News The magazine for our customers
Issue 1/07
Biomass - Incineration technology and treatment - CRAMBO news - New star screens: MULTISTAR M3 and XXL - new TOPTURN X67
Foreword
Table of Contents
Dear readers, With an export quota exceeding 95% and an average turnover growth of 20% over the last five years, the KOMPTECH group is amongst the most dynamic medium-sized private companies in Austria. This dynamism, of which innovation plays a key role, has escalated KOMPTECH, still a relatively young company, to the position of European market leader in a very specialised niche. With a group turnover of Đ70m, 75% of which is achieved in Europe, 25% outside of Europe, KOMPTECH has succeeded in earning a prominent position world-wide. With this in mind, it fills us with particular pride to have been awarded the Export Prize from the Austrian Chamber of Commerce in 2007. Overall, Austrian companies have been successful in improving their positioning in the field of environmental technologies, even on the global stage. One of the major contributing factors is the general framework in which Austrian companies operate. Very progressive legislation has set an example and was responsible for injecting crucial proactiveness at an early stage in Austria. One of the activities the Austrian Foreign Trade Organisation is currently focusing on is the promotion of international marketing for environmental technologies from Austria – and these activities are already bearing fruit. The on-going initiative by the Austrian Ministry of Agriculture, Forestry, Environment and Water should bolster international positioning of “environmental technology made in Austria“. As a business, we would like to thank our public institutions for this. The main focus of this edition is the treatment of woody biomass using technology from KOMPTECH. Given the fact that the debate on the climate is “heating” up, this topic is very much in the news. The new “EU roadmap“ stipulates a figure of 20% renewable energy, as a percentage of the total primary energy consumption, by the year 2020. This figure is currently 7-8%. The target for 2010 is 12%. If our current position is anything to go by, we will fall woefully short of this figure. For biomass (intended to make a significantly contribution to the increase in renewable energy sources), this means a quadruplication of quantities being used today.
Export successes Renewable energies
4/5
Incineration technology for biomass
6/7
CRAMBO news
8
CRAMBO Forest
9
New products: MULTISTAR M3/XXL HURRIKAN S
10/11
Our customers: Schernthaner GmbH
12/13
The new TOPTURN X67
14/15
The CRAMBO stationary solution
Good news for anybody actively involved in this field. I trust you enjoy reading this edition.
Yours, Josef Heissenberger
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INPRINT Publisher: KOMPTECH GmbH; Editorship: Andreas Kunter, Josef Heissenberger, Joachim Hirtenfellner; Photos, Layout & Graphic: Alexandra Gaugl;
16
Export successes
Josef Imp Gesamtverantwortlicher Vertrieb
New Sales Operation for the USA
KOMPTECH is the winner of the Austrian Export Prize 2007 KOMPTECH GmbH has won one of the most prestigious business awards in Austria, this year’s Export Prize from the Austrian Chamber of Commerce. The company now exports in excess of 95% of its products and services to more than 50 countries world-wide. During the ceremony at the Palais Liechtenstein in Vienna, the prize was handed over by the Austrian Minister of State for Trade and Industry Martin Bartenstein and the President of the Chamber of Commence Christoph Leitl to General Managers Josef Heissenberger and Rudi Pretzler as well as Sales Director Josef Imp. In 2006, KOMPTECH achieved the largest turnover growth in Western Europe in Germany (the largest environment technology market world-wide), Italy, Spain, France, the Benelux countries and Great Britain.
But KOMPTECH has also been able to penetrate the market in Eastern Europe and has completed projects in Poland, Hungary, Rumania and Turkey. Australia, Iran, Japan and the USA are the primary markets outside Europe for high-tech products from KOMPTECH. Exporting its products to more than 50 countries across the globe, the company posted a turnover of Đ 70 m last year, an increase of over 20% compared to the previous year. It goes without saying that the successful sales strategy of relying on experienced, independent sales partners based in their own countries will remain in place. KOMPTECH sales operations are only started up in markets where KOMPTECH can not penetrate the market as a result of a lack of suitable partners. It is for this reason that a KOMPTECH sales organisation was started up in the USA at the beginning of the year, as was representation in China and Poland. With the established products in the shredding/screening/separation/ composting technology sectors, and the numerous new products currently under development, KOMPTECH aims to be turning over in excess of Đ 100 m by 2010.
