News The magazine for our customers
Issue 2/06
NEW RASOR
Post-shredder for RDF-production NEW: TERMINATOR direct drive MULTISTAR M3 / XXL FLOWERDISC
Neues aus der Sternsiebtechnik MULTISTAR L2/L3
Neuvorstellung MUSTANG S
Neuheiten bei CRAMBO und TERMINATOR
Dear reader! A leading international environmental technology fair, such as this year‘s Entsorga Enteco in Cologne, provides KOMPTECH with a new platform to present what the brand is synonymous with:
• customer benefit through tangible innovation • quality across all services • dynamism, effectiveness and efficiency • authenticity (“KOMPTECH stands by its values“) It is the first point, “customer benefit through tangible innovation“, that is being highlighted by the many new developments KOMPTECH is presenting in Cologne. Technical innovation at KOMPTECH is always geared towards improving customer benefit, i.e. investment in KOMPTECH products must return higher profitability for our customers. Given that disposal revenues are continually under pressure and legal frameworks are constantly changing, this is a stipulation that can not be stressed enough. KOMPTECH is concentrating on key components such as shredding, screening and separation technology and ensuring that they can be combined into perfectly coordinated systems. Project sales are focused on ”tasks“ with the aim of trying to develop ideal solutions in partnership with our customers – be they end customers or suppliers of complete systems. KOMPTECH’s strategic positioning in the future will be towards being a specialist for system solutions in the sectors of composting, fermentation, household and commercial waste processing, separation of packaging waste as well as processing of refuse derived fuels and renewable energy sources. Hence the catchphrase:
Processing refuse derived fuels
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Benefits of direct drive
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SuperF – new shredding Equipment for the TERMINATOR
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CRAMBO goes plastic
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FLOWERDISC – mobile and stationary
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KOMPTECH INSIDE in as many systems as possible
KOMPTECH RASOR I trust you enjoy reading this edition.
Yours
Post-shredder for refuse derived fuels
The new MULTISTAR M3 and XXL
KOMPTECH Research Center
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10/11
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Josef Heissenberger
IMPRINT Publisher: KOMPTECH GmbH.; Editorship: Andreas Kunter, Josef Heissenberger, Joachim Hirtenfellner; Photos, Layout & Graphic: Alexandra Gaugl
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OR
RAS I MK
BRIN C
RDIS
TE
F
OR S
AT RMIN
WE FLO
Processing refuse derived fuels The new machinery lines from KOMPTECH The processing line for the generation of defined refuse derived fuels is complete: Perfectly coordinated components generate fuels from waste high in calorific value. What they all have in common: The KOMPTECH name, guaranteeing maximum customer benefit, even with complex systems technology. The processing line illustrated is designed for commercial waste with high synthetic material fractions. The feeding of production waste having suitable material properties is also possible. The aim is to generate a fuel that is high in calorific value and injectable.
Pre-shredding TERMINATOR SuperF The slow-running single-shaft TERMINATOR shredder is at the front of the processing line. In this particular case, a TERMINATOR with electromechanical drive and SuperF shredding unit performs pre-shredding. High degree of shredding, no troublesome overlengths and resistance to massive contraries are just some of the features of the new SuperF unit. The newly developed drive can boast low operating costs and a high efficiency level of the mechanical power transmission.
Screening FLOWERDISC 150 After shredding comes the separation of the oversized particle high in calorific value by screening. A FLOWERDISC
disc separator is used for this task, representing the perfect solution in regard to throughput, resistance to contraries and operational reliability within this application area. On the FD 150 version there is a screen section in the range of 120 - 250 mm, depending on rotation speed. Both undersized and oversized particles are generally subject to Fe separation (also NE separation if so required).
Ballistic separation BRINI MK The BRINI MK ballistic separator separates the oversized particle high in calorific value into a two-dimensional light fraction free of contraries, a fine fraction and an inhomogeneous, threedimensional heavy fraction. The light fraction high in calorific value is made up primarily of foil and packaging fractions and is the input material for the last processing stage. In contrast to traditional wind sifting, customers clearly benefit from the simplicity of the sturdy system which combines high efficiency with low operating costs.
Post-shredding RASOR A newly developed, slow-running postshredder is used for the generation of furnace-ready fuel. The RASOR generates both an injectable fuel fraction (< 30 mm) and a particle size (< 100 mm), known as the fluidised bed fraction. A quick-change system for the screen baskets allows short changeover times. Additional benefits of the RASOR product are the continual material feed using feed screws and consistent power consumption. Automatic adjustment of the cutting gap means that the low-vibration, low-dust, slowrunning shredding process requires minimal energy. All these system technology components are available in the most sensible performance categories and hence allow perfect tailoring to the capacity of the overall system.
