stationary_machines_eng_2012

stationary machinesshredding screening preparation separation

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Komptech is a leading international technologysupplier of machinery and systems for the mechanicaland mechanical-biological treatment of solid wasteand for the treatment of biomass as a renewableenergy source.The product range includes over 30 different types ofmachines, that cover all key process steps in modernwaste handling - shredding, separation, and biologicaltreatment.By combining the right products from our ownportfolio with proven components by other leadingmanufacturers, we can deliver solutions to addresscomplex challenges.The focus is always on innovative technology andsolutions that ensure the maximum customer benefit.

komptech gmbh

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Contents shredding

terminator ...................................................................................................4/5Single-shaft shredder for pre-shredding

crambo ...........................................................................................................6/7Dual-shaft shredder for wood and green waste

raSor ...............................................................................................................8/9Post-shredder

screening

multiStar ....................................................................................................10/11Star screen

Drum ScreenS ...........................................................................................12/13

flowerDiSc ..................................................................................................... 14Disc separator

preparation

maShmaSter ................................................................................................... 15universal mixer

separation

Screw PreSS .................................................................................................... 16

hurrikan ......................................................................................................... 17windsifter

balliStor ....................................................................................................18/19ballistic separator

terminator

Drum Screen

multiStar

hurrikan

balliStor

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terminatorThe Terminator is a slow speed, high torque single-shaft shredder for hard-to-shred waste. C&D, railroad ties, carpet, MSW and tires are no problem for the rugged teeth mounted on the shredding rotor and opposing counter comb. The stepless cutting gap allows adjustment of the size of the output material.

There is a choice of two drive systems – either a hydraulic system with optional disconnection from the shredding unit for constant power, or mechanical direct-drive for maximum efficiency.

Shredding of the most difficult materials

Rugged design as pre-shredder provides high degree of shredding

Variable particle size by adjusting cutting gap

Hydraulic drive with constant power control and optional separated design or direct-drive with optimum degree of efficiency

single-shaft shredder for pre-shredding

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specifications Details

materials

500 2200 3400 3400S 5000 5000S 6000S

Drive

Hydraulic rating (kW): - 1 x 132 1 x 160 1 x 160 1 x 200 1 x 200 2 x 160

Mechanical rating (kW):

1 x 37 1 x 132 1 x 160 2 x 75 - 2 x 110 2 x 160

Shredding unit

Length (mm): 3000

Drum diameter (mm): 1050

Drum rpm: hydraulic:

- max. 29 max. 29 max. 27 max. 29 max. 29 max. 38

Drum rpm: mechanical:

3 17/13 19/14 14/10 - 20/14 28/20

Weight

Hydraulic:(assembled unit)

~ 15.1 ~ 15.5 ~ 16.5 ~ 15.8 ~ 16.8 only separated

unit

Mechanical: ~ 11.8 ~ 13.6 ~ 14.0 ~ 15.0 - ~ 15.3 ~ 15.8

Throughput (dependent on material)

Hydraulic (t/h): - up to 30 up to 45 up to 50 up to 60 up to 80 up to 100

Mechanical (t/h): up to 6 up to 20 up to 30 up to 35 - up to 55 up to 75

HyDraulic Drive: Besides the standard stationary frame, separation of the drive unit from the shredding unit is provided as an option. The advantages: Better protection of drive unit (less dust, better cooling) and space-saving integration of the shredding unit into the process cycle.

SHreDDing: Applications of the drum/counter comb system range from coarse pre-crushing to defined shredding. The continuous cutting gap adjustment allows adjustment of the particle size for the intended use.

MecHanical Drive: The cost-effective mechanical drive offers low energy costs due to high efficiency. The installation into the plant chain is simple: Set up - connect - power on. Further features are two speeds for adaption to material and automatic reverse control.

Householdwaste

Waste woodBulky waste TiresCommercial waste

ShowcaSeMachine type: TM 5000 Sapplication: commercial wasteThroughput: 50 t/h

The highly variable content ofcommercial waste can requireextreme shredding power –which is exactly what you getfrom the Terminator S version,with its dual drum drive.The hydraulic drive providesthe highest shredding powerand prevents jamming andblockages. clearing byreversing is possible at alltimes.

