magazine 1/2013
RESEARCH Komptech goes Danish practice Concentrated RDF power practice
Jørgen Nestor POWERS UP
THE RDF PROS. Incredibly tough: The Terminator direct
Shaken, not stirred: The Ballistor
Stationary single-shaft shredder for pre-shredding with direct drive
Stationary ballistic separator
A fine thing: The Rasor
Stationary post-shredder for RDF
The rest is in the brochure. And at www.komptech.com.
A-8130 Frohnleiten, K端hau 37 | T +43 3126 505 0 | info@komptech.com
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CONTENTS Practice WELL PREPARED FOR THE RDF MATCH How Slovakia’s t+t company is meeting a lot of goals with Komptech’s RDF line – a team report.
Karl Rose about the future 4
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INTERVIEW THE EARTH IS HEATING UP Karl Rose is one of the world’s most respected climate experts. He paints a gloomy picture of the future.
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Practice ICING ON THE CAKE Layering it on with the Terminator - a special recipe in Boone County, Iowa.
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Practice ONE GOOD TURN DESERVES ANOTHER The MBT in Myslenice is one of the most advanced in Poland, and is reducing the burden on regional landfills.
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Sverker Rosdahl’s investment has paid off
KOMPTECH INSIDE WITH THE POWER OF THE SUN Each year Komptech generates over 205 MWh of power with the new solar array on the roof of its Slovenian plant.
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KOMPTECH INSIDE Bella Italia Compagnia Generale Trattori S.p.a. (CGT): Off to new horiizons with a new sales partner.
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BUSINESS AN INVESTMENT THAT HAS PAID OFF In Halmstad in southern Sweden, Sverker Rosdahl has taken Komptech´s largest stationary trommel screen into profitable operation.
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research DANISH INSTITUTE RESEARCHES FOR KOMPTECH Turning forestry waste into an industrial heating briquette cooperative research between the Danish Technological Institute and Komptech.
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INNOVATION GREETINGS FROM THE AXTOR A machine goes on tour and brings home a wealth of new experiences.
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INNOVATION PRODUCT SPOTLIGHT: THE AXTOR Six reasons why the Axtor is the best machine in its class.
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BUSINESS REFINERY TO GO Andreas Zeller talks about his plans for the future, and why it’s important to get your hands dirty sometimes.
Andreas Zeller and his “refinery to go” 22
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Practice ISRAELI PIONEERS Three partners had a vision, and within five years built one of the largest composting operations in the world in the Jordan valley.
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Practice MORE MUSCLE Jørgen Nestor and his new Crambo Heavy Duty. More hp for more profit – an interview.
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Practice A LEARNING JOURNEY A 25-person delegation of British organic waste specialists visited Austria and took lots of good ideas back home with them.
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LETTERS TO THE EDITOR Q&A Komptech has answers to urgent questions about service and technology. Title picture: Jørgen Nestor powers up
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Compost OR, Israel’s compost pioneers 30
Publisher: Komptech GmbH, Kühau 37, A-8130 Frohnleiten T +43 3126 505 - 0, F +43 3126 505 - 505, info@komptech.com, www.komptech.com Editors: Andreas Kunter, Joachim Hirtenfellner, Martin Wellacher Layout & graphics: Alexandra Gaugl Photos: Komptech GmbH Frequency: periodically
TECHNOLOGY FOR A BETTER ENVIRONMENT
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THE KOMPTECH TEAM
Terminator
Terminator
Single-shaft pre-shredder Max. throughput 50 t/h
Flowerdisc
Rasor
Multistar
Ballistor
The five pros in the Komptech RDF team
WELL PREPARED FOR THE RDF GAME At the t+t plant in Slovakia, a team of Komptech machines is ready to face any challenger. RDF stands for Refuse-Derived Fuel. Figuratively speaking, it’s the ball that goals are made with. If you can make high-quality RDF, you win - or at the very least, you can do good business. The t+t company in Žilina, Slovakia has taken an RDF plant into operation with a strong team of machines that can stand up to any contender. All wear green, and all are from Komptech: Terminator, Flowerdisc, Multistar, Ballistor, Rasor. From 04
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mixed household waste they create a premium RDF - no easy matter for standard machines, but no problem at all for these top-shelf Komptech players. CONCRETE CUSTOMER The main customer for the premium RDF is a company called ecorec, which delivers it to the Holcim cement works in Rohožník. ecorec also takes the recycling fraction, consisting of
the rolling materials from the Ballistor (PET, HDPE, heavy items). HIGHLY MOTIVATED A good match takes team spirit and top players. t+t is a motivated and visionary player in the Slovakian waste business. Founded 20 years ago and headquartered in Žilina, it employs 185 people, made revenues of 8 million euros in 2011, and operates extensive waste collection
flowerdisc
Ballistor
multistar 2-se
Rasor
Disc screen
Ballistic separator
Star screen machine
Post-shredder
Max. throughput 50 t/h
Max. throughput 60 t/h
Max. throughput 30 t/h
Max. throughput 10 t/h
services, two landfills, and now a refuse-derived fuel plant. It started as a successor to “Žilina Technical Services” and is today the majority owner of a PPP together with the City of Žilina that provides landscaping and city cleaning services. The company takes in 40,000 tonnes of mixed household waste each year from about 100 municipalities in northern Slovakia, as well as schools, hospitals, supermarkets and restaurants. The disposal fees they pay cover the costs of processing the waste. The main customer is the City of Žilina. With a population of 85,000, this university and industrial city is the metropolis of northern Slovakia. PIONEERS TEAM UP Two years ago, two pioneering companies got together here - t+t and Komptech. Their shared vision of modern resource and waste management led them to team up, and they quickly planned, built and commissioned the Žilina RDF processing facility. Now, in Dolný Hricˇ ov a Terminator 3400 S, Flowerdisc, Multistar 2-SE, Ballistor 6300 and Rasor 5400 run twelve hours a day to
turn customers’ household waste into products t+t can sell at a profit. Plant director Juraj Hollý and manager Miloš Dˇurajka together bring 50 years of experience to bear. MEETING UP AT A MATCH The companies have also met, if not on, then certainly at the playing field. Markus Maierhofer of Komptech’s Sales department is an amateur footballer. He and Vladimir Solokovský, Board Chairman of t+t and a fan of MSK Žilina, got together at a European Cup game of Slovakia’s national champion side. Their shared professional interest is matched by shared personal interests. What does Vladimir Solokovský associate with Komptech? “The Terminator is your top player. It best shows what Komptech is all about.” BAD TIMES FOR LANDFILLS The new facility means slimmer pickings for landfills in Slovakia. Landfill space is already scarce, and in any case landfilling untreated waste is increasingly seen as an environmental problem, even though it is not yet prohibited in this country.
