Innovative recycling of boilers for Decons Sas

Boiler recycling is an increasingly important issue in industrial waste management and environmental sustainability.
In a world seeking more environmentally friendly and responsible solutions for the treatment of special waste, FOR REC has developed an innovative line for boiler recycling, capable of processing 5.5 tonnes of boilers per hour.

Why boiler recycling is crucial for the environment

Once decommissioned, these units contain significant amounts of recyclable materials such as aluminum, steel, and copper. If properly separated, these resources can be recovered and reused in new production cycles.

But that’s not all: boilers also contain ozone-depleting gases which, if not handled safely, can cause serious harm to the ecosystem. In particular, the polyurethane used as insulation can release hazardous gases such as CFCs, which are known for their damaging effects on the atmosphere.

Our project with DECONS SAS: an innovative solution

FOR REC’s new boiler recycling plant is the result of a collaboration with DECONS SAS, a well-known French company specialising in industrial metal recycling. The project stands out for its advanced technology, which allows for the separation of ferrous and non-ferrous metals, as well as the isolation of polyurethane present in boilers.

The plant has been designed to safely separate ozone-depleting gases through an activated carbon adsorption system, followed by a cryogenic condensation phase that converts them into liquid form for safe disposal.

The line is capable of processing 5.5 tonnes of boilers per hour, operating 24 hours a day, 7 days a week. This is a significant achievement that demonstrates the plant’s effectiveness in addressing the challenges of industrial recycling.
In addition, the plant is Weeelabex certified, an important recognition that guarantees compliance with European regulations on electronic waste, ensuring a transparent process that complies with international standards.

Stages of the recycling process: from separation to valorisation

Stage 1 – Unloading and shredding

The treatment of electric water heaters begins with the draining of residual water from the boilers. The material is then loaded onto a chain conveyor and sent for grinding, which is carried out by a TBB 2000H twin-shaft shredder and a TQB 2000H four-shaft shredder.

Stage 2 – Separation of materials

The shredded material is collected in a screw conveyor and lifted by a chain conveyor, initiating a complex separation process. A vertical hopper starts the sorting, followed by magnetic separation to isolate the iron, which is then sent to a Z15 hammer mill for further refinement.
Non-magnetic materials are first processed through a nutating screen to separate limestone, and then undergo air separation to divide the light fraction (polyurethane foams) from the heavy fraction (metals, plastics, and stainless steel).
Finally, an eddy current separator distinguishes copper and aluminum (positive fraction) from plastics, stainless steel, and cables (negative fraction).
The process ensures highly accurate separation, with high purity levels in the recyclable fractions.

Stage 3 – Gas extraction

An innovative aspect of this plant is the management of gases released during the process. Gases such as CFCs are extracted and treated through an activated carbon adsorption system, then converted into liquid form via cryogenic condensation, and finally stored in pressurized cylinders for safe disposal.

Stage 4 – Pelletisation of polyurethane

The extracted insulating polyurethane is pressed and heated in a pelletizer, a process that allows gas to be extracted. The material is then cooled and stored in big bags for disposal.

Results and benefits: why choose FOR REC

The project has brought numerous benefits to the customer, both in environmental and economic terms:

• Material recovery: this line makes it possible to recover ferrous and non-ferrous metals (such as copper and aluminium).
• Safe gas management: elimination of harmful gases contained in boilers through a safe and efficient process.
• Weeelabex certification: the plant complies with European standards for electronic waste management, contributing to the reduction of waste sent to landfill.

The future of industrial recycling: opportunities and trends

The growing focus on sustainability and industrial waste management is driving the industry to evolve towards increasingly innovative and environmentally friendly solutions. The project with DECONS SAS is just one example of how we intend to lead the future of industrial recycling. Thanks to our internal R&D team, we are constantly searching for innovative solutions to continuously improve our recycling lines and contribute to the sustainable growth of our customers.