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News

The magazine for our customers and partners

CRIBUS 3800

A new generation of drum screens

NEW: AXTOR

CRAMBO direct

SPLITTER - Treatment of biomass - Success for stationary and system technology - Customer reports

Issue 2/2009

Table of contents Foreword The correct parth to the fuel

4/5

AXTOR - The machine for any assignment

6/7

Direct brings benefits - CRAMBO 5000 direct

8

SPLITTING made easy

9

The main thing is that it is a CHIPPO

10/11

New: Drum screen CRIBUS 3800

12/13

The modern compost plant

14/15

A partner for a clean environment

16/17

The optimal solution - Wrexham compost plant

18

Our partner Waste Treatment Technology

19

A tall order - Waterbeach MBT plant

20

INPRINT Publisher: Komptech GmbH; Editorship: Andreas Kunter, Josef Heissenberger, Joachim Hirtenfellner; Photos, Layout & Graphic: Alexandra Gaugl;

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3

Foreword

Dear reader

What is innovation?

For Entsorga-Enteco in Cologne in October 2009, Komptech will present a series of new products in an attempt to consolidate its image as an innovation leader in the industry. The question raised here is whether everything new is also innovative, or put another way, which new products are actually deserving of being called “innovation“?

The word innovation has unfortunately become a vogue term. All manner of products are called innovative or an innovation, very often hiding a cheap ploy aimed at drawing attention.

So what is an innovation at Komptech?

ease of use and hence less stress for the operator.

Ultimately therefore something resulting in higher profits for our customers, after investment when new Komptech products are used.

We at Komptech feel a sense of commitment towards this.

On this note, I trust you enjoy reading this edition.

Yours

Josef Heissenberger

“Innovation is the creation of something new which offers a previously unknown benefit or a higher level of benefit than the best technology previously available“, so something which has a higher value to our customers – be it in the form of a resolution of a problem previously solved inadequately or not at all, higher energy efficiency, lower wear and tear costs and hence lower operating costs, or better

3

Biomass treatment

The correct path to the fuel Solid biomass is intended to play a decisive role in the transition from fossil to renewable energies. True to our slogan “Technology for a better environment“, we see it as our remit to develop the right strategies and the most cost-effective machines for this challenge.

With the right technology, generally by shredding, screening and separation, a marketable fuel is produced from different input materials. The diagram below shows the material-specific recycling methods.

Wood trunks not recycled because of their properties are processed into high-quality wood chippings by the CHIPPO chipper. The mobility of the machines allows processing

near to the source, but at the same time appropriate logistics must be in place for high-performance machines for utilization reasons. Large chippers are therefore used more at processing and loading points.

A fuel with a more coarse structure can be generated from woody green waste, clean waste wood and forest wood residue by shredding with the general-purpose AXTOR wood shredder. Subsequent separation by Komptech star screens, drum screens or wind sifters brings a marked increase in quality – fine fractions are passed to the composting process and contraries are separated off using Fe separation or wind sifting.

Linking machines together creates a high level of flexibility but this only

usually takes place on the firm ground of a compost plant or biomass yard due to space.

The slow-running CRAMBO shredder is used if the quantity of contraries increases, such as stones in forest residue and metal in waste wood.

Fuel is produced depending on the screen basket selected - usually in combination with a screen machine to recycle the overlengths or prebroken for subsequent, quick-running shredding. With its many variants, from the stationary machine to the autarkic machine with its own crane and built-in screen mechanism, the CRAMBO is the right solution for many tasks.

dirtied

Root stocks

Forest residue

CRAMBO direct Slow-running shredder

AXTOR Fast-running shredder

Biomass heating station MULTISTAR Star screen

Wood trunks TOPTURN X Compost turner

clean 4

CHIPPO Drum chipper

Private heating installations

Biomass treatment CRAMBO Slow-running universal wood shredder The dual-shaft CRAMBO shredder shreds all types of wood and green waste to a fraction size predefined by the screen basket.

This fraction size can be adjusted using easily exchangeable screen baskets (mesh width 80 to 300 mm). The slow speed gives a high level of insensitivity to contraries.

The power ranges from 242 to 429 kW. The hook lift platform, the 3-axle chassis and the tracked chassis options guarantee mobility according to requirement. With its integrated fine fraction separator and own loading crane, the CRAMBO becomes the perfect processing machine for root stocks and soiled forest wood residue.

