Creating The Future. Machines Plants Process Solutions

Transcription

1 Creating The Future Machines Plants Process Solutions

2 Machine technology UNI-CUT UC rotary shears Endlessly versatile in pre-granulation >>> Page 6 The diversity of the MeWa range of machines is aligned to the requirements for the size reduction of different types of waste. As a single machine or integrated in complete plant solutions, recycling machines from MeWa have already proven their worth more than 1000 times. UNI-CUT SP tyre wire cleaner Clean steel wire from tyre recycling >>> Page 17 High-performance UNI-CUT UG granulators For individual grain sizes from 8 to 100 mm >>> Page 6 Hammer mills UNI-CUT UHM Effective purification >>> Page 17 UNI-CUT CC CableCutter The specialist for all cable waste >>> Page 8 UNI-CUT USM cutting mills The perfect cut for small grain sizes >>> Page 8 UNI-CUT AC AlphaCutter Single-shaft pre-shredder for difficult materials >>> Page 10 UNI-CUT SB 2 Smash Boom Bang Gentle and effective >>> Page 12 The patented UNI-CUT QZ Querstromzerspaner Perfect in separation. Perfect in the result. >>> Page

3 Plant engineering Recycling plants for used tyres From old tyres to ActiMeWa >>> Page 6 Over 300 large-scale plants worldwide speak for themselves: with size reduction machinery from in-house development as well as the specific separation, sorting and conveying technology, MeWa delivers turnkey recycling solutions at one stop. Modular construction means that the systems can be put together quickly and efficiently to meet individual requirements. Increased gas output by up to 30 % Life s a gas with the QZ >>> Page 18 Cable recycling plants High-quality fractions in primary raw material quality >>> Page 8 Processing of domestic and industrial waste Solid recovered fuels with high energy content >>> Page 10 Refrigeration recycling plants Highest recycled resource rates complete CFC separation >>> Page 14 Processing plants for electrical and electronic scrap Single-stage and fully automatic >>> Page 14 Metal-cleaning plants Effective separation >>> Page

4 Tyre recycling Rotor shears and granulator From old tyres to fine rubber powder Three-stage process delivers high-quality secondary raw material millimetres with a final purity of percentage by weight. Active fine milling MeWa integrated the newly developed fine milling process as a third process stage for the first time in both plants in Hungary and Kazakhstan. Powdery ActiMeWa of the highest purity is the result at the end of the process. It can be added directly to the new rubber to manufacture rubber products. ActiMeWa Deployment in road construction ActiMeWa is also used in road construction as an additive to bitumen. The rubber granulate not only balances out temperature differences to a considerably better degree, thus preventing the formation of cracks, but the mixture also dampens the noise level of the road surface and provides significantly greater adhesion for vehicles in the rain. Active fine milling. A double plus With the active fine milling process for used tyres, MeWa produces a substitute raw material of a single material type. The fine granulate (ActiMeWa) can be mixed with other materials without difficulty to manufacture rubber products. In road construction, there is a great demand for ActiMeWa as an additive to bitumen. Recycle before incineration this guiding principle also applies to used tyres from passenger cars and trucks. In Hungary and Kazakhstan, MeWa recently built two highly modern processing plants for old tyres, producing ActiMeWa for direct deployment in road construction. In the three-stage processing principle (pre-granulation, granulation, fine milling), rotary shears first of all fragment the complete used tyres into shreds the size of the palm of your hand. With their reliability, the versatile granulators and rotary shears have advanced to become the truly successful team of machines in the MeWa machine pool. Together, the two machines fragment above all tyres, cables, oil filters and mixed wastes into homogeneous fractions in all desired grain sizes. Perfectly geared to one another The duo is deployed at several hundred locations in pre-granulation and finish-crushing. Here, operation times of more than 70,000 hours of operation are no rarity. As far as throughput is concerned, the team of machines is perfectly co-ordinated. The precisely machined cutters of the UC are seated on a polygon-shaped rotor. This enables the machine to achieve optimised power transmission. Even with metallic parts, the UC shows its irresistible bite. The rugged machines have been conceived for metal processing, which means they display exceptional stamina even in highly demanding applications. Granulation line. Subsequently, a granulation line processes the pieces of tyre step by step into a rubber granulate of a single material type. In a complex process, various separation processes separate the steel and textile fibres from the pieces of rubber. The size of the granules is between 0 and 4 Universal rotary shear UC 150. UG cutting mechanism. 6 7

