Erkan Batukan Email & Phone Number

Kocaeli, Türkiye

• TBRC Furnaces Design: Engineered Top Blown Rotary Converter furnaces with varied inner volumes of 1m³, 3m³, and 6m³, tailored to optimize the recycling of electronic waste. These designs facilitated the efficient thermal processing of e-waste, significantly improving the recovery of valuable metals while minimizing environmental impact.• Sulfuric Gas Heat Exchanger: Created a large-scale vertical heat exchanger (ø4mt L.22mt) designed to efficiently manage thermal energies and reduce emissions from high-temperature processes.• Ball Mill Line for Catalytic Converters: Developed a robust ball mill line capable of processing 300 kg/h, aimed at pulverizing catalytic converters to facilitate the extraction of precious metals. This system was designed to increase throughput and recovery rates, reducing overall processing time.

• Project Overview: Spearheaded the design of an integrated scrap copper recycling factory, aimed at transforming scrap copper into high-purity copper anodes with an emphasis on process efficiency and environmental sustainability.• Rotary Furnace Design: Developed a rotary furnace optimized for the smelting of scrap copper, featuring advanced refractory materials for enhanced heat distribution and durability under high temperatures and corrosive conditions.• Casting Wheel System: Implemented a casting wheel system with 16 molds to automate the copper anode casting process. This system includes precise temperature controls to ensure consistent quality and structural integrity of the anodes.• Ancillary Equipment and Safety Features: Integrated essential ancillary equipment such as a ladle for molten copper transport and a spoon mechanism for accurate pouring, alongside an innovative cooling system to rapidly solidify anodes. The design incorporates extensive safety features, including emergency shut-offs and heat shields, to ensure a safe working environment.• Environmental Management: Designed the facility with a focus on minimizing environmental impact, including systems for waste heat recovery and the treatment of by-products, ensuring compliance with stringent environmental standards.

• Designed a 0.1m³ Top Blown Rotary Converter (TBRC) furnace specifically for the thermal processing of electronic waste, aimed at the efficient recovery of precious metals such as gold, silver, and copper.• Engineered the furnace to operate at high temperatures necessary for smelting and separating metal composites, integrating advanced lining materials and cooling technologies to enhance durability and performance.• Developed robust double and single-shaft shredders for effective processing and finer shredding of e-waste, improving volume reduction and material purity for recycling.• Implemented a laboratory-scale pyrolysis system for decomposing organic e-waste materials under high-temperature, inert conditions, facilitating the recovery of valuable chemicals and energy-rich char.• The system’s design allows for experimentation and optimization of pyrolysis parameters, supporting the scalable development of recovery processes and the analysis of by-products for new material or energy source creation.

Kayseri, Türkiye

• Designed a fully integrated system comprising a palletizer, wrapper, and conveyor to automate the end-of-line packaging processes. This system was tailored to handle varying product sizes and weights, ensuring versatility across different production lines.• Designed the palletizer for optimal stacking accuracy and speed, reducing manual labor and increasing throughput. The system features adaptive gripping technology to handle products delicately, minimizing damage during stacking.• Designed a high-capacity tin plating line capable of handling large volumes of metal substrates, intended to significantly boost Mega Metal’s production capacity and coating uniformity.• Configured the line to include a series of chemical baths and drying stations that ensure consistent application of tin coatings, crucial for enhancing corrosion resistance and solderability of metal products.• Engineered a state-of-the-art waste management and chemical recycling system within the plating line to minimize environmental impact. This system reduces hazardous waste and recycles chemicals back into the plating process, optimizing resource use.• Oversaw the assembly and commissioning of the systems on-site, ensuring that all components worked cohesively and met design specifications.

Kocaeli, Turkey

• Designed custom-designed M85 and MM85 Rodbreakdown machines to accommodate various grades and sizes of copper wire, enhancing flexibility and precision in wire production.• Engineered the MMH101 and MMH50 to handle multiple wires simultaneously, drastically increasing output without compromising the quality. Designed to accommodate various wire diameters and materials.• Designed a continuous tin plating line tailored for high-volume wire production. The system included cleaning, pre-treatment, plating, and finishing stages, ensuring high-quality coating adherence and uniformity.

• Designed and implemented an expanded tank house and electrolysis system capable of handling 7000 TPM for copper cathode production.• Coordinated with cross-functional teams including R&D, operations, and safety departments to ensure a holistic design approach.• Managed timelines and budgets, ensuring project delivery within the specified constraints.• Designed a modular tank house layout to allow for scalable operations and future expansions.• Employed advanced cathode stripping machines that improved the purity of copper cathode and operational efficiency.• Designed waste treatment facilities within the plant to handle and recycle by-products and effluents, adhering to stringent environmental regulations.• Optimized process parameters through pilot testing to achieve maximum yield and quality of copper cathode.• Developed comprehensive training programs for operators and maintenance staff, ensuring smooth operation post-implementation.• Oversaw the commissioning phase, troubleshooting initial operational issues to achieve designed throughput and quality standards.

Kayseri, Türkiye

• Designed a copper anode casting factory capable of processing 30 tons of scrap copper into anodes every twelve hours using a rotary furnace.• Developed a casting wheel with 16 molds, including a ladle, spoon, and anode cooling system.• Designed Rodbreakdown machine M85 type and drawing machine M30 type.• Implemented a foam-skin insulation line for telecommunication cable production.• Created comprehensive designs for energy cable production including insulation lines, jacketing lines, extruders, cross-heads, pay-offs/take-ups, drum twisters, and buncher twists.• Developed a continuous casting line (upcast system) capable of producing 16 wires at 1000 TPM.• Designed a tank house and electrolysis system for producing copper cathodes at 2000 TPM.