AXTOR Fast-running universal wood shredder The range of products in the field of biomass treatment is now complete with the AXTOR. As a fast-running shredder, material for composting is produced - at reduced speed in chipper mode, fuel for heating plants is produced. The input material determines whether the material is chipped or shredded with hammer tools. The material spectrum ranges from untreated waste wood, green waste, bush cuttings and bark to wood trunks, pre-broken root wood and forest wood residue.

A 3-axle central axle trailer, a semi-trailer or a chain drive lend the AXTOR mobility.

CHIPPO Drum chipper The role of the CHIPPO family is to produce quality wood chippings cut to precision and with the lowest of fine fraction.

The right machine can be found for every requirement from the ever-growing product portfolio. The family starts with one of the most powerful tractor-operated drum chippers (CHIPPO 510 C), includes in the mid to top performance range a variant with lorry drive (5010 C direct) or with own motor (5010 C) and ends with a large-scale chipper rated at more than 700 HP (7010 C).

Lorry-mount, trailer chassis and chain drive options are available for the machines with their own motors.

MULTISTAR Star screens A fine fraction, a medium fraction and a coarse fraction are produced in one screen operation with the Komptech star screen technology. The medium fraction generally represents the usable fuel fraction. The screen material is freed of any adhesions as it passes over the rotating stars, ensuring high quality of usable fraction for forest wood residue and root stocks in particular.

The product range for mobile machines starts with the simple EASYSTAR screen deck and then extends from the compact, mobile multistar M3 and L3 star screens (M2, L2: 2-fraction screens) to the high-performance multistar XL and XXL screens.

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new The introduction of the new AXTOR impressively underlines our expertise in the field of biomass treatment. A broad range of applications combined with a perfect level of customer benefit are hallmarks of every Komptech machine.

The conversion of customer requirements into technical features has been particularly successful on the AXTOR. The machine is currently undergoing the final touches for market launch in an intensive test phase at selected customers.

This is precisely the right time to inform our customers which machine is set to revive the biomass sector next year.

In a nutshell, the AXTOR is a fast-running shredder with a longitudinal-feed, a shredding drum with two different speeds of rotation and three different shredding tools. However these attributes make the AXTOR a machine with the broadest

AXTOR

The machine for

6

AXTOR 7012 - Universal wood shredder application spectrum – with highest output quality and throughput at the same time. To give you an idea, the three typical tasks at compost sites and biomass yards are discussed.

Shredders for composting Green waste with a higher leaf or grass content is a valuable input material for composting. Fibrous shredding increases the surface area for speedy microbial decomposition. For this, freely swinging tools with a special, slim-line profile and carbide tip are used on the AXTOR, shredding the material like a hammer mill at high drum speed.

Filling is best performed with two wheel loaders simultaneously to satisfy the machine’s appetite. The AXTOR 7012’s drive rating of more than 700 HP (712 HP, 1200 mm drum diameter) is efficiently converted to throughput – everything landing on the feed table with a maximum feed length of 6 metres is grabbed instantly by the active feed system and pulled in automatically.

Suitable for forest wood residue Bulky, interlinked mixtures made up of arms, branches and treetops present no problem for this combination of vertical and two overhead horizontal

feed rollers, taken from the CHIPPO chipping machines. Hardly surprising considering the maximum feed opening is 1610 mm in width and 1000 mm in height. In the drum itself at reduced speed, static hammer tools generate a lumpy product, defined by a surrounding screen basket.

High quality in chipper mode Simply exchanging the hammer tool for a static chipping cutter with reversing blade converts the AXTOR into a powerful chipping machine. Because contraries can not be ruled out, the static tools have a patented overload protection system which prevents subsequent damage to the base drum body, the shaft and the bearing on contact with a solid contrary.

A 1600 mm wide discharge belt then conveys the material stream orderly out of the machine and its length permits piles up to 5 m in height.

Power is provided by a sturdy power band. This power is transferred to the drum via a manual gearbox and comes from a Caterpillar C18 in the underfloor mounting position on the AXTOR 7012.

Unlike competitors’ products, this design provides a free, open feed area and perfect accessibility to the engine compartment.

