News The magazine for our customers
November 2007
Treatment of woody biomass - CRAMBO Forest - CHIPPO 500/7000 - MULTISTAR star screens
CRAMBO
Dual-shaft wood shredder
Treatment of forest wood residue It is widely recognised that wood is a CO2-neutral energy source and more wood regrows than is used. This makes it ideal for recovery – and targets for recovery in biomass combined heat and power systems have been raised accordingly. Fuel from woodland plays a significant role, but woodland does not automatically equate to fuel. New strategies and solutions are needed to be able to meet the increase in demand forecast for woody biomass. One of the development focuses at Komptech is the treatment of woody biomass for energy recovery – in particular the shredding and subsequent conversion into usable fuel.
Forest wood residue as the base material As well as timber, woodland residue is also suitable for fuel production. In order to slow down already spiralling prices and competition between energy recovery and material recycling, woodland residue should also be used for recovery. Woodland residue is the collective name for treetops and branches
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that accumulates when harvesting timber and for root stocks that accumulate during uprooting. Including root stock, woodland residue makes up about one third of the total mass of trees (irrespective of tree type) and is regarded as being on a par with wood chippings in regard to legislation and grants. But woodland residue has a high volume compared to its weight, so transportation of unshredded material should be kept to a minimum. Shredding must take place as close as possible to the clearing area. Because of the presence of contaminants, mainly stones, only slow-running shredders can be considered in the long-term. They also offer clear benefits in terms of product quality. The KOMPTECH solution is simply called CRAMBO Forest. Using a modular system, the CRAMBO with bio-cutter is mounted on a semi-trailer chassis, a three-axle chassis, on steel tracks or onto a four-axle lorry, with slewing ring if required. Loading is via a mounted crane with grab.
Technical details CRAMBO Forest Motor (diesel motor) Model: Number of cylinders: Power rating:
Caterpillar® C18 6 429 kW/584 PS
Loading heights Fill height: 4000 mm Discharge height: up to 5000 mm Fine particle discharge height: up to 2600 mm Transportation dimensions L x W x H:
9100 x 2470 x 4000 mm
(without tractor-trailer machine)
Weight
(without tractor-trailer machine)
~ 32 t
Shredding tools Number of screws: Length: Diameter: rpm: Cutter elements: Screen basket hole size (mm):
2 2820 mm 610 mm max. 40 min -1 134 80, 100, 125, 150, 180, (250, 300)
Option Separation of fine fraction:
Star screen deck 0/15...30 mm
Crane Load moment: Swivel range: Max. range: Unladen weight:
Epsilon E165Z95 153 kNm 425° 9,5 m 3165 kg
Throughput
(dependent on material)
up to 75 t/h
Deploying the CRAMBO Forest The CRAMBO Forest is mainly used in stockyard and processing areas located near forests and woods. Extend out the supports, fold out the conveyor belts and the machine is ready to use. The combination of the 9.5 metre crane range and swivelling chassis creates a high degree of flexibility when feeding and when discharging shredded material. Everything is under control from the crane – from the positioning of a root stock several tonnes in weight to all of the machine’s functions. Everything that fits into the large (2.8 x 2.0 m) shredding area - root wood, tree trunk or branches - is shredded. Two counter-rotating shafts with robust teeth seize the material and press it in a cutting/splitting action against the cutter bar and screen baskets located underneath. The slow turning action (rotation speeds up to 40rpm) shreds the wood into small chunks and the material does not exit the shredding area until the particle size matches the hole size of the screen basket used. This means the quantity of shredded material in the desired particle size is maximised. There is no additional generation of fine fractions and overlength fractions are reduced to a minimum. Additional benefits of this shredding technique are the high degree of tooth resistance to damage caused by contaminants and the low noise and dust emissions.
Fine fraction separator option When shredding root stocks, forest wood residue and green waste, soil, needles and leaves can reduce the quality of the shredded usable fraction for recycling and increase transportation costs at the same time. Using the fine fraction separator option, one operation is sufficient to minimise the fine fraction in the output. The separator is standard on the Forest version and optionally available on other Crambo models; it is only evident from outside by an additional, swivellable discharge system at the rear. A star screen deck, integrated into the discharge duct and with CLEANSTAR cleaning system and adjustable screen section, carries out the separation work. The results are impressive: up to 40% by weight of material less than 15 mm is separated off as fine fraction.
