Report: Optimizing the Process of a Rolling Magnetic Separator Plant

This report provides a detailed analysis of process optimization for a rolling magnetic separator in an industrial waste sorting plant. It begins by mapping the sorting process, which involves separating ferrous and non-ferrous materials using eddy current separators and magnetic rotors. The report outlines the responsibilities of personnel working on the sorting line, including manual sorters, line workers, technicians, and software supervisors. It then identifies the challenges hindering effective metal sorting, such as personnel issues, lack of expertise, unreliable equipment, and difficulties in separating non-ferrous materials. The report proposes several recommendations to improve the sorting line, including creating awareness, involving inhabitants, promoting communication, and educating the public. Additionally, the report includes a shop floor layout, material flow diagrams, and an analysis of the layout, along with suggestions for further improvements focusing on communication, worker involvement, and enhanced recycling station maintenance.

Running head: PROCESS OPTIMIZATION FOR ROLLING MAGNETIC SEPARATOR 1
Process Optimization for Rolling Magnetic Separator
Student’s Name
Affiliate Institution
Instructor’s Name
Course
Date

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Introduction
An eddy current separator has been used in the past to separate ferrous and non-
ferrous materials. The technology applies the use of a conveyor belt to separate the non-
ferrous materials autonomously and continuously. The conveyor belt results in a uniform
distribution throughout the system hence making the separated material to arrive as a
monolayer. However, the separation of the non-ferrous metals depends on three factors,
including the electrical conductivity of the materials, the material density, and the ratio of the
electrical conductivity and the material density. These factors determine the success of the
separation. For instance, it becomes an easy process when the electrical conductivity is
greater with the material density being low. In addition, the size of the material as well plays
a role in determining the success of the operation. (Cossu et al., 2012).
This assignment details the mapping process of the Ferrous and Non-Ferrous Metal
Sorting Plant, alongside the people working on the sorting line and their responsibilities.
Additionally, the report details information on why the metal sorting practice is unpopular
and the strategies which can be employed to improve the sorting line. Finally, the report
provides a sample layout and material flow of a shop floor together with an analysis of the
sorting line.
Process map for the of the Ferrous and Non-Ferrous Metal sorting plant
From the basics, metal sorting entails the separation of the ferrous from non-ferrous
materials. The ferrous materials are attracted by magnets and contain iron hence making it
easy for the elimination of steel and iron, while the use of an electromagnet eliminates large
prices (Niemirowicz et al., 2012). The process map for the Ferrous and Non-Ferrous Metal is
described in the section below
Mapping

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The eddy current separator comprises of a conveyor belt, short in length with a
location of a drive on the return end as well as a high-speed magnetic rotor system which is
located on the discharge end. In a separately attached rotating non-metallic turn is a magnetic
rotor which rotates at a speed of 3000 revolutions in a single minute during the working of
the conveyor. On the other hand, the outer drum rotates at a similar speed to the speed of the
eddy currents conveyor belt (Yang et al., 2012).
When the high-speed eddy currents systems rotor rotates, an electric current gets
induced within the conducting metals. When this electric current is induced, a magnetic field
is generated that acts in the opposite direction to the field generated by the rotor.
Consequently, this magnetic field generated opposes the conducting materials in an already
positioned splitter plate. Other materials, for instance, the glass, plastics as well as dry
recyclables will fall freely into the rotor, alienating themselves from the repelled materials
(Miyagi et al., 2010).
Since a majority of the product streams contains ferrous elements such as iron, the
eddy currents will entail a defferisation module at the start of the sorting machine. This
module will help in eliminating the ferrous metals using a separate route prior to the actual
non-ferrous material separation. Alternatively, a ferrous metal separation equipment can be
used before exposing the sorting machine to specifically non- ferrous materials. The strong
magnetic force which is generated by the rotor attracts the ferrous material firmly (Cossu et
al., 2012). The diagram below illustrates the flow diagram for the ferrous and non-ferrous
separation.

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People working on the Sorting Line: Responsibilities and Activities.
So far, the automatic waste plastic sorting machine employs most of the
communication devices, such as sensors to manipulate various operations. The process is
different from the manual system, which solely depends on the plant personnel who is
responsible for the visual removal and separation of the non-ferrous components. In this
system, approximately five staff are required. The staff at the end of the process which is
responsible or manual sorting for quality assurance, a technician, supervising personnel, and
line workers (Shuttleworth eta l., 2012)
 Manual personnel- usually, at the end of the sorting process, most of the sorting
plants would turn to the manual sorting of the particular materials. This implies that
there is a need for manual personnel who will handpick the different types of non-

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ferrous and place them in separate bins. This helps in ensuring quality assurance is
achieved.
 Line workers: at most two or three: The line worker is responsible for ensuring that
the system runs smoothly. However, they have little or no work to as the system can
be monitored from a remote place within the connections of a computer system.
 Technician- a technician, is responsible for repairing various mechanical parts that
have failed or slowed down. Further, they help in assisting in the maintenance of the
hardware parts of the sorting system (Cossu et al., 2012).
 Software supervisor personnel- the software supervisor, is responsible for monitoring
of the system from a remote place. Technically, this process has been designed to
operate autonomously, implying that no human labor should be involved in the
process unless in minimal instances. The software supervisor will thus monitor the
system via a central point whereby the various communication devices such as the
sensors and actuators will be detecting various changes in the process and relay the
signals. Further, just by some simple manipulations within the central processors, the
software personnel can perform manipulative operations in case there is a system
breakdown.
Why Metal Sorting Is Not Doing Properly:
Metal sorting is one of the techniques of separating a dry material (metal) from a
mixture of other waste products. Despite being a superior technology, metal sorting has not
gained much popularity in the field of sorting. Some of the problems as to why metal sorting
is not doing properly including
 Personnel is not properly doing their duties- the assigned persons over the past have
not been keen when handling the metals, thereby allowing insufficient separation of
the metals (Reck & Graedel, 2012).