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The Crambo dual-shaft shredder shreds all types of wood and green waste, as well as pre-treated synthetic fractions, to a set particle size. Slow-running screws with shredding tools minimize fine particle and noise/dust emissions, and build up resistance to contamination.

The particle size is adjustable by simply exchanging screen baskets. A hydraulic drive with load-dependent speed control ensures maximum utilization of motor output. Optional disconnection of the shredding unit from the drive simplifies integration into the system.

High throughputs with general-purpose use

Aggressive feed with 2820 mm long, counter-rotating shredding drums

Variable particle size with less overlengths and low fine fraction

Quick-change system for screen basket and tools – screen basket change in minutes

crambodual-shaft shredder for wood and green waste

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materials

3400 5000 6000

Drive

Power (kW): 1 x 160 1 x 200 2 x 160

Shredding unit

Number of screws: 2

Drum rpm: max. 31 max. 32 max. 40

Drum length (mm): 2820

Drum diameter (mm): 610

Cutting elements: 134

Weight (t)

assembled unit ~ 16.0 ~ 16.8 only separated unit

Throughput

Throughput performance (t/h): (dependent on material)

up to 45 up to 60 up to 100

Drive: With load-dependent speed regulation, the hydraulic drum drive ensures that full advantage is taken of the engine output. Besides the standard stationary frame, separation of the drive unit from the shredding unit is provided as an option

SHreDDing: Low-speed drums with shredding teeth minimize fine particle and noise/dust emissions and resist contraries. The particle size is configurable by simply exchanging screen baskets.

applicaTion: The shredding concept provides a wide range of possibilities. Established applications are the shredding of bio-waste for composting, the shredding of market waste and food/kitchen waste for a anaerobic digestion or the pre-shreddding of roof shingles.

Waste wood Forestry waste Green waste Root stocks

ShowcaSeMachine typ: crambo 5000application: waste woodThroughput: 50 t/h

when shredding waste wood, the wear-resistant teeth in combination with the hydraulic drive provide a high level of resistance to contraries.counter-rotating shafts, together with the special shape of the teeth, produce a perfect feed, even for fractions with high board content.

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rasorThe Rasor is a post-shredder for the generation of refuse derived fuels from pre-treated waste fractions. The continuous material feed with screws ensures uniform power consumption.

The material is shredded (practically dust-free) by slow-running cutters in the enclosed shredding unit. A simple cutting gap adjustment guarantees minimum energy expenditure during the shredding process. Best accessibility to the counter-cutter, the wearing parts and screen basket ensure short servicing times.

Continuous material feed with simple cutting gap adjustment for uniformly low power consumption

Shredding with low levels of dust and noise

Swivelling counter-cutter carrier provides optimal service accessibility

Replacement of wearing parts with minimal servicing times

post-shredder

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materials

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5400

Drive

Power (kW): 250

Material feed

Type: electric 3 x 7.5 kW

Number of screws: 3

cutter/rotor

Length (mm): 1320

Diameter (mm): 1000

Rpm: 149

Cutters: 3 x 18

Screen basket hole size (mm): 25, 30, 40, 60

Dimensions

L x W x H (mm): 4007 x 2689 x 2570

Weight (t): ~ 16


Throughput performance (t/h): up to 15

FeeDing: Three feed screws transport the material into the shredding area. Material is pressed continuously against the shredding rotor This guarantees consistent power consumption. Dust emissions are prevented due to the enclosed shredding area.

SHreDDing: The “Endless” shear cut between the rotor cutters and the counter cutter saves power and reduces vibration and noise. The rotor runs at a moderate 149 rpm, with high throughput. Particle size is defined by the screen baskets around the rotor.

MainTenance: The Rasor offers good access to all maintenance areas. The pivoting advance frame provides an ideal working position for all maintenance in the shredding area. An auxiliary crane is available for screen basket changing.

ShowcaSeMachine type: Rasor 5400application: comercial waste, shreddedThroughput: 5 t/h (Screen basket 30 mm)

Depending on the screen basket chosen, the fuel size can run from 60 mm diameter down to 30 mm premium blow-in RDF, or even smaller fuel for coal-fired power plants. continuous feed by the screws and the ideal cutter/counter-cutter arrangement gives a high efficiency.

