News
The magazine for our customers and partners
Expansion of the chipper range New CHIPPO 5010 C direct
- Operating report CHIPPO 500 - Treatment of RDF - Customer report
Issue 1/2009
Table of contents Foreword The CHIPPO is on the march
4/5
Chipping is Gerhard’s delight
6/7
Biomass made by Lengel
8/9
TERMINATOR F - The universal genius
10/11
Treatment of RDF
12/13
Hello Mr. Binman
14
>> MAGNUM RELOADED
15
CRAMBO In use across the globe
16
INPRINT Publisher: Komptech GmbH; Editorship: Andreas Kunter, Josef Heissenberger, Joachim Hirtenfellner; Photos, Layout & Graphic: Alexandra Gaugl;
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Foreword
Dear reader,
Which business has a future? The global crisis has imposed upon the real world economy a situation comparable to a massive earthquake spanning the globe. It was triggered by a financial industry greedy and uninhibited in every respect and made possible, or even promoted, by the leading governments of Western industrialised nations that have in no way honoured their responsibilities as regulatory authorities. Many of those things conceivable just a year ago are inconceivable and reciprocated today. The waste management industry, and with it the environmental technology industry, is also being hit hard, a sector acknowledged to have the best prospects for the future and to be immune from crises although it is obvious the drastic downturns in the manufacturing industry and in business are also impacting the waste generated there and the waste management industry is having to confront sensitive revenue losses. Private consumption has barely suffered so far, meaning downturns in the municipal waste sector are staying within limits. In emerging markets and developing countries, there is a massive shift of priorities back to basic requirements, meaning urgently required investment in modern waste management with an industrial infrastructure currently appears to be a dispensable luxury in some places.
But every crisis has its positive sides. Things that were “out of balance“ are being put back into place. Much that was escalating away from reality is falling back down to earth. A new kind of modesty and a more piercing view of what is essential are becoming possible. Energy and climate policy has not changed in the meantime. It has been moved a little to the background. But it is this sector in particular that is offering waste management, or resource management as it is now known, the best potential for the future, both in regard to “waste to energy“ and the entire biomass sector. On that note, I trust you enjoy reading this edition.
Yours
Josef Heissenberger
So the global economic crisis has also hit all facets of global waste management, affecting even the poorest who are having to earn their living on the landfill sites of third world countries with recycling products.
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Technology
The CHIPPO is on the march CHIPPO 5010 C direct Drive Power rating:
via lorry diesel engine (MAN) with special power divender 353 kW / 480 HP
Chipping unit / Rotor Length: Diameter: Feed width:
1000 mm 1050 mm 1000 mm 1610 mm with vertical feeder drums 750 mm 400 and 560 rpm 12
Feed height: Drum rotation speed: Number of blades: Loading heights Fill height: Length of feed table: Discharge range of exaust pipe: Discharge height of conveyor belt:
1910 mm 2400 mm to 20 m ~ 4,7 m
Transport position L x W x H (without conveyor belt): 8215 x 2550 x 4000 mm Weight (without conveyor belt) Throughput (dependent on material): CHIPPO 5010 C direct:
< 26 t
to 220 m3/h
50xx ... 500 PS xx10 ... 1000 mm rotor diameter C ... entrance cros
Everywhere the new Komptech CHIPPO 5010 C direct has been demonstrated so far, the census of opinion has been unanimous - here is a machine that is virtually unbeatable in regard to mobility, working comfort and cost-effectiveness. The new model is a mounted variant driven directly from the lorry. A TGS 6x4 lorry from MAN delivers a drive power of 480 HP / 353 kW. The CHIPPO module sits directly above the two rear axles powered, guaranteeing traction in virtually all conditions. If deployment on extreme terrain is planned, a 6 x 6 variant with a front axle powered with Hydrodrive can be chosen as an option. The operator sits in the comfortable lorry cab on the converted passenger seat. The large window panes provide the operator a perfect view, enabling full concentration on working with the powerful Epsilon crane. This is also necessary because the machine has a huge appetite as a result of the efficient power transmission.