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 The limited number of highly trained experts- metal sorting is one of the sophisticated
processes which requires high knowledge and skills. However, there has been a
challenge with the number of trained experts who can handle the process. Most of the
line workers are not quick enough nor accurate, and this has over the past affected the
metal sorting (Phillip et al., 2010).
 Further, most of the metals which are sorted out are not reliable- reliability is one of
the essential factors in helping to achieve sustainability. However, with the metal
sorting techniques, most of the equipment’s or rather machines which are employed
does not result in reliable products being sorted out, thus, jeopardizing the sector.
 Another realization is that it is a bit difficult to spate non- ferrous materials. Since
technology applies a magnetic mechanism to spate the materials, the non-magnetic
materials become a little bit difficult to separate. They end up mixing with the other
waste products after separation. In addition to this, the available knowledge is not
sufficient enough to handle non-ferrous materials (Kim et al., 2013).
 In addition, there is no flexibility when handing the metallic wastes. Some of the
metallic wastes have different surfaces, thereby hindering the smooth running of the
automated machine. This will either interfere with the machining process or slow
down the process. When the prices are slowed down, the programming part of the
machine is affected, thereby resulting in a problem with the metallic sorting system.
 Also, some of the metallic substances are harmful - the sorting line workers may not
be knowledgeable of some of the destructive nature of metallic wastes and ends up
getting some sought of harm. This has also contributed to the unpopularity of the
metallic sorting (Qun-hu et al., 2011).
Recommendation to Improve the Sorting Line.

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It is essential to improve the sorting line so that the sorting of various products
becomes easy. When the sorting line is improved, it becomes easy to separate the various
products. However, enhancing the sorting line dates back to various practices art the source
of the wastes. Sustainable practices, when employed, will thus help in making it easy for the
sorting line. Some of the various practices which can be adopted or recommended to assist in
improving the sorting line includes
i. Creating an awareness aimed to address specific methodologies of collecting garbage.
Under normal circumstances, the wastes are just collected in the same bin, thereby
making it difficult when it comes to sorting out various products. Labels should be
used when disposing of the wastes so that when these materials are taken into the
sorting machines, it becomes easy for the sorting line to handle the products (Qun-hu
et al., 2011).
ii. Involvements of inhabitants on the system development. Ordinarily, the inhabitants
have numerous ideas on how the sorting can be enhanced, when they are involved,
they become more motivated and thus would be very careful when disposing of
materials so that the sorting line is maintained, which eventually improves it from
damages (Cesaro & Belgiorno, 2014).
iii. Additionally, promoting effective communication across the inhabitants is essential in
promoting best practices in line with the sorting line system.
iv. Creation of visits for the inhabitants into the sorting stations so that they experience
the benefits of organized sorting of the wastes. In this way, they will personally feel
motivated and appreciate the process.
v. Educating the masses through the media on various benefits of sorting of products.
This can as well involve spreading the information to institutors. The children would

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quickly grow, knowing the essence of a sorted collection of waste, and the culture will
develop across (Kim et al., 2013).
vi. Also, the application of an MR indicator to the system helps in ensuring the quality of
the products, if in case the quality is not desirable, then an improvement into the
system would be necessary
vii. Enhancing the recycling sorting stations by better cleaning and maintenance practices,
placing of lights and camera, other sensors as well as putting quickly comprehendible
signs to the operators.
viii. Finally, keeping in touch with the waste researchers is also one of the recommended
practices which help in providing the best information for the sorting line system.
Material flow in shop floor and layout the sorting line
Shop floor
A shop floor is defined as an area in the production facility or manufacturing facility which
houses the production or assembly activities either through a series of automated activities or
labourers or a combination of both. Among the things included are storage areas, inventory,
and equipment. Some of the components of the shop floor are: (Lee et al., 2012)
 Material- either natural resources or human made.
 Machinery/equipment- either electrical, mechatronics, electronic, or thermal tool
alongside other tools. The diagram below summarises the shop floor.

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Shop Floor Layout
Material Flow in Shop Floor And Layout The Sorting Line

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Feedback
Analysis of the layout
The analysis comprises of designing alternative layouts with regards to the physical
building constraints, information gathered as well as the design criteria. A words arts work is
used to perform the block layout. The weekly distance trips for the raw materials and
working process in all the departments are assessed, which helps in enhancing the optional
handling equipment’s.
Scope for improvement
The improvements would be made on the sorting line where effective promoting
communication across the inhabitants is essential in promoting best practices in line with the

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sorting line system. The workers can also be Involvements on system development. In
addition, the sorting line can also be enhanced for this case by improving the recycling
sorting stations by better cleaning and maintenance practices, placing of lights and camera,
other sensors as well as putting easily comprehendible signs to the operators (Yang et al.,
2012).
Conclusion
The existing automated sorting system might require high investments, especially
those which deploys near infra-red technologies as they are suitable for the recycling
operations that need high throughput. A ferrous and non-ferrous waste sorting machine has
been detailed in this report alongside some recommendation which should be applied on the
sorting line. Further improvement in terms of research will help in coming up with a better
system with increased efficiency and a high level of safety. A refinement in artificial
intelligence techniques will be of great benefit for future soring systems.

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