Commercial waste

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multistarStar screen technology from Komptech is regarded as one of the most effective separation methods for organic waste. Precise separation selectivity irrespective of material moisture and adjustment of the particle size at the press of a button are particular features of the Multistar star screen.

Stationary Multistar star screen systems leave no customer requirement unaddressed. With its modular design, screen decks, feed metering container, wind sifter and stone/magnet separation are tailored perfectly to the job at hand, generating up to 4 fractions in one operation.

Separation into 3 fractions (4-SE: 4 fractions), wind sifting, Fe-separation in one compact machine

High throughput with precise selectivity – even with moist materials

Simple speed control at the screen deck to change particle size in seconds

Flexibly tailored solutions for specialist customer applications

star screen machines

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materials

MulTiSTar 2-Se MulTiSTar 3_Se

Drive

Power (kW): 12 40

Screen segments

Length x width (mm) / area (m²): Fine screen 5985 x 1000 / 6.0or

Coarse screen 5863 x 1000 / 5.9

Fine screen 5863 x 1200 / 7.0 and

Coarse screen 3998 x 1200 / 4.8

Feed hopper

Hopper volume (m³): - 20

Screen sections

Fine (mm): 8 ..... 2010 ..... 25

8 ..... 20Standard: 10 ..... 25

Coarse (mm): 30 ..... 6060 ..... 90

90 ..... 120

30 ..... 50Standard: 60 ..... 90

90 ..... 120


Throughput performance (m³/h): up to 150 up to 400

Drive: The core of the star screens consists of one or more screen decks, depending on the model. The electrical drive of the star shafts with electric motors and frequency converters gives quiet, efficient and economical operation.

parTicle Size: Particle size can be controlled by varying the rotation speed of the star shafts. In just seconds the particle size can be changed within the range provided by the star size. The different star dimensions and arrangements cover screening sections from 8-150 mm.

ShowcaSeMachine type: Multistar 3-Seapplication: compostThrouhput: 180 m3/h

Screening is always in season with an stationary star screen. high throughput and selectivity are retained, even with variations in moisture content and various rotting stages, because each star has a wear-resistant cleaning finger that clears the gap to the surrounding stars on each rotation.

Compost Waste shreddedBiomass Bark, wood chips Waste wood shredded

cleaning: On the Multistar screeners, the screen units are kept continuously clean by carbide, ceramic or specially coated cleaning elements, as appropriate for the specific application. This keeps wear to a minimum, for economical operation.

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drum screensWith stationary drum screens, a corresponding screening machine is available for every system size. Directly driven heavy-duty supporting wheels (1845/2055: DRUMGRIP-drive) provide quiet drum operation and top efficiency with reduced energy consumption and noise emissions. Variable configuration of sub-structure, servicing accessibility, enclosure and drive simplify adaptation to on-site conditions.

Designed for continual operation: optimal screen drum operating characteristics with reliable cleaning

Variable configuration for perfect adaptation to deployment and locality

Options: » Screen segment drum with segment change without dismantling drum

» Special drum with anti-dirt strips for screening of residual waste

» Three-fraction screening by using different screen drum hole sizes

» Special carrier drum with interchangeable screening segments

1845, 2055, 2255, 2278, 2290, 2590, 25120

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materials

Compost Waste shreddedBiomass Soil, Gravel, SandWaste wood

Drive: The screen drum is driven by two to four direct drive units. Power is transferred directly to the supporting wheels via a pinion slip on gear mechanism and then on to the screen drum via traction. The positioning of the drive motors is freely selectable.

Screen DruM: On stationary screen machines, drums up to 2.5 meters in diameter and up to 12 meters in length are used. A high throughput performance is guaranteed by feed screws welded on the inner side of the drum.

MainTenance: A high degree of flexibility applies to the design of the gangways, steps etc. - everything can be tailored to customer requirements. Doors and a removeable tarpaulin cover allow comfortable access to the screen drum for cleaning.

ShowcaSeMachine type: SM 2278application: household wasteThroughput: 180 t/h

ample space between screen drum and sidewalls also makes operation with large screen hole sizes go smoothly. For these hole sizes, outside scrapers are more effective than circular brushes for drum cleaning. For residual waste screening, a special drum with anti-dirt strips is also available.

