Commissioning A Standard ALS2 Containerised Plant In Australia
A standard ALS2 containerised plant is designed to make precious-metals recovery from electronic waste more compact, controlled and practical. Rather than relying on conventional acid-based refining, the system uses Ikoi S.p.A.’s acidless separation technology to process selected WEEE and e-waste streams in a contained industrial environment. Commissioning is the point at which the delivered equipment becomes a reliable operating asset, and it requires more than simply switching on the machinery.
For an Australian operator, the programme must account for feedstock quality, local electrical standards, site access, environmental obligations and the distance between major cities and regional recycling facilities. A realistic schedule usually runs from several weeks to a few months after the container reaches site, depending on preparation work and the condition of the incoming material. The timeline below describes the usual sequence while allowing for project-specific engineering and regulatory requirements.
Planning Before The Container Arrives
The commissioning timeline begins well before transport. The operator, technology provider and site contractor establish the plant layout, process objectives, utilities, safety controls and expected feedstock. This stage confirms where containers will sit, how materials will be unloaded, and how recovered fractions and residues will be stored. It also identifies whether the site can support the required power supply, ventilation, drainage, fire protection and communications systems.
Feedstock preparation is equally important. Printed circuit boards, connectors, cables and other electronic components vary considerably in metal content, size and contamination. A plant intended for material sourced from Sydney or Melbourne collection networks may receive a different mixture from a regional Western Australian or Queensland facility. Samples should be assessed before commissioning so the initial test campaign reflects the material the plant will actually process.
Australian operators also need to coordinate transport and site access carefully. A container travelling to Perth may face a longer logistics chain than one delivered to an industrial estate near Brisbane, while facilities outside Adelaide or Newcastle may need additional planning for heavy-vehicle access. Confirming lifting equipment, crane availability and delivery windows early can prevent a container from arriving before the site is ready.
Factory Checks And Site Readiness
Before dispatch, the containerised unit should undergo a factory acceptance review. This normally covers mechanical assembly, electrical panels, instrumentation, safety interlocks, pumps, separation equipment and control software. The review may include dry runs using water or inert material, inspection of cable identification, verification of emergency stops and confirmation that operating documents match the installed equipment.
At the destination, site readiness checks are completed before energisation. The foundation or hardstand must be level and capable of supporting the operating load. Services are connected according to the approved design, and the team checks earthing, power quality, lighting, access routes and weather protection. In tropical Queensland, heat and humidity can influence enclosure ventilation and storage conditions; in parts of Victoria or Tasmania, cold weather can affect water systems and outdoor work.
Worker induction is a practical part of this stage. Everyone involved should understand restricted areas, personal protective equipment, material handling, spill response and lockout procedures. Long shifts during installation can also increase fatigue, so supervisors should plan breaks and access to drinking water; general hydration guidance can support a sensible site welfare routine without replacing the project’s formal safety plan.
Installation And Cold Commissioning
Once the container is positioned, technicians connect site services and complete the mechanical and electrical installation. This includes linking feedstock handling equipment, discharge points, control interfaces, extraction or ventilation systems and any auxiliary equipment included in the project scope. The team then checks that guards, doors, sensors and interlocks operate as intended before live process material is introduced.
Cold commissioning follows installation. During this phase, the plant is operated without precious-metal feedstock, or with a safe substitute, to verify the sequence of operations. Pumps are checked for correct direction and flow, conveyors or handling systems are observed under load, and control signals are compared with field conditions. Alarm functions, emergency stops and shutdown sequences are tested individually and as part of the wider control system.
