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Scrap steel shredder shipped to Vietnam
A scrap shredder, also known as a metal shredder or scrap crushing line, is a heavy-duty industrial machine that uses shearing, tearing, and squeezing to break large, heavy scrap metal (such as car hulls, scrap home appliances, scrap steel, and oil drums) into smaller, denser, and purer fragments. It is a key piece of equipment in the modern scrap metal recycling industry.
I. Core Working Principle
The working principle of a scrap shredder is simple, but it places great emphasis on power and strength:
Feeding: Large volumes of scrap metal are fed into the shredder’s feed port via a chain conveyor or steel grabber.
Shredding: The core of the equipment is two counter-rotating blade shafts (main shafts) equipped with high-strength blades. Upon entering, the material is hooked and engaged by the rotating blades, subjecting it to intense shear and tearing forces between the two rows of blades.
Compression: Simultaneously, the material is compressed and ground within the blade housing, continuously breaking it down.
Discharge: Crushed material below a certain size falls through the mesh at the bottom and is transported by a discharge conveyor. Material that does not meet these requirements continues to be shredded within the shredder until it can be discharged.
The entire process is typically automated, supplemented by a powerful hydraulic system (for material movement, overload protection, etc.) and an electrical control system.
II. Main Components
A complete scrap shredding line consists of much more than just a main machine. It typically includes:
Feeding System: A chain conveyor or heavy-duty steel grabber feeds the main machine evenly and continuously.
Main Machine (the heart of the shredder):
Blade Case: A sturdy steel structure housing all core components.
Blade Shaft Assembly: Consists of the main shaft, blades, spacers, bearings, and more. The blades are typically made of a special alloy steel for wear and impact resistance.
Power System: Two high-power motors (usually two) drive the blade shaft at low speed and high torque via a speed reducer or belt.
Hydraulic System: Provides power to the pusher box, pushing the material toward the blade shafts; it also automatically reverses in the event of an overload to protect the equipment.
Discharge System: A vibrating conveyor or belt conveyor transports the shredded material.
Sorting System (Optional but Important):
Magnetic Separator: Separates ferromagnetic metals (such as steel and iron).
Eddy Current Separator: Separates non-ferrous metals (such as copper and aluminum).
Wind Separation System: Removes lightweight debris (such as plastic, rubber, and dust).
Control System: A PLC intelligent control center monitors the entire production process, enabling automated operation and fault diagnosis.
III. Main Equipment Types
Based on the number and arrangement of blade shafts, the following are common types:
Dual-Shaft Shredder (Shear-Type Shredder): The most common type, with two blade shafts shearing against each other, relying primarily on shear force. The output size is controllable and is suitable for processing medium- and thick-walled plates, profiles, and household appliances.
Four-Shaft Shredder: Provides greater shredding force and enhanced pre-processing capabilities, making it suitable for processing very thick or bulky materials. Pulverizer: Typically used for secondary crushing after shredding, it uses high-speed rotating hammers to impact the material, making it smaller and denser.
IV. Outstanding Advantages and Features
Volume Reduction and Densification: Crushes large, fluffy scrap into small, dense pellets or blocks, reducing volume by up to three-quarters, significantly saving transportation and storage costs.
Improved Purity: During the crushing process, impurities such as paint, dirt, and plastic adhering to the metal are largely separated. After passing through a sorting system, high-quality scrap steel with a purity exceeding 98% is obtained.
Improved Melting Efficiency: The crushed material is uniform in size, high in density, and has a large specific surface area. This allows for more compact charging and faster heating in electric furnaces, significantly reducing energy consumption, lowering burnout, and improving steel mill production efficiency.
High Level of Automation: The entire production line operates continuously and automatically, requiring minimal labor and achieving high production efficiency.
Wide Processing Range: Capable of processing a wide range of scrap metals, including car hulls, scrap home appliances, scrap rails, paint cans, bicycles, and more.
V. Main Application Areas
End-of-Life Vehicle Recycling: Core equipment for processing end-of-life vehicle bodies (ASR).
Used Home Appliance Recycling: Processes refrigerators, washing machines, air conditioners, and more.
Scrap Steel Processing and Distribution Centers: Processes recycled scrap steel into high-quality furnace feedstock.
Metal Products Factories: Process scrap and defective products generated during their production processes.
Environmental Protection: Safely handles discarded oil and chemical drums, preventing pollution.
Summary: A scrap shredder is more than just a simple shredder; it is a comprehensive scrap metal pre-processing solution integrating mechanical, hydraulic, electrical, and intelligent control systems. It physically transforms low-value scrap metal into high-value, high-quality steelmaking raw materials. It serves as a critical bridge between the scrap metal recycling and steelmaking industries, playing a vital role in promoting a circular economy and resource regeneration.