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TERMINATOR with direct drive There is a new kid on the block in the stationary shredder market - an electromechanical drive is also now available as a power source. All of the features which make shredding with the TERMINATOR so efficient have been kept. There is just one change: Operating costs are lower.
Rugged system The new electro-mechanical drive has been specially designed for use in waste splitting and processing plants. In this case, input material and throughput are specified and all of the components are aligned to them. This results in a clearcut function for the initial process stage, pre-shredding, which can be solved perfectly by an electro-mechanical drive. Technically, the requirement was for a simple, rugged system combined with the high demands of a waste shredder: Power is transferred to a reverse gear/manual transmission unit, and then on to the drum drive, by a standard asynchronous motor using a Powerband belt system. The tooth force applied corresponds to that of the hydraulic drive.
Just as reliable as a hydraulic system If a contrary causes a blockage, a reverse cycle is initiated (as with the hydraulic drive). The drum reverses, frees itself and continues to turn in the shredding direction. Even a high number of blockages within a short space of time does not cause thermal or mechanical damage. The electric motor continues to run and need not be turned off or have its direction of rotation changed. There are no undesired current peaks. This allows cost-efficient operation without frequency converter or soft-start. The drive has two gears: Gear 1 with high speed for easily shreddable material such as residual waste. Gear 2 with a low speed but higher tooth power, such as for bulky waste.
Operating cost reduction The electro-mechanical direct drive mechanism leads to a reduction of specific operating costs (cost per ton of shredded material). Since there are no hydraulic components, no costs are incurred by servicing and maintenance resources such as hydraulic oils. Of particular significance is the reduction of specific energy costs attained as a result of the high efficiency level of the mechanical system.
Hydraulic drive for the highest of demands If difficult material is shredded, however, and demands continually change, the hydraulic drive is still the best solution. Precise regulation of throughput, in conjunction with constant output control, perfectly tailoring the tooth power and speed to the shredding process, are features that are implemented perfectly using the hydraulic drive. The proven KOMPTECH hydraulic system therefore remains in the portfolio unchanged.
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NEW SuperF A new shredding unit for the single-shaft TERMINATOR is now available which manages to effectively combine customer requirements previously uncombinable â&#x20AC;&#x201C; high degree of shredding on the one hand and rugged pre-shredding on the other. Besides household waste, input material for waste splitting systems is containing an increasingly higher content of commercial waste (with a high synthetic material fraction) and production waste. For example, ductile-elastic to rigid, rolled up or reeled, containing metallic contraries. Pre-shredding must bring this material down to the required particle size and prevent problematic overlengths for subsequent processing. A high level of resistance to contraries is just as important. With new cutting geometry and new teeth attachment, the SuperF satisfies this demand.
SuperF: Super fixed The solution for attachment of the drum tooth is completely new: The shredding teeth are inserted into recesses in the drum cladding. The tooth holder itself is seated in the inner of the drum pipe and is well protected. Damage to the holder is impossible, even if a wear tooth is used far beyond its intended service life. The tooth is fixed securely in the holder with insert cotters. Basic hand tools are all that is required to exchange a tooth. Tooth and opposing tooth can both be used several times on wear through deposit welding.
SF - Equipment (SuperFine) Application: Defined shredding for e.g. treatment of commercial waste
SuperF: Super fine On the SuperF, overlengths >100 mm are reduced considerably when compared to the F-version and parts >400 mm are virtually ruled out completely. Technically, this benefit has been realised by reducing the gap between drum tooth and opposing tooth. Raised wear rings between the tooth spirals prevent material from being pulled through unshredded. The special contour of the drum tooth, with a long tip approx. 20 mm in length, simplifies penetration of the shredded material and provided better feed. The low-cost wear plates around tooth and opposing tooth are easily exchangeable.
F - Equipment (Fine) Application: Pre-shredding with wide range of use (waste splitting, MBT, RDF etc.)
The diagram below illustrates particle size distribution of the three different shredding configurations, SF (Super Fine), F (Fine) and U (Universal). 95 percent of the material quantity is smaller than 100 mm on the SF.
Commercial waste
SF
95% < 100 mm
95% < 150 mm
F
0 mm
100 mm
200 mm Screened material
â&#x2030;&#x2C6;
95% < 400 mm
U
400 mm
U - Equipment (Universal) Application: Pre-shredding with high resistance against contraries
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CRAMBO goes plastic There is an interesting alternative to the fine, precise cutting shredders for the shredding of fractions rich in synthetic material: The multi-talented CRAMBO generates particle sizes up to the fluidized bed fraction (depending on screen basket) - with respectable throughput and high degree of resisdance to contraries.