A typical cold commissioning period may take several working days, although modifications can extend it. The priority is to identify installation errors before valuable material enters the process. Any changes should be recorded in a punch list, assigned to a responsible person and closed with evidence. This documentation becomes useful for operator training, maintenance planning and future audits.
| Commissioning phase | Typical duration | Main activities | Release condition |
|---|---|---|---|
| Pre-delivery planning | 2–6 weeks | Feedstock review, layout, utilities, permits and logistics | Site and material plan approved |
| Factory acceptance | 2–5 days | Equipment inspection, control checks and dry testing | Dispatch package accepted |
| Site installation | 3–10 days | Positioning, service connections and safety checks | Mechanical and electrical installation complete |
| Cold commissioning | 3–7 days | Functional testing without production feed | Interlocks and operating sequence verified |
| Wet or process commissioning | 3–10 days | Controlled introduction of process material | Stable operating parameters established |
| Performance trial | 1–3 weeks | Throughput, recovery and quality monitoring | Agreed performance evidence recorded |
| Handover and ramp-up | 1–4 weeks | Training, reporting and production optimisation | Operator takes routine control |
Introducing Feedstock In A Controlled Way
Process commissioning starts with a limited quantity of representative e-waste. The first campaign is not intended to maximise throughput. It allows the team to confirm how the actual feed behaves, whether particle size and composition are suitable, and whether adjustments are needed to process settings. Operators monitor material movement, separation behaviour, residue generation and the condition of critical components.
Sampling is central to this stage. Input material, intermediate fractions and recovered precious-metal outputs should be sampled according to an agreed method. Results help establish a baseline for recovery performance and product quality. Because Australian e-waste can arrive through a mixture of municipal collection programmes, commercial dismantlers and specialist recyclers, the plant may require operating recipes for different feed categories rather than a single universal setting.
The commissioning team should increase throughput gradually. A stable short run is more informative than an ambitious first shift that creates blockages or inconsistent separation. Operators record operating hours, feed mass, stoppages, maintenance observations and analytical results. These records show whether the plant is ready for a performance trial and provide a reference point for later optimisation.
Performance Verification And Operator Handover
The performance trial evaluates whether the ALS2 plant meets the agreed project criteria. These may include throughput, recovery, product consistency, availability, energy use and safe handling of residues. The precise acceptance limits depend on the feedstock and contract, so they should be defined before the trial begins. Testing must account for normal variation in electronic scrap rather than relying on one unusually rich batch.
Precious-metal output may be sent for further analysis or downstream treatment when required. Operators reviewing the wider value chain can consult information about secondary refining steps to understand how ALS2 output can fit within a route to higher purity. This is separate from commissioning the container itself, but it helps align plant results with commercial product specifications.
Handover follows successful performance verification. The technology provider transfers operating procedures, maintenance schedules, spare-parts information, calibration records and training materials to the site team. Operators should demonstrate competence in start-up, normal running, shutdown, emergency response, cleaning, sampling and fault reporting. In Australia, the handover file may also support internal environmental reporting and discussions with state or territory regulators.
Reaching Routine Production
After handover, the plant enters a controlled ramp-up rather than immediate full-scale production. The team reviews each shift, compares actual results with the commissioning baseline and adjusts feed preparation or operating parameters where necessary. Early production data can reveal issues that are not visible during a short acceptance trial, including wear caused by abrasive material or changes in feedstock supplied by different customers.
Maintenance discipline is especially important for a compact plant. Daily inspections should cover wear points, seals, guards, electrical indicators, collection areas and housekeeping. Preventive maintenance intervals can then be refined using operating hours and observed conditions. A facility near Port Melbourne may have easy access to specialist contractors, while a remote operator may need a larger stock of consumables and stronger remote-support arrangements.
The final timeline depends on how quickly the site closes outstanding actions, how consistent the feedstock is and whether local approvals impose additional steps. A well-prepared project can move from delivery to routine production in roughly six to ten weeks, while a more complex installation may take longer. The strongest outcome is a documented, safe and repeatable process that supports precious-metals recovery without relying on acid-based refining methods.
For organisations evaluating an ALS2 installation, the practical next step is to assemble a site data pack covering feedstock samples, expected volumes, utilities, access, compliance requirements and target products. Sharing that information with the project team allows the container configuration, commissioning plan and training schedule to be matched to the Australian operating environment. With preparation completed early, commissioning becomes a measured route to dependable e-waste recovery rather than an improvised start-up exercise.