1845 2055 2255 2278 2290 2590 25120

Drive

Power (kW): 15 18.5 2 x 9.2 2 x 11 2 x 11 4 x 7.5 4 x 9.2

System: electrical via DRUMGRIP

electrical via DRUMGRIP

electrically via direct

drive


drive


drive


drive


drive

Screening drum

Diameter (mm) (exterior): 1800 2000 2200 2200 2200 2500 2500

Length (mm) (exterior): 4500 5500 5500 7800 9000 9000 12000

Screening area (m²): 22.5 30 32 48 56.5 61.5 85

Dimensions

Length (without walkways, mm):

6250 7350 7500 9800 11100 11100 14100

Width (mm): 2300 2700 3100 3100 3100 3400 3400

Height (mm): 3250 3400 3600 3600 3600 4000 4000


Throughput performance (m³/h):

up to 120 up to 160 up to 190 up to 250 up to 250 up to 275 up to 300

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flowerdiscThe Flowerdisc represents a further technology for the screening of pre-shredded commercial, bulky and bio-waste, a technology which combines high throughput, selectivity and resistance to contamination. Material is transported by shafts with rugged steel discs working on the disc screen principle. Movable jacketed pipes positioned between the discs prevent seizures and blockages by contraries.

Designed for separation of oversized particles from commercial waste, bulky waste, household waste and fresh bio-waste

High throughput, low energy expenditure

Sturdy design allows smooth, low-wear operation

Modular design for flexible configuration in stationary systems

disc separator

materials

FloWerDiSc

Drive

Power dependent on configuration (kW): 17.5-22

Screen segments fine or coarse

Length x Width (mm): FD 40: 5840 x 1200FD 80: 6080 x 1200

Screen sections (standard)

FD 40 (mm): 30 ..... 50

FD 80 (mm): 80 ..... 100


Throughput performance (t/h): up to 40Household

wasteCommercial

wasteBio waste

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mashmasterWet organic waste, woody structure material and various aggregates (residual waste and sewage sludge) are treated by the general-purpose Mashmaster mixing shredderinto an output mixture ideal for the rotting process.Four electrically driven screw shafts keep the material in an intensive mixing motion.Rugged tools on the screws disentangle the material and provide shredding and homogenisation.

Shredding-mixing-homogenization in one machine

Accurate definition of the mixing ratio, and automation with conveyor belt feed possible with electronic scales

Prolonged service life with wear-resistant tools, tray with interchangeable base

universal screw mixer

materials

MaSHMaSTer

Drive

Power (kW): 2 x 75 elektric

container

Volume (m³): 15

Mixing unit

Assembly: 4 screws / mechanical drive

Dimensions

L x W x H (mm): 6740 x 2200 x 2133

Weight (t): 13.7


Throughput performance (t/h): up to 55Household waste Bio waste Green waste

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screw pressThe screw press can separate wet bio-waste into a solid fraction for composting and a liquid fraction for wet fermentation. Two screw shafts in the mixing container keep the material in an intensive mixing motion.Crushing is performed by two press screws. Other applications include drainage of organic material leachate during fermentation processe.

Mixing and crushing in one machine

Different degrees of crushing attainable using various screen baskets

Prolonged service life by using wear-resistant tools and tray with exchangeable base

Corrosion-resistant steel used for all parts coming into contact with material (with exception of the press screw)

materials

ScreW preSS

Drive

Power (kW): 1 x 132 kW electric

Mixing unit

Container capacity (m3): 15

Mixing equipment: 2 screws / hydrostatic drive

press

Number of press screws: 2 (Duplex)

Length of press screws (mm): 4300

Compression ratio: to 1 : 7


Throughput performance (t/h): 12-20 Bio waste

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hurrikanThe stationary Hurrikan high-performance windsifter allows effective cleaning of over-sized screened particles. The unit is extremely compact for a windsifter and can be integrated easily into a system chain. The patented „pressure-suction“ principle is used to separate plastic with a high degree of selectivity.