Shredding synthetic material with the CRAMBO Cutters A configuration including sickle teeth and a fully-populated countercutter is ideal. Screen baskets from 80 mm to 180 mm are used - the former corresponding to the shredding result of a fluidised bed fraction (in excess of 95% >100 mm, 60% between 30 - 80 mm). Metal components (up to a size of 60mm) that cause serious damage in the quick-running post-shredder present no problem to the CRAMBO.
Synthetic material program A special drum control unit keeps the material constantly in motion and shreds without pre-shredding. Pre-programmed reverse cycles are used for automatic drum cleaning.
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The universal adaptability of the CRAMBO is a huge benefit. Anything that fits into the 3-metre wide shredding area, and is free of massive contraries, can be shredded. Typical fractions are pre-sifted fractions such as screen overflow, hand-sorting or wind sifter fractions and waste made up of production processes that are either more or less tainted with contraries depending on type and pre-treatment. The CRAMBO can be operated as a mobile machine or as a stationary machine as part of a chain within a plant. For example, a process chain for household and commercial waste could comprise of a TERMINATOR pre-shredder with Fe separation, a FLOWERDISC disc separator for separation of over-sized particles rich in calorific value and a CRAMBO operating as a post-shredder. Two slow-running, counter-rotating screws with cutters, one countercutter positioned centrally, and screen baskets defining particle size make the CRAMBO both resistant to contraries and highly flexible during the shredding process. A special control program automates drum cleaning. Assuming comparable motorisation, this allows a throughput on the level of specialist fluidised bed shredders. In your role as plant operator or contractor, the rugged, fail-safe CRAMBO could be the solution when confronted with the treatment of many waste steams varying in quantity and composition. After all, you are getting one of the best wood shredders on the market.
FLOWERDISC – mobile and stationary
Extremely positive market feedback to the FLOWERDISC system has prompted us to extend the product line for this technology: A mobile star screen with disc separator connected upstream is now available alongside the stationary versions. Although not on the market for long, the FLOWERDISC disc separation system has evolved into an important element within the KOMPTECH screen technology sector. The FLOWERDISC was designed for the screening off/separation of coarse contaminants from separately collected bio-waste. This is still one of the main application areas. No other technology can separate off effectively coarse contaminants (mainly plastic sacks and packaging fractions) without being negatively impacted by either contraries or moisture. Other new applications are the upshot of the necessity to treat commercial waste and other fractions previously landfilled. The benefits of the FLOWERDISC system come into their own for inhomogeneous, contaminated fractions often with reellike components. Movable jacketed pipes prevent blockages and seizures
between the shafts. Designed from wear-resistant steel, it is resistant even to massive contraries and guarantees smooth operation with low operating costs. Three different screen sections are new, extending the application area for waste splitting.
MULTSTAR L3 FLOWERDISC The new MULTISTAR L3 FLOWERDISC is the perfect screening machine for mobile treatment of commercial waste. The first stage is pre-shredding – ideally with a TERMINATOR F-(fine) and then separation into three fractions with screening. The volume flow from the shredder ends up directly on the disc separator of the L3, large components >80100mm are separated off. This fraction is usually highly calorific and is suitable for subsequent processing into refuse derived fuels. The screened material is separated further by a star screen – the fine fraction (0/10...25), generally an inert fraction, ends up on the landfill site. The medium particle is processed further, depending on input, or, if it has the right calorific value, used as a medium calorific fraction for fluidised bed furnaces.
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Post-shredders for the generation of secondary fuels are nothing new. But when KOMPTECH decides to build such a machine, one thing is sure: The issue of post-shredding has been thoroughly reviewed and is the subject of concentrated KOMPTECH innovation. The result is called RASOR and has decisive benefits when compared to competitive products. With this technology, partially implemented with completely new solutions, we have been successful in increasing customer benefit significantly in many areas.