Special gearing for maximal power A key component of the new CHIPPO 5010 C direct is certainly the special power take-off drive, developed by Komptech in collaboration with a manufacturer of gearing mechanisms. The gearbox, 4
designed for a rating of up to 700 HP, sits directly in the drive train running from the diesel engine to the axles. This makes the full power of the lorry available for working with the chipper.
Two chipping speeds The shredding speed is adapted to the material on the CHIPPO. This means higher rotor speed and hence higher cut frequency for smallwood and shrubbery, or reduced rotation speed but higher cutting power for trunk wood. Control gear on the rotor delivers the two speeds. A pushbutton on the operator console is used for switchover. The active feed system, taken from the CHIPPO 500, is also suitable for high performance of the chipper rotor. The large rotor diameter of 1050 mm makes possible an inlet opening of 750 x 1000 mm. If shredding of trunks greater than 750mm in diameter is required, the lorrymounted, fold-out wood splitter (option) is called into play. Next to the machine, on ground level and in perfect view of the crane operator, the trunk is placed into the mounting and split using a hydraulic splitting wedge. Not even the trunk length presents a problem - the Chippo has a 2400 mm long feed table that can be extended to
CHIPPO 5010 C direct 3300 mm using the fold-out table extension. This effectively prevents the tilting over of trunks.
EFFICIENCY is paramount After the feed mechanism and the chipping rotor, the discharge system is the third component that differentiates a CHIPPO from the competition. Three generously dimensioned screw conveyors ensure uniform flow to the blower. An adjustable blower rotation speed allows precise tailoring to the requirements. The speed can be reduced for light wood chips easily tossed. This reduces power consumption and the wood chippings are post-shredded less due to the blower. Energy usage is even more efficient when the conveyor belt option is used instead of the blower discharge. This discharge variant guarantees homogenous, pelletised wood chippings and requires up to 50 kW less drive performance. The bottom line is perfect wood chip quality at the lowest price. Energy usage is between 0.3 and 0.4 litres of diesel per cubic metre of wood chippings. This then yields an operating time that can not be achieved by any tractorpulled chipper. The CHIPPO 5010 C direct is available today and represents another addition to the CHIPPO family. More family members are planned for 2010 - this is when the variants with mounted motor are launched (see below).
NEW: CHIPPO 7010 C Construction
Chipper on 4-axle-lorry
Drive Power rating:
Diesel motor Caterpillar速 C18 522 kW / 710 HP
Chipping unit / Rotor Length: Diameter: Feed width: Feed height: Drum rotation speed: Number of blades:
1000 mm 1050 mm 1000 mm (1610 mm with vertical feeder drums) 750 mm 400 and 560 rpm 12
Transport position L x W x H: (without conveyor belt) 9200 x 2550 x 4020 mm Weight (without conveyor belt)
32000 kg
Throughput (dependent on material):
to 300 m3/h
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Our customers Gerhard Ronsberger had to wait a long time, but finally it was time. At a demonstration last autumn, he saw the CHIPPO 500 from Komptech in action and everything was sorted - “this machine was built for me”. The machine was delivered by Thurnbauer, Komptech’s sales partner for chippers in Southern Germany. Thurnbauer is a distributor for Finnish manufacturer Kesla, specialists in wood harvesting machinery, and a master dealer for agricultural machinery manufacturer John Deere, the powerful models from whom represent ideal drive machines for the CHIPPO 500. Gerhard Ronsberger’s machine is also configured accordingly. The tractor is a brawny John Deere 8430 rated at 350 HP and a Kesla Foresteri 7000 serves as an extended arm.
The best feeder “Just look at that feed“, says Gerhard Ronsberger, pointing to an entire apple tree as is disappears trunk first into the CHIPPO. Following the trunk is the unwieldy top of the tree, compressed
Chipping is Gerhard’s
6
CHIPPO 500 orderly and aligned by the combination of vertical and horizontal feed drums. “There is no long stopping, stuffing or anything else necessary here, the CHIPPO feeds itself and I am already getting new material – after all, I want to finish as well“, smirks Ronsberger. Time is an important factor for him because he often visits more than one customer in a day.
