Mixed metal powders present a unique challenge for manufacturers, recyclers, and material recovery companies. Whether the goal is to reclaim high-value metals, improve material purity, or prepare powders for reuse, efficient separation can be the difference between waste and profitable recovery.
One common misconception is that if a batch contains two different types of metal powders, they can’t be separated. In most cases, that’s not true.
Recently, Elcan Industries was approached by a company in the metal recovery space that had several million pounds of a nickel and copper powder blend. The material had been generated during a production process and was sitting unused because they were unable to isolate the two metals economically. The question they asked was straightforward: Can the metals be separated? The answer came down to one critical factor — particle size.
Why Particle Size Matters in Metal Separation
When metals are in powder form, separation methods often rely on physical differences between the particles. If the different metals have distinct particle size distributions, high-precision screening or classification can be used to split them into separate fractions. This is where advanced sieving and air classification technologies become essential, such as the Hi-Sifter and Elbow Jet Air Classifier.
In the case of the nickel and silver mixture, the first question was whether the nickel particles were a different size from the copper particles. If the particle sizes overlap too closely, mechanical separation by screening becomes far more difficult and may require additional pre-processing steps; however, in most cases, Elcan’s advanced sieving technologies can separate these materials into different usable fractions.
If you’re not sure about the size of your particles, Elcan can help you analyze the particle size distribution of your material to determine whether screening or air classification is a viable path forward. We work with customers who have everything from fully characterized powder blends to buckets of unknown scrap. Even a small sample is often enough to start the testing process.
So, What’s The Role of Advanced Screening Technologies in Separating Materials by Particle Size?
When particle sizes are sufficiently different, Elcan Industries can separate mixed metals to tight specifications using equipment like the Hi-Sifter high-energy sieving system or the Elbow-Jet Air Classifier. The Hi-Sifter uses high-frequency energy to keep particles moving across the mesh surface, preventing screen mesh blinding and allowing for accurate size cuts down to 10 microns. For even finer separations, the Elbow-Jet uses airflow and the Coanda effect to classify particles as fine as 0.5 microns without rotating parts that could cause contamination.
This type of separation is beneficial when dealing with valuable metals like silver, nickel, and copper and others. By isolating each material, the recovered powders can be reused in manufacturing, sold as pure commodities, or further refined.
Applications Beyond Nickel and Copper
The same approach can be applied to many other mixed metal powders. Examples include:
- Cobalt and nickel from battery scrap
- Tungsten carbide and cobalt from tooling
- Aluminum and steel powders from manufacturing waste
- Precious metals recovery from electronic scrap
In each case, success comes down to understanding the particle size distribution of the mixture and selecting the right screening or classification process.
Turning Mixed Metal Powders into Valuable Materials, again
Material that may otherwise be considered scrap can often be reclaimed through particle size separation. For companies handling expensive metals, this can represent a significant return on investment. With the right equipment and process control, even complex mixtures that may at some point have been considered useless material, can now be separated into clean, usable fractions.
If you have a batch of mixed metal powders and need to know whether separation is possible, the first step is to determine if the particle sizes are different enough for screening or classification. From there, we can run trials to confirm the separation efficiency and deliver a plan to recover your materials.
To learn more or schedule a test, contact Elcan Industries at info@elcanindustries.com or www.elcanindustries.com
Call today to schedule your trial!
📞 914-381-7500
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