Outstanding windsifting using "pressure-suction" principle in conjunction with vibration

At high throughput, in excess of 90% selectivity by precise adjustment of settings to material properties

Simple integration into new or existing systems

windsifter

materialien

Hurrikan Hurrikan S

Drive

Electric motor (kW): 28 47

Diesel generator (kVA): 53 60

Feed

Conveyor belt width (mm): up to 1200 up to 1200

Dimensions

L x W x H (mm): 7250 x 2000 x 4200 9800 x 2460 x 4000

Weight (t): ~ 3.5 ~ 6.0


Throughput performance (m3/h): up to 40 up to 60Compost Biomass

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ballistorThe Ballistor is used to separate out usable fractions from waste and potential recyclables. By combining ballistic separation with screening, separation is performed in one operation in accordance with the criteria 3/2-dimensional, rolling-cubic-rigid/flat-soft-narrow, or undersized/oversized particles.

With a choice of separation into three or four fractions, five sizes and many options, the Ballistor separator can be configured to suit the application.

Wide range of applications – from municipal waste (household waste, commercial waste) to potential recyclables and building material waste

High degree of selectivity with setting of separation limit

Efficient drive design with low power requirement

Rugged design with long service life and low operating costs

ballistic separator

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materials

2 D3 DFine

fraction 1Fine

fraction 2

4300 4400 6300 6400 8300 8400 10300 10400 12300 12400

Drive

Power (kW): 5.5 5.5 5.5 5.5 11.0 11.0 11.0 11.0 11.0 11.0

Screen elements

Number of fractions: 3 4 3 4 3 4 3 4 3 4

Number of screening elements:

4 4 6 6 8 8 10 10 12 12

Length screening elements (mm):

5600 6800 5600 6800 5600 6800 5600 6800 5600 6800

Screening area (m²): 9.6 11.6 14.4 17.4 19.2 23.3 23.9 29.1 28.7 34.9

Dimensions

Length (mm): 7475 8675 7475 8675 7475 8675 7475 8675 7475 8675

Width (mm): 2400 2400 3250 3250 4100 4100 4960 4960 5810 5810

Height without inlet cap (mm):

1930 1930 1930 1930 1930 1930 1930 1930 1930 1930

Transport width (mm):(pre-assembled unit)

2150 2150 3000 3000 3940 3940 4800 4800 5650 5650

Weight (t): ~ 5.75 ~ 6.5 ~ 7.0 ~ 7.75 ~ 8.5 ~ 9.25 ~ 9.75 ~ 10.5 ~ 11.0 ~ 11.75


Throughput performance (m³/h):

up to 60

up to 80

up to 100

up to 120

up to 130

up to 150

up to 160

up to 180

up to 200

up to 220

SeparaTion pHySicS: The 2-dimensional fraction is transported upwards. The 3-dimensional fraction is moved downwards by the ballistic movement, and removed. Variable hole sizes of the screen elements further sort the rising material to separate out the fine fraction.

reliable: A new drive system using an electric motor, crankshaft, and elastic connecting link provides long service life. Automatic lubrication options combined with electronic monitoring make the machine dependable even under heavy-duty operation.

loW operaTing coSTS: The low power requirements of the simple yet efficient mechanism keep energy costs low, they are at 4 - 8 kW.Three screen element designs and a choice of different materials lets the operator select the best configuration for the task, to reduce the wear and maintenance costs.

ShowcaSeMachine type: 6400application: commercial wasteThroughput: 100 m3/h

The rigid screen elements are arranged lengthwise and facilitate excellent turning ofthe material and hence a high degree of sorting. The separation threshold between the light and heavy fraction can be tailored to the material on site by adjustment of the in-feed flap and the inclination.

Commercial waste Household waste Bulky waste

Komptech GmbHKühau 37, A - 8130 Frohnleiten[t] +43 3126 505-0[f] +43 3126 505-505[e] [email protected]

teChnology for a better environment

www.komptech.com

We reserve the right to make technical changes in the course of ongoing development. E2012

Komptech UK Ltd.Forge End, Lodge Farm KinetonWarwickshire, CV35 0JH[t] +44 1926 64 29 72[f] +44 1926 64 29 71[e] [email protected]

stationary_machines_eng_2012

Documents

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