But pressure from Brussels to comply with the European landfilling directive, and the introduction of a landfill tax, will make it easier for t+t to turn its pioneering role into a profitable one. Currently the cost of processing cuts into profits, and landfilling is still cheaper than treating waste. THE NEXT STEP But t+t is already planning the next step - biological treatment downstream from the RDF processing plant in Dolný Hricˇ ov. This vision will make the company even better.
poland
Czech Republic
Žilina
UKRAINE
Slovakia austria
Bratislava
hungary
romania
facts
Company: t+t as Location: Žilina, Slovakia Commissioning: 15 December 2011 Annual throughput: 40,000 tonnes Hourly throughput: 23 tonnes Employees: 7 Website: http://t-t.sk
Director Juraj Hollý and manager Miloš Dˇurajka are enthusiastic fans of the Komptech team.
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Karl Rose is Senior Fellow of the World Energy Council, London, and heads the development of global energy scenarios for 2050. 06
interview
Photo: Fischer
The earth is heating up Economics research Karl Rose considers climate goals unreachable. He predicts a four-degree rise in temperature and a doubling of energy consumption, and considers the actions of individuals to be the key to a sustainable economy. Across Europe, there is discussion of renewable fuels. Do we really need to choose between fuel and food? KARL ROSE: No, that’s a much too narrow perspective. Whether or not Austria introduces renewable fuel has no effect on world hunger. But if fossil fuel were to be replaced with renewable fuel worldwide, it would be a different story. Governments are holding to the Copenhagen climate goal of no more than two degrees global warming. Is that still realistic? ROSE: We will most definitely not reach that goal. That would require tremendous political shocks or technology leaps that are not presently on the horizon. What do you mean by political shocks? ROSE: A planned economy that intervened to a massive extent in resource use. Like the “car free days” of the 70s. That is incompatible with our democratic way of doing things. We already have enough heated discussion if the vice-mayor of Graz does away with a few parking places at the train station. And then there are the new middle classes in China and India... ROSE: Yes. They have an enormous appetite for energy, and feed it mostly with coal. That will remain the case for decades, whether or not we
in Europe approve. But we need to use new technologies, like carbon dioxide scrubbing and storage. We need to make these technologies as cheap and widespread as possible, as quickly as possible. How much global warming do you project? ROSE: Our scenarios are horrific. By 2050 global energy consumption will double. I project three and a half to four degrees global warming, and that’s if everything goes well. What will that mean? ROSE: It’s difficult to predict, because the scenarios are hard to model. But perhaps it will be less apocalyptic than we assume. Is it true that the economic crisis was the most effective climate protection measure thus far? ROSE: Yes. A recession is actually the best thing that can happen for the climate. It sets the clock back 7 to 10 years, but then we have other problems. Unemployment and lack of purchase power are not fun. What can individuals do?
have to get people to move back into the cities. There are people who commute because they must, and those who commute because they can. Laws are made more for those who commute because they can. If that weren’t the case, Austrian drivers wouldn’t get a tax writeoff for commuting. ROSE: And, many tax-advantaged company cars are SUVs or other highend vehicles. If I were in politics, that’s where I would start, because people will tolerate that.
With the kind permission of the Kleine Zeitung, Graz, Austria
BACKGROUND In Austria, commuters get a tax deduction based on the distance between their residence and workplace. The deduction is applicable only if using public transport would take an excessive amount of time.
ROSE: Actions by individuals are the key to achieving a sustainable economy. It horrifies me that young people buy a new mobile phone every six months. That’s wasteful. We have made huge mistakes in our use of space and the way residences are spread out across the landscape. We interview
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The Boone County Landfill team is proud of their new Terminator Heavy Duty.
Icing on the cake Scott Smith, landfill administrator for Boone County, Iowa, is proud of his new Terminator 5000S Heavy Duty Edition by Komptech. It maximizes his landfill capacity, while minimizing downtime. He had originally been looking for a replacement compactor when a friend at a nearby RDF plant alerted him to what Komptech grinders could do. Scott took a look, saw a demo, ran the numbers, and ended up convinced that a Terminator was the way to go. Of key importance in his decision was the huge increase in uptime due to the low-speed grinding action. Unlike a fast shredder, when the Terminator encounters
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something it can’t handle the drum simply comes to a stop, instead of jamming and breaking down. That means no lengthy repairs or unplanned maintenance headaches. Focus on ease of maintenance Scott also liked the way that the machine is designed to make servicing easy – just swing the side panel up and away, and everything is accessible.
“Our guys can work safe and standing up. There’s no crawling under the machine,” he said, adding that since the Terminator doesn’t jam and break down when it encounters something it can’t grind, “we’ve only had to open the panel four times in 3 months, and we never need to bring a torch.” According to Scott, the Terminator also gives comparable or even better uptime than conventional compactors, while cutting waste
volume by half. For example, some of the waste that comes to the landfill is already baled and very tightly compressed. The compactor can’t really do much more to it, but the Terminator can open up and grind the bales to half of their previous volume. “On a bad day, we can reduce our total volume by 40%; on a good day we can reduce it by 60%,” said Scott. Adding it up, that means the landfill will be able to stay in operation 14 years longer than planned, without adding acreage. Since the landfill makes money every year it is in operation, this makes the Terminator a very profitable investment.
Canada
New Hampshire Massachusetts Vermont
Maine
Washington Montana
North Dakota Minnesota Wisconsin
Oregon
South Dakota
Idaho
New York Michigan
Illinois Utah
Kansas
West Virginia Virginia Kentucky
Missouri
Connecticut New Jersey
Indiana
Colorado Komptech USA Inc.
California
Maryland
Ohio
Nebraska Nevada
Rhode Island
Pennsylvania
Iowa Boone
Wyoming
Delaware
North Carolina Tennessee
Oklahoma Arizona
New Mexico
South Carolina
Arkansas
Alabama Mississippi
Texas
Georgia
Louisiana Florida
mexico Icing on the cake In addition, by grinding the waste into same-sized particles, the Terminator reduces the amount of cover dirt needed to just a third of what the landfill was using previously. At the end of every workday the landfill covers the waste with 15 cm of dirt, “and now I’m frosting a cake instead of using extra dirt to hold down mattresses and fill in around bales,” as Scott put it. He opted for a ferrous separator on the Terminator, which lets the landfill separate out and sell scrap metal for an additional revenue stream. He also has other ideas on how to maximize profit at the landfill. For instance, the landfill can now do brush and post-disaster grinding, which were formerly contracted out. Scott is also looking at regrinding waste for RDF. This way the landfill can fill the trucks which currently leave the landfill empty, for additional revenue.
facts
The Boone County landfill handles municipal solid waste, C&D waste, and compatible commercial and industrial waste, all told about 100-150 tons per day. The planning district it serves is one of only two in Iowa to meet the state’s goal of 50% waste diversion; currently it diverts 55% of waste through source reduction, reuse, and recycling; regrinding waste for RDF would boost that to 65%.
The Terminator beats any waste compactor. Komptech USA Inc. Headquarters: Denver, USA CEO: Marcel Vallen 2011 revenues: > 15 million euros Number of distributors: 13 and rising
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Director Jerzy Podmokły and CEO Ewa Kęsek in front of the Komptech Mashmaster.
PREPARING FOR THE FUTURE Good preparation and good decisions - the two key factors in managing a waste handling facility. Ewa Kęsek knows whereof she speaks.