The specifics of the North American market were the driving force behind the decision by KOMPTECH to establish its own sales operation for the USA at the beginning of 2007. The new 100% subsidiary, KOMPTECH USA Inc., will be headquartered in Denver (Colorado). Johannes Pohl, former Area Sales Manager, will take over the running of the sales operation. The size of the market and the different requirements in individual States were decisive factors. This now makes a close-knit network of dealers, as well as the direct support of these dealers, necessary locally. KOMPTECH USA Inc. should make a significant contribution to the future growth of the company as a whole. The aim in the USA is an annual turnover of Đ 10 m by 2010. This target is to be achieved with a very offensive marketing strategy in which exhibiting at the most important trade fairs, numerous machine demonstrations and comprehensive product information for the media play a considerable part. (see also www.komptechusa.com) In conclusion, I would like to express my sincere thanks to all our sales partners for the excellent work over the last few years. Without them, the fantastic success of winning the Austrian Export Prize would not have been possible. We trust the continued teamwork will bring success for all and wish all partners the very best! Yours, Josef Imp
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Renewable energies
Renewable energy on the march? Pricing of fossil energy sources such as oil and gas have demonstrated a clear and steeply rising trend over the last few years. Although progression over the next 20 years can in no way be predicted reliably, it would be irresponsible not to begin laying the foundations to secure energy supplies in the future. A further attempt is a Communication from the Commission to the Council and Parliament dated 10th January 2007, the ”Roadmap for Renewable Energies“. This is supposed to determine the development of renewable energy sources in the 21st Century. In 1997, the European Union began to contemplate the issue of developing renewable energy sources. During this period, the decision was made to work towards a figure of 12% for renewable energy sources (as a percentage of primary energy consumption) by 2010 – representing a doubling compared to the “base year“ 1997.
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Although the percentage of renewable energies has risen by a nominal 55% since then, the target of 12% will not be achieved. If anything, it would appear improbable that the EU exceeds 10% by 2010. This must be viewed as a failure of policies and as an inability or lack of willingness to follow up political rhetoric with actions. The fact that the targets have, in the main, been met by a relatively small number of Member States, also hides the danger of a distortion of the single European Market. The 2001/77/EC Directive, which laid down national targets for renewable energy sources as a percentage of power consumption for all Member States, was a key component of this strategy. By hitting all target figures for the individual countries, the aim was to achieve a figure of 21% for renewable sources as a percentage of the total power consumed by the EU-25 by 2010. Based on information available today, the EU is likely to achieve a figure of 19% with current strategies.
Renewable energies Nine Member States, amongst them Germany, are well on their way to achieving their target, in parts even earlier. Besides development of hydroelectric power, it has been wind power, solid biomass and biogas that have contributed most significantly to the increase. Despite this progress, the majority of Member States must still make massive efforts to make up for the partially drastic shortfall behind agreed targets. One of these is Austria. Since the adoption of the 2003/30/EC Directive, there has also been some progress in the use of bio-fuels for transportation. Conversely, efforts in the field of heat and cold production from renewable energy sources have been waning since the 90s. For the development of energy recovery for biomass, the Commission published the “Action Plan for Biomass“ on December 7th 2005, to be used as a guideline for the development of biomass usage within the EU. This document suggests measures to meet the primary targets for 2010. For biomass, a doubling was deemed to be completely realistic in the period 2003 to 2010. For specific cases, such as for Austria in 2006, detailed plans from the paper were drawn up for individual States. Definitive successes have yet to be assessed. According to the Commission, the type of aid within the EU must be changed in order to develop all renewable energy sources in the future. The EU legal framework in force must also be sustained and developed. The Commission is of the opinion that it is desirable, as well as being feasible from a technical and economical viewpoint, to increase the usage of renewable energy sources, as a percentage of primary energy consumption, to 20% by 2020. Just how high extra expenditure (estimations range from Đ10.6bn to Đ18bn annually)
will actually be when compared to supplying with “conventional” fuels depends on the rate of innovation and pricing for these energy sources. In turn, this primary overall target from the EU must be reflected in binding national targets, whereby national framework conditions should be taken into consideration. This also includes a certain degree of “leeway“ for Member States with which they can fulfill their respective potential and address their main focuses. States should provide specific information on the implementation of their targets in national action plans which are submitted to the Commission after finalising. What is important to the Commission is the determination of legally binding targets for overall renewable energy sources as a percentage of the EU energy mix as well as of binding minimum targets for bio-fuels. According to the new EU roadmap, this strategy should create a true single market in which technologies for renewable energies can flourish. It should also provide companies security and the necessary stability they require for investment decisions and also leave Member States sufficient leeway for them to be able to support this strategy in line with their domestic agenda. The EU is looking to publish the first binding act for the implementation of these targets as earlier as 2007. We wait with baited breath this time around for the balancing act between ”greatest degree of commitment“ and ”leeway for individual States“. Past experience tells us to use the all-too articulate question mark. Once again it remains to be seen to what degree lip service is followed by figures that result in a real change in the current and highly unsatisfactory situation in regard to adherence to the defined targets.