The neatest wood chips But for Gerhard Ronsberger, the quality of the wood chips is more important than the high throughput. “No machine chips more neatly than the CHIPPO. Customers quickly get used to neat wood chips where I work with the CHIPPO – this makes it difficult for other to get a foot in the door.“ There is no pulling the wool over his eyes in terms of the quality of wood chips after all, Gerhard Ronsberger has been in this business for fifteen years and has “got through“ more than one chipper in this time. He attributes the high level of quality to the large, open rotor and a far-reaching blade advance. The power necessary for
a far-reaching advance is delivered to the CHIPPO with a reduced drum speed of 400 rpm, and the machine therefore has a markedly higher cutting force than comparable machines. “This is why I cut large wood chippings that do not crumble so easily and that can be transported away quickly by the open rotor. Nothing stays in the system – this would cause higher fine fractions and, as a result of friction, braking of the rotor. Wood chippings of size G50 (corresponding to ÖNORM M 7133) or coarser are increasingly being requested by customers. So why chip everything finer wasting energy?
Equal to all requirements The economy of the CHIPPO reveals itself at the filling station - “My tractor has a 680 litre tank and can chip for a long time. Even if I really take the machine through its paces, fuel consumption barely increases to over 45 litres per hour“, reports Gerhard Ronsberger. With a high advance, 80 mm screen basket and neatly stacked wood trunks,
a fill volume of 150 cubic metres per hour is possible. Conditions are rarely this perfect, however. Gerhard Ronsberger has just returned from a job in neighbouring Czech Republic. “Maintenance of forestry roads, meaning mainly shrubbery and smallword. Here I choose the higher drum speed and switch on the variable feeder controller. This way I can attain high throughput with this material”. In addition, the rotating, vertical feed drums prevent blockage of the bulky shrubbery and provide pre-compression for precision chipping. Gerhard Ronsberger is looking optimistically to the future. “The demand for wood chippings is increasing continually, but there are also more service providers out there than before. Those looking to stay in business need accurate calculations. After exhaustive testing, I opted for the CHIPPO 500 from Komptech. Put simply, it enables me to produce the best quality at the lowest operating costs”.
delight
7
Our customers “This is what it has to look like“, says Alexander Lengel expressing satisfaction as he lets a handful of biomass fuel slip through the fingers. The material is dry and has a consistent feel. Fine contraries and foreign bodies such as clingwrap are not apparent. The material is now only awaiting loading and transportation to the biomass cogeneration plant to live up to its promise - one kilogram of this renewable fuel generates 3-4 kilowatt hours of energy. Given the consistently high quality, the company has succeeded in agreeing to long-term supply contracts with operators of cogeneration plants. This gives reliability in planning, but also demands expertise and the right technical equipment to cope with the changing quality of the raw material. This is because the “primary energy source“ is green waste, the consistency of which is influenced heavily by the prevalent vegetation period.
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Treatment of biomass
made by A company full of energy Lengel is a pioneering company in the processing, or even better, the conditioning of organic waste into profitable products. In addition to the operation of a composting plant and generation of substrate for horticulture and landscaping, biogas is generated from biowaste, spoiled food particles and leftovers using a modern fermentation system. At the age of 24, Alexander Lengel is now an integral part of the company. Following his training at a horticultural college, he worked his way up through all of the positions at his parents’ company and is now responsible for material planning, consultancy services, sales and marketing. Biofuel production also falls into his realm of responsibilities.
How is biofuel made? “We can’t let you in on everything“, answers Alexander Lengel to the question of how, “but the major steps are pre-selection, shredding and then screening, combined with wind sifting. Our workforce knows exactly what goes into the biomass production process and what does not. Material with too high a green fraction or not having a sufficiently woody structure lands up in
Biomass
the composting process“. After a short surface-drying phase, the material is shredded with a Komptech CRAMBO 6000. “The CRAMBO generates exactly the shape and size we need. We usually use the 250 mm screen basket – if we need anything finer, we switch screen baskets and this is not a problem,“ explains Alexander Lengel. Alexander Lengel is also satisfied with the broad range of applications the CRAMBO can be used for. “Because we, as a service provider, are also out and about, we are faced with all manner of material from root stocks to wet grass and it is often anything but clean. But the machine copes with this”. After shredding, the material is stored for about a week and then screened off. “We worked with drum screens at the beginning but soon realised it was not possible to work economically this way. Material quality and throughput were not adequate and we were always using two machines, three if you count the wind sifter“, says Alexander Lengel, explaining the early days. Today, this job is performed professionally and competently by MULTISTAR star screens.
