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RDF Production of refuse derived fuel
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Production of RDF
The task at hand The use of refuse derived fuel is part and parcel of today's regulated waste disposal. Triggered by judicial specifications that ban the landfilling of untreated waste, or at least hamper it, this fuel is continually gaining in importance in light of climate protection and rising energy costs. Potential recyclables are now separated off from commercial waste, production waste, bulky waste and screen fractions high in calorific value being processed into defined refuse derived fuels.
Commercial waste Production waste
Depending on calorific value and particle size, this fuel is used in industrial fluidised bed firings and cement works and will, in the future, be used in separate RDF power plants. Refuse derived fuel continues to be a hot subject for us. A processing line for commercial waste is now available in which Komptech products are used for all of the major process stages.
Bulky waste
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Expertise The following steps are performed on the way from waste to fuel: Pre-shredding Pre-shredding brings the input material down to a homogeneous particle size and prevents problematic overlengths for subsequent processing stages. Separation The focus is ballistic separation of the material stream with ferrous and non-ferrous separation interfaced upstream and downstream. Post-shredding A newly developed, slow-running post-shredder is used for the generation of furnace-ready fuel.
Screen fractions
Komptech GmbH Komptech is a leading international supplier of technology for machines and systems for the mechanical and biological treatment of solid wastes and biomass. The Komptech product portfolio comprises more than 25 different types of machines, covering the key process stages in modern waste treatment – shredding, separation and biological treatment. Self-contained all-in-one solutions for mastering complex challenges can be created by combining products from our own portfolio with proven components from reputable manufacturers where required. Innovative technology and solutions that maximise customer benefit is always our focus.
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Production of RDF
Commercial waste Production waste etc.
Pre-shredding
Recyclables Sorting systems
Post-shredding Ballistic separation
Heavy fraction to MBT
Process Pre-shredding The TERMINATOR pre-shredder, which reliably shreds the material down to the desired particle size, is an integrative component of such a plant. The highest degree of material opening is achieved using the XF shredding unit. The U unit is resistant to contaminants and is used when a coarser size is required. Separation After Fe-separation (optional Non-Iron) the material flow is diverted into four fractions by the ballistic separator: flat, rolling and as two screen fractions, with holes of 0 - 30 and 30 - 80 mm for example. Usually the smaller screen fraction is biologically stabilized in a mechanical biological-treatment plant. The coarse screen fraction has a calorific value of 12 - 18 MJ/kg and enables a saving of fossile fuels when used in fluidized bed incineration plants.
Fluidized bed fraction
Solid recovered fuel high calorific
• broad range of input materials possible • flexible process configuration • automated operation with low servicing overhead • low operating costs using efficient components • wide range of available installation sizes and performance categories
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Key components
Pre-shredding TERMINATOR
Ballistic separation BRINI
Post-shredding RASOR
Potential recyclables, or fractions high in calorific value, can be separated off from the rolling fraction for postshredding using inductive and optical sorting systems. The remaining fraction is again fed to the shredder. Fe separation is a sensible option for all fractions. Post-shredding The flat fraction (calorific value 18 - 25 MJ/kg) is made up primarily of foil and packaging fractions and is the input material for the last processing step - post-shredding with the RASOR. Depending on the inbuilt screen basket the machine generates both an injectable fraction (< 35 mm) and a particle size (60 - 100 mm) known as fluidized bed fraction. Components All these system technology components are available in the most sensible performance ranges, to allow perfect tailoring to the capacity of the overall system.
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Production of RDF
Terminator Robust universal waste shredder Pre-shredding must bring the input material down to a homogeneous particle size and prevent problematic overlengths for subsequent processing stages. A high level of resistance to contraries is just as important. The TERMINATOR XF (eXtraFine) addresses these requirements with a new cutting geometry and innovative teeth attachment. The continuous cutting gap adjustment allows tailoring of the produced particle size to subsequent usage. A high degree of decomposition is reached by a closed cutting gap. Then the machine is working like a "medium" shredder producing a particle size for fluidized bed incineration. If coarser particles are required the cutting gap can be opened or replaced by another shredding for production of coarser fractions (XF<F<UF<U). A choice of drives is available – either a hydraulic system (with optional separation from shredding unit) or a mechanical direct-drive with optimal degree of efficiency.