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Combustion technology for biomass
Combustion technology for biomass – current level of technology and requirements of material quality Combustion technology for biomass has made leaps and bounds over the last few years. Large-scale plants specified at over 500kW are a particular technical challenge. Below is a brief overview of the current level of technology as well as the requirements made of the quality of the fuel used. Biomass combustion plants in the performance spectrum above 500kW make high demands of materials used. For the conveyor technology alone there are different feed methods depending on the fuel used. Besides the more well-known mechanical screw conveyors, chain conveyors and thrust base systems, there are also pneumatic feed methods in which fuel is injected directly into the combustion chamber. Even conventional feeding using wheel loaders/various crane systems is still being used in many cases. The combustion technology used is tailored to the fuel characteristics. The following parameters are of particular significance: - type of fuel - size, density, porosity - water content - chemical composition (and hence calorific value) - volatile component content - pyrolysis behaviour - ash content and melting behaviour of ash
Material
Treatment
Chippings
With no subsequent treatment
Industrial wood chippings
Usually direct usage without any subsequent treatment (especially wood processing and treatment industry/ paper industry)
Wood chippings/ Thinning left-overs/ Energy wood chippings Bark
Usually no treatment, chopping in individual cases
Waste wood
Extensive treatment necessary: Visual sieving of contraries, chopping (usually in 2 stages), metal separation, optional non-ferrous metal separation
Table 1: The materials used and the treatment necessary in each case
firing. Fluidised bed firing differentiates between stationary versions, with gas speeds up to 3m/s, and circulating fluidised bed firing in which gas speeds of up to 10m/s are possible. Figure 1 illustrates the most significant firing technologies for biomass. For underfeed firing, fuel particle sizes smaller than 50mm (max. 100mm in exceptional circumstances) as well as the sole use of fuels low in ash are recommended. Low investment costs, as well as simple and continual load control by continual fuel feed, are
Incineration technologies for biomass distinguish between grate, underfeed, direct and fluidised bed firing. The selection of combustion technology and plant control must be tailored to the type and properties of the biomass to be used. Grate firing distinguishes between inclined, advancing, travelling and vibrating grate, depending on design. Even rotating cone firing and cigar burners are possible technical solutions. Underfeed firing is implemented using an internal or external grate. Muffle and direct dust injection firing and cyclone burner variants are available for direct
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For quality wood chippings, chopping and partial sieving necessary
Fuel
Fuel
Fixed-bed firing (grate firing)
Grate firing also has relatively low investment and operating costs. Dust loading of the flue gas is low, meaning plants are less susceptible to slagging than fluidised bed plants. The major drawbacks of the technology are the
Fuel
Ash
Air
distinguishing features of underfeed firing. Low emission light-load operation is possible by metering. Limiting factors are the technology in regard to ash content and uniform fuel consistency (screw feeder is very sensitive to inhomogeneous fuel). Use of bark as fuel is out of the question.