Advantage star screentechnology “Three fractions are separated out in just one operation. Fine fractions are fed into the composting process and oversized particles are shredded once more. A wind sifter runs at the same time above the coarse and mediumsized particles. Fe separation is also integrated“, says Alexander Lengel, pointing out the benefits of the compact MULTISTAR star screens. 2006 saw the purchase of an L3, and an XL has also been in use since the beginning of the year – in “constant use“ according to Alexander Lengel. “The XL is often in use 10 hours a day, but we still only need to fill up every 3-4 days. One wheel loader is normally only filling, a second helps with the transporting away of the screen fractions“. The screen process is tailored to the varying material qualities by adjusting the particle size with the rotation speed of the star screens. “This is of paramount importance to us because this is the only way we can generate constant product quality tailored to the requirements of the customer“, says Alexander Lengel, stating another benefit and then declares “there is no intelligent biomass production without MULTISTAR star screens.“ 9
Technology
TERMINATOR F The universal genius Continual product improvements through active product management are a hallmark of Komptech. This enables quick reaction to changes in the marketplace and, at the same time, customer experience is channelled into continued development. One example of this is the TERMINATOR which, with the new generation of the F(fine) shredding unit, represents the perfect machine for generalpurpose deployment.
New tooth attachment The previous connector system has been replaced by a bolted assembly for the roller teeth. The wear tooth has a form-fit seating in the holder and is secured with a central bolt. 10
The benefits of the new F roller • high protection against tooth loss, even for high wear • even better cutting effect with cutting edge brought forward on one side • same shredding quality as before, overlengths reduced further • dual-use teeth (rotation by 180° and offsetting to 2nd spiral) • improved protection against roller pipe wear
Reliable shredding Effective waste splitting demands as consistent a particle size as possible in the range 25-150 mm. A TERMINATOR with the F shredding unit is designed for this particle size range - the roller teeth are arranged
in the form of two slightly overlapping spirals. Material moves right up to the roller body and is grabbed by the full height of the tooth. This arrangement of teeth increases throughput by virtue of the good conveying effect and yields uniform shredding. This is because several teeth immediately grab one after another (especially for longish parts). There are even more issues when a mobile shredding machine is considered from the viewpoint of a service provider. On the one hand, the requirement is to perform all shredding jobs, meaning being capable of processing a broad bandwidth of different material, and that within the shortest possible time. On the other hand, the intention is not to wreck the machine when
TERMINATOR F performing various jobs and to keep wear and tear low. The TERMINATOR satisfies precisely this requirement with its hydraulic system containing constant power control - a high roller speed and hence higher throughput for easily shreddable material, a slower speed but a torque four times as high for difficult to shred material. Only by doing this is the shredding of various commercial waste, including tires, mattresses and rolls of carpet, possible at all.
No fear of difficult material
„A TERMINATOR shred all“
You can also approach difficult waste with a TERMINATOR. As protection against blockages and closing, the machine has an adjustable cutting gap and provides the ability to reverse the roller – manually or automatically with pre-programmed reverse cycles. Usually the most tenacious of material is shredded by reversing and moving forward again. If a solid contrary enters the shredding chamber, the hydraulic overload protection mechanism prevents breakage of tools and machinery. The machine switches itself off and the warning light signals assistance is required. Conventional mechanically-driven systems are clearly at a disadvantage here. If the shredding force is not sufficient, blockage of the roller, and hence stopping of the motor, can only be prevented with safety measures, such as the folding away of the opposing comb. Unshredded material can enter the output material in the process, making subsequent
recycling difficult. If the machine comes to an unplanned stop even so, start-up is often not possible until after manually cleaning the shredding area. Even reversing under power or at periodic intervals is generally not possible and makes the shredding of material that tends to get snagged (steel springs from mattresses, wire, etc.) problematic.