All those interested in what else the machine can do can find out at one of the many demonstration events.

any assignment

7

new

Direct brings benefits The new CRAMBO 5000 direct What happens when we think long and hard about efficiency increases in the field of biomass treatment? We invent the CRAMBO direct, whose forest configuration is the ideal machine for virtually all tasks involving forest wood residue - especially when contraries or contamination make chipping or fast-running shredding uneconomical.

On the slow-running CRAMBO shredder, the tools move at 1-2 m per second whilst they rotate 10-20 times as fast when chipping or running at the fast speed. This makes the CRAMBO insensitive to embedded stones or the “lost“ iron parts from the wood harvest.

The CRAMBO 5000 direct gets its mobility from mounting on a MAN 4-axle lorry. The drive engine also serves as the power source for the shredder. Power is transferred “directly“ to the hydraulic system with the familiar constant power controller via a specially developed power divider in the lorry’s drive chain.

Direct on the forest road The CRAMBO direct drives “directly“ into the forest – in contrast to its bigger brother, the more powerful Crambo 6000 whose forest configuration is designed as a semitrailer, mainly for processing sites close to the forest.

Forest residue stored beside the road is picked up by the mounted Epsilon cab crane and transferred into the biocutter. Using the 150 mm or 180 mm screen basket gives a granularity which can be used “directly“ in heating plants designed specifically. A star screen deck underneath the shredding area separates off the fine fractions. Minerals and part of the organic fraction remain at the original source.

The quality of the fuel of course increases at the same time.

The fuel is discharged “directly“ into containers via the discharge belt and an additional, newly developed foldable and rotatable belt. Filling is possible in a consecutive line or parallel to the shredder.

A minimum of operator intervention increases the costeffectiveness of the overall process and is an incentive to also increase the potential of the previously much unused forest wood residue.

8

NEW

Trailer

SPLITTING made easy The fact that Komptech is closely engaged in the field of separation and that it has a broad bandwidth of technologies is certainly nothing new to our customers. What is new however is the SPLITTER, a compact spiral shaft separator whose features open up a wide range of applications for material difficult to screen and high in contraries.

Normally positioned after a shredder, the SPLITTER separates out coarse fractions and overlengths from pre-shredded fractions. The separating cut is selectable in the range 60 to 300 mm. The range of applications includes waste wood, biomass, commercial waste, residential waste, bulky waste and source-separated materials such as old tyres, scrap steel and other materials difficult to screen – they can be handled easily by the powerful and blockage-free technology of the SPLITTER. Depending on the variant, the efficiency of the overall process can be increased with automatic return of the coarse fractions into a shredder interfaced downstream.

The mobile versions of the splitter are available as a 2-axle central axle trailer or as a hook lift module. On the stationary side, the screen deck as a basis variant or the system variant with frame and conveyor belts allows simple and space-saving integration into the plant technology. A further important side effect is the generation of an uniform material flow into the following treatment.

Fine particle – fall through the screen deck to the bottom

Cubic parts are laterally separated

Long particle – are moved off in the conveying direction

Patent number EP 1 570 919 A1

Highlights • Greatest screening performance over the smallest area • Screening process is completely free of blockages and wrap-arounds • Up to 3 fractions in one operation • Sturdy, simple and wear-resistant technology • Usable with a broad range of machines interfaced upstream and downstream • Low power requirement • Very low noise mode of operation • Mobile and stationary concept solutions

Waste wood

Commercial waste

Steel scrap Hook

Household waste

9

NEW

10

CHIPPO 7010 C / CHIPPO 5010 C

CHIPPO 5010 C direct

The CHIPPO 7010, with its own engine, is a high-performance machine that wants to be fed. Unbeatably low operating costs can be achieved if there is enough to do. It can be used either lorrymounted, with a chain drive or as a trailer.

It is virtually impossible to go wrong with a CHIPPO 5010 C long operating range, powerful in continuous operation on chipping sites yet compact and manoeuvrable to perform tasks in open countryside.

CHIPPO 7010 C

CHIPPO 5010 C

CHIPPO 5010 C direct

Drive diesel engine:

Caterpillar速 18 522 kW / 710 HP

Caterpillar速 113 328 kW / 446 HP

Mobility:

Truck (lorry 8x4) Trailer Track (track assembly)

Drive:

via lorry diesel engine (MAN) with special power divider 353 kW / 480 HP

Mobility:

Truck (lorry 6x4 )

Throughput:

to 220 m3/h

Throughput:

to 300 m /h

Important options:

Loading crane Two drum speeds Conveyor belt discharge

Important options:

Lorry with mowing cab and loading crane Lorry with cabin crane Two drum speeds Conveyor belt discharge

3

to 220 m /h 3

The main thing is that it is a CHIPPO The right machine every time

Although our entry into the mobile chipping machine market was relatively recent, the name CHIPPO has spread within the “chipper scene“.

