DE-XRT Pro Series Intelligent X-ray Sorter A Single-layer Crawler-type Model

A single-layer crawler-type model custom-developed for aluminium recycling. It adopts dual-sensor fusion technology to remove heavy metals through density detection based on DE-XRT for aluminium fraction purification. Meanwhile, AI-powered surface analysis via HRGB visible-light cameras enables the separation of wrought aluminium and cast aluminium. Trained with real production data via deep learning, its sorting accuracy can be continuously optimized.

Aluminium recycling faces a critical sorting challenge: the alloy composition and impurity content directly determine its commercial value. Mixed aluminium scrap Zorba contains complex wrought aluminium alloys, cast aluminium alloys, and heavy metal contaminants such as iron, zinc and copper, with unpredictable proportions of each component. For aluminium recyclers and secondary smelters, the key to producing clean, alloy-classified aluminium products, securing market premiums and meeting strict raw material requirements for downstream remelting is to separate heavy metals from aluminium fractions and effectively distinguish wrought and cast aluminium alloys based on inherent material properties rather than unreliable visual features.

The Donar DE-XRT Pro Series is a machine vision-based intelligent sorting system. It integrates advanced dual-energy X-ray transmission (DE-XRT) technology with high-resolution RGB (HR-RGB) visible light imaging technology, equipped with self-developed AI algorithms. It efficiently recovers aluminium fractions from material streams and converts mixed aluminium scrap Zorba into high-purity, high-value aluminium products. The system identifies and removes heavy metals from Zorba by analysing atomic density differences to purify aluminium alloys. Combined with AI-enabled surface feature analysis, it achieves efficient separation of wrought aluminium and cast aluminium.

The AI-powered surface feature recognition algorithm is trained by deep learning on real production data for continuous sorting accuracy optimization. It maintains stable high-precision sorting for Zorba with varying compositions and impurity levels. It helps metal processors maximize alloy-classified recovery rates, completely eliminate heavy metal contamination, and deliver high-purity secondary aluminium feedstock that meets stringent secondary smelting standards with consistent sorting performance.

The separation of aluminium fractions and heavy metal impurities in Zorba fundamentally relies on their significant differences in atomic density.

When dual-energy X-rays penetrate the material stream, the system measures the attenuation difference between high-energy and low-energy X-rays. Aluminium is a light metal with low atomic density and weak attenuation of X-rays. In contrast, heavy metal impurities such as copper, brass, zinc and stainless steel have far higher atomic density and strongly absorb X-rays. By calculating the Dual Energy Ratio (DER), the system can accurately determine the inherent atomic density of each particle and effectively eliminate interference caused by material thickness. Accordingly, the system efficiently identifies heavy metal impurities and triggers pneumatic ejection for rejection, retaining purified aluminium fractions.

The separation of wrought aluminium and cast aluminium mainly depends on subtle differences in atomic density and surface texture.

Although both wrought and cast aluminium are aluminium-based materials, cast aluminium (commonly used for engine blocks, etc.) contains a high proportion of silicon (Si). Its atomic density and X-ray absorption rate differ notably from wrought aluminium (typically low in silicon). With high-precision X-ray transmission technology, the system identifies and rejects high-silicon, high-density cast aluminium alloys, greatly reducing the content of high-silicon cast aluminium in the material stream.

However, some cast aluminium alloys have a density very close to wrought aluminium and cannot be distinguished by X-ray transmission alone. Cast aluminium usually presents specific texture, colour and luster on its surface (e.g., traces left by mould casting). AI deep learning detects subtle visual features imperceptible to human eyes, allowing the system to efficiently reject low-alloy cast aluminium with similar density but different material composition. This serves as a powerful complement to X-ray transmission sorting and maximizes the value of recovered aluminium streams. (At this stage, the material stream consists almost entirely of wrought aluminium, though mixtures of different wrought aluminium alloy grades may remain. Further fine separation will be realized with more advanced LIBS technology for higher value.)

• Dual-Sensor Fusion Technology An advanced integration scheme combining dual-energy X-ray transmission (XRT) and high-resolution RGB visible light imaging technology. It removes heavy metals via atomic density analysis to guarantee aluminium purity, and efficiently differentiates wrought aluminium and cast aluminium based on atomic density and surface texture.
• Self-Developed AI Deep Learning Algorithm It innovatively simulates manual picking by importing and training various sorting criteria and features into the system. The AI algorithm continuously improves sorting precision, and the model can be retrained with newly added production samples via deep learning.
• Reliable High-Performance Pneumatic Valve Ejection System Self-developed and manufactured high-power high-speed pneumatic ejectors ensure efficient rejection and stable operation under high-capacity sorting conditions.
• Flexible Modular Design Available in 1300 mm and 2000 mm belt width specifications. Processors can flexibly select according to capacity requirements. Suitable for auto dismantlers, aerospace aluminium recyclers, packaging material recyclers and incineration bottom ash (IBA) recyclers.

◆ Aluminium Scrap Recycling  ☆ Architectural window & door scrap recycling  ☆ Aluminium can recycling  ☆ Aluminium recovery from Electronic Waste (E-Waste)

◆ Separation of Wrought Aluminium and Cast Aluminium  ☆ Sorting of End-of-Life Vehicle Shredder Residue (ASR)  ☆ Industrial machinery scrap sorting  ☆ Aerospace aluminium recycling  ☆ Consumer electronics housing recycling

◆ Stainless Steel Recycling  ☆ Incineration Bottom Ash (IBA) Recycling  ☆ End-of-Life Vehicle Shredder Residue (ASR) Recycling