At the Industrial Recycling Centre in Bramsche in Lower Saxony, innovative processes and specialised installations are used to prepare and recycle hazardous waste (e.g. paint, lacquer, adhesives, binders and fillers). These types of industrial waste are transformed into a highly calorific, substitute fuel – which can be used in its solid form for firing furnaces in the calcimer process within the cement industry – in the RENOTHERM®process.
The cement industry places very high demands on a consistent quality. Therefore, the substitute fuel produced in Bramsche is subject to strict ongoing inspections. Characteristics such as the calorific value and grain size play a prominent role in this process.
The RENOTHERM®production process
In the production of solid substitute fuel using the RENOTHERM® process, the industrial waste is analytically tested and then shredded, homogenised and solidified with conditioning agents (e.g. sawdust) during the individual process steps. The dry, pourable material is then finally fed into the separation process from which the end product in the form of a finished substitute fuel mixture with a grain size of 40 mm is created.
The key to success
A smoothly functioning production process in which all process steps and components are optimally synchronised with one another is the key to success. This applies to the properties of the end product just as much as the efficiency of the overall process. Every interruption to the process poses a risk to the quality of the subproducts and may in certain circumstances result in considerable costs to resolve the problem.
Optimising processes using SPLITTER technology
Before switching over to SPLITTER separation technology, a bar screen was used for screening the end product. Unsatisfactory screening results made it necessary to cover this screen with screen mats (with size 40 holes).
Disadvantages of the bar screen
- High level of wear on the screen mats
- Blocking of the holes (the impurities had to be manually removed from the holes on the screen mats 3 – 4 times a shift)
» The time lost as a result ultimately led to reduced production times.
SOLUTION with the SPLITTER unit
While searching for possible solutions for optimising the separation process, Benedikt Gerbrand, Branch Manager at REMONDIS Bramsche, stumbled across the SPLITTER spiral shaft separation technology from Anlagenbau GÜNTHER in Wartenberg. After trying out a number of test screens at the plant in Bramsche, the decision was made to replace the bar screen with a SPLITTER Unit 420 Special with a hopper and transfer units, oversized grain collector belt and control cabinet for the electric control. The SPLITTER has been in operation since March 2016.
More about the SPLITTER Unit
Feedback from the customer
Malfunctions and costs caused by wear and blockages are a thing of the past. The quality of the screening result is consistently very good.
- The plant has a 3-shift operation.
- There are no blockages, adhesions or clumping.
- There is thus is no need to clean the screen.
- The absolutely essential pourability of the product is also maintained even after screening.
- The ratio of oversized grains to usable material (undersized grains) is considered ideal.
- The daily throughput has been measured at 320 – 340 tons.
- As a result, the volume of finished substitute fuel has been increased by 35 – 45 tons of material per day.
“The cooperation with the company GÜNTHER – from the consultation and project planning through to the integration of the SPLITTER Unit into our existing plant – functioned superbly. All tasks were smoothly coordinated with one another and implemented. No reworking at all was required. The plant is operating in a completely stable and trouble-free manner and we are very satisfied. It has been possible to significantly increase the productivity of the production process. It would be fair to say that this has been a flagship project”, concluded Benedikt Gerbrand about the “SPLITTER Unit” replacement project.