“The most important things in managing this facility were the preparations and then the decisions we made. We looked for advice and chose consultants we could trust. Komptech is one of them,” says Ewa Kęsek, CEO of Zakład Utylizacji Odpadow Sp. z o.o., the company that provides waste handling services for the city of Mys´lenice in the Voivodeship of Lesser Poland. What was the most important decision? Kęsek: “Whether or not to go ahead with it.” 10
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A QUESTION OF NEGOTIATION SKILLS Ewa Kęsek, was entrusted with the waste handling for Mys´lenice in 2007. At the time, that meant landfilling. But Ewa Kęsek had a plan. She knew about the waste handling requirements that resulted from Poland’s entry into the EU, and repeatedly brought up the subject with the mayor. “We started with a budget of 500,000 Złoty (125,000 euros), and each week another million was added.
Finally we were at 47 million Złoty (12 million euros) and were able to start investing.” The decision was made for a mechanical-biological waste treatment system (MBT). Thanks to well-chosen advisers the city was able to do its own planning work. The system was tendered out, constructed and taken into operation. Since 1 April 2012 Komptech machines have been working with three sorting lines and a box composting system from Austrian supplier MUT.
Lithuania
Baltic Sea
Republic of Belarus
Recyclables recovery in Mys´lenice.
Warsawa
poland
germany
NEW BUSINESS FIELDS The plant produces cleanly sorted recyclables, refuse-derived fuel for the cement industry and a landfill cover material. There are no tipping fees for these material streams, and the recyclables bring in revenues. Thanks to the Komptech Ballistor, an unusually clean ferrous fraction can be extracted from the rolling fraction. Currently it is selling for 175 euros per tonne, and higher amounts are paid for the handsorted PET, the foil and aluminium. “Sales of recyclables is its own business field for us. Currently we sell at daily spot prices, but we’re looking for long-term contracts,” reveals Jerzy Podmokły, Director of the Mys´lenice MBT. The environment also profits, since not even half as much material as before goes to the new landfill. The success is visible. A COMPACT PLANT FOR A BIG JOB The compact dimensions of the facility are obvious at a glance. Just two halls were built next to the new
landfill section, but these two halls handle 30,000 tonnes of household waste annually from Mys´lenice and its surrounding area. With Terminator, Ballistor, Multistar and Mashmaster, Komptech supplied the core machinery for the mechanical processing, as well as a Topturn for turning the windrows. Naturally there was opposition to Ewa Kęsek´s plans. Some neighbours were afraid of what the changes might mean, but ultimately they could not prevail against the many benefits of the latest waste handling techniques. “The strong vision of this new era in waste handling in Poland has established itself,” says Ewa Kęsek, adding a crisp “I finish what I start.” It’s something that could also be said of Komptech.
Mys´lenice UKRAINE
Czech Republic
slovakia austria
hungary
romania
facts Company: MBA Mys´lenice of Zakład Utylizacji Odpadow Sp. z.o.o. Location:
Mys´lenice, Poland
Throughput:
30,000 t/year (one shift) 60,000 t/year (two shifts)
Upfront cost:
47 million Złoty (12 million euros)
Commissioning: 1 April 2012 Installed power: 1.2 mW Employees: 50 Website: www.skladowisko.com.pl
http://www.agrex-eco.pl/
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With the power of the sun germany
austria
hungary
slovenia italy
Ljutomer
Ljubljana Komptech CEO Josef Heissenberger, C Farmtech GT pACEO Sonja Rajh and Project and Production Manager Franz Jantscher with theS new solar Direarray.
croatia
BosniaHerzegovina
Adriatic Sea
zione G enerale Filiali d : MILA i Venadyear Slovenia has up to 2300 hours of sunshine ita, N- uato the top of the NO - 200 o e Usto ● ANC Rajh it only madevsense European charts. So for CEO Sonja atoinstall ONA te , Noleg l. 0new gio e A 71.72factory 027 Oof a huge solar power array on the60roof the building in 7 71 sim 1o, Via A Loc. As . Volta fax 071.71083 pits Ljutomer when Komptech expanded io Tfacility 31 15 erm there.
facts Farmtech d.o.o. Activity: Component manufacture for Komptech and production of agricultural machines Location: Ljutomer/Slovenia CEOs: Sonja Rajh, Franz Jantscher, Borut Kapun Employees: 265 Total production space: 11,200 m2 Machines produced per year: 1500
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komptech inside
e - Zon ● AOST a Ind.le A 11020 Q tel. 0165.7748 1 - fax uart Lo With 927 modules of 205 watts output an 0active role in calitotàplay ● AREZ “We, want Ameriq 165.765192 ue tel.transition each, the array has a rated output52of ZOthe to renewables,” said 100 Via 0575.394.1 P. Cala CEO- Josef over 190 kW. “This lets us generate Komptech Heissenberger f a man re x 0575.356 ● BAR 608this i, 3motivation I tel. in about 205 megawatt hours of current explainingdthe for 05 0 8 0 .586111 700 1 per year, saving almost 160 tonnes 26 Modflagship project. “So the installation fax 080 ugno, Z .5 217 another ● BERG na Inarray of CO2,” said project leader Franz a newosolar was32just 9 dustria AMOof / le S.S. B R ● f ax 030.6 logical E IA But that’s not all as Jantscher. 96 -km tel. 030 857215 SCstep.” . 1 1 8 .6 - 25050 year’s expansion ● BOLO of the The investment costs were about Passira 57681 GNA tepart of next n o l. , ● IM V 001up 0 Frohnleiten facility, the company 320,000 euros. The array was 4put ia 5 1.6477.1 2 Calde S.Anto nio, 4/B r a f r a a x 18 d plans to replace its existing gas by a Slovenian company, Pro-Sigma 0 ● BOLZ i no, 51.7274 ANO te furnaceRewith Vaiamodern 50 P e chip-fired r d.o.o., and went into operation in late s l. 0471.8 39044 E icetana ● LIV 2451 gna, Via ,4 heating 2012. fax 047 degli Aplant. 570 ● CAG 1.824 rtigiani, LIA 14 - Zo 590 09030 E RI tel. 070.21 ● MIL na Ind.l 12 lmas, V e Sud ia Sern 71 - fax 070.2 ● CARR 2006 agiotto 40377 A Snc 54031 A RA tel. 0585.5 ● PADO 0 venza, Via Au 771 - fax 0585 ● CASE 35030 r .5 e lia, ang 5296 RTA t
Aosta
Vercelli
Milano
Sondrio
Bergano
Bolzano
Treviso
Italy is one of the largest waste markets in Europe. With significant unresolved public waste disposal challenges, especially in the south, there is much potential for development in the coming years. Renewable energy is also gaining importance in Italy. For this reason, Komptech has decided to leverage this potential with a new partner, Compagnia Generale Trattori S.p.a. (CGT).