Efficient power usage The TERMINATOR can compensate for the higher (system-related) power requirement of the hydraulic system with an efficient shredding unit. The specific fuel consumption (litres per ton of shredded material) is the same, or only marginally above, comparable motorised, mechanicallydriven shredders, but without the risk of blockages and with a shredding guarantee. Machines are often not working at full capacity in day-to-day operation. To minimise fuel consumption during these idle times, the TERMINATOR has a power save function. In ECO mode, the machine detects an idle state and motor and roller rotation speeds are reduced. Once filling starts again, the machine automatically returns to the operational state set previously. The fuel consumption of a TERMINATOR 5000 shredding waste wood over a test period of several hours (day-to-day operation, throughput approx. 30 t/h, ECO mode) is about 25 litres per hour.
NEW: F-tooth-holder
- tooth loss is reduced to a minimum - better cutting effect - dual purpose use
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Machine technology Current situation
Figure 1: Komptech Technology Pre-shredding TERMINATOR XF
flat >80 mm cubic >80 mm Post-shredding RASOR
Ballistic separation BRINI MK 0-30 mm
30-80 mm
Screening MULTISTAR
Biological treatment
EBS Premium
EBS Classic
The current situation regarding waste treatment in the European Union is showing dynamic growth in waste treatment technology. This is essential in satisfying the requirements of the EU Framework Directive on Waste and to drive forward material recycling and energy recovery – as opposed to landfilling. Over recent years, reliable technologies have been developed that have been able to be used for the processing of mixed waste, such as residual waste and commercial waste, and for the extraction of potential recyclables. Refuse derived fuels are one of the primary products of this waste and are frequently deployed to replace conventional fossil fuels. Heat and power for public and commercial purposes can be extracted here. RDF is offered in different qualities and has a calorific value >10 MJ/kg (this is mainly made up of plastics, paper, wood and textile content). Quality is determined by the selection and combination of input materials and by the selection of processing methods. Low quality RDF is burnt in grate firings, medium quality RDF is burnt in industrial firing plants for power generation and RDF of high quality is burnt in cements kilns, power stations and, as of recently, also in steelworks. The trend over recent years has brought with it noticeable changes in the quality requirements made of RDF. Whilst high quality RDF was being pelleted in 2001 and had a particle size of <10 mm, the largest quantity of in-demand RDF in 2004 was not pelleted and had particle sizes of <30 mm or <80 mm. Today, a dynamic market showing falling prices demands from treatment plants continual flexibility to benefit their partners at incinerator plants. 2004 saw 26.2 m Mg of plastic waste produced within the European Union. Of that, 65% was landfilled, meaning the unused potential for material recycling and energy recovery was 17 m Mg. The recycled 35% was mainly processed into RDF, 3.5 m Mg of it (more than 1/3) in Germany. The treatment technology comprises mainly of machines working mechanically so as to keep treatment costs low. This way, RDF is extracted by separating off contraries and other recyclable fractions.
Table 1: Komptech Definition of 3 RDF Qualities Table 2
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Ballistic separation
Windsifting
Specific Investment [¤/Mg]
35
43
Specific Power Consumption [kWh/Mg]
5,2
6,6
Specific Operating Costs [¤/Mg]
18
22
“EBS Low” “EBS Classic” “EBS Premium”
Calorific value [MJ/kg]
12-16
12-18
>22
Particle size [mm]
<300
20-100
20-50
Oversized particle fraction [%]
<3
<2
<10
Inert fraction [%]
<3
<1
<1
Chlorine content [%]
<1
<0,8
<0,8
-
<20
<12
Ash content [%]
Technology
for the processing of refuse derived fuels Potential input materials RDF treatment plants process a wide range of waste, including • domestic waste and materials extracted from it, such as oversized particles high in calorific value and packaging materials • mixed commercial waste with calorific values >10 MJ/kg and materials extracted from it, such as lightweight material from wind sifting • Source-separated materials from commercial waste, such as carpets and foil. These fractions are often used for the presetting of certain parameters for a defined RDF quality • Sorting residues from packaging waste collected separately State-of-the-art RDF treatment plants often use wind sifters to separate off contraries from RDF. Comparing a “wind sifter dominated“ technology to a “ballistic separator dominated“ technology shows clear differences in regard to power requirements, investment and operating costs. Revenues and costs for the input and output materials are not factored into the calculation of operating costs.