The CHIPPO was developed uncompromisingly with highest wood chipping quality in mind. Service providers using competitive machines must now measure themselves by this benchmark. The CHIPPO also impressively underlines that highest product quality does not contradict optimal cost-effectiveness. Numerous features, from active feed and efficient cutting geometry to conveyor belt discharge, increase throughput and also keep low servicing and energy costs as well as costs attributable to wear and tear.

The CHIPPO family Following the successful establishment of the tractor-driven CHIPPO 510C drum chipper on the market, there is now also an ideal machine for the mid to top range. The compact, general-purpose talent goes by the name of CHIPPO 5010 C direct – this is because the drum drive comes directly from the main drive of the MAN lorry via a special transmission system.

Mounting on a 3-axle lorry gives an operating range with which no tractor-driven chipper can compete.

The middle of next year will also see the arrival of variants with their own engines - the CHIPPO 7010 C, a mobile, highperformance chipper with a rating exceeding 700HP and a machine that generates the highest of throughputs, even when handling strong wood trunks, and after this the CHIPPO 5010 C for the mid range. There are options in mobility as the chipper unit with engine is available as a trailer, as a tracked chassis, as a lorry-mounted version or as a hook lift version.

Highlights • active feed system with two overhead feed rollers for defined transfer to the chipper drum • pre-compression by vertical feed rollers for shrubbery

CHIPPO 510 C As a tractor-driven chipper, the CHIPPO 510 C is the ideal machine for larger agricultural and forestry companies and for all those planning on entering the professional chipping business.

CHIPPO 510 C Drive:

via PTO tractor up to 370 kW / 500 HP

Mobility:

Trailer (2-axle-chassis)

Throughput:

to 180 m3/h

Important options:

Loading crane Two drum speeds Conveyor belt discharge Variable blower speed „Type A“ crane support

• 2 shredding modes - high cutting frequency for shrubbery, low cutting frequency with high torque for wood trunks

• Perfect wood chipping quality with large drum (Ø 1050 mm) and configurable blade advance (to 25 mm) • Always exact cutting gap with movable, easily advancable counter-blade carrier • Intelligent screen basket linkage for opening and closing of screen basket whilst chipping • Choice of discharge: - gentle on the material and power-saving via conveyor belt - flexible and accurate via variable speed blower • Highest degree of stability and reliability by virtue of sturdy design • Numerous options for the individual tailoring to the tasks at hand

11

NEW

CRIBUS 3800

The new generation of drum screens The CRIBUS 3800 signals the start of a new generation of mobile drum screens from Komptech. Numerous innovations create a machine with the highest level of functionality and costeffectiveness and at the same time set new benchmarks.

The CRIBUS 3800 is currently the largest mobile drum screen as a central axle trailer. The underlying drum dimensions open up a broad range of applications. The large drum diameter and a convenient distance to the side walls allow a smooth screening-off process – even for large screen hole sizes. A peak value for the effective screen length is synonymous with optimal screening results in regard to throughput and product quality. To remain within the dimensions of a central axle trailer, the fine particle discharge belt (in transportation position next to the hopper) is moved to the working position (next to the screen drum) using the patented movement mechanism.

The drive system represents the foundation for the extremely high degree of cost-effectiveness - everything on the CRIBUS is driven electrically, from the hopper to the discharge belts.

This minimizes the energy, wear and servicing costs of the whole machine, supported by the newly developed direct "WHEELGRIP" drum drive. The power for the electrical drives comes directly from the mains, is generated by an integrated diesel generator or is provided by a separate power generator.

The CRIBUS also offers compelling solutions in regard to servicing 12

and operational safety. Large flaps and doors, simple exchange concepts for screen drum and conveyor belts and well-thoughtout safety mechanisms are hallmarks of the machine design.

A sturdy exterior shell, premium quality components on the inside, convenient operation combined with a high level of operational safety and numerous options make the CRIBUS a valuable tool for tough daily usage and one which contributes to the bottom line.

