ASR Recycling Plant Solution
1. Solution Overview
As End-of-Life Vehicle (ELV) recycling continues to evolve worldwide, most ferrous and non-ferrous metals are recovered during the primary shredding process. However, Automobile Shredder Residue (ASR) still contains a significant amount of valuable recyclable materials, including copper, aluminum, stainless steel, brass, zinc, PCB metals, mineral fractions, and combustible light materials.
Traditionally regarded as landfill waste, ASR has become an increasingly important secondary resource due to stricter environmental regulations, rising raw material prices, and the growing demand for circular economy solutions.
SIMVIC Group provides complete ASR Recycling Plant Solutions based on our System Engineering philosophy. By integrating secondary liberation, particle size classification, air separation, magnetic separation, eddy current separation, sensor-based sorting, high-value metal recovery, environmental protection, and intelligent automation, we transform complex ASR into multiple marketable products with maximum resource value.
Rather than treating ASR as waste, SIMVIC considers it the final opportunity to unlock valuable resources within the metal recycling process. Through the coordinated optimization of Material Flow, Energy Flow, and Control Flow, we help customers maximize recovery rates, minimize landfill disposal, improve operational efficiency, and generate sustainable long-term returns.
2. Target Feed Materials
Standard ASR Recycling Process
ASR Receiving
⬇️
Secondary Liberation
⬇️
Air Separation
⬇️
Particle Size Classification
⬇️
Fine Magnetic Separation
⬇️
Eddy Current Separation
⬇️
Sensor-based Sorting(XRT / AI Vision)
⬇️
High-value Metal Refining
⬇️
High-value Recycled Products
Typical Product Outputs
| Process Stage | Typical Output |
|---|---|
| Air Separation | Light Fraction / Fluff / SRF-RDF Feedstock |
| Magnetic Separation | Recovered Ferrous Scrap |
| Eddy Current Separation | Aluminum and Non-ferrous Metals |
| Sensor-based Sorting | Copper, Brass, Stainless Steel, PCB Metals |
| Final Refining | High-purity Non-ferrous Metal Products |
| Residual Fraction | Mineral Aggregate or Further Recovery Feedstock |
Design Principles
Every SIMVIC ASR Recycling Plant is engineered to achieve:
- Maximum material liberation
- Maximum recovery of valuable metals
- Minimum landfill disposal
- Higher product purity
- Lower operating cost per ton
- Compliance with international environmental standards
3.Scope of Supply
SIMVIC offers flexible solutions ranging from individual equipment and process modules to complete EPC turnkey plants.
Liberation System
- Secondary Shredders
- Twin-shaft Shredders
- Fine Liberation Equipment
Environmental Protection System
- Central Dust Collection
- Air Circulation System
- Exhaust Gas Treatment
- Noise Control
Intelligent Control System
- PLC Control
- SCADA Monitoring Platform
- Production Data Management
- Remote Diagnostic System
4.Performance Targets
Every SIMVIC solution is customized according to the composition of incoming ASR and customer-specific recovery objectives.
Typical performance goals include:
| Performance Indicator | Target |
|---|---|
| Resource Recovery | Maximized |
| Product Purity | High-value Market Grade |
| Automation Level | Highly Automated Operation |
| Labor Requirement | Significantly Reduced |
| Landfill Disposal | Minimized |
| Processing Cost per Ton | Continuously Optimized |
| Plant Availability | Stable Long-term Operation |
Key Value Drivers
- Higher recovery revenue
- Increased value from high-grade metals
- Reduced landfill costs
- Improved environmental compliance
- Enhanced long-term return on investment (ROI)
5.Environmental & HSE
ASR recycling involves complex mixed materials, dust, and lightweight fractions, making environmental protection and workplace safety essential components of plant design.
SIMVIC integrates Environmental, Health, and Safety (HSE) principles throughout the entire recycling process.
Environmental Protection
- Fully enclosed conveying systems
- Closed-loop air circulation
- High-efficiency dust collection
- Source dust control
- Exhaust air purification
Occupational Health
- Reduced dust exposure
- Lower noise levels
- Minimized manual sorting
- Improved working conditions
Sustainability
By maximizing material recovery and minimizing landfill disposal, SIMVIC helps customers achieve:
- Circular Economy objectives
- ESG commitments
- Carbon reduction targets
- Sustainable resource utilization
6.Reference Plants
SIMVIC provides scalable ASR recycling solutions to meet different plant capacities, feedstock compositions, and investment requirements.
Standard ASR Recovery Plant
Suitable for:
- ELV shredding facilities
- Small to medium-sized recycling companies
Features:
- Air separation
- Eddy current separation
- Basic metal recovery
Integrated Circular Economy Recycling Park
Suitable for:
- Large-scale recycling parks
- National resource recovery centers
Features:
- ELV recycling
- Advanced ASR processing
- Motor recycling
- Aluminum upgrading
- Multi-product resource recovery
7.Service & Expansion
SIMVIC integrates environmental protection, operational safety, and occupational health into every stage of plant design.SIMVIC delivers more than equipment—we provide comprehensive lifecycle support from project planning through long-term plant operation.
Project Development
- ASR composition analysis
- Resource value assessment
- Process engineering
- ROI and feasibility studies
Operational Support
- Remote technical support
- Spare parts supply
- Process optimization
- Production data analysis
Future Expansion
SIMVIC’s modular plant design allows customers to expand production capacity and introduce new recovery technologies as market demands evolve.
Expansion options include:
- Copper recovery modules
- Stainless steel recovery
- PCB metal recovery
- SRF/RDF production systems
- AI-powered sorting upgrades
- Intelligent packaging and automated warehousing
8.System Engineering Value
Recovering value from ASR requires far more than adding additional sorting equipment. True performance depends on how effectively liberation, classification, separation, and intelligent process control work together as one integrated system.
At SIMVIC, every process stage is engineered to create the optimal conditions for the next. By coordinating material flow, energy flow, and control flow across the entire plant, we maximize metal liberation, improve product purity, increase plant availability, and reduce overall operating costs.
The result is not simply an ASR processing line, but a future-ready recycling plant capable of delivering higher resource recovery, lower landfill dependency, stronger environmental performance, and sustainable long-term profitability.
SIMVIC Group is committed to maximizing resource value through System Engineering.
Contact Our Engineers
Get an Integrated Plant Solution
Request Technical Information
Provide material type, capacity, and project details to receive a tailored solution.