Comparison between ballistic separation and wind sifting on system level Three types of RDF were defined “RDF Low”, “RDF Classic” and “RDF Premium”. Every type was generated in consideration of three applications (see Table 1). The results yield a recommendation for an RDF treatment plant process (see Figure 1). With this method, it is possible to produce all three types of RDF and to guarantee sufficient flexibility in the event of future changes to RDF quality requirements and also changes in input material composition. The output material ratios of the ballistic separator dominated RDF treatment plant show differences to a wind sifter dominated RDF treatment plant, such as a lack of a fraction for grate firing. An RDF treatment plant dominated by ballistic
separators shows benefits compared to one dominated by wind sifters. Table 2 shows these, and they amount to a -27% difference in power consumption, a -23% difference in investment and a -22% difference in operating costs. The benefits of a ballistic separator dominated RDF treatment plant lie not only in the replacement of the wind sifter by the ballistic separator, but result in addition from the use of an innovative pre-shredding technology that reduces overlengths greater than 100 mm to less that 5% by weight. The rolling fraction from the ballistic separator can be fed back into the pre-shredder after Fe and non-ferrous separation. In every cycle, the rolling fraction is reduced by 50% and lands up in the undersized particle fractions of the ballistic separator. This prevents the formation of a fraction for grate firing (the most expensive disposal variant), as is the case in wind sifter dominated technology.
In addition, better scrap qualities are attained with ballistic separator dominated RDF treatment technology because metal wires, chiefly responsible for the adherence of non-metallic impurities, move over into the flat fraction. Although these wires are metallic, they do not impact the fine shredder because they have a relatively short diameter. After fine shredding, they can simply be removed from the RDF material using magnets. The development of suitable machines, together with adherence to quality requirements for RDF and other potential recyclables, makes possible modern treatment plants with low power consumption and operation at low cost. Two new plants, in Hagenbrunn, Lower Austria (A), and Bernburg, Saxony (D), have since been built in accordance with the ballistic separator dominated RDF treatment technology depicted.
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Our customers
Hello
Mr. BINMAN If you drive to the South West of Ireland, it will only be a question of time until you come across one of “Mr. Binman’s“ yellow refuse collection lorries. What was a small family-run business with one refuse lorry 16 years ago is now one of the largest disposal companies on the Green Isle. Besides collections, their focus today lies on the recycling of waste in their own treatment plants.
Pre-shredding increases recycling Martin Sheahan Jr. Managing Director of the company, willingly explains the activities of the recycling plant in Luddenmore, near Limerick. Here, in addition to the treatment of potential recyclables collected separately, the maximum possible level of recycling material is extracted from residual municipal and commercial waste. “At the beginning, this waste stream was only treated with screening, sifting and sorting“, says Martin Sheahan, “but tests have shown that pre-shredding increases the recycling quota. The quota is laid down to us in national and EU legislation. With this procedure, we are now extracting much more material high in calorific value with wind sifting. It is pressed into bales and then used for the production of refuse derived fuels”. Over the past few months, a TERMINATOR 5000 S with direct mechanical drive has assumed the function of pre-shredder - and to his complete satisfaction, Martin Sheahan assures us. “We tested several machines but only the TERMINATOR convinced us. Because no new machines were available at short notice, we conducted testing with a secondhand machine. The fact that a machine with several thousand operational hours behind it still worked so well is an indication of high reliability and this certainly influenced our decision.“
TERMINATOR with direct drive as the best solution The functionality and cost-effectiveness of the machine were of course also important. “Opting for the mechanically driven variant was actually a logical decision“, says Willie Doyle, Komptech sales partner for Ireland. “This is because we are dealing with broadly identical waste composition and we need constant performance for subsequent treatment – ideal for a TERMINATOR direct”. From a technical viewpoint, power is transferred from the electric motor to a reverse gear/manual transmission unit having two different gears and a high performance clutch (designed in-house), and then on to the drum drive, by a maintenance-free Powerband belt system. With lower power and maintenance costs of the mechanical drive, this design simplifies the functionality of a hydraulic drive in regard to protection from contraries and reversing capability. Another benefit is the low space requirement and hence easy integration of the compact unit into an existing system. 14
Technology
>> MAGNUM RELOADED From the outside, the new design instantly gives away the most powerful drum screen machine from Komptech. Smooth surfaces make cleaning easy, large doors and flaps give easy access to all servicing points and struts in loaded areas guarantee even stability on any terrain. A 2-axle semi-trailer is now used as a chassis frame – perfectly adequate for the weight despite the sturdier frame.