5 Cable processing CableCutter CableCutter and USM The modern copper mine Turnkey cable processing plants from MeWa have been delivering the highest output qualities for years. A processing plant in Budapest has now integrated the newly developed UNI-CUT CC CableCutter into its plant. Initial conclusion: grade 1 in economic efficiency. Electrical scrap, telecommunications, old cars, mining, high-voltage cables - today, approximately 150,000 metric tonnes of cable waste is produced per year in Germany alone. Underground, millions more kilometres have been laid, and these have to be replaced at some time or other. With the copper, aluminium, lead and steel metals they contain, the lines are extremely rich in recyclable resources. In Hungary s capital Budapest, a company has specialised in recycling cables. Not far from the banks of the Danube, the facility has installed a processing line with pre-granulation, granulation and fine granulation. CableCutter CC Specialist for cable fragmentisation The company has now invested in an additional special machine that can further increase the efficiency of processing. The cutting geometry of the new CC 1200 CableCutter from MeWa has been specially geared to taking cables apart. With a throughput of up to three metric tonnes per hour, this technical innovation is highly effective. The easy-to-change granulating screen achieves grain sizes of 10 to 50 millimetres in diameter. Special sizes are available as required. The input shaft is 2.30 metres wide, i.e. configured for loading by means of power shovels. Copper sorted by material type The initial processing with the new unit is so precise that even one subsequent granulation stage is sufficient to be able to feed the material directly to the final cutting mills. The result: copper in primary raw material quality. Partner for precision work If aluminium, copper cables, plastics or tyres are to be granulated, the UNI- CUT USM cutting mill handles the precision work. The rugged MeWa cutting mill is in demand everywhere small grain sizes are required. In cable processing, the cutting mills cut the enclosed metal from its cladding. Co-ordinated cutting and separation units then extract metal fractions of a single material type, for example copper. Plastics and rubber from the insulation material are left behind. In the modern tyre processing plants, the machine is often set up in a row of four located upstream of the cutting and separating units. In a number of runs, the rubber granulate is cleaned and finally fragmentised by the 5.5 metric tonne machine to a size of less than 4 millimetres in diameter. Cutting mill USM

6 Solid recovered fuels AlphaCutter Turnkey MeWa plant in Ghent with vibrating screen, wind screening, metal separator and granulation line. Pre-granulation takes place outside of the shop. Manufacture of Solid Recovered Fuels Flywheel mass drive For more than 20 years now, MeWa granulators have been driven by flywheels weighing 3 to 5 metric tonnes. The flywheel serves simultaneously as a belt pulley for a simple V-belt drive that works with the lowest possible losses due to friction. The energy of the disk flywheel covers the peak torques required in the short term. This means that the electrical drive motor runs smoothly, significantly below the rated voltage range. Expensive peak loads do not occur in the first place. Maintenance-free coupling system A sophisticated coupling and control system monitors the speed, torque and current consumption of the machine. This prevents high start-up peaks of the electrical drive motor and in the event of sudden blocking the flywheel is uncoupled so that the machine is not damaged. The new AlphaCutter series from MeWa is equipped with four disk flywheels. Two of these on each side gear down the speed of the drive motors from 1500 revolutions to approx. 70 revolutions. MeWa has developed the high-performance AlphaCutter for large throughput volumes and materials that are difficult to process such as mattresses, truck tarpaulins, large compressed bales or rolls of foil. The unit is handling the pre-granulation in plants for the manufacture of solid recovered fuels. MeWa CEO Ulrich Hink in front of two of the four disk flywheels of the AlphaCutter XXL The first encounter leaves a lasting impression: the AlphaCutter is hungry. The new bulky waste shredder devours enormous quantities of household, commercial and industrial waste. The homogeneous fragmentation means that the throughput can also be increased in the downstream granulation line by more than 30%. Particularly in the Der Schwungmassenantrieb im AlphaCutter XXL case of materials that are difficult to process such as mattresses, truck tarpaulins or large compressed bales, the progress made compared to other machine solutions is enormous. AlphaCutter XXL for high throughput The AlphaCutter XXL 3700 is particularly suitable for facilities that have to handle very large volumes of waste. Up to 60 metric tonnes of mixed wastes per hour can be processed with the high-performance unit. Depending on requirements, version L with a rotor length of 2200 millimetres and version XL with a rotor length of 3200 millimetres supplement the range of available products. Turnkey plants MeWa builds and delivers turnkey plants for the processing of household and industrial waste, providing services from the first draft design to commissioning at one stop. Depending on the requirements of the customer, MeWa creates pure sorting plants with manual sorting or mechanical separation all the way to complex plant concepts with sophisticated cutting/separating techniques for the manufacture of solid recovered fuels. Near Ghent, for example, the British Shanks Group operates a complete MeWa plant for the processing of mixed construction waste. Three granulators Following pre-granulation, vibrating screens, wind screening, metal separators, near-infrared technique as well as three large granulators ensure output sorted by material type and a throughput of 35 metric tonnes per hour The main purchaser of the high-calorific substitute fuels is the cement industry in Belgium