CRIBUS 3800 - drum screen

Highlights • Largest mobile drum screen as a central axle trailer • 15% more screen area and 15% more effective screen length versus competition • 20% more feed cross-section versus competition • Processing of a broad spectrum of materials presents no problem with hole sizes up to 100 mm • Electrical drive of all components for highest energy efficiency • New drum drive concept without chain via patented “WHEELGRIP“ • Further reduction of operating costs with new conveyor technology in the machine and out of the machine • High degree of maintainability with optimal accessibility and no-maintenance solutions • Operator-friendly and operationally safe with modern machine design

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Our customers

When Finn Andersen switches on his computer early in the morning, he immediately knows what is going on he can see where microorganisms are busy at work, where intervention is necessary and where a product, i.e. premium-quality compost, is ready for “harvesting”.

With experience and the right machine technology, the site of the “Odense Environmental Centre“ here in Odense (DK) is producing the “Odense Bio Compost”, a valuable nutrient supplier for agricultural soils from suitable sludge and green waste.

Finn Andersen is responsible for the compost plant and tells Komptech how he is succeeding in managing a continually constant and smooth process in open windrow composting.

It starts with the composition of the right initial mixture. A computer program is used to make the right mixture from sludge, green waste and straw. Taken into consideration here are the water content, density and nutrient ratio – even the weather forecast for the first rotting phase is included in the calculation. In more damp periods, a coarse, shredded structure material is generally used for working and the mix ratio is changed to benefit the drier fractions.

With recipe in hand, the wheel loader driver now builds up the windrow. The ingredients are not heaped up layer by layer in a haphazard way, but accurately using a weighing scoop. Once the 14

windrow is complete, it is immediately mixed with the turner.

“Using straw has proven useful and this can make up about six percent by weight depending on the situation. This allows us to achieve quick starting of the biological activity and we often come up to a temperature of 70° Celsius within one day“, says Finn Andersen, alluding to another point - “Immediately after the turning process, each windrow is given a “hood“ made up of screen residual for the first two weeks – this performs the function of a bio-filter and hence minimises odour emissions“.

He attributes the fact there is no odour problem for the neighbours to several factors - “It is very important we take an active approach and adopt an open information policy in regards to what happens on the site. We also conduct all our activities in line with the weather conditions and keep an accurate time log for this. Our new TOPTURN X67 may appear to be somewhat big for our site, but it allows us to leverage perfectly the right time windows with its high performance reserves”.

The rotting process takes eight weeks, whereby the windrows are turned once a week and displaced further with side displacement. Radio sensors in the windrows provide information on temperature and allow corrective action to be taken in good time. Following the cooling phase is a post-maturing phase and then screening and laboratory analysis. All of the data collected in this

time period, from incoming inspection to final analysis log, is stored for every windrow and ensures consistent quality control.

Finn Andersen is convinced his decision to opt for the TOPTURN X67 with side displacement unit was the correct one “The high level of surface utilisation, ease of use and reliability both in regard to the machine and servicing were crucial for us. This is because the X67 replaces a TOPTURN 4000 which is still being used on a smaller site. So there has been a relationship in place for a long time which we have come to appreciate through the perfect support given by local Komptech sales and service partner Aksel Benzin AS“.

The willingness to pass on knowledge gained in the field of composting in the form of training and consultancy has been exemplary.

Odense Waste Management Company

The modern compost plant

15

Our customers

Treatment of refuse derived fuels Manfred Fritz is extremely satisfied in regards to the output quality of the new RASOR. “We are convinced that the other technical features of the machine will contribute towards achieving the perfect process cycle. The uniform material feed with screw conveyors, the simple adjustment of the cutting gap and, not least, the compact design all contributed towards the decision. Given that the machine is standing right next to an established competitor, we of course have very good opportunity to compare“, says Manfred Fritz explaining the reasoning.

In the RDF system, the input material is fed into a metering hopper, freed of metal by a magnetic separator comprised of an overhead magnet, magnetic drum and a nonferrous metal separator and then post-shredded to 25-30 mm.

With a calorific value over 25,000 kJ/kg and a chlorine content <1%, all of this fuel is taken by the cement industry as a substitute for fossil fuel.

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MÜLLEX-Umwelt -Säuberung GmbH

A partner for a clean environment About 30 years ago, Müllex, as a municipal waste disposal company, began to take an active role in a cleaner environment and has remained true to this policy to this day. In 2009, the company is well positioned as a system partner for a number of local authority and business enterprises and is a company engaged heavily in recycling and the production of refuse derived fuel besides pure collection.

