How To Operate A Copper Cable Recycling Machine

I. Pre-Start Preparation and Inspection
Before starting the equipment, be sure to complete the following checks to avoid malfunctions or safety hazards during operation:

1. Confirm that the power connection is stable, the voltage meets the equipment requirements (usually 380V), and the grounding device is intact.

2. Check that all bolts are tight, especially those on the blades and bearings, to prevent loosening that could cause vibration or damage.

3. Check the wear of the blades. If significant dulling or nicks are found, replace them immediately. YG8 alloy tungsten carbide blades are recommended for improved wear resistance.

4. Clean the crushing chamber and conveyor belt to ensure there are no residual materials or foreign objects obstructing the flow.

5. Start the dust removal system, confirm that the negative pressure is normal and the filter bags are undamaged to prevent dust from overflowing and polluting the environment.

II. Standardized Feeding Operation
The correct feeding method is key to ensuring stable equipment operation:

1. Pre-cut the waste cables into short sections ≤90mm for even feeding and to avoid clogging.

2. Use an automatic conveyor belt for feeding; manual pushing is prohibited to prevent entanglement risks.

3. Adjust the feeding speed according to the cable type: Reduce the speed when processing thick cables (Φ>8mm) to prevent motor overload; increase the speed appropriately for thin cables (Φ3-5mm), improving processing efficiency to over 15m/min.

4. For oil-containing cables, it is recommended to remove grease using a 60℃ constant temperature cleaning tank before crushing to avoid contaminating the copper granule purity.

III. Multi-stage Crushing and Separation Process During equipment operation, the material undergoes multiple processing stages:

1. Primary Shredding: The cable is initially torn apart by a twin-shaft shredder, separating the outer sheath from the conductor, with the speed controlled at approximately 120r/min.

2. Secondary Crushing: The cable enters a high-speed crusher (speed up to 400r/min) to completely separate the copper and plastic, reducing the particle size to below 6mm.

3. Vibrating Screening: A three-layer vibrating screen removes fibrous impurities and agglomerates, ensuring the purity of materials entering the sorting stage.

4. Air Separation: Based on the density difference between copper particles and plastic, initial separation is achieved in an air classifier; heavier copper particles sink, while lighter plastic floats.

5. Electrostatic Separation: For fine particles still mixed after air separation, a high-voltage electric field (30-50kV) is used for fine purification. The difference in conductivity causes the plastic to become charged and adsorbed, while the copper particles fall freely, achieving a copper purity of over 98.5%.

6. Secondary Electrostatic Separation: Trace amounts of copper powder entrained in the plastic are further separated, further enhancing the recycling value of the plastic.

IV. Discharge and Subsequent Processing
After separation, the products should be collected and processed promptly:

1. Copper granules and plastic should be collected through separate discharge ports to avoid secondary mixing.

2. An optional copper wire baler can be installed to compress loose copper granules into high-density blocks (density exceeding 5 tons/cubic meter), significantly reducing transportation costs by 60% and minimizing oxidation losses.

3. Baled copper blocks are easier to store and smelt. Actual data from a smelter shows that using baled copper blocks can increase single-furnace capacity by 20%.

V. Shutdown and Routine Maintenance
After operation, proper shutdown and maintenance can effectively extend equipment life:

1. Stop feeding first, and let the equipment idle for 1-2 minutes to drain residual material before disconnecting the power.

2. Clean the crushing chamber, screen, and electrodes, especially the corona electrodes of the electrostatic separator, which should be wiped with anhydrous ethanol to maintain conductivity.

3. Apply high-temperature grease to bearings and other moving parts to prevent corrosion.

4. Store in a dry, well-ventilated place, avoiding moisture that could cause corrosion of metal parts.

⚠️ Safety Tips: Protective gloves, goggles, and dust masks must be worn throughout the operation. Never reach inside the equipment while it is running. When handling high-voltage or armored cables, a qualified professional must disconnect the power and disassemble the equipment first to ensure safety.