Udine
Torino Verona 02.274271 - fax 02.27427554 Padova Cuneo Piacenza Parma Genova Bologna ENZA tel. 0971.485519 - fax 0971.485525 0 Tito Scalo, Zona Industriale Imperia di TitoCarrara
NI tel. 0541.623473 - fax 0541.623589 2 Santarcangelo di Romagna, Via del Pino, 5 Livorno
A tel. 06.82601 - fax 06.8260358 7, Via Nomentana, 995
SARI tel. 079.2637401 - fax 079.260609 0 Zona Industriale Predda Niedda Strada n. 18
Sassari
NO tel. 011.8963511 - fax 011.8963556 6 Settimo T., Via Leinì, 130
Rimini
Arezzo
Ancona
Teramo
Perugia
DRIO tel. 0342.493802 - fax 0342.493794 0 Colorina, Loc. Piani della Selvetta Nazionale, 620
AMO tel. 085.946541 - fax 085.9462123 5 Scerne di Pineto, Via Piane Vomano
Firenze
Roma
ISO tel. 0422.724166 - fax 0422.724168 7 Spresiano, Via Marmolada, 8
NE tel. 0432.85071 - fax 0432.853408 9 Tricesimo, Via S. Giorgio, 15
Caserta
Foggia
CELLI tel. 0161.2951 - fax 0161.295226 0, Via Torino, 45Cagliari
CELLI Divisione Energia tel. 0161.290300 Via Ettore Ara, 1 161.290370 - 13100,
Potenza
ONA tel. 045.825041 - fax 045.8201179 6 Sommacampagna, Via dell’Agricoltura
Cosenza
Palermo
Bari
Based in Milan, the company is Caterpillar’s general representative in Italy, and has an accordingly dense network of locations across the country. “The Komptech brand is already well-established in Italy, and Komptech is recognized as the most innovative. What was missing was a broader, full-coverage sales and service organisation that could make use of the existing potential and successfully go up against the current market leader Cesaro Mac Import,” said CSO Josef Imp of the reason for the decision.
“CGT is a sales partner who brings exactly this to the table, and is also very interested in getting more deeply involved in environmental technology,” he continued. “As the CAT sales organisation, the 090 Vim odrone company is definitely in a position to make - Strad a Stata good use of the considerable potential le Pada Assiste synergies, from the CAT engines used nza Tec na Sup eriore, nica in Komptech’s mobile machines to the 19 - tel . ● CUN 0 2 . 2 74271 - same customer segment for CAT handling EO faxmachines 12045 F tel. 0172.638 02.2 in disposal companies.”
Catania
01 ossano 7427554 , Via To - fax 0172.69 ● FIRE r 1 in 4 64 o, 57 NZ These facts speak for themselves, and 50041 C E tel. 055.886 04.1 - f alenza ● P encourage both partners to hope that by O a T no, Via x ENZA t ● FOGG G. Zane 055.8860428 el. 0971 8 5 joining forces they can substantially grow IA tel. 0 5 0 lla, 11 .4 Tito Sc 088 71100 Z 9alo, Zo 8551Komptech’s of the Italian market in ona Ind 1.680405 - fa ● RIMI na Indu fax 0971.4share 85525 x 0881.6 NI tel. ustriale stcoming ● GEN r ia 0 le the years, with above-average profit 8 5 C 4 0 4 d .s 7 4 1 i Tito OV 822 Sa 04 o del M ntarca .623473 - fopportunities ezzogio 16163, A tel. 010.723 a x for both companies. n 0 gelo di 541.623 ● ROM rno km Via Lun 6 589 RoWe’re .3 A tel. 0 go Torr .1 - fax 010.75 magnalooking 6 ente Se 0767 MPERI .8 0 , Via de forward to seeing it unfold. 0 2 1 6 37, Via 01 - fax A tel. 0 cca, 64 l Pino, Nomen 1 8018 Ta 5 rosso tana, 9 06.8260358 ● SASS ggia, R 84.46461 - fax 95 ARI tel. egione 0 1 8 4 .4 0 079.263 7100 Zo 64646 VORNO Perian e snImp na InKomptech), left to right: Josef (CEO c (CSO Komptech), Josef Heissenberger 0586.9 dustria 7401 - fax 079 017 Sta tel.Front, ● S 4 le Pred 40.1(CEO .2 ONDirector gno,Lino Vincenzo de Benedectis (Managing DRI t CGT) - faxCGT), da Nie 60609 ViaTedeschi 0586.9Kulmer el.Ewald Aurtoeliright: 0342.4 dda Str 3010 Co O Rear, left Christian Italy), Konrad 41606(Komptech Area Sales2Manager LANO a 9 380 ada n. te rina, LManager), Via Na lo Sales Manager Komptech), Paolo Vivani (Earthmoving 18 .92364Area oc. Pia 2 - fax 0342.4 61 Caru l. 02(Senior zioGeneral 1 -(Earthmoving n n 9 a i 3 gateAndrea le f d a 7 Elli Marketing Manager) e , 9 x 02.92 ll 6 4 a 2 , Strad 0 ● S elvetta TERAM a Provin 364430 komptech inside OVA te O tel. 0 ciale 1 l. 049.8 6 8 4 5 0 .9 2 2 5 4 1 6541 Scerne 0 Sarm 73371 f
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Sverker Rosdahl is doing good business with his new trommel screen.
An investment that has paid off The 25/120 is Komptech’s largest stationary drum screen. In early 2012, the first Swedish customer took delivery of one. Stena Recycling Production Manager Sverker Rosdahl reports on how the machine has worked out so far. Stena Recycling in Halmstad, Sweden had clear requirements for a new screener - high throughput and high reliability. The company needed a new trommel to handle “difficult” media. After detailed research of the products on the market, Sverker Rosdahl determined that Komptech machines met his requirements. Together with Daniel Carlberg of Pon Equipment, 14
business
Komptech’s Swedish representative, he visited Komptech to take a closer look at some of them. Four fractions in one pass Finally, he decided on a stationary 25/120 trommel screen. The numbers stand for 2.5 meters drum diameter and 12 meters drum length. What clinched the deal was the ability to screen out four
fractions in one pass. The machine sorts out non-ferrous metals for recycling. “Our input material is difficult, because it has wires and cables in it. So we ordered the machine with anti-dirt bars to prevent the material getting stuck in the holes. It has worked very well and so far we have not had to clean the drum once,” emphasizes Sverker Rosdahl.
Arctic Ocean
The Stena Group The Stena Sphere Group was founded in 1939 and is one of the largest family companies in Sweden. It consists of three subsidiaries, Stena AB, Stena Sessan AB and Stena Metall AB. All told, these three companies employ about 19,000 people, and in 2009 made revenues of around 5.6 billion euros, for a pre-tax profit of about 200 million euros. Environment and recycling are the group’s fastest-growing business categories and are handled by Stena Metall AB, headquartered in Göteborg with 250 locations in Scandinavia. In recent years, there has been a major emphasis on research and development, with cooperative efforts with wellknown Swedish universities (Göteborg, Linköping, Lund, Kalmar). Sverker Rosdahl is Production Manager at the facility in Halmstad in southern Sweden.