Numerous services ranging from container services to mobile shredder systems complete the business activities.

In Sankt Margarethen an der Raab in Styria, Austria, the company employs about a hundred people and operates a mechanical processing plant for residual and commercial waste, a sorting plant for packaging and a plant for the generation of refuse derived fuels (RDF).

When we visited, we not only met the new RASOR, brought into service shortly beforehand as part of the expansion of RDF processing, we also met “two older gents“ - a TERMINATOR with 14,000 operational hours (made in 2003) and a CRAMBO (made in 2004) with a respectable 11,000 hours on the clock.

“Both machines are still working to our full satisfaction“, says Managing Director Manfred Fritz assuredly in discussion with Komptech, and this is what we expect from quality machines otherwise we can not earn any money. As a medium-sized business standing alongside the large disposal companies, it is only possible to survive today by building up stabile customer relationships and with machine and system technology which can be universally deployed as flexibly as possible“.

An important reason for procuring Komptech machines was their general-purpose application. The TERMINATOR hook (hook lift) functions as a pre-shredder for the RDF line by loosening and coarsely shredding the pre-sorted waste high in calorific value (delivered in bales).

For the rest of the time, the machine is used as a pre-crusher for the mechanical processing line, mainly for bulky and commercial waste, and is allowed to tackle mattresses, rolls of carpet and all sorts of other material.

“This method has a proven track record here and we have been able to markedly reduce blockages in the stationary system chain. At the start of the chain is another TERMINATOR, this time electronic and stationary, producing the perfect particle size for the subsequence separation process using the new F shredding unit and a narrow cutting gap“, says Manfred Fritz demonstrating his expert knowledge.

The CRAMBO is shredding waste wood a short distance away.

“We separate into treated and untreated waste wood. The former is delivered pre-crushed to the pallet industry and the latter, mainly shredded pallet wood, is supplied to heating plants. Some customers require a fine particle size and so we often work with screen baskets in the 80-150 mm range“, says Manfred Fritz explaining the process.

“With the rip tooth, a tooth with a relatively wide cutting surface area, we have here very good cutting results in regard to throughput and service life of consumable parts“.

Machine availability and operational cost-effectiveness are of great importance to him in particular. “We can not afford any mistakes here.

We analyse very accurately what our machines cost and what they accomplish for it. It is for this reason we opted for Komptech, even if we still want more in our role as an operator“, says Manfred Fritz at the end, his parting comment to send us on our way.

For these requirements to become reality soon, Müllex is one of our partners with whom we develop and trial new innovations in the consumable parts sector.

17

Our customers

Two processes determine whether biowaste becomes a valuable soil conditioner - the mechanical processing and post-processing by shredding, screening and sifting, and the biological process of the rot for conversion of the source materials into compost. When two companies whose core competencies lie in precisely these fields join forces, there can only be one clear winner - the customer, receiving the ideal process from one source.

The optimal solution Wrexham compost plant

This was the situation in Wrexham in the North East of Wales (UK) where recently a compost plant for separated, collected biowaste started up operations. Waste Recycling Group, one of the leading disposal companies on the island, is constructor and operator of the plant.

Waste Treatment Technology B.V. (NL), contractor and specialist in enclosed aerobic and anaerobic plants, together with Komptech as a supplier of innovative machine technology in the field of shredding and separation technology, were able to secure this interesting contract and constructed a composting plant tailored specifically to the requirements of the customer.

Smart solutions Course pre-separation takes place first in the delivery area â&#x20AC;&#x201C; material from the bio-waste container goes directly to the stationary MUSTANG E drum screen machine which is unable to deny its similarity to the mobile machines. No sooner is it set up and connected that the compact unit is ready to use. In the stationary, general-purpose CRAMBO shredder interfaced upstream, material is only shredded when necessary â&#x20AC;&#x201C; for oversized particles from the screening process and coarse material from the delivered material.