Air Stationary fluidised bed
Fuel
Ash
Air Circulating fluidised bed
Fig. 1: The most significant biomass firing technologies for industrial use
Air Dust firing
Combustion technology for biomass necessary, and very complex, NOx reduction and the lack of uniform combustion conditions. A higher oxygen surplus reduced the efficiency of the plant. Low emission light-load operation generally proves to be difficult. Very good load control and quick load change are possible with direct firing. A low surplus of oxygen increases the efficiency and reduces the flue gas volume flow. Air grading and swirling generally make a good level of NOx reduction possible. The limitations in the use of this technology are the limited fuel particle size (< 10-20 mm) and the high erosion and thermal loading of the firing chamber walls. The use of an ignition burner is also necessary. Fluidised bed firing is divided into stationary and circulating fluidised bed firing. The firing equipment essentially comprises a cylindrical combustion chamber with a perforated base plate. The fuel is fed into the preheated bed material suspended in the firing equipment (glass sand, ash or limestone/dolomite). The fuel fraction is 2-10% by weight in this mixture. Primary combustion air is injected over the base plate in an amount that results in fluidising the bed. The intensive mixture of bed material, fuel and combustion air can result in a very low surplus of air. The incineration temperature must be kept low (800-900°C) to prevent the melting of ash and bed agglomeration. Firing method
Cyclone
Superheater Superheater
790 890°C
Superheater
Air Vaporiser Economiser
Fuel
Fig. 2: The circulating fluidised bed in detail
The benefits of the stationary fluidised bed are that there are no moving parts in the hot combustion chamber and a good level of NOx reduction is possible using air grading. Furthermore, the technology is very flexible in regard to particle size, water content and type of biomass and even the use of fuel mixtures is possible. As with direct firing, a lower oxygen surplus increases efficiency and reduces the flue gas volume flow. Fluidised bed firing is generally associated with very high investment and operating costs. Even the fuel particle size is limited (<80mm). Also, the flue gas is loaded with more dust and the susceptibility in regard to melting ash is also higher. The circulating fluidised bed (see Fig. 2) has all the benefits of the stationary
Performance range Particle size
Direct firing
870°C
910°C
< 5- 20 mm
Water content
variant plus others due to the high thermal transfer capacity as a result of higher turbulence. The fact that the addition of additives is easier is another benefit. The level of dust loading in the flue gas in circulating fluidised beds, investment and operating costs, and susceptibility to melting ash are all high. Other limiting factors for use are the limited fuel particle size (<40mm) and the susceptibility of the thermal exchange pipe to erosion. Table 2 provides an overview of the separate firing technologies, their performance ranges and correlation of fuel properties. Generally speaking, fluidised bed and grate firing are suitable for use in the “top-end“ performance range whilst direct and underfeed firing are possible in the low-end performance brackets.
Type of fuel
< 30 % by weight
Underfeed firing
< 6 MWth
< 50 mm
flexible
Low ash content; possible homogeneous fuel properties; use of bark not possible;
Grate firing
< 50 MWth
< 500 mm
flexible
High fuel flexibility (type, particle size, water content); no wood and stem material mixture possible;
Stationary fluidised bed firing
> 20 MWth
< 80 mm
flexible
High fuel flexibility (type, particle size, water content); also suitable for fuel mixtures;
Circulating fluidised bed firing
> 30 MWth
< 40 mm
flexible
High fuel flexibility (type, particle size, water content); also suitable for fuel mixtures;
Table 2: Overview of fuel properties correlation to firing types
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CRAMBO news NEW: CRAMBO with fine part separator A new innovativ option is available immediately for the new CRAMBO: Shredding and screening – combined in one machine. This is a sensible option when e.g. shredding root stocks, forest wood residue and green waste. A large amount of clingy soil, needles, leaves, etc. reduces the quality of the shredded usable fraction for recycling and increases transportation costs at the same time. Using this option, one operation is sufficient to effectively reduce the fine fraction in the output.
CRAMBO - Update 2007 sees the introduction of the general-purpose CRAMBO wood shredder with best ever cost-efficiency. Innovative nurturing of the model has effected a lowering of energy consumption and a prolonging of service life – even when working in adverse conditions. This, together with its broad pallet of applications, makes the CRAMBO one of the best machines on the market.