7 Querstromzerspaner Smash Boom Bang Where the hurricane rages inside The Querstromzerspaner and Smash Boom Bang revolutionise recycling technology Electrical and electronic scrap, refrigeration devices, aluminium composites, plastic-metal composites of all types, but also biological waste - the Querstromzerspaner is deployed everywhere different material mixtures have to be broken down. The patented QZ was developed to separate a wide variety of composite materials. In the meantime, the technology that works according to a completely new concept has developed into the most successful machine in the MeWa range of products. In contrast to cutting tools, the Querstromzerspaner separates the material with its acceleration instruments. Here, the chains generate a kind of cyclone in the processing chamber. The QZ exploits the physical forces of the impact energy, thus guaranteeing particularly fast and gentle material separation. Even after a few seconds, secondary metals of high purity that are fit for the market exit from the drum of the machine. millimetres, the suitable machine for every requirement is on hand. Smash Boom Bang the solution for small electrical appliances In the field of pre-granulation of electrical and electronic scrap, MeWa has conceived a supplementary solution: the Smash Boom Bang. This technical innovation is particularly suitable for small electrical appliances. After processing, the housing, processor boards, motors, cables, transformers lie exposed; parts containing pollutants, for example capacitors and batteries, remain intact. The individual components can be easily taken from the conveyor belt by hand in the next operation. The dismantling machine saves the time-consuming and costly manual pre-dismantling of the electrical appliances while still enabling the plants to carry out combined processing of the wastes in one mechanical and manual system. Low wear costs Compared to cutting processes or swing-hammer pulverisers, the resulting wear costs are significantly lower. In the meantime, the patented Querstromzerspaner is deployed worldwide in a wide variety of plant variants. The patented UNI-CUT QZ Querstromzerspaner has replaced the traditional fragmentation technology with chain tools and thus thoroughly revolutionised the process with a level of success that literally makes a bang. The new Smash Boom Bang is the junior partner in electrical scrap recycling. Refrigeration devices and electrical scrap in particular can be gently and economically fragmented with MeWa technology. With different drum sizes from 900 to 2500 Smash Boom Bang

8 Fridge recycling Fridge recycling Single-stage, fully automatic and environmentally friendly WEEE processing plants for electrical scrap and refrigerators convince with their economic efficiency and the highest environmental standards In line with the WEEE Directive of the European Union, many nations have established an effective recycling system for electrical and refrigeration devices. Very often, the Querstromzerspaner (QZ) from MeWa plays the main role in this process. The machine takes the appliances apart in a single-stage process in a particularly efficient and gentle manner. Electrical appliances and refrigeration devices constitute the flow of waste with the highest growth in Europe. Alongside numerous recyclable resources, however, the devices and appliances also contain harmful substances. Across Europe, more than 200 million CFC refrigeration devices are still operated. These generations of devices are now coming in for recycling. The environmentally harmful chlorofluorocarbons are in the refrigerant and in the appliance insulation. In Austria, a country that requires particularly high environmental stan- dards in this area, MeWa commissioned a highly modern refrigeration device recycling plant recently. The new operators and attending guests from the field of politics agreed at the opening: With MeWa technology, we are setting new standards in the disposal of refrigeration devices in Europe. The plant achives 900,000 metric tonnes of CO 2 reduction Up to 300,000 refrigeration devices per year will be processed here in future, recovering around 90 metric tonnes of CFCs. The functioning principle of the plant corresponds to an annual reduction in the environmental burden of 900,000 metric tonnes of CO 2. For this Environmental Award for the MeWa fridge recycling plant: Daphne in gold. Fully automatic WEEE-plant in Daventry. Refrigeration device processing plants from MeWa convince with high rates of recycled resource recovery and complete CFC separation. achievement, the plant in Kematen received the Austrian environmental award Daphne in gold in March With the Querstromzerspaner technology, CFC and pentane appliances can be processed simultaneously without their having to be sorted beforehand. Not only the recovery rate of the CFC is exceptionally high, but also the economical operation of the plant and the high recycled resource rate with ferric, aluminium / copper and plastic fractions sorted by material type at the end of the process have led to the plant type being deployed in almost all European countries. MeWa plants for processing household appliances, home electronics or computers are even more widespread. With the first plants in Canada and California, the step across the Atlantic has been made. The patented Querstromzerspaner also handles the dismantling work for electrical scrap processing. The parts containing pollutants, for example capacitors or batteries, remain intact in the chain fragmentation process and can then be sorted without difficulty using separating techniques or by hand. At the end of the process, more than 90% of the input volume is available, cleanly separated and sorted according to different material fractions. Ferric fraction, separated into a single material type. Fully automatic operation In Daventry, England, a highly modern MeWa plant configured for fully automatic sorting was recently commissioned. After processing in the Querstromzerspaner, metal detectors, ferric and non-ferric separators, plastic sorting devices, circuit board separators, proximity infrared devices as well as air separators separate the material into different material flows. Only four to six employees per shift are responsible for ongoing operation. The combination of refrigeration device and electrical scrap processing can also be implemented using QZ technology. In St. Helens, England, MeWa put Europe s biggest processing plant into operation for mixed treatement with devices classified according to the European WEEE Directive