NEW KOMPTECH RASOR Post-shredder for secondary fuels All good things come to those who wait - something not everybody can afford to do in times of high pace of change. But this is the decision KOMPTECH has taken in the development of the RASOR. To arrive late on the market after monitoring the competition and producing the perfect solution. Post-shredders for refuse derived fuels have the job of generating a precisely defined particle size from already treated fractions high in calorific value by shredding. Post shredders are generally installed in process chains installed within enclosed buildings. A range of product benefits have been incorporated into the RASOR based on this information and with customer requirements in mind. Starting with the size of the machine: Since room in enclosed spaces is a cost factor, the extremely compact design (only 4250 mm in length, maximum width 2550 mm) eases integration into a machine chain. Build-up of noise and dust are also familiar problems that occur with fast-running shredding of as dry as possible fractions often tainted with fine components. The slow-running RASOR shreds in an enclosed
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shredding area which remains permanently closed because of the continual material feed using screws. The low rotor speed of 93 rpm reduces vibration and guarantees low noise emissions with its smoothrunning screws. Shredding results and throughput are of fundamental importance. Operating efficiency is important in governing success in the marketplace. The efficient operational mode reduces the power consumption of the RASOR. The material feed allows consistently low power consumption. Automatic adjustment of the cutting gap guarantees minimal energy use during the cutting process. In addition, the cutting gap is always exact and keeps
wear of the low-cost cutters down to a minimum. If metallic contraries do enter the shredding area despite upstream separation, they are located by integrated sensors and the material feed is stopped. Overload protection isolates the system from power. The “sandwich“ design, using external segment plates, allows just the area affected to be exchanged quickly and easily if damage to the rotor does result. Exchange of all of the expendable parts and screen baskets without the need for tools ensures extremely short servicing times. This way downtimes (always associated with cost) can be kept short. The concept of low-cost and simplicity applies to all expendable parts. Swivellable for servicing purposes, the frame section provides ideal accessibility to the shredding area.
Benefits of the RASOR • broad application spectrum: from the injectable fuel fraction (< 30 mm) to the fluidised bed fraction (< 100 mm) • continual material feed with automatic cutting gap adjustment for consistently low power consumption • low rotor rotation speed ensures shredding with low levels of dust, noise and vibration • swivellable counter-cutter carrier provides optimal service accessibility Counter-cutter carrier • exchange of expendable parts without the need for tools means minimal servicing times
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Material feed
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Shredding system
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Automatic cutting gap adjustment
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Quick-change systems
Up to three feed screws with load-dependent control transport the material into the shredding area. Material is pressed continually against the shredding rotor â&#x20AC;&#x201C; in contrast to competitive products which operate intermittently. This guarantees a constant power consumption with high shredding effectiveness.
Material is grabbed by a slow-running rotor with cutters in the shredding area and cut at an opposing cutter. Particle size is defined by the screen baskets around the rotor. The rotor itself is built from a carrier tube with segment plates. Because of their special shape, the dual-purpose cutters are fixed in axially running seating slots in the segment plates and are not screwed on to the rotor.
The counter-cutter is held by a hydraulic clamp. Feed of the cutting edge to the rotor cutters is automated by servo-motors and provide accurate positioning with minimal cutting gap. Counter cutter and screws are located on the movable frame section which makes the shredding area accessible when swivelled. Contrary discharge and cutter exchange present no problem.
Exchange times are minimum thanks to a general decision to stay away from screwed solutions. On the optional automatic cutter-change system, a new cutter is pushed hydraulically into the seating slot and a used one is ejected. The screen baskets are inserted and then positioned by a clamping system. The baskets are made from simple laminations and are dual-purpose.
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The new MULTISTAR M3
The word is spreading within the industry on the benefits of KOMPTECH star screen technology. In addition to the broad spectrum of applications, it is the high operating efficiency in particular that convinces many plant operators to acquire this technology – there is an impressively high number of MULTISTAR star screen machines in large composting plants. But there is also a perfectly sized machine for mid-sized plants – the new MULTSTAR M3. The MULTISTAR M3 combines proven solutions from KOMPTECH drum screen technology with unique benefits of threefraction screening taken from MULTISTAR star screen technology. With a new design and an array of benefits, the new M3 will be superior in a wide range of applications.
Easy feed The close association with drum screens is unmistakable on the feed side. It is of benefit both here and there: A loading width of 4000 mm makes filling easy, even with a large scoop width. The low feed height of just 2800 mm allows an ideal view of the hopper and loading state. The hopper size of more than five cubic metres makes workflow economical. Some of the well-proven features have
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3 fractions in one operation
been retained: straight line travel control of the hopper belt, automatic loaddependent control unit that prevents overfilling of the screen deck, and the ability to exchange hopper belt on-site. A metering roller, familiar from star screen technology, guarantees consistent feed of the coarse screen deck.