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CHIPPO 500 New
The all-rounder Aggressive intake due to 2 horizontal and 2 vertical feed drums
The line of shredding technology products is being extended. Komptech is introducing a new generation of mobile chippers under the CHIPPO product name. In a comprehensive product portfolio - from a tractor-driven chipper for green waste and timber to large heavy-duty, lorry-mounted chipper with or without its own drive - we have everything required in the sector of mobile wood chipping.
Universal-chipper CHIPPO 500
12 massive cutting tools with ingenious mounting on the rotor
Starting in the second half of 2008 the first model, the CHIPPO 500 will be introduced as the perfect generalpurpose machine for the professional contractor. The CHIPPO 500 is not just another tractor-driven chipper it has been specifically designed for the requirements of the market. The machine boasts ground-breaking features which are best demonstrated in practical use. The machine can be brought into the working position in just a few minutes from its transport configuration. The operator folds out the feed table and extends out the loading crane. He needs only to leave the cab to position the conveyor belt.
Choice of discharge
Easily accessible for servicing
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The CHIPPO 500 offers the choice between “material-friendly”, energysaving discharge via conveyor belt or conventional discharge via a blower featuring variable rotation speed. The press of a button switches from
one to the other – there is no more flexible or convenient solution for material removal. The feed system is also impressive – not only do whole trunks disappear at high speed into the massive 1m x 75 cm intake, bulky green waste is also pulled in aggressively. This is achieved by a clever combination of horizontal and vertical feed drums, providing precompression and active redirection into the shredding area. The perfect geometry of the two horizontal feed drums provides a precise transfer to the cutting rotor.. Lateral turning of the residual fraction, and hence chipping across the grain, is prevented. This means no production of overlengths and assures the highest product quality.
Two speeds The machine provides two principles for chipping: This rotation speed depends on the A. Low rotation speed with maximum power for heavy-duty use in wood trunks
Drum chipper
Technical details CHIPPO 500 Drive Drive via PTO:
Tractor up to 370 kW
500 HP Blower with variable rotation speed to adjust throwing range
Loading heights Fill height:
1,65 m
Discharge height conveyor belt: 5,2 m Exhaust pipe length:
1500 or 2500 mm
Machine dimensions Transport position Length:
7037 mm
Weidth:
2900 mm
Height:
3995 mm
Total weight:
19 t
Cutter / drum
B. High rotation speed combined with load-dependent control ensures the correct feed speed to the rotor and therefore a maximum throughput for scrap wood and green waste.
Length:
1000 mm
Diameter:
1050 mm
Drum rpm:
400 and 560 min -1
Feeder width:
1000 mm (1675 mm)
(with vertical feeder rollers)
Feeder height:
750 mm Different rotation speed of the rotor ensures adjustment to the input
Throughput Trunk wood Ø hard:
Smart: The mounting of tools On the rotor itself are 12 solid cutting tools whose ingenious attachment system allows quick-change and easy and precise positioning. Should a solid contaminant enter the shredding area, the cutting tool is pushed back into the rotor on impact and stopped, preventing any further damage from rotating tool components. In addition, the hydraulically clamped counter-blade can move downwards to dislodge the obstruction.
up to 56 cm
Trunk wood Ø soft:
up to 75 cm
Throughput:
up to 180 m3/h
(dependent on material)
High throughput, best quality A razor-sharp cut is the prerequisite for product quality and efficient energy usage. This is why the CHIPPO 500 is equipped with fully-automatic sharpening equipment for sharp tool elements at all times. The machine is ready-for use again immediately and downtime is kept to a minimum. The use of the perfect tool steel and the option of multiple re-sharpening guarantee minimum wear and tear costs. Particle size is governed by easy to exchange screen baskets. To exchange, completely extend the screen basket from the shredding area and remove/insert from above. The robust design and use of premium components make a drive rating of up to 500 HP possible. This guarantees previously unattainable throughput in its class – and that with highest product quality.