This saves on the need to take a screening machine in many cases - a major cost factor since the treatment of these fractions is often de-centralised and typically carried out by contract companies. The separator available for the trailer and track versions is only evident from
an
additional,
swivellable
discharge system at the rear. A
star
screen
deck,
integrated
into the discharge duct and with CLEANSTAR cleaning system and adjustable screen section, carries out the separation work. With surprising effect: by shredding root stocks up to 40% by weight < 15 mm (related to input) is separated off as fine fraction.
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By converting to low-emission CATACERT motors, the CRAMBO has been gone over with a fine tooth comb and effectively been “put on a diet”. The measure prescribed is called the ”efficiency increase program“ and works on several levels. A new temperature management system provides the machine performance, even in high outside temperature conditions. Temperature measurements regulate drum rotation speed and the ventilation of the water cooler. This ensures there is no downtime due to overheating. In economy mode, the machine detects a state of no-load operation and automatically reduces motor and drum rotation speeds. Normal operation is resumed after feeding in material – detectable by a variation in motor load. The upshot is a marked reduction in operational costs – and the service life of the machine is prolonged at the same time.
These measures, together with the optimisation of the drum drive, effect a lowering of fuel consumption by up to 25%.
Prolonged service life Hard root stocks, tough eucalyptus wood or fibred oil palms – shredding can be a tough job. The drum has been reengineered to extend the service life of the CRAMBO even further. Higher wall strengths at the drum pipe, optimised transition to the flange area and stronger gears withstand the highest levels of loading in the long run. In addition, the option of a reinforced drum is available with immediate effect.
CRAMBO Forest
A CRAMBO for the forest The message is clear: Wood is a CO2-neutral energy source and more wood regrows than is used. Actually ideal conditions for recovery â&#x20AC;&#x201C; and targets for recovery in biomass CHPs have been raised accordingly. But forest is not the same as fuel. New strategies and solutions are needed to be able to cover the increase in the demand forecasted for woody biomass. An interesting approach: The CRAMBO configured for the forest. On the one hand, an increased demand for wood can be expected over the coming years â&#x20AC;&#x201C; on the other hand, there is already a Europe-wide shortage of wood trunks. According to experts, this gap can only be addressed by using forest wood residue.
Input forest wood residue Forest wood residue is the name given to the inhomogeneous fraction made up of treetops and branches that accumulates when harvesting wood. This term also includes root stocks that accumulate during uprooting. Forest wood residue, including root stocks, makes up about 1/3 of the total mass of trees (depending on tree type). The expectation is that previously unused forest wood residue left behind will become a major component of our fuel mix in the future. This is because forest wood residue is on a par with wood chippings in regard to authorisations and aid. By-products from sawing and green waste, on the other hand, are not authorised as input material for all biomass CHPs and using them may result in a reduction of the pricing for the electric work produced.
Forest wood residue has a low specific weight. Transportation routes for unshredded material must be kept as short as possible for economic reasons. Shredding must take place as close as possible to the clearing area. Because of the presence of contraries, mainly stones, only slow-running shredders can be considered in the long-term. They also offer clear benefits in regard to product quality.
The solution: CRAMBO Forest
The KOMPTECH solution is called simply CRAMBO Forest and comprises of a semi-trailer chassis on which a CRAMBO (swivellable using a slewing ring) is positioned. A mounted crane with cab takes over the filling work, saving the use of a wheel loader. Using the (optional) integrated fine part separator, needles and soil fractions are separated off straight away on shredding. The biomass fuel is fed directly into a container via the discharge belt of the CRAMBO and transported to the next heating plant.
Input
Output 9
New products
MULTISTAR M3
Organising a machine was such was the product from electric drive.
demonstration tour for the new MULTISTAR M3 star screen not easy. Every site visited could have kept the machine enthusiasm. The M3 is the entry-level star screen technology KOMPTECH. It is quiet-running and economical due to the
But the M3 has even more interesting features that could sway any procurement decision. The hopper, for example: With a volume of more than 5 m3 and a loading height of only 2800 mm, the hopper, known from KOMPTECH drum screen technology, is a particularly appealing feature. But star screen technology lies at the heart of the machinery: A coarse screen and a fine screen positioned underneath separate into three fractions – always with the perfect degree of selectivity thanks to the CLEANSTAR cleaning system. Material is only discharged at the rear of the machine using three conveyor belts (fine, medium and coarse particle). This way the pulling mechanism remains accessible whilst working. Thanks to graphical visualisation, operation is extremely simply – and extremely economical thanks to high throughput at low operating costs.