• sturdy, contrary-insensitive pre-shredder • variable particle size by adjusting cutting gap • hydraulic drive with constant power control and continously variable throughput control or • mechanic direct drive with two-gear transmission unit
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Pre-shredding
TERMINATOR Station At the standard version the drive is mounted directly at the shredding unit. With load-dependent rotation speed regulation (constant power control), the hydraulic drum drive ensures full advantage is taken of the engine output. Overload protection prevents unshreddable contraries from ruining the tool elements.
TERMINATOR
TERMINATOR Isolated design Isolation of the drive unit from the shredding unit is provided as an option for the hydraulic version. This way the drive unit can be protected from dust and be installed easily and accessibly in containers or in a utility room. The compact shredding unit can be integrated into the process cycle without taking up too much space.
3400S
TERMINATOR Direct drive At the mechanical drive power is transferred to a reverse gear/manual transmission unit, and then on to the drum drive, by a standard asynchronous motor using a Power belt system. If a contaminant causes a blockage, a reverse cycle is initiated (as with the hydraulic drive).
500
2200
3400
5000
5000S 6000S
1 x 37 kW
1 x 132 kW 1 x 132 kW
1 x 160 kW 1 x 160 kW
1 x 160 kW 2 x 75 kW
1 x 200 kW -
1 x 200 kW 2 x 110 kW
2 x 160 kW 2 x 160 kW
~ 11,8 t
~ 18,4 t
~ 18,8 t
~ 19,8 t
~ 19,8 t
~ 20,8 t
plant specific (only isolated design possible)
3000 mm 1050 mm max. 3 min -1
3000 mm 1050 mm max. 29 min -1 max. 19 min -1
3000 mm 1050 mm max. 29 min -1 max. 19 min -1
3000 mm 1050 mm max. 27 min -1 max. 14 min -1
3000 mm 1050 mm max. 29 min -1 -
3000 mm 1050 mm max. 29 min -1 max. 20 min -1
3000 mm 1050 mm max. 38 min -1 max. 28 min -1
Drum drive on both sides
Drum drive on both sides
to 80 t/h to 50 t/h
to 100 t/h to 75 t/h
Motor Asynchronous motor Hydraulic rating: Mechanical rating:
Weight (assembled unit)
Cutter / Drum Length: Diameter: RPM hydraulic system: RPM mechanical system:
Drum drive on both sides
Throughput (dependent on material)
Throughput hydraulic system: Throughput mechanical system:
to 6 t/h
to 30 t/h to 20 t/h
to 45 t/h to 30 t/h
to 50 t/h to 35 t/h
to 60 t/h -
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Production of RDF
Brini Ballistic separation Brini separators are used to separate out usable fractions from shredded waste stream. In contrast to traditional wind sifting, customers clearly benefit from the simplicity of the sturdy and compact system which combines high efficiency with low operating costs. Using an optional material distributor, the material mixture in the feed area falls onto rigid screen elements which are arranged lengthwise and slope upwards. The elements are mounted onto a crankshaft at each end, and the elements oscillate during rotation. The two-dimensional fraction comprises of smooth, flat, slender fragments which are cleansed of contaminants by the shaking and rotation as they are transported upwards by the screen elements. This fraction, high in calorific value and free of contaminants is the input for post shredding. The three-dimensional fraction consists of rigid, hard/heavy and cubic fragments which are not separated off by the screen holes selected. The movement causes this fraction to roll and drops it downwards, in addition the ascending material flow is separated into oversized and undersized fractions according to the selected screen holes.
• wide range of applications – from municipal waste (household waste, commercial waste) to potential recyclables (packaging waste, waste paper) and construction & demolition waste • High degree of selectivity with adjustment of separation angle • proven, efficient drive design with low power requirement • rugged design with long service life and low operating costs
rolling fraction
fine screen fraction coarse screen fraction
flat fraction
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Separation other components
FLOWERDISC Also a FLOWERDISC disc separator can be used for separation of shredded material into oversized and undersized fraction. Material is transported by shafts having rugged steel discs working according to the disc screen principle. Movable jacketed pipes positioned between the discs prevent seizures and blockages by contraries.
BRINI MK Motor rating Machine dimensions Length 3 fraction machine: Length 4 fraction machine: Width 3 and 4 fraction machine: Height (machine only): Weight 3 fraction machine: Weight 4 fraction machine:
Screen
Screen elements: Screen elements L x W 3 fraction machine: Screen elements L x W 4 fraction machine: Screening area 3 fraction machine: Screening area 4 fraction machine:
Throughput
(dependent on material)
Drum screens Drum screens also have an entitlement in the separation by particle size. The variable machine configuration in regard to sub-structure, servicing accessibility, enclosure and drive simplify tailoring to on-site conditions. A maintenance-free direct drive minimises energy costs, wear and noise emissions.