9 Metal composites Resistance is pointless QZ separates metal composites ready for the steel mill When breaking down metal-plastic mixtures, the Querstromzerspaner delivers particularly good results. One of the tasks is to clean metals that have already run through magnetic separators in sorting systems for domestic and industrial waste. Companies that specialise in processing special scrap have moved into industrial centres with very good transport links. At first glance, the volume of waste collected there in the yard and in the shop High quality fractions in primary raw material qualities. looks like normal domestic and industrial waste. Processing for use in steel works However, the composition differs fundamentally. The waste consists of more than 60 % metal. The plants have specialised in processing the so-called metal separation fraction from sorting or metal processing plants so that it can be used in steel works. The delivered metal fractions, for example tinplate cans, still adhere to a great extent to external materials. The MeWa Querstromzerspaner has proven to be the ideal technology to separate these stubborn composites. The positive results have led a number of companies to invest in this direction in the past few months. Existing plants Input motor blocks: the QZ separates brass-aluminium composites. have also extended their processing to include other lines with the patented Querstromzerspaner. Low wear costs Together with the separating techniques that are geared to it, the chain principle of the MeWa QZ ensures high throughputs, output fractions sorted by material type and low wear costs. Particularly in the last point, the advantages compared to cutting shredder systems are huge. Metal composites of all types As a general principle, the QZ process is suitable for the separation of a wide variety of metal composites. Applications involving components made of aluminium are just as frequent as the processing of swarf and metal chips. After all, the result is plastic, non-ferric and ferric fractions ready for collection by the steel works and resmelting shops that are connected by the relevant transport systems. Tyre wire cleaner separates steel and rubber Tyres contain a substantial amount of steel wire. For this content, MeWa has developed the UNI-CUT SP tyre wire cleaner. This special machine removes textile and rubber residues from the steel wires, fully recovering the metal in the highest quality. In order to protect the machines in the downstream tyre recycling process steps against excessive the wire is removed from the process directly after the first granulation step by magnetic separators. This fraction, however, is in a very unclean state at this point. Along with the wires, around 10 to 35 percentage by weight of rubber and textiles is also withdrawn. This proportion is too high for use in a steel smelter. MeWa has now specifically devoted its attention to this fraction. Equipped without sensitive blades, the tools mounted on the rotor shaft rub Tough refinement The double swing-hammer mill uses a kinetic impact effect to pulverise the material to be ground. Two rotors, to which steel hammers are attached, rotate in a metal housing. The impact of the hammers pulverises the conveyed materials. The hammers sling the units against the grinding wall, where the impact breaks them up further. The ground material remains in the pulverisation zone until it is small enough to pass through a defined screen. This screen determines the output size of the material. A characteristic of the hammer mill is also the spherical output. the rubber and steel mixture on the stator shaft of the machine against one another, thus exposing the individual fractions. Specially configured vibration channels and magnets separate the exposed wire, textile and rubber fractions. The entire separation plant is encapsulated. This enables exposed textiles to be blown out via air separation devices and captured in a filter. The turnkey MeWa line is also equipped with its own control system. At the end, the wire emerges with a purity of greater than 98% ready to use in a steel smelter. The UNI-CUT UHM Hammer mill has proven effective in the preparation of material mixtures of plastic, aluminium and copper. The advantage: fractions sorted by material type can be extracted in defined grain sizes. This is frequently a requirement for the manufacture of new products from recycling material. Output: Copper and aluminium. Tyre wire cleaner and Hammer mill 16 17

