Donar DE-XRT Pro AI-Driven Sorting System

Aluminum recycling presents a sorting challenge where alloy composition and impurity content directly determine commercial value. Zorba, the mixed aluminum shredder product recovered from end-of-life sources, not only contains heavy metal impurities such as copper, brass, zinc, and stainless steel, but is also mixed with wrought aluminum alloys and cast aluminum alloys of varying values. In particular, aluminum and zinc both present a silvery-white metallic luster under visible light, and wrought aluminum alloys and cast aluminum alloys are highly similar in surface color. Relying solely on surface features makes it impossible to effectively identify and remove these 'visually identical' impurities, let alone achieve refined classification of aluminum fractions. 

The Donar DE-XRT Pro series is an intelligent machine-vision-based sorting system tailored for this exact scenario. It adopts deep fusion of dual-energy X-ray transmission (DE-XRT) technology and high-resolution RGB (HR-RGB) VIS imaging, combined with proprietary AI deep learning algorithms, to convert Zorba into high-purity aluminum fractions. By analyzing atomic density differences, the system identifies and removes heavy metal impurities from Zorba to purify aluminum fractions, and achieves efficient separation of wrought aluminum alloys from cast aluminum alloys based on AI-driven surface feature recognition.

Empowered by AI-driven surface feature recognition algorithms, the system can conduct deep learning training based on real production data, continuously optimizing the detection accuracy for wrought and cast aluminum alloys. This means the equipment’s performance is not fixed at the time of factory shipment; instead, it continuously adjusts and improves with the accumulation of production data, delivering stable and reliable sorting performance to help aluminum scrap recyclers and secondary smelters consistently produce high-purity aluminum fractions, capture market premiums, and meet the strict raw material requirements of downstream remelting processes.

Sorting Principle of Donar DE-XRT Pro AI-Driven Sorting System

Purifying Aluminum from Zorba (Heavy Metal Impurity Removal)

The separation of aluminum fractions from heavy metal impurities in Zorba is fundamentally based on the significant differences in atomic density between these materials.

When dual-energy X-rays penetrate the material stream, the system measures the attenuation differences between high-energy and low-energy X-rays. Aluminum, as a light metal with low atomic density, exhibits weak X-ray attenuation. In contrast, heavy metal impurities such as copper, brass, zinc, and stainless steel possess significantly higher atomic densities, resulting in strong X-ray absorption. By calculating the Dual-Energy Ratio (DER), the system accurately determines the intrinsic atomic density of each individual particle, effectively eliminating interference from variations in material thickness. Based on these atomic density differences, the system efficiently identifies heavy metal impurities and triggers pneumatic ejection to remove them, leaving behind purified aluminum fractions.

Separating Wrought Aluminum from Cast Aluminum

The separation of wrought aluminum alloys from cast aluminum alloys is primarily based on subtle differences in both atomic density and surface texture.

Although both wrought and cast aluminum are aluminum-based materials, cast aluminum (commonly used in components such as engine blocks) contains a higher proportion of silicon (Si). This results in a distinct atomic density and X-ray absorption rate compared to wrought aluminum (which typically has lower silicon content). Leveraging high-precision X-ray transmission technology, the system can identify and eject high-silicon, high-density cast aluminum particles, significantly reducing the content of high-silicon cast aluminum in the material stream. However, some cast aluminum alloys have densities very close to those of wrought aluminum, making them difficult to distinguish via X-ray transmission alone. Cast aluminum surfaces, however, typically exhibit specific textures, colors, or sheens (e.g., traces left by mold casting). By utilizing AI deep learning to detect minute visual features imperceptible to the human eye, the system can also efficiently eject low-alloy cast aluminum that shares similar density but differs in material composition. This serves as a powerful complement to X-ray transmission sorting, significantly enhancing the value of the recycled aluminum stream. (At this stage, the material stream consists almost exclusively of wrought aluminum, though it may still contain a mixture of different wrought alloy grades. Further refined separation of these alloy grades is achieved through more advanced LIBS technology to unlock even higher value.)

Technical Features

● Dual-Sensor Fusion Technology

Deep integration of dual-energy X-ray transmission (DE-XRT) and high-resolution RGB (HR-RGB) VIS imaging enables efficient identification and removal of heavy metal impurities, significantly improving aluminum fraction purity. By combining atomic density analysis with surface texture recognition, the system achieves intelligent, high-efficiency separation of wrought aluminum alloys from cast aluminum alloys.

● Proprietary AI Deep Learning Algorithms

Trained against comprehensive identification and sorting standards, the system uses deep learning to replicate the surface-feature judgment logic of manual picking. The AI model can be continuously optimized with new production data, driving ongoing improvements in sorting accuracy.

● High-Performance Air Ejector

Equipped with in-house, high-power, high-speed air ejectors, the system delivers high-precision material rejection and ensures long-term stable operation even under high-throughput sorting conditions.

● Multi-Specification Model Portfolio

Available in two models with belt widths of 1300 mm  and 2000 mm, to meet varying throughput requirements. The system is suitable for auto dismantlers, aerospace aluminum recyclers, packaging material recyclers, and incineration bottom ash (IBA) recyclers of all scales.

✦ Recovery of Aluminum Scrap

✩ Building Window/Door Recycling

✩ Beverage Can Recycling

✩ E-Waste Aluminum Recycling

✦ Separation of Wrought Aluminum and Cast Aluminum

✩ Auto Shredder Residue Sorting

✩ Industrial Machinery Scrap

✩ Aerospace Aluminum recycling

✩ Consumer Electronics Housing

✦ Recovery of Stainless Steel

✩ IBA (Incinerator Bottom Ash) Recycling

✩ ASR (Automotive Shredder Residue) Recycling

Specifications are approximate and subject to change without notice. Lauffer Vision reserves all rights for modifications.