Undersized particles from the screening process and shredded material from the CRAMBO are then fed together into the enclosed rotting tunnel for the first rotting phase. A wheel loader assumes the filling and emptying tasks. After a week of controlled rotting, the material is discharged, watered in a hopper, mixed and the rot is continued for a further week. The efficient process controller concludes the main rotting process within this period - the compost is hygienised and has perfect screening properties. Screening itself is performed by a PRIMUS drum screen machine and the oversized particles are separated off are also cleaned of contraries by a HURRIKAN wind sifter. Both machines are essentially mobile but can also be operated in enclosed buildings with the electrical drive (electro-hydraulic drive for PRIMUS). The compost undergoes further storage prior to being used as a soil conditioner for the planting of vegetation. Simple yet efficient solutions with tried and tested technology keep investment costs low and, later down the line, operating costs and show that smaller composting plants (in this case for 24,000 tons of annual input) can certainly keep pace with large-scale plants in regard to cost-effectiveness.

18

Our partner´s Komptech group secures option for plant manufacturer WTT

Waste Treatment Technologies B.V. The company WTT – Waste Treatment Technologies B.V. – was founded in 1996 and develops and builds environmental friendly waste treatment facilities all over the world. The facilities differ from sorting stations for domestic, industrial or other waste, to complete installations for recovering reusable materials in combination with use of biological processes.

WTT established itself as a well-known international supplier of turn-key solutions for waste treatment technology. Due to an extensive and experienced team of project engineers, specialised in developing and constructing waste treatment projects in all sizes, WTT is able to permanently improve its products and reliability.

WTT is an ideal partner for planning, building, constructing and maintaining high-tech turn-key solutions for waste treatment, customized to client wishes, requirements and expectations regarding cost-efficiency.

WTT is specialised in solutions for: • Wet AD (Anaerobic Digestion) • Dry AD • MBT • Aerobic Composting • Bio Dry

Berthil Lubbers Managing director

Having started in 2003 with the construction of the mechanicalbiological waste treatment plant in Frohnleiten, the cooperation between the Austrian machine manufacturer and the Dutch plant manufacturer is set to intensify with an option for a majority shareholding (51 percent).

The core competencies of WTT, enclosed fully controlled systems for composting/ AD/ MBT/Biodry/ Hybrid plants, are ensuring that the Komptech group is able to expand its expertise in stationary technology for the biological treatment of waste.

In return, the comprehensive Komptech sales network gives plant constructor WTT the opportunity to win further projects across the whole of Europe. Dutch plant manufacturer Waste Treatment Technologies B.V. (“WTT“) is set to post a turnover of about €14 m for the current financial year.

Future market are primary within Europe and secondary worldwide in countries with potential development in waste treatment necessarity as great Britain and eastern Europe, such as countries in their next step in waste treatment like hybrid composting AD plants in Germany and Italy.

19

A tall order

Waterbeach MBT plant There is more good news from our stationary and system technology division.

Commissioning of the mechanical-biological waste treatment plant in Waterbeach in Cambridgeshire (UK) is currently underway, making it one of the largest plants in this sector with a processing capacity of 170,000 tons of household waste.

The modern design, more reminiscent of an airport than a waste treatment plant, continues on inside where everything is leading edge technology.

The customer and operator is Donarbon Waste Management as part of a private finance initiative. General contractor BAM Nuttall opted for German-Austrian machine and system technology. Main contractor KELAG Umwelttechnik GmbH is responsible for the construction of the compost plant whilst Komptech, in its role as a supplier, is responsible for all of the processing technology.

The purpose of the plant is the separation of recyclable fractions - iron, nonferrous metal and plastics and the composting of the organic fraction.

The core components in this multi-stage

Komptech GmbH K端hau 37 A-8130 Frohnleiten [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] info@komptech.com 20

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

treatment process are two TERMINATORs with direct drive which, as pre-shredders, receive the waste delivered, and two CRAMBOs for post-shredding of the organic fraction before composting.

Komptech screening and separation technology Working between the pre-shredding and post-shredding stages is leading edge screening and separation technology from Komptech. Stationary 2290 drum screens carry out coarse pre-separation and a MULTISTAR star screen carries out the fine screening - BRINI separators separate according to ballistic properties.

Resistant material separators, NIR (Near Infrared) sorting systems, magnets and nonferrous separators extract the required recyclable fractions from the material flow. Everything is connected up with 68 conveyor belts and, to give you an idea of size, with 700 metres of structural steelwork.

In the rotting hall, itself 200 metres long and 75 metres wide, two powerful, fullyautomatic paddle wheel turners and a ventilation system in the floor provide ideal rotting conditions.

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