New solutions After folding down the belts and extending out the 4 hydraulic supports, the machine is ready for use immediately - moving the hopper for transportation purposes is no longer necessary. The dimensions of the new Magnum are virtually the same as the predecessor model nonetheless, possible with a modified folding mechanism for the rear belt and a slightly shorter screen drum. The effective screening area remains unchanged at a proud 47 m². The drum drive has been revamped now the smooth, low-wear Drumgrip® drive system is used on both inlet
and outlet sides. The hopper size is aligned to the high screen performance and enables convenient working with a volume of up to 7 m³. With the free filling length of 4.4 metres on the filling side, large scoops can be used with no problem. When used for soil and rubble, a hydraulically foldable hopper pre-screen can be mounted as an option for the separation of coarse bodies. All operators of drum screens are aware that unintentional emptying of the hopper often entails a deterioration of the screening end product. This can be effectively prevented with the newly available hopper sensor controller that uses ultrasound to measure the fill level of the hopper and stops, and starts again on filling, the hopper conveyor belt, the drum and the discharge belts. The new MAGNUM is also available as a 3-fraction screen machine. The fine particle and the medium particle belts can be mounted on the right or left. The design allows retrospective changing of the discharge sides, and hence also the fill side. 15
Our customers
CRAMBO CRAMBO Stationary solutions • electric drive for high degree of efficiency and minimal maintenance • perfect integration into a process chain • Separated design option: - protection of the drive unit (dust protection, improved cooling) - space-saving integration of the compact shredding unit
Komptech GmbH Kühau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] info@komptech.com 16
In use across the globe Hundreds of CRAMBOs are going about their daily work around the globe. Also in the US, where more and more customers are opting for efficient CRAMBO technology despite stiff competition from giant high-speed machines. And also Greg Schoenbachler, General Manager of Silver Springs Organics in Rainier in the state of Washington. The compost plant opened in 2007 and is state-of-the-art with covered windrows, suction ventilation and cleaning of outlet air with bio-filters. The right treatment method for the input material was also selected with care. Greg Schoenbachler was looking for a machine with a high level of reliability, low operating costs, simple maintenance and minimum environmental impact. Lastly, the machine was also to be capable of being fed with a large wheel loader. Many companies had the opportunity to demonstrate their machines, but only a CRAMBO 5000 was ultimately allowed to stay. The CRAMBO was the only machine able to take on Greg’s 9m3 wheel loader scoop and the only one not to be bothered about foreign bodies containing metal or stones.
Komptech UK Ltd. Forge End, Lodge Farm, Kineton, Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 info.uk@komptech.com
This is namely one of the greatest benefits of the CRAMBO – insensitivity to contraries and hence lower maintenance and wear and tear costs. The counter reading shows 910 operational hours and only 2 teeth were replaced in this time (the fault of a crankshaft). Greg Schoenbachler estimates the first replacement will not be due until 1100 hours. Operating costs were another major factor in the decision-making process - the Crambo is electrically driven. The energy costs are significantly lower than those of a diesel motor because of the higher level of efficiency. Records were kept from the very first hour of operation and these show an average value of 15 dollars (€11.25) per operational hour. These figures confirm his decision was the right one. “I would do exactly the same again today“, says Greg Schoenbachler, “and can only advise anyone looking for an efficient and general-purpose machine to take a look at the Crambo”. Adequate utilisation is guaranteed given that Silver Springs Organics processes 120,000 tons annually, including green waste, biowaste, waste wood and residue from agriculture and forestry.
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