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Full Description
A systematic guide to mechanical recycling—from particle properties to plant design and operation
Mechanical recycling separates, concentrates, and upgrades material streams while largely preserving their chemical composition. Mechanical Recycling Technologies: From Fundamentals to Applications combines the scientific and engineering foundations of mechanical processing with practical examples, fully worked calculations, and examination-style problems. It places the individual unit operations within the broader context of the circular economy.
The book develops the subject systematically, beginning with particle properties, material flow analysis, and the behavior of bulk solids. It then covers comminution, classification, and the major sorting processes used in industrial recycling. The final chapters address the design, construction, commissioning, and operation of recycling plants. Step-by-step calculations and detailed solutions help readers translate theory into engineering practice.
Readers will find:
A concise introduction to waste management, resource conservation, and the circular economy
Detailed treatment of particle characterization, liberation, material flow balancing, and bulk solids behavior
The scientific foundations and practical application of industrial separation processes
Fully worked examples with step-by-step solutions
Examination-style problems for independent study and self-assessment
Practical guidance on recycling plant design, commissioning, operation, and throughput optimization
Written for bachelor's and master's students in environmental, mechanical, and process engineering, as well as engineers and practitioners in the recycling industry, this textbook provides a structured path from fundamental principles to plant-level application.
Contents
User Manual xiii
Acknowledgments xv
Looking Back xvi
Symbols and Abbreviations xvii
Photo and Image Credits xxi
About the Companion Website xxii
Part A Fundamentals 1
1 Introduction 3
1.1 Paradigm Shift: From Waste Management to a Circular Economy 4
1.2 Importance of Recycling for Waste Management 7
1.3 Limits of Recycling 10
1.4 Mechanical Recycling: Process-engineering Context 15
1.5 Fundamentals of Mechanical Recycling 16
2 Material Properties 25
2.1 Physical Material Properties Relevant to Processing 25
2.2 Material Groups and Their Recycling-Relevant Properties 32
3 Particle Geometry 37
3.1 Shape 37
3.2 Particle Size 39
3.3 Angularity 42
4 Distributions of Particle Characteristics in Bulk Solids 45
4.1 Particle Size Distribution 45
4.2 Liberation of Composites 67
4.3 Distribution of Particle Densities and Magnetizability 86
5 Mechanics of Bulk Solids 93
5.1 Porosity, Bulk Density 93
5.2 Angle of Repose 97
5.3 Flow Behavior/Agglomeration 99
5.4 Segregation 107
6 Collection and Examination of Sample Material 111
6.1 Collection of Representative Samples 112
6.2 Minimum Required Sample Size 115
6.3 Sampling in the Field 131
6.4 Sample Preparation 133
6.5 Characterization of the Sample 141
7 Particles in Flows 149
7.1 Laminar and Turbulent Flow 149
7.2 Sedimentation 1517.3 Fluid Flow Through Particle Beds 162
Part B Process Engineering Operations 167
8 Management of Material Flows 169
8.1 Mass and Material Flows 169
8.2 Balancing 172
9 Separation Processes 185
9.1 Fundamentals 186
9.2 Classification 188
9.3 Sorting 209
9.4 Link Between Separation Performance Curve and Partition Curve 227
9.5 Technical Optimization of Separation Performance 247
9.6 Economic Optimization of Separation Performance 257
9.7 Methodology for Developing a Separation Process 262
10 Fundamentals of Size Reduction 267
10.1 Comminution 267
10.2 Deagglomeration 278
10.3 Attrition 279
Part C Equipment and Plant Engineering 283
11 Comminution Technology 285
11.1 Coarse and Fine Comminution: Crushers and Mills 286
11.2 Brittle Comminution 287
11.3 Ductile Comminution 299
11.4 Disintegrators 302
12 Screening Technology 309
12.1 Ballistic Screening 310
12.2 Horizontal Screening 338
12.3 Trommel Screens 342
12.4 Gravity Screens 344
12.5 Particle Shape Separation 350
13 Flow Classification Technology 359
13.1 Overview of Classification Processes 360
13.2 Gravity Classifiers 361
13.3 Mechanical Classifiers 365
13.4 Centrifugal Classifiers 366
13.5 Ballistic Classifiers 375
14 Density Separation 379
14.1 Introduction and Overview 379
14.2 Float-Sink Separation 387
14.3 Flow Separation 392
14.4 Jigs 396
14.5 Spiral Separators 398
14.6 Shaking Tables 403
14.7 Aero Ballistic Sorting 407
15 Sorting Based on Magnetism and Electrical Conductivity 411
15.1 Magnetic Sorting 411
15.2 Sorting by Electrical Conductivity 422
16 Single-particle Sorting 441
16.1 Manual Picking 441
16.2 Sensor Sorting 444
17 Unconventional Separation Processes and Outlook 459
17.1 Sorting According to Hydrophobicity: Froth Flotation 459
17.2 Magnetic Oil Separation 462
17.3 Magnetohydrostatic Separation 463
17.4 Thermographic Sorting 465
17.5 Fiber Separation 465
17.6 Film Separator 466
17.7 Outlook 467
18 Construction and Operation of Recycling Plants 471
18.1 Plant Engineering from the Operator's Perspective 471
18.2 Plant Operation: Practical Recommendations for Operators 485
18.3 Maintenance 494
18.4 Instrumentation and Control Systems 497
18.5 Cost Structures of Processing for Selected Waste Streams 502
Appendix 511
Exercises 511
US Mesh vs. Aperture Size 562
Separation Sharpness: κ vs. Bu 563
Glossary 564
Index 572
