In Magdeburg, Mitteldeutsche Schlackenunion (MDSU) is establishing a benchmark in circular economy solutions. Through its advanced plant for metal recovery from bottom ash, the company highlights the critical role of reliable, high-performance sorting technology, reinforcing STEINERT’s position as the preferred partner for industrial metal recovery.
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MDSU is transforming how the industry views incineration residues. At municipal solid waste incineration (MSWI) plants, 20 to 30 per cent of processed material remains as bottom ash, a resource-rich byproduct containing aluminium, copper, brass and stainless steel.
Recognising this potential, MDSU has launched a cutting-edge recovery facility featuring advanced X-ray technology, setting a new standard for sustainable resource management and circular economy practices in the sector.
Germany’s largest bottom ash recovery facility in Magdeburg
Launched at the close of 2024, MDSU’s state-of-the-art sorting plant in Magdeburg now processes around 1.5 million tonnes of incinerator bottom ash each year, establishing it as the largest facility of its kind in Germany. Managing Director André Hartl emphasises that the plant’s mission is “to extract the maximum value from the slag.”
Despite being operational for only a few weeks, the facility is already delivering impressive results, with recovered metals meeting the highest standards of purity and volume. This performance is driven by technology precisely tailored to MDSU’s requirements. Central to this achievement is the strategic partnership with STEINERT of Cologne, whose advanced sorting systems form a core part of the Magdeburg operation.
Advanced X-ray technology drives optimal metal recovery
At the heart of MDSU’s metal recovery process is a multi-stage sorting approach. Initially, eight high-performance STEINERT Eddy Current separators extract non-ferrous metals from the mineral carrier, producing a ZORBA fraction with a high metal yield that sets the stage for downstream fine sorting.
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For more precise separation within this mixed non-ferrous fraction, the facility employs a STEINERT XSS T EVO 5.0 system featuring X-ray transmission technology (XRT). Unlike conventional optical systems, XRT analyses the internal structure of materials, allowing light metals such as aluminium and magnesium to be reliably distinguished from heavier metals like copper, brass and zinc based on atomic density.
In the final sorting stage, the non-ferrous heavy metal concentrate is graded using a STEINERT CHUTEC chute sorting system, which relies on X-ray fluorescence (XRF). This technology focuses on the elemental composition of individual particles rather than density, making it ideal for fine particles down to 5 mm. The process delivers highly pure metal fractions, including copper, brass, zinc, and stainless steel which are ready to re-enter industrial material cycles, completing the recycling loop.
André Hartl, the Managing Director of MDSU, stated, “We have trusted STEINERT technology for years. It underpins all our operations, and we will continue to rely on it moving forward. Our engineering team tested the concept system on-site, bringing large volumes of our material to Cologne for full-scale trials. These insights allowed us to configure the system precisely for our requirements, exactly as it operates today in Magdeburg.”
Tailored solutions for bottom ash processing
Processing bottom ash presents unique challenges, including residual moisture and corrosive components, demanding highly robust sorting solutions. STEINERT addressed these with targeted adaptations where MDSU’s Eddy Current separators feature fully stainless-steel casings, protecting against chemical wear from wet materials.
Additionally, the STEINERT Splitcontrol add-on was explicitly developed for bottom ash applications. It continuously monitors the flight trajectory of sorted materials and automatically adjusts belt speed as needed. This ensures consistent metal recovery despite variable material properties, minimising the need for manual intervention and optimising operational efficiency.
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