MK 41
MK 61
MK 81
Star screens Downstream separation stages are often performed using MULTISTAR star screens. With their building block design and numerous extendable screen options, they are perfectly suited for the separation of the fine fraction, or as a safety screen to keep back overlengths. Also available is the combination of disc separator and star screen.
MK 101
MK 121
5,5 kW
5,5 kW
2 x 5,5 kW
2 x 5,5 kW
2 x 5,5 kW
7475 mm 8675 mm 2400 mm 1930 mm 4200 kg 4700 kg
7475 mm 8675 mm 3240 mm 1930 mm 5000 kg 5600 kg
7475 mm 8675 mm 4480 mm 1930 mm 6000 kg 6700 kg
7475 mm 8675 mm 5366 mm 2010 mm 6800 kg 7500 kg
7475 mm 8675 mm 6220 mm 2010 mm 7900 kg 8700 kg
4 5600 x 422 mm 6800 x 422 mm 9,7 m2 11,8 m2
6 5600 x 422 mm 6800 x 422 mm 14,5 m2 17,6 m2
8 5600 x 422 mm 6800 x 422 mm 19,2 m2 23,4 m2
10 5600 x 422 mm 6800 x 422 mm 24,0 m2 29,2 m2
12 5600 x 422 mm 6800 x 422 mm 28,8 m2 35,0 m2
to 80 m3/h
to 120 m3/h
to 160 m3/h
to 200 m3/h
to 240 m3/h
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Production of RDF
Rasor Post shredder A newly developed, slow-running post-shredder is used for the generation of furnace-ready fuel. The RASOR generates both an injectable fuel fraction (< 30 mm) and a particle size (< 100 mm), known as the fluidised bed fraction. A quick-change system for the screen baskets allows short changeover times. The continuous material feed using one or more feed augers ensures uniform power consumption. The material is shredded by slow-running cutters (93 RPM) in the enclosed shredding unit in a virtually dust-free process. The automatic cutting gap adjustment guarantees minimum energy consumption during the shredding process. So specific energy costs are up to 30% lower than those of competing products. Minimal downtime is ensured by tool-free exchange of the counter-cutter and a quick change system for all wearing parts.
• continual material feed with automatic cutting gap adjustment for uniformly low power consumption • quick change system for all wearing parts ensures minimal downtime • retractable counter-cutter carrier provides optimal service accessibility • low rotor rotation speed ensures shredding with low levels of dust and vibration
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Post-shredding
Material feed Up to three feed augers with loaddependent control transport the material into the shredding area. Material is pressed continuously against the shredding rotor â&#x20AC;&#x201C; in contrast to competitive products which operate intermittently. This guarantees consistent power consumption. Dust emissions are prevented due to the enclosed shredding area.
RASOR
Shredding system Material is presented to a slow speed rotor with cutters in the shredding area and cut at an opposing knife. Particle size is defined by the screen baskets around the rotor. The rotor itself is built from a carrier tube with segment plates. This way, damage can be rectified quickly and cost-effectively.
Automatic cutting gap The counter-cutter is held by a hydraulic clamp. Servo-motors automatically control the feed of the cutting edge to the rotor cutters and provide accurate positioning with minimal cutting gap. This results in a permanently low energy consumption during the cutting with a positive effect on energy costs.
3600
5400
1 x 160 kW
1 x 250 kW
electric 2 x 7,5 kW 2
electric 3 x 7,5 kW 3
Length: Diameter: RPM: Cutter: Screen basket hole size:
880 mm 1000 mm 93 min -1 2 x 12 35, 60 mm
1320 mm 1000 mm 93 min -1 3 x 12 35, 60 mm
Weight
~ 10000 kg
~ 13000 kg
Lenght: Width: Height:
4250 mm 2050 mm 2620 mm
4250 mm 2550 mm 2620 mm
Throughput (dependent on material)
to 10 t/h
to 15 t/h
Motor
Asynchronous motor rating:
Material feed
Type: Number of screws:
Cutter / rotor
Dimensions
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Technology for a better environment
Komptech GmbH K端hau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] info@komptech.com
Komptech UK Ltd. Forge End, Lodge Farm, Kineton, Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 info.uk@komptech.com
www.komptech.com
We reserve the right to make technical changes due to ongoing development.
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