Atlantic Ocean
sweden FINLAND
Gulf of Bothnia
norway
Stockholm estonia
Halmstad lativia denmark
Baltic Sea Lithuania
www.stena.com germany
poland
From two to one, from four to two The new Komptech 25/120 trommel screen replaces two older machines, and has significantly improved Stena’s operations in Halmstad. “The screen has an incredible capacity and meets all our expectations. It let us switch from four shifts to two shifts, with the same output as before. The investment has absolutely paid off,” says Rosdahl, proud of his decision. Less noise In addition to high capacity, Sverker Rosdahl also mentioned the operational safety of the drum, thanks to the four separate electric motors. “An additional requirement we had was that the new screen be environmentally sound, including low noise and dust emissions. Here again the new Komptech is significantly better than its predecessors.”
Screen model
Length
Diameter
Max. throughput
1845
4500 mm
1800 mm
120 m3/h
2055
5500 mm
2000 mm
160 m3/h
2255
5500 mm
2200 mm
190 m3/h
2278
7800 mm
2200 mm
230 m3/h
2290
9000 mm
2200 mm
250 m3/h
2590
9000 mm
2500 mm
275 m3/h
25/120
12000 mm
2500 mm
300 m3/h business
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DANISH INSTITUTE RESEARCHES FOR KOMPTECH
The DTI is recognised as a world leader in the conditioning of woody fuels.
A new biomass fuel has been developed in a unique cooperative effort between the Danish Technological Institute and Komptech. Woody material that was heretofore unusable can now replace coal in power plants. Joint research on the use of forestry waste as fuel - the 1300 km between Frohnleiten, where Komptech is based, and Stenderup, home of the Pelletizing Test Center of the DTI (Danish Technological Institute), presented no obstacle. The Danish researchers confirmed the validity of the idea, and together with Komptech developed the process for making the new fuel. Previously the input material was left in the forest or composted. Today, with the help of the newly developed process, it can replace fossil fuels.
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It takes the form of an industrial briquette and has an energy density of 3.6 MWh/m³. It’s ideal for coal-fired power plants looking for a renewable fuel for co-firing. The energy density of fuels has a huge influence on their transportation costs and thereby on their radius of use. Wood chips only have 0.7 MWh/ m³, making them unsuitable for longdistance transportation, but this new briquette has five times that energy density, and 15 percent higher than conventional pellets - and pellets are already shipped from North America
to Europe for co-firing in coal power plants. The market is growing rapidly, since power plants can save CO2 certificates by co-firing wood with coal. AWAY FROM OIL, GAS AND COAL Komptech is researching in new directions. Inspired by our customers and motivated by their visions, the company is trying new approaches to meet future EU rules. In few areas are the goals as ambitious as they are with renewable energy, where regulations calls for 20 percent of the EU’s energy needs to be covered by
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PROPERTIES OF THE INDUSTRIAL BRIQUETTE The industrial briquette has an energy density of 3.6 MWh/m³ and a heating value of 4.7 kWh/kg. It is ideal for coal power plants needing a renewable fuel for co-firing. Wood chips only have 0.7 MWh/m³, making them unsuitable for longdistance transportation, but this new briquette has five times that energy density and 15 percent higher than conventional pellets. The dimensions are 75 mm diameter and 50 mm length. The water content is <10%, as is the ash content.
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facts renewable energy in eight years, by 2020. That means moving away from petroleum, gas and coal, and to sun, wind, water and last but not least wood. Feverish research is underway in every area in order to meet this goal. Komptech is also researching and extending its biomass expertise. THE PROJECT TEAM To complete the development project, Komptech formed a project team consisting of six partners: Naturgut GmbH, Andritz AG, the Danish Technological Institute, KWB Kraft und Wärme aus Biomasse GmbH, KCO Cogeneration and Bioenergy GmbH (Kohlbach) and Komptech. THE INPUT MATERIAL The new process increases the amount of biomass that can be used for energy as opposed to composting. Undersizes from forestry residue are a by-product of biomass harvesting in the relevant European markets. It has a relatively moderate ash content, which is beneficial for the new preparation process. This undersize material can now be turned into industrial briquettes.
THE PROCESS The material first goes through a star screen at the finest setting, then a conveyor dryer and compressing machine (briquette press or pellet press). That’s all there is to it. Compared with conventional wood pellets, the new briquettes show no peculiarities that standard techniques cannot handle. Georg Payer of Kohlbach said “This fuel can be used in Kohlback’s furnaces without problems. It burns great!” This despite the fact that the visible pine needle content would seem to indicate problems with the ash melt properties and emissions; however, these do not arise. CONCLUSIONS Komptech recommends making briquettes instead of pellets. At 3.6 MWh/m³ the attainable specific energy density is higher than with pellets, while briquettes are incomparably easier to make than pellets. It can further be expected that the wear on the briquetting machine is lower, since there is less contact surface per material volume. We expect that this process will make it possible to use another 25 percent of fresh forestry residue material for industrial briquettes. COAL POWER PLANTS, HERE WE COME!
The Danish Technological Institute is a self-owned, non-profit institution that develops, implements and disseminates technology-based knowledge for the Danish and world business sectors. It works in close collaboration with leading Danish and international research and educational institutions on development projects which are of use to society. The DTI also carries out consultancy and standardisation services, which contribute to a dynamic and harmonious development of society. Its most important task is to ensure that new knowledge and technologies can be quickly converted into value for its clients, in the form of new or improved products, materials, processes, methods and organisations. The DTI works with new and established companies, individually and in groups, on new ways to enhance technological and management restructuring and efficiency, in industry as well as in leading ancillary sectors.
President: Søren Stjernqvist Year founded: 1906 by Gunnar Gregersen Revenues in 2011: EUR 132 mill. Revenues from R&D: EUR 33 mill. Employees in 2011: 953, whereof 876 academics Website: www.dti.dk
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GREETINGS FROM THE
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un b e l e c Toate
Cheer
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Six countries, six jobs, one machine. Or, what a demo unit goes through in just a few weeks. The Axtor is a universal highperformance chipper for green cuttings and wood. Says Komptech. To make sure it is familiar to all interested parties, our demo machine travelled the length and breadth of Europe.
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INNOVATION
USED WOOD, FINELY CHOPPED Location: Kent (UK) Date: 20 June 2012 The British used wood market demands a finer granulation than most. The Axtor’s output was at first too coarse, and customers were distinctly “not amused” by the many overlengths. After some rummaging in the tool box, the Axtor’s bite was made tighter, and it was fitted with a special used wood screen basket and new, solid free-swinging teeth. Now it chews its food much more thoroughly.
READY FOR COMPOSTING Location: South Holland Date: 10 August 2012 The input material properties are extremely important in composting, we were told by the operator of a Dutch tunnel composting facility for green cuttings and organic waste. The Axtor knows this, and when working in shredder mode with free-swinging teeth it delivers a consistent output material without destroying the structures that are critical for ventilation. Demonstrating its chipping ability the very next day is another matter, but not really a problem, since conversion from shredder to full chipper mode doesn’t take more than three hours.
