The flagship recycling facility, that has started operations in Magdeburg, targeting the recovery of valuable metals, including aluminium, from waste incineration, is prepared for harsh conditions. Run by Mitteldeutsche Schlackenunion (MDSU), it is now the biggest and most advanced bottom ash treatment plant in Germany.
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Image source: https://www.winkelmanengineering.nl/
Commissioned in late 2024, this site is built to process up to 90,000 tonnes of incinerator bottom ash annually. However, the current throughput is around 60,000 tonnes, which is likely to increase at the operational scale.
The launch of this bottom ash recycling facility is a business imperative. The bottom ash, which was considered a waste byproduct before, still comes with a huge volume of non-ferrous metals such as aluminium, copper, zinc, brass, and stainless steel. Recycling these materials not only meets the shortage of secondary raw materials in the industrial supply chain but also lowers the disposal cost significantly. It also reduces excessive reliance on virgin mining and strengthens the circular economy.
Multi-stage sorting process
The new facility is backed by a multi-stage separation system supplied by STEINERT, a company specialising in sensor-based sorting. It helps in seamless recovery that begins with Eddy Current Separators. It removes non-ferrous metals from the mineral fraction to produce a ZORBA mix.
The material thus received is further processed using X-ray transmission (XRT) technology, which differentiates between lighter metals like aluminium and magnesium and heavier ones such as copper, zinc and brass.
Also read: World Recycled ALuminium Market Analysis Industry forecast to 2032
Final refinement is carried out using X-ray fluorescence (XRF), which sorts metals by elemental composition and can handle particles as small as 5 mm. The result is high-purity output suitable for direct re-entry into industrial supply chains.
The facility is adapted for harsh conditions
However, it is also true that processing bottom ashes comes with its unique set of challenges. There’s too much moisture in the bottom ash, and at the same time, it is corrosive. To deal with this, the plant is designed with stainless steel housings. In addition, an automated Splitcontrol system adjusts conveyor speeds in real time, ensuring consistent separation results and reducing the need for manual oversight.
Before commissioning their recycling plant, MDSU carried out extensive trials at STEINERT’s Cologne testing facility. As a result, it was specifically tailored to the specific demands of bottom ash recycling.
A circular economy benchmark
Industry analysts have described the Magdeburg site as a “lighthouse project” that demonstrates how bottom ash residues can be transformed into valuable secondary raw materials. It’s not just a profitable move for the business as a whole but also a smart move to produce industrial-grade fractions of aluminium, brass, copper, zinc and stainless steel without depending on the mines every time. This way, the shortage can also be addressed while keeping mining expenses at bay. It directly contributes to Europe’s circular economy targets and reduces dependence on primary metal extraction.
André Hartl, Managing Director of MDSU, summed up the plant’s mission: to extract the maximum from the slag.
The growing demand for recycled raw materials in recent years has positioned the Magdeburg facility as an important player in ensuring resource efficiency while cutting waste volumes. Its combination of scale, technological precision and sustainability focus positions it as one of Europe’s most significant developments in modern waste treatment.
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