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MULTISTAR M3
Drive diesel-electric
53 kVA
L x W coarse screen
2132 x 1138 mm
L x W fine screen
3591 x 1138 mm
Volume feed hopper
> 5 m3
Loading edge height
2800 mm
Throughput (dependent on material)
to 120 m3/h
MULTISTAR It is quite apparent that a high-tech screen machine the size of the MULTISTAR XXL is associated with significant investment. But anyone calculating the operating costs and only by doing so can the costeffectiveness of a machine really be assessed - will hardly believe that, per tonne or cubic metre, the XXL is virtually unbeatable. Provided of course the machine is loaded accordingly. Because the XXL is at home where large quantities are shifted on a daily basis: from composting plants where compost, biomass and bark are screened, to plant operators who operate several sites and contractors serving their customer base. Its design as a semi-trailer, with a transport width of 2540 mm, poses no problem for transportation by road. A single wheel loader driver would have severe difficulties. If the machine is configured for performance, one wheel loader is occupied solely with feeding the 11 m3 hopper. Another is occupied with transportation of the output material. It is now widespread knowledge that the MULTISTAR star screen technology allows splitting into three fractions. The dimensions of the screen decks are worthy of note. A coarse screen with more than 6 m2 and an 11 m2 fine screen are responsible for throughputs of up to 400 m3/hour – with a fuel consumption
New products
HURRIKAN S Cleaning stages during the process cycle are indispensable in the production of quality compost. Wind sifters for the cleaning of the oversized fraction are often a bottleneck when compared to a screen machine connected upstream. It would be more accurate to say “were“ – because the new HURRIKAN S can now compete with large screen machines.
R XXL of no more than 10 litres/hour. The CLEANSTAR system with carbide cleaning finger protects the screen stars from wear. Additional, optional features of the XXL are magnet drum, roll separator for oversized particles and wind sifter fan for medium particles. Highest degree of user comfort using touch panel with intuitive menus – is delivered as standard by KOMPTECH.
MULTISTAR XXL
Drive diesel-electric
98 kVA
L x W coarse screen
5064 x 1250 mm
L x W fine screen
8910 x 1250 mm
Volume feed hopper
11,5 m3
Loading edge height
3700 mm
Throughput (dependent on material)
Screening at the end of the rotting process generates the usable fraction and a screen oversize. This is again perfect for use as structure material, provided however that as many spurious contraries as possible (mainly light material such as plastics) have been removed. The mobile HURRIKAN wind sifter from KOMPTECH is a benchmark in this field. Its patented “pressure-suction” process ensures an excellent degree of selective.
series. Volume flow per fan remains unchanged. This prevents drawing in screen oversize and retains the blowing into commercially-available, net-covered containers (one per fan). The throughput of the S version is up to 50% higher than that of the normal HURRIKAN (dependent on material). The proven diesel generator, stone trap and magnet drum options are of course still available - resulting in a new ”dream pairing” for composting: MUSTANG and HURRIKAN – both in the “S” version.
HURRIKAN S
Dual-action suction However, since screen machines have become increasingly powerful over the last few years, KOMPTECH has addressed customer requirements for a wind sifter with an adequate performance specification. The result is called HURRIKAN S and is based on the principle of the HURRIKAN. The increase in performance has been achieved by enlarging the suction section - realised technically by a second suction fan in
Drive diesel-electric
60 kVA
Machine dimensions LxWxH 11800 x 2550 x 4000 mm Total permissible weight
10 000 kg
Throughput (dependent on material)
to 60 m3/h
to 400 m3/h
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Our customers
Sigi Schernthaner Junior CEO Composting and substrate production Schernthaner GmbH KOMPTECH:
Mr
Schernthaner,
production of biomass fuel – a shortlived adventure or a stabile business segment? Sigi Schernthaner: The latter definitely. It is important to build up long-term business relationships with customers and to supply consistent quality. We know our input material and know how we can produce constantly high product quality over the year. KOMPTECH: What significance do you attach to machine technology used? Sigi
Schernthaner:
With
technology that decides whether a particular job is worthwhile or not. We know KOMPTECH builds good machines. But the reason for the many green machines is simply that KOMPTECH can supply exactly the technology we need. An active exchange of experiences, as fostered by KOMPTECH, is without a doubt helpful – perhaps we have been able to provide the odd tip or two for channeling into the development process. KOMPTECH: Are there are implications for composting? Sigi Schernthaner: No, the production of compost with a guaranteed quality rating remains unchanged. Extracting woody fractions from the composting process does not negatively impact end product quality. I believe that the market for compost and substrate will get bigger again. Given our machine technology, we are certainly on the safe side and well positioned for the
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Forward-looking for generations
the
volumes we work with, it is the right
future.