Automatic sharpening equipment guarantees sharp tools at all times
Extend the screen basket from the shredding area and remove from above
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CHIPPO 7000
Drum chipper
New
The high-performance chipper The CHIPPO 7000 is a further new mobile high-performance chipper to arrive on the scene. In contrast to the CHIPPO 500, the emphasis of the CHIPPO 7000 is designed for chipping large wood trunks. The feed system is dimensioned accordingly and comprises of front drum, conveyor belt as well as two infeed drums at the top and two at the bottom. During the feed operation, fine fractions left behind are directed past the rotor with the bypass system. The shredding system has an inlet width of 90cmx1.2m. The rotor is 1.2m in diameter. Larger trunks can be broken up beforehand
using an optional wood splitter. Easy to exchange screen bars facilitate the production of different particle sizes. With a power rating greater than 710 HP (522 kW), hourly throughputs of up to 250 m3 are guaranteed. A particular feature is the “materialfriendly”, energy-saving and dustfree discharge of chipped material via the conveyor belt. Rotatable and telescopable at the same time, this system allows material discharge all the way around the machine at a radius of up to 5m. Travel to the work site is via a four-axle lorry; loading uses an Epsilon mounted crane with a reach of 10m.
CHIPPO 7000 Drive (diesel engine) Model:
Caterpillar® C18
Zylinder:
6
Power:
522 kW / 710 HP
Loading heights Fill height:
1,8 m
Discharge height conveyor belt: 3,3 - 5,8 m Machine dimensions L x W x H Transport position: 9985 x 2550 x 3995 mm Crane range:
10 m
Elevated load at 10 m:
1,4 t
Total weight:
32 t
Cutter / drum Length:
1200 mm
Diameter:
1200 mm
Feeder width:
1200 mm
Feeder height:
900 mm
Throughput Trunk wood Ø hard:
up to 70 cm
Stammholz Ø weich:
up to 90 cm
Trunk wood Ø soft:
up to 250 m3/h
(dependent on material)
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MULTISTAR
Star screen technology
Screen technology with stars Komptech star screen technology is the best route to defined fuel. A fine fraction, a medium fraction and a coarse fraction are produced in one screen operation. The medium fraction generally represents the usable fuel fraction. The rotating stars knock any adhesions off the screen material as it passes through the screen segment. For woodland residue and root stocks in particular, this guarantees a high quality of usable fraction since soil, sand and stones are separated off as fine fraction. The coarse fraction is made up of
MULTISTAR M3
overlengths which are shredded again. Particle size is governed by the size of the star screens. Fine adjustment is carried out with the rotation speed of the stars. Besides biomass and waste wood, the star screen is also highly capable when screening bark, compost, biowaste and residual waste. This is because the screen decks are cleaned continually by the patented CLEANSTAR cleaning system, avoiding problems with adhesion of wet material and wraparound.
MULTISTAR L3
Virtually all customer requirements are addressed by our well-positioned product range. The spectrum of mobile technology ranges from the simple EASYSTAR screen deck which, in conjunction with shredders, represents an ideal solution for mobile treatment, to the compact MULTISTAR M3 and L3 (M2, L2: 2-fraction screens) mobile star screens, right up to the high performance XL and XXL screen machines. Stationary, precisiondesigned 2, 3 and 4-fraction screening units are also available – all combining innovation and attention to detail.
MULTISTAR 3-SE
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Product range Coarse shredding - CRAMBO Forest
Type Semi trailer
Type 3-axle-chassis
Type Track
Type 4-axle-lorry
Chipping - CHIPPO
CHIPPO 500
CHIPPO 6000/7000
Screening - MULTISTAR star screens
MULTISTAR M3
MULTISTAR L3
Komptech GmbH is headquartered in Frohnleiten (Austria) and is the European market leader in machinery and systems for the treatment of biomass and solid waste. The company now employs more than 450 people at 9 locations in 6 countries world-wide. One of the development focuses within the company is the treatment of woody biomass for energy recovery – in particular, the shredding and subsequent conversion into usable fuel. The product portfolio includes the CRAMBO family with forestry configuration for the coarse shredding of forest wood residue, root stocks and green waste, the CHIPPO family for the production of wood chippings from wood trunks and green waste as well as MULTISTAR star screen machines for the classing of fuel qualities.
CRAMBO Forest
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MULTISTAR XXL
www.komptech.com
KOMPTECH GmbH A-8130 Frohnleiten, Kühau 37 [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 [e] info@komptech.com INPRINT Publisher: KOMPTECH GmbH; Editorship: Andreas Kunter, Josef Heissenberger, Joachim Hirtenfellner; Photos, Layout & Graphic: Alexandra Gaugl;
CHIPPO 500
MULTISTAR L3