric arc furnace (EAF) steelmakers use scrap as 70-100% of their metallic charge. Precision foundries require high-purity scrap because metallic contaminants (copper, tin) cannot be removed during melting.
The price differential between mixed and premium scrap is justified by: less slag (higher metallic yield per heat), lower energy and correction additive consumption, and superior final product quality.
Equipment for Ferrous Scrap
Dual-Shaft Shredder — D Line (D690 and above)
Learn about the D Line 2-shaft shredder →
| Feature | D690 |
|---|---|
| Power | 2x 200 hp (400 hp total) |
| Cutting chamber | 1,392 x 1,905 mm |
| Rotation | 20-40 RPM |
| Rotor diameter | 690 mm |
| Blade width | 50-100 mm |
| Weight | 21,100 kg |
Hexagonal shafts with 4 bearings per shaft. Blades with replaceable inserts — 500-1,000 h lifespan on ferrous scrap. Triple sealing system against metal dust. PLC with automatic reverse.
Disc Classifier — CDD Series
1.5 m width, 2 m modules (2 to 8 m length configurations). Adjustable disc spacing from 20 to 200 mm. Power 10 to 20 hp. Typical capacity 5-15 ton/h for shredded ferrous scrap.
Magnetic Separators
Suspended electromagnets (overband), magnetic drums and magnetic pulleys with high-intensity permanent magnets. Multi-stage configuration based on composition and target purity. Learn about the Ferrous Metal Extractor →
Expected Results
| Indicator | Before (mixed scrap) | After (processed) |
|---|---|---|
| Purity | Mixed, contaminated | Clean ferrous fraction, defined per project |
| Value increase over base price | — | Premium for clean, classified scrap |
| Fines generation (< 10 mm) | 30-40% (hammermill) | < 10% (D Line) |
| Non-ferrous revenue | Lost in the mix | Separated and sold for recycling |
| Light contaminants | Mixed into lot | Separated and sellable |
Operator Profile
- Medium recyclers (1,000-3,000 ton/month) selling mixed scrap who want to serve foundries and steelmakers with quality requirements.
- Demolition companies and automotive scrap processors with heterogeneous material.
- Companies serving the export market with defined scrap specifications.
- Foundries and steelmakers with in-house processing internalizing beneficiation to reduce refining costs.
Frequently Asked Questions
What is a ferrous scrap shredder?
A ferrous scrap shredder reduces mixed scrap to a uniform particle size, liberating contaminants trapped in metal parts so downstream classification and separation can recover a clean, high-purity ferrous fraction. The D Line dual-shaft shredders described on this page operate at low rotation to minimize fines generation.
What is the difference between ferrous and non-ferrous scrap?
Ferrous scrap contains iron and responds to magnets, which is why it can be recovered with magnetic separation. Non-ferrous scrap (copper, aluminum, zinc, brass and bronze) does not respond to magnets and is recovered by eddy current separation. Stainless steel is a special case: its magnetic response depends on the grade and processing history, and austenitic grades like 304/316 are normally non-magnetic.
How does separation work in a ferrous scrap line?
The line combines magnetic and non-magnetic stages: permanent magnet separators remove ferrous metals, eddy current separators recover conductive non-ferrous metals, and sensor-based or induction sorting handles materials such as non-magnetic stainless steel, depending on the configuration. Before that, the disc classifier separates light contaminants by particle size.
What materials can be processed?
Typical feed includes appliance carcasses, structural steel, automotive scrap and drums, with light contaminants (plastics, rubber, paper and glass) separated along the line and sold for recycling or energy recovery. Materials that cannot be processed are removed during manual sorting at reception.
How do I specify a ferrous scrap processing line?
Start from your feed composition and target purity: the line described here upgrades mixed scrap to a clean ferrous fraction, with the purity gain defined per project. Precision foundries and electric arc furnace steelmakers pay a premium for clean, classified scrap. Throughput, particle size and separation stages follow from there, and our team can help size the line for your operation (contact us).