Schernthaner GmbH When a business is active in the field of horticulture/landscaping and composting, one thing is an absolute given: An understanding for nature and the environment. Add a period of 20 years, in which knowledge and specialist expertise has been continuously passed on to the next generation, and you have the perfect ingredients for a stabile family-run business. If there is also a willingness to take risks, to try out something new and to take on the pioneering role, then only one name fits the bill: Schernthaner GmbH The wheel loader slows briefly, there is a friendly nod from the cab and it accelerates off again. Anyone wanting to interview Sigmund „Sigi“ Schernthaner (responsible for composting and substrate production) will have to get up at the crack of dawn. A van from a garden centre waits to be loaded with substrate compound, behind that is an empty articulated lorry waiting for biomass. A CRAMBO wants to be filled, etc., etc., etc.... There is intensive activity again today at the composing plant on the outskirts of Munich. The term “composting“ falls well sort of describing the multitude of activities and services at the specialist and certified disposal company. The comprehensive collection of machinery includes shredders, turners and screen
machines that are not only used on this site – machinery also ventures into the local area and even further afield. Now a brief period of serenity returns during our brunch of bread and meat. The boss takes time out to explain the operational procedure and the buzz of activity.
Biomass and compost It is not just quality compost for their own production of substrate that is produced at the plant. Biomass fuel for energy recover is also produced.
„We started out in 2002“, Schernthaner states, „only low quantities at first, but after experimentation and incremental tailoring of our machinery to the requirements, quantities shot up. The demand has convinced us that we must be doing something right.“ Two segments have established themselves: By shredding and screening, a fuel fraction is produced directly from root stocks, driftwood, uncontaminated pallets, etc. For greenery collected by local authorities, composting is necessary beforehand.
Its all about technology Everything first runs through the CRAMBO, equipped with bio-cutter. The boss lets us in on a little secret: „We only use large baskets, 250 mm, sometimes 180 mm. This produces exactly the right material we need for our process - everything else is too fine and would just need unnecessary energy“. Whilst the woody fractions are then ready for screening directly afterwards, shredded greenery is send off to the triangular windrow. Ten windrows lie in the middle of the site and a TOPTURN X53 stands at the start of the windrow ready for action. „We make sure we start with the right level of moisture. Additional watering is only necessary in summer. We turn two to three times a week and the condition of the windrows is checked regularly.“ The intensive rotting process is completed after two weeks and the material is taken from the windrow and screened. The new MULTISTAR XXL flagship machine is used here – the largest star screen machine from KOMPTECH. The star screen technology has won over the admiration of the company. Hitting the nail on the head, Schernthaner
says „We simply rely on it for our process cycle“. The star screen generates three fractions from the rotted material: Medium particle makes up about 3040% of the volume of the input quantity. With a particle size of 25-70 mm, it can be used in most heat plants without any problem. We have a special customer for the oversized particles. A total of 50,000 cubic meters of this biomass fuel was produced and sold on the market last year. The consistency of the product is tailored to the requirements of the customer. Undersized particles end up on a table windrow. After a maturation time of several months, they are screened down to 15 mm. The finished compost is then processed into premium quality BIOTANA plant soil in the composting factory on-site. A part is mixed directly with other substrates at the plant and sold in bulk. The break is over. Wheel loaders are whizzing around the site again, all of them connected up via radio link and coordinated perfectly from the weighing machine. The star screen needs two wheel loaders. Screening of bark is the order of the day. After all, another 10,000 cubic metres of paper wood bark is being processed into bark mulch. One wheel loader fills, another transports the material away. KOMPTECH drum screens are also in use. Two MUSTANGs, one of them the “S“ version, are being used to mix substrates and to screen excavated earth, humus and sand. The HURRIKAN is a powerful wind sifter and is available should any screen overflow need to be cleaned. We wait with anticipation to see what more the small team of Sigi Schernthaner, father Franz and, not forgetting of course, grandfather Josef will achieve in the field of composting and biomass. After all, they are not in the business of waiting around and watching.