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ella Italia! LIKE IT WAS MADE FOR BARK Location: Baden-Württemberg (D) Date: 22 August 2012 Several tests have already shown that the Axtor is well suited to chopping bark. Now we have confirmation, from one of Germany’s largest producers of decorative bark and mulch, that it is the ideal machine for the task. With fixed teeth it creates the ideal chip shape, whether the bark is wet or dry, and with a throughput of 250 m³/h it is also extremely economical to operate.
BUON APPETITO FOR THE LEFTOVERS Location: Friaul-Julian Venetia (I) Date: 05 July 2012 In Italy, energy wood plantations make an important contribution to renewable energy. The stumps and rootstocks that are left behind after the harvest can also be chipped into a useful biomass fuel if you have a tough machine like the Axtor. The huge feed area makes it easier, as does the active intake system that dependably pulls bulky items in for chipping.
OVERLENGTHS UNWELCOME Location: Styria (A) Date: 12 September 2012 “Thou shalt have no fines nor overlengths” - the first commandment of good chip quality. Especially when overlengths can clog furnace feed systems. The heating plant operator, in this case a large industrial operation in Austria, wanted 40 x 40 mm for the formerly coal-fired plant he is converting to use wood. Throughput OK, screen analysis OK, order OK? HOT TIMES IN ROMANIA Location: piatra Neamt (RO) Date: 18 July 2012 Over 40°C in the shade, dust all over everything, and chipping without letup. No fun for man or machine. But extreme conditions like this let us know where the limits are, and supply valuable information for developments and improvements. For instance, now we know how to seal dust out of the Axtor, and how to protect it from heat stroke.
INNOVATION
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Active feed
The feeder specs are impressive - 1.6 m wide and 1 m high, fed by what is probably the best intake system in this machine class. The combination of horizontal and vertical feed rollers and a wide sectional steel belt ensure active intake into the machine, even with bulky green material.
01 Huge feed area At over 2 m wide and up to 6 m long (7.5 m for the semi-trailer version), the movable feed hopper can accept the bulkiest items from the biggest shovels or grippers, without blockages.
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Man and machine
A colour display clearly shows all functions and the operating status. Colour-coded graphics help the user quickly locate the right controls for each function. The optional remote control has all the functions needed to control the machine.
ht: the axtor In shredder mode, there are three freeswinging tools in each tool mount, for 108 tools on the drum. In chipper mode, there is a fixed blade holder in each position that can take chipper or shredder blades. Conversion takes about an hour.
03 or chipping
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Shredding
Easy maintenance
Designers and service technicians worked together on the Axtor right from the start, to give it easy maintenance access few other machines can match. The Axtor is the only machine anywhere to combine an underfloor engine, swingout screen basket, easily accessible shredding chamber and individual mounting of tools on the drum.
The fixed holder can turn on its shaft, but is held in position on the drum by a shear bolt. In the event of a large contrary, the shear bolt breaks and the holder swings into the drum body, preventing additional damage in the shredding area. Contrary-safe in
04 chipper mode
AXTOR 8012 Drive Engine / Power:
CAT ÂŽ C18 / 570 kW / 780 HP
Material feed Feed table L x W (mm): Feeder opening H x W (mm):
Trailer: 6000 x 2100
Semi-trailer: 7500 x 2100
1000 x 1610 (with vertical feed rollers 2100)
Shredding unit Drum diameter x drum width (mm): Tools: Drum rpm:
1250 x 1630 108 pieces free-swinging tools or 36 pieces fixed tools 730 (shredder mode) or 400 (chipping mode)
Dimensions Transport dimensions L x W x H (mm):
Trailer: 10600 x 2550 x 4000
Semi-trailer: 11535 x 2550 x 4000
Working dimensions L x W x H (Conveyor belt 35°, mm):
Trailer: 15000 x 2550 x 4700
Semi-trailer: 16455 x 2550 x 4700
Weight, dependent on equipment (t):
Trailer: ~ 26.0
Semi-trailer: ~ 30.0
Throughput (dependent on material) Throughput performance (m3/h):
up to 400
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refinery to go Andreas Zeller and his new star screen, which can process up to 200 cubic metres of green and shrub cuttings to renewable fuel every hour.
The green refinery is on the outskirts of Mutterstadt (Germany). Unlike its fossil counterparts with their steel gantries, smokestacks and gas flames, it basically consists of a shredder and a screener. The raw material is not fossil but “freshly grown”, in the
form of brushwood, logs, rootstocks and untreated used wood, all of which absorbs as much CO2 when it grows back as it gives off when burnt. It is harvested locally, mostly from landscaping, and it is also used locally - instead of being piped thousands of kilometres through unstable regions, it is trucked short distances to area heating plants. ZELLTHERM CUSTOM QUALITY Thanks to a certain stubbornness, the Zeller company has grown to become an established regional vendor in a
relatively short amount of time. It supplies power plants as well private customers within a 100 kilometre radius with customised Zelltherm brand fuel. Zeller can tailor the grain, heat value, ash content and ultimately the price to individual customer needs. “We sell customers exactly the fuel that makes the best business sense for their system. There is no point in making top grade when it’s not needed for good combustion, and when it costs too much in the long run,” says Andreas Zeller confidently.
QUALITY From green cuttings, shrub cuttings, untreated used wood, energy wood, forestry residue and rootstocks, the Zeller company makes customised fuel under the Zelltherm brand. Zelltherm is CO2neutral, economical, and keeps value creation in the local area. Fuel
Fuel Zelltherm G100
Heating oil
Natural gas
State
Solid
Liquid
Gaseous
Energy content in kWh
10 kWh
10 kWh
10 kWh
Weight in kg
3.8 kg
0.860 kg
0.840 kg
Volume in litres
15 Liter
1 Liter
1000 Liter
Price per kWh
1.4 cents
10.45 cents
8.62 cents
CO2 emissions per kWh
neutral
263 g
198 g
10 kWh is the energy required to heat 860 litres of water by 10 C°. 22
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Source: Österreichischer Biomasse-Verband, LWF (D), Zeller GmbH (D)
Andreas Zeller has built a refinery. It’s small, compact, and mobile when it needs to be. With it, he makes renewable fuel from local raw materials, for local customers.
“Transparency is our philosophy. We take prospects, for example the mayor of a town with a heating plant, to see our operation and show them exactly how we make the fuel and what we make it from. We supply the material for a test phase, and if everything turns out as promised, we’ve gained a new customer.” The range of services extends from straightforward fuel sales to heat contracting, including operation of the heating plant and a guaranteed fuel supply. DESIRE AND REALITY Everybody talks about getting away from fossil fuel. But it’s easier said than done. Biomass heating and power plants face tough competition from conventional power plants backed by gas and oil giants that are not going to just fade away. The price pressure is often passed along to suppliers of renewable fuels. Andreas Zeller knows all about it: “Biomass heating plants can only pay a certain maximum rate for fuel. If the price of gas sinks they come under pressure and look around for cheaper fuels. What’s more, the fuel market is very flexible, not to say opaque. Different fuel grades, seasonal surpluses and shortages, and the many middlemen just make it confusing.” To cope with this dynamic situation, Andreas Zeller has invested in a modern screening system.