10 Bio QZ Bio QZ Extract the maximum Biogas plants: Querstromzerspaner from MeWa prepare substrates ideally for the bacteria up the input materials, the Bio-QZ works with the principle of a pestle and mortar. This creates a significantly larger contact surface for the bacteria, enabling a significant rise in the energetic yield of the substrates. Rotating chains on the floor of the machine chop up the fuel crops in seconds. This gives the substrate a homogeneous composition, making it much more palatable for the bacteria, so to speak, says a biogas plant operator in describing the result. Corn silage. Red beets. The principle provides sustained effects above all in the case of agricultural plants that feed fuel crops from the field into the fermenter. Where the Bio-QZ has been retrofitted, a significantly more stable operating state of the entire biogas plant has been achieved. The homogeneously prepared substrate can not only be pumped more easily, the energy-intensive stirring periods in the fermenter can also be more than halved. Floating layers disappear very quickly. A farmer in Nördlingen, Bavaria, describes the situation in his plant: The material in the fermenter now moves of its own accord. It s visibly alive. Fruit and vegetables. Slaughterhouse waste. Increasing the gas yield, stabilising the operating state, reducing the holding time in the fermenter in short: many plant operators will soon be optimising existing biogas plants. With the Querstromzerspaner (QZ), MeWa offers a solution that starts right at the front of the process chain. Properly preparing substrates is the simple but effective formula for the patented machine. Whether fuel crops from the fields, expired foodstuffs, biological waste from bins, slaughterhouse waste or surplus seasonal crops there is a great deal of energy in the biomass. Converting this energy quickly and efficiently into usable biogas is the task of modern fermentation plants. This is how around 5,000 biogas plants in Germany produce environmentally friend- ly power and heat, and the trend is on the up and up. However, an important process step has often been neglected during planning. Exploitation of the substrates in fermentation can only be optimised with the right separation. This means that the strains of bacteria in the fermenter can only begin their decomposition process quickly and Querstromzerspaner QZ 900. effectively when the cell structure of the input materials has been broken up. With the patented Querstromzerspaner (QZ), MeWa offers the suitable solution for this application. Instead of cutting 30 % more gas yield Depending on the input material used originally, up to 30 % more gas yield is measured in plants with Bio-QZ operation. Evaluations have also indicated a higher methane content in the biogas. And an even more far-reaching difference can be determined compared to before: in the plant in Nördlingen, the yard now stockpiles not only corn silage but now also seasonal crops such as red beets, potatoes, oil radish, sugar beets or grass cuttings. It is now much more flexible to feed the plant, enabling me to exploit seasonal business, says the farmer. Insensitive and versatile In the meantime, the machine has proven its suitability for the preparation of substrates on a wide variety of plant categories. Alongside the renewable resources plants that operate with a high dry-substance content, the principle also delivers the same positive results in municipal fermentation plants with biological waste bins as well as for slaughterhouse waste and packaged foodstuffs, for example. The machine is also insensitive to metal parts or stones and completely unwraps packaging. In a downstream separator circuit, the packaging can be easily removed from the biomass. Packaged food. The QZ 1600 at work. Sugar beets

11 MeWa Recycling Maschinen und Anlagenbau GmbH has been playing a leading role in the recycling industry for more than 25 years. The core business is on developing and building recycling machines and engineering turn-key plant solutions. MeWa machinery is processing electricand electronic scrap, fridges, tyres, domestic and industrial waste, oil filters and organic waste for biogas plants. Being an international market leader, MeWa s innovative technology is patent-protected. At the headquarters in Gechingen/ Germany and in other international sites more than 150 employees are working for MeWa /E Company Mewa Recycling Maschinen und Anlagenbau GmbH Gültlinger Straße Gechingen/Germany Tel. +49 (0) Fax +49 (0) info@mewa-recycling.com