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The new TOPTURN X67 A first-hand account Everything is still quiet. The windrows are lying calmly and peaceful at the break of dawn. But then the cab door is opened and the operator takes his seat. He puts down his hot coffee and then turns the ignition key. The new 446 HP TOPTURN X67 immediately roars into life. The central information panel springs to life and confirms the machine is ready for action: On the press of a button, the cab starts to move and swings upwards. At a height of nearly five metres, the air is not thin - but it is controlled at a comfortable temperature â&#x20AC;&#x201C; thanks to automatic air conditioning with protective ventilation. The operator has a command of the situation from up here. The right hand grasps the handy joystick. One push forwards and the machine starts to move forwards, up to 6km/h if needed. The first windrow is in sight: 6 metres wide and nearly 3 metres windrow height, not an easy task. With one hand on the multi-function lever, lower machine. The green button starts the drum. Another warning is sounded to all before it starts up. Then into the windrow, really apply the power after the first few metres. The giant rotating drum, 1.75 m in diameter, eats through the windrow, material swirls around in the air and a large cloud of steam rises up. A perfectly shaped triangular windrow becomes visible if it becomes distorted. Now turn on some music, lean back, relax and leave everything else to the X67. Unfortunately, with a performance of up to 5000 m3/h, the end of the windrow is reached all too quickly.
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The TOPTURN generation TOPTURN 300 Drive:
Traktor gezogen
max. working width:
3000 mm
max. windrow height:
1600 mm
max. windrow cross-section:
approx. 2,4 m2
Throughput (dependent on material):
to 500 m3/h
TOPTURN 3500 G Motor:
112 kW / 152 HP
max. working width:
4500 mm
max. windrow height:
1800 mm
max. windrow cross-section: Throughput (dependent on material):
approx. 5,2 m2 to 1000 m3/h
TOPTURN X53 Motor:
242 kW / 330 HP
max. working width:
5000 mm
max. windrow height:
2400 mm
max. windrow cross-section: Throughput (dependent on material):
approx. 6,5 m2 to 3500 m3/h
TOPTURN X60 Motor:
242 kW / 330 HP
max. working width:
5700 mm
max. windrow height:
2800 mm
max. windrow cross-section: Throughput (dependent on material):
approx. 8,5 m2 to 3500 m3/h
TOPTURN X67 Motor:
328 kW / 446 HP
max. working width:
6400 mm
max. windrow height:
2950 mm
max. windrow cross-section: Throughput (dependent on material):
approx. 10,5 m2 to 5000 m3/h
X 67 X 53 Windrow cross-section 2
6,5 m
X 60 Windrow cross-section 2
Windrow cross-section 2
10,5 m
8,5 m
1m
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Stationary CRAMBO The efficient solution If mobility is not required, a stationary solution with electric drive is the best solution from an operational efficiency viewpoint. Given their energy efficiency, electrical drives are the solutions of choice â&#x20AC;&#x201C; especially for large-scale plants with long machine operating times. Further arguments are the low servicing overheads of electric motors and control-related benefits when integrating into the conveyor equipment. A stationary CRAMBO can be tailored perfectly to local conditions.
Besides the standard stationary frame, isolation of the drive unit from the shredding unit is also supported as an option. This way the drive unit can be protected from dust and be installed easily and accessibly in boxes or in a utility room. The compact shredding unit can be integrated into the process cycle without taking up too much space. The shredder can be filled from all sides.
www.komptech.com KOMPTECH GmbH KĂźhau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 info@komptech.com
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KOMPTECH UK Ltd. Forge End, Lodge Farm Kineton Warwickshire CV35 OJH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 info.uk@komptech.com