ONE SCREEN - FOUR FRACTIONS The heart of the system is a new Multistar star screen, painted bright yellow. It is fed by upstream shredder via an intermediate hopper, which allows the addition of other material. The Multistar separates into four fractions: Fines for composting, two fuel fractions with different grain, and woody oversizes which go back for reshredding. Electronic conveyor scales give precise data on output, which Andreas Zeller can access remotely at any time. His motto is “it has to pay”, and he regularly examines volume flows and material streams to adjust his system and processes for the optimum economy. He likes the way the screening system gives him to the flexibility to do that. “I can respond to different material properties or new customer requirements instantly just by changing the screen cuts. You can’t do that with trommel screens.” THE BOSS GETS HIS HANDS DIRTY Andreas Zeller spends a lot of time at a desk, but that doesn’t prevent him from regularly doing hands-on work. “When I help with the maintenance on a machine or operate a wheel loader a couple of hours loading the star screen, it lets me know what really works versus what only works on paper.” He’s always had this close contact with his machines - for as long as he
can remember, the family business was the determining factor. “Home and business were one and the same, and when I was little I would drive my go-kart around among the containers. Later, before I went to school I would often turn our compost windrows in the morning and then show up at school smelling of compost, which not every teacher thought highly of.” Sometimes during a quiet moment he reflects on what he has accomplished at a young age - turning what was originally a container service into a broadband recycling operation, and entering the challenging field of biomass energy. Andreas Zeller is convinced that it will be of enormous importance to his business, and to the future environment.
facts
The Zeller company is a recycling and container service provider for the Rhine and Vorderpfalz region, as well as a leading manufacturer and vendor of biomass fuels. At the heart of its biomass production is a new Multistar 4 SE star screen. www.zeller-recycling.de
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Israeli pione One of the world’s largest composting plants is located in the Jordan valley.
Three partners are revolutionising waste management in Israel. In the middle of the Jordan valley, within just a few years one of the world’s largest composting operations has taken shape. In Tuvlan in the Jordan valley, Daniel Unger, Jacob Abraham and David Reiner formed Compost OR in 2007. At that time the company handled 4000 tonnes of sewage sludge and 1000 tonnes of green waste each month on about 4 hectares of land. Since then the area has tripled and the throughput quintupled to 20,000 tonnes per month, giving 12,000 cubic metres of valuable compost for agriculture.
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The magic formula: 24/7 The plant runs 24 hours a day, seven days a week. Ten employees make it possible. Fresh greenwaste is piled up, and a frontloader dumps sewage sludge on that to create a triangular windrow. A Topturn mixes the windrow evenly and shapes it to measure five metres wide and two metres high. The windrow is then turned once a week by the Topturn for four to six weeks. The temperature inside the windrow reaches up to 70 degrees centigrade, evaporating the excess moisture and disinfecting the material. At the end of the process a high-value compost is obtained. This is screened by a Mustang electric trommel, and then cured for 30 to 60 days in a pile.
High environmental standards During the curing process, independent licensed laboratories test it to make sure that it contains no bacteria or pathogens. Since Israel’s standards for wastewater are among the world’s highest, the heavy metal concentration in the material is generally very low, and the finished compost can be used on fields without any problems. Big plans The three Compost OR partners have big plans. Starting in 2013 they want to get into decontamination, and have added another seven hectares to make room for it. The idea is to clean up soil contamination with oil or fuel. A Topturn X67 would keep the aerobic process working.
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In the next few years the company also plans to build enclosed rotting halls with exhaust air scrubbers, in order to be able to process any kind of organic waste. Here again Komptech will have a major role to play. A successful partnership The partnership with Komptech has expanded as the company has grown. The experienced Compost OR team has tried out machines from several other manufacturers, but ultimately keeps returning to Komptech. The first Topturn X53 turned in over 8000 operating hours before it was replaced by a new one. The Mustang E also has over 8000 hours under its belt.
Jacob Abraham
With this positive experience, the company will continue to work with Komptech in the future. Because experts only stand to learn from each other...
Compost OR is a private company belonging to three partners. Daniel Unger, a mechanical engineer by training, is CEO. David Reiner is operations manager. Jacob Abraham, a civil engineer by training, is responsible for legal issues as well as the expansion plans. The three partners have extensive experience in the development, planning, construction and management of landfills, reloading stations and composting facilities. The Tuvlan facility handles organic waste from Haifa, Karmiel, Nahariya, Netanya, Ramat Gam and Raanana. http://www.compostor.co.il/len/
The Mustang E ensures a quality substrate.
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More muscle
The Crambo can pile the material up to four metres high.
The Danish biomass industry is enjoying good times. Right in the middle of it is Klintholm director Jørgen Nestor. We asked him if more horsepower means more profit. What does Klintholm I/S do at present? We are a waste company jointly owned by six municipalities on the island of Funen. We treat waste from nearly 200,000 residents. At Klintholm we crush and screen C & D waste, screen contaminated soil, and last but not least turn greenwaste, roots and stumps into biomass. You recently bought a Crambo 5000 HD-version – what do you use it for? All the greenwaste generated at the six municipalities we work for is collected and transported to our site. First of all we shred it in order to reduce the volume. By doing that we save space – we actually reduce it to 1/3 of the original volume of the waste. Naturally it also has to be shredded, since our biomass customers have certain size requirements.
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Our new HD version performs extremely well, particularly with roots and stumps. At Klintholm you used to work with an “ordinary” Crambo 5000 – why did you upgrade to the HD version? We were definitely happy with our old Crambo 5000, which was built on a trailer chassis. But our new Crambo 5000 HD is built on a “Track Fast” chassis, and it really makes a great difference when we do onsite jobs on muddy and slippery ground. In addition, our new HD machine is stronger than the old Crambo 5000 we used to have, since it has more horsepower. More muscle means higher capacity in the shredding business – it’s as simple as that! Another nice feature is the larger gearbox and the armoured shredder rollers – now we don’t have to do repair welds on the rollers for a very long time. What does the extra capacity mean to you? We are happy that we have managed to achieve an additional capacity of
Klintholm director Jørgen Nestor. approximately ten percent with the new HD version compared to the old Crambo 5000. It means that we can finish our shredding jobs faster and get on to the next jobs. And our customers are pleased too. At Klintholm we bill by the hour, so now we're able to shred the same amount of biomass at a lower price. What does the mobility mean to you? Mobility is of great importance for us, since most of the shredding jobs are on-site at our customers’ transfer
An unbeatable team: Together, Crambo and Cribus produce a top-grade biomass fuel.
stations. From April to October we are constantly on the move, doing shredding at the six municipalities that jointly own Klintholm I/S. Last year you bought a Cribus 3800 E trommel screen. Do you use it for cleaning the biomass? Yes, after the greenwaste, roots and stumps have been shredded by the Crambo 5000 HD we upgrade the biomass quality by screening it with the Cribus 3800 E. Obviously our customers don't want to pay for soil, stones and other impurities.
We take pride in producing a biomass of high quality, and our Cribus 3800 E trommel screen helps us do that. It is also extremely cost-efficient since it is diesel-electric. Its diesel consumption is only around 5 litres per hour. For Klintholm, which produces green sustainable energy, it means a lot that we can work green.