Star screening technology is regarded as one of the most effective separation methods for organic waste. The benefits of this technology come to the fore when screening compost, bark and biomass. A coarse screen deck, with a fine screen deck below it, allows separation into three fractions in just one operation. Particle size can be changed within seconds by varying the rotation speed of the star shafts. Selectivity is virtually independent of the moisture of the material – thanks to the patented CLEANSTAR cleaning system.
Reduced operating costs with electric drive
No blockages thanks to CLEANSTAR
The drive concept of the dieselelectric variant reduces the installed performance by about 40 percent compared to a diesel-hydraulic system. In other words - same throughout, lower diesel consumption. Energy costs are reduced further when the machine is driven completely electrically without generator.
Both screen decks are continually cleaned by the CLEANSTAR system. With each rotation, wear-resistant cleaning plates grip the stars and a “cleaning finger“ clears the space between facing stars. In contrast to competitive products, our machines prevent both material wrap-around and adhesion caused by wet material.
Discharge only at rear
MULTISTAR XXL Somebody has to be biggest. The new MULTISTAR XXL wins the title for the largest mobile star screen machine hands down. But is a machine of this size required at all ? Categorically: Yes
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. The conveyor belts are folded up during transportation to save space.
Large flap The large flap on each side of the machine provides optimal accessibility for cleaning and servicing purposes. Motor access is as with the drum screens. Doors each side fold upwards and open up to a spacious motor compartment also housing the wellprotected control cabinets. Designed as sub-assemblies, important elements such as conveyor belts and screen decks can be removed as complete units when exchanging. Take screen decks as an example: The fine screen deck can be pulled out from the rear as a unit. The coarse screen deck can be removed upwards.
With all the comforts Two operating units are used for operation. With its self-explanatory graphical display, the main operator console below the hopper makes work childâ&#x20AC;&#x2122;s play - operator errors are practically impossible. A second operator console, at the rear of the machine, provides a good view of the conveyor belts being folded out and adjustment of the machine using hydraulic rear supports. Sensible options extend the functionality of the MULTISTAR M3, making the machine a key component within any system.
High loading volume (> 5 m ) at low feed height 3
Coarse screen and below fine screen for 3 fractions in one operation
The MULTISTAR XXL addresses the requirement for an extremely highperformance machine. These types are machines will of course only be used at plants where the necessary infrastructure is available and where the highest of demands are placed upon throughput and material quality. Even large wheel-loaders have their work cut out at throughputs of up to 400 m3 per hour. In contrast to the XL variant, the machine is designed as a semi-trailer and everything, from the hopper capacity to the screen decks to the discharge belts, is one size bigger. A comprehensive range of standard features and optional equipment allow exact tailoring to customer requirements.
Technical Specifications Drive
97 kVA
Transport position LxWxH (mm)
13900 x 2540 x 4000
Working position
Optimal accessibility for cleaning and servicing
L x W x H (mm)
18600 x 6740 x 4000
Weight
260000 kg
Coarse screen surface area
6,3 m2
Fine screen surface area
11,1 m2
Hopper capacity
12 m3
Loading height
3700 mm
Particle sizes Fine
0/10...25 mm
Medium
10...25/60...80 mm
Oversize
> 60...80 mm
Throughput
400 m3/h
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KOMPTECH Research Center
Rudi Pretzler
KOMPTECH extends capacities. Located in St. Michael bei Leoben, and due for completion by mid 2007, the KOMPTECH Research Centre will be responsible for all new product development within the organisation. “We want to increase innovation dynamics in the development of new products“, comments Rudi Pretzler, KOMPTECH company founder and Head of Engineering, explaining the expansion phase. In addition to the existing research and development departments at the competence centres in Frohnleiten, Oelde and Lauterbach, the KOMPTECH Research Centre is to focus on the development of new products. Isolated from day-to-day business activities, this should be a guarantee for other groundbreaking innovations to be initiated. “Personnel resources have been the limiting factor to now. This problem will be addressed by creating ten new highly qualified positions within Research & Development“, explains Pretzler, going into more reasons for the project, costing around € 2 m. Neighbouring the Anton Mayer GmbH waste treatment plant in
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St. Michael bei Leoben, the KOMPTECH Research Organisation is taking shape on a 5,000 square metre industrial plot (total development area 850 square metres) and will focus on preliminary development of new products under the leadership of Rudi Pretzler. There will also be a prototyping and trials department, allowing all machines to be tested in real-.world conditions. Furthermore, cooperation with research institutes working in this field, such as the Montan University Leoben in the direct vicinity, is to be driven forward.
www.komptech.com KOMPTECH GmbH Kühau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 info@komptech.com
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