Iron & steel recycling is a long-established and strategically important industrial sector. Scrap metals are a valuable raw material resource for both scrap recycling companies and iron & steel producers. Today, in line with the decarbonization targets of the sector, production technologies based on traditional blast furnace and converter methods (BF/BOF) are being replaced by scrap-based methods such as electric arc furnace and induction furnace (EAF/IF). This transformation is a critical step not only for reducing greenhouse gas emissions but also for utilizing low-quality scrap and lowering the operational costs of melting processes. Scrap sources are generally divided into two main groups: new scrap and old scrap. New scrap is generated during production processes, has a known composition, and usually does not require any pre-treatment. Thanks to its homogeneous structure, it stands out as being directly suitable for remelting. In contrast, old scrap is obtained from end-of-life products and is generally heterogeneous in structure, potentially containing various contaminants. The physical and chemical properties of old scrap can vary significantly depending on its source, such as building demolitions, vehicle recycling, or household appliance waste. Today, the most commonly available type of scrap in the market is this old scrap.
One of the most widely used methods in the iron & steel industry, particularly for scrap recovery, is the Electromagnetic Drum Separator application (Electromagnetic Drum – BAS®). The main advantage of this technology is its ability to generate a strong magnetic field and the ability to control the intensity of this field precisely. The separator consists of electromagnets with opposing poles and magnetic field concentrators placed between them. The system is designed to effectively separate ferromagnetic metal particles from non-magnetic materials. In electromagnetic separators, the magnitude and direction of the magnetic force are critically important, as they directly affect the ferromagnetic materials. The success of the separation process depends on the amount of recovered metal, that is, the separation efficiency. For effective separation, the applied electromagnetic force must exceed the total of opposing forces (gravity, friction, etc.). To maintain the equipment’s performance at maximum level, it is essential to correctly calculate the design, electrical, and electromagnetic parameters of the equipment, and to conduct a sufficient number of experimental studies to validate these calculations. This approach is crucial for improving process efficiency as well as optimizing energy and cost.