Power to spare Heay Duty means 481 HP
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facts Klintholm I/S on the Danish island of Funen in the Baltic is a pioneer in the Danish biomass business. Recently Klintholm added a Crambo 5000 Heavy Duty Edition shredder and Cribus 3800 E trommel screen to its machine park, to turn still more greenwaste into valuable renewable energy. Komptechâ&#x20AC;&#x2122;s Danish sales partner Aksel Benzin supplied those machines and all processing technology for Klintholm.
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A learning journey Travel, it is said, broadens the mind. In July of last year Komptech invited a 25-person delegation from Great Britainâ&#x20AC;&#x2122;s Association for Organics Recycling to have a look at the waste business in Austria and Slovakia.
The UK has some distance to go if it is to meet European Union requirements for reduction of the organic component in landfilled waste by 2020. Austria leads Europe in waste handling, and the British organic waste specialists came to get a personal impression of how things are done there. First stop: Malacky, Slovakia Komptech built a renewable fuel processing plant in Malacky in 2010. The facility handles 23 tonnes of waste per hour and transforms it into a high-quality fuel. Consisting of several Komptech machines, the plant was of interest to the visitors because this kind of waste treatment is still in its infancy in Great Britain. More can be expected in the coming years.
Learning 1: The plastic recovered from mixed solid waste at waste to energy facilities is a useful fuel resource of high calorific value.
Next stop: Lobau, Austria In Lobau, the City of Vienna operates a composting plant that receives 150,000 tonnes of organic waste each year from the greater Vienna area. Since 1999 it has been transforming this waste into a valuable soil improver with the help of composting technology from Komptech. A total of 60,000 tonnes of compost leave the facility each year, some to area farmers, some as bagged compost shipped throughout Austria. The oversize fraction is sent to a nearby incinerator. This type of waste handling is already important in the UK and will become more so in future.
Learning 2: This vast site relies on a straddle windrow turner to oxygenate, thoroughly mix and hydrate particles in the windrows. Such turners have the potential to maximise the biodegradation rate and minimise the formation of odours, yet diseconomy of scale and other factors seem to result in little use of this kind of machinery in the UK.
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The UK specialists also visited a bioenergy plant.
Makes the best of waste: The Frohnleiten MBT The mechanical-biological treatment facility in Frohnleiten near Graz, Austria, was one of the largest projects in the history of Komptech. Here, a biological treatment stage processes 65,000 tonnes of organic residue each year, which it gets from a mechanical treatment plant in Graz. The material is biologically stabilised in a building which hosts 13 in-vessel tunnels and the stabilised organic material is then sent to landfill. The higher-calorific material is separated out and burned in an incineration plant. Systems of this type will also help the UK to meet European regulations.
Learning 3: The system here minimises the use of mobile vehicles, benefitting from initial MSW sorting and shredding at a pre-treatment facility.
Gas from food? Finally, at Bioenergie GmbH in Marchfeld near Vienna the visitors had a look at a wet anaerobic digestion plant. Each year it processes 15,000 tonnes of organic waste, specifically restaurant waste, over-aged food and grocery store waste, some of it still packaged. The food and liquid biowastes are broken down into gas which is then used as a fuel in a district heating plant. After anaerobic digestion, the solids are separated from the liquid and then composted. Here too, all of the machinery used for preparing the waste was supplied by Komptech. At present, anaerobic digestion is being especially encouraged and promoted in Great Britain, and many plants will come on line in the next several years.
Learning 4: This well thought-out facility links the digestion and composting processes by diverting some food waste solids and post-digestion separated fibre to composting. With resource efficiency in mind, the design engineer had the foresight to use process water to get food waste out of its packaging.
With many new ideas and impressions, the delegation returned to the island nation. Waste treatment in the UK today The European landfill directive (1999/31/EG) requires Great Britain to reduce the organic component of landfilled material by 50 percent by 2013, and by 65 percent by 2020, both compared with the amount landfilled in the benchmark year 1995. By 2010 the UK had achieved a reduction of only 39 percent. The “Waste Strategy” (in England) and the “Zero Waste Policy” (in Scotland, Wales and Northern Ireland) require that by 2010 a total of 30 percent of household waste be recycled or composted. By 2015 this needs to be increased to over 50 percent.
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Q&A Customers have questions - Komptech’s specialists have answers.
How can I get more biomass out of green cuttings? And is there any news on fuel consumption and energy efficiency? Asked by telephone
Heinz Leitner, CEO Komptech Frohnleiten, answers: We’ve been getting this question more and more recently. To get more biomass out of green cuttings we developed the Bio-Basket XL, a screen basket with wide mesh and biomass cutters. It offers distinct advantages: Up to 40 percent higher throughput with up to 40 percent lower specific fuel consumption, and considerably higher fuel yield. All of our customers who use it are very happy with it. For the Crambo we also have a new change system for the screen basket cartridge, which can be installed and removed simply, as a single unit. This lets users change screens very quickly, regardless of how dirty they are. For even higher energy efficiency, Komptech is currently working on a new drive for the Crambo which will let it work much more efficiently. We’ll present the machine at the start of 2013.
I saw a mobile variant of the Stonefex on the Komptech website. Will a stationary version of the machine also be offered? Question placed by online contact form.
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letters to the editor
Bernd Thielepape, CEO Komptech Oelde, answers:
I’m in a market that is distant from Komptech, so spare parts availability is very important to me. What are Komptech’s replacement parts logistics like? Asked at IFAT, May 2012
Manfred Harb, Group Service Manager, answers: Machine reliability is of course very important for users, since downtime costs money. In recent years the availability of customer service and spare parts has become a priority, as processes involve more and more machines. More and more, we are being compared with construction machinery manufacturers like Caterpillar and Liebherr, or agricultural machine makers like John Deere and Fendt. Customers expect that parts required for functioning will be available in less than 24 hours. We are meeting the need through our staff’s high level of commitment and a completely revised logistics system. For example, all machine parts are marked with their importance for functioning. High-importance parts must be in stock in sufficient quantity in the markets so that they can be sent overnight. To facilitate this, they are stored ready to ship.
The new Bio-Basket XL for more biomass fuel.
Komptech employee packing spare parts.
The Stonefex was developed for electric drive, so it’s a great fit for stationary systems. A stationary variant was taken into consideration during the concept phase of the mobile Stonefex. We’ve installed the first such system in England, and the customer is very satisfied. In other words, yes, we have solutions for stationary use.
The Stonefex is now also available in a stationary version.
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The world is getting greener.
Nicer chipping: The Chippo
Pure design: The Topturn
Drum-roll: The Cribus
The universal genius: The Crambo
Provides for fresh wind: The Hurrikan
A real bigmouth: The Axtor
Screening with a star: The Multistar
The end of the stone age: The Stonefex
Incredibly tough: The Terminator
Of course we´re not the only people helping to make the world a greener place. But we´re still very proud of our solutions for handling waste and biomass!
Kühau 37, A-8130 Frohnleiten | T +43-3126 505 0 | info@komptech.com