Compact System For Secondary Fuels

% Maximum flexibilityconcerning fuels to be used

% Limited space requirements

% Reliable conveyorequipment

% Low energy consumption

% Simple safety technology

% Low operating costs

Application

The Compact System ForSecondary Fuels is designed togenerate a continuous mass flowfrom combustible recycling productsof the most diverse nature.

Fitted with large cross-sections, theconveyor equipment can handleflakes, fibres, plastic shredders aswell as compounds.

The system is primarily used for thefeeding of fuels into rotary cementkilns. The feed rate for thisapplication is typically between 1and 10 t/hr.

Equipment

The system comprises:% Docking stations with live

bottom bin for semitrailerswith walking floor

% Troughed belt conveyor% Weighfeeder with non-

standard features% Blow-through rotary feeder of

special design% Rotary piston blower% Pneumatic conveyor line% Measuring, control, and

supervisory electronics forcontinuous operation

The design is protected by utilitymodel registration and patent.

Function

The fuel is supplied on semitrailers.Via the integrated walking floor, thefuel is fed into the live bottom bin ofthe docking stations.

The screws feed the fuel into thetroughed belt conveyor whichsupplies the weighfeeder.

The weighfeeder feeds the fuel intothe rotary feeder and determines theconveying speed of the upstream livebottom bin.

BV-D 2145GB

Schematic Diagram

Module DescriptionDelivery Site

Function

The secondary fuels are supplied on semitrailers in theform of loose products. Any vehicle type conforming to thelocal Road Traffic Regulations may be used.

The delivery surface is to be designed for a minimum oftwo vehicles so that the system can be operated inalternating or parallel mode.

The semitrailer backs into the docking station. The trailersare properly positioned with the aid of guide tubes and tyrelimit stops.

Fitting close with the semitrailer's outline, the lateral rubberaprons of the docking station accomodate different vehiclewidths and heights. This helps to keep the delivery siteclean. After opening the rear doors inside the dockingstation, unloading can take place.

The tractor is now no longer required. The readysemitrailers assume the function of a silo.

A stationary hydraulic unit drives the semitrailer's walkingfloor system during unloading. The hydraulic pipes comewith a double jacket ensuring any leaked oil returns intothe oil sump.

This reduces the risk of soil contamination through leakinghydraulic oil.

Technical Data

% Bottom plate:- Asphalt or concrete

% Dimensions:- Length: 13,500 mm- Width: 5,000 mm- Ground slope: < 2%

% Hydraulic unit (for walking floor):- Twin-unit equipped with oil sump- Hydraulic pipes with double jacket

% Dimensions:- Length: 1,750 mm- Width: 1,150 mm- Height: 850 mm

% Power consumption: 2 x 7.5 kW

Semitrailer withwalking floordischarge system

Docking station with screw-conveyed live bottom bin

Troughed belt conveyor

Weighfeeder

Rotary piston blower

Blow-through rotary feeder

Conveyorline

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M

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Delivery Site With Docking Stations

Docking Station

Function

For reception of the secondary fuels, normally twoparallel docking stations are available ensuringcontinuous fuel supply.

The individual cabins are fitted with a sealing systemdesigned to adjust to the semitrailer's degree ofunloading. This helps to keep the environment clean.The docking stations are equipped with a photocellhopper level control system cycling the upstreamwalking floor live bottom.

The feed screws mounted in stations transport thesecondary fuel discharged from the semitrailer to theadjacent troughed belt conveyor.

Depending on the selected feed rate, the four feedscrews are controlled in pairs for alternating operation,so good fuel prefeeding and uniform discharge of thedocking station are ensured.

Technical Data

% Steel plate construction mounted on IPE supportswith ground clearance

% Four feed screws per station% Rubber apron sealed vehicle reception% Prime coat approx. 12 µm

% Dimensions (per station): - Length: approx. 4,000 mm- Width: approx. 2,240 mm- Height: approx. 4,400 mm

% Weight (per station): approx. 2,500 kg

% Power consumption (per station): 2.2 kW

Options:

% Roller gate on reception opening% Special seals on reception opening% Suction system in station% Expansion to four stations% Top coat in other RAL shades

Troughed Belt Conveyor

Troughed Belt Conveyor

Function

The docking station screws feed the secondary fuel intothe lateral inlet holes of the troughed belt conveyor.

Driven by revolving chains on both sides, drag platespull the feed material over the rising conveying troughto the weighfeeder's inlet shaft.

The conveyor chains are driven jointly via a sprocketshaft arranged in the upper belt strand. Two chaintensioners mounted in the lower belt strand ensure safechain running.

Technical Data

% Steel construction supported on floor beams

% Transport via individually tensioned roller chains

% Totally enclosed to prevent dust escape

% Prime coat: approx. 12 µm% Feed rate: max. 60 m³/hr% Conveying speed: 0.5 m/sec% Height of lift: approx. 2,000 mm

% Dimensions- Length: approx. 4,500 mm

- Width: approx. 1,000 mm - Height: approx. 2,500 mm

% Weight: approx. 800 kg

% Power consumption: approx. 3.0 kW

Options

% Special constructions in other RAL shades

Weighfeeder, MULTIDOS type

Weighfeeder, MULTIDOS type

Function

The material is discharged from the troughed beltconveyor into the weighfeeder's infeed hopper.

The weighfeeder controls the docking station feedscrews and the walking floor discharge system in anetworked control loop.

The weighfeeder is specially designed and equippedfor the feeding of light bulk solids (bulk density < 0.2kg/cm³).

In addition, special skirt boards guide the material andprevent its lateral escape between the belt andlimitation. A segmented belt scraper ensures good beltcleaning.

The weighfeeder is completely enclosed and can beequipped with a suction system in accordance with thecharacteristics of the material fed.

The discharge hood is fitted with an inspection flappermitting weighfeeder and rotary feeder below to beserviced.

Technical Data

For general data, see Spec Sheet BV-D2080.% Special variant for light bulk slids% Special belt, continuously vulcanized% Automatic belt tensioning and tracking station% Belt slip monitoring% Mechatronic design% Feeder drive with integral frequency converter% Integrated weighing electronics, DISOCONT type% Fieldbus for serial data exchange

% Dimensions (as a function of feed rate):- Axle spacing: approx. 2,700 mm- Belt width: approx. 800 mm- Height: approx. 730 mm

% Weight: approx. 800 kg

% Power consumption: approx. 1.5 kW

Options:

% Suction system with bio filter% Electrical equipment in control cubicle% Top coat in other RAL shades% Belt scrapers

Blow-through Rotary Feeder

Blow-through Rotary Feeder

Function

Mounted flush with floor level below the weighfeeder'sdischarge chute, the rotary feeder accommodates thematerial discharged from the weighfeeder in itschambers.

The fuel stored in every rotary chamber is dischargedby force and blown through the conveyor line to theburner.

Every rotary feeder is tailored to the specific project.The chambers surface cross-sections are tuned to theassociated blower rate. This type of sizing reduces theescape of air across the feeder inlet.

Depending on the composition of the secondary fuel, arubber- or metal-sealed variant can be installed. Theseals can be inspected through the inspection flap onthe weighfeeder discharge and serviced, if necessary.

Technical Data

% Steel plate construction supported on IPE supportswith ground clearance

% Stuffing box shaft seals% Rubber or metal chamber seals (exchangeable)% Chain drive% Prime coat approx. 12 µm

% Filling funnel: 800 x 230 mm% No. of chambers: 6 – 12 chambers% Rotary feeder rate: max. 100 m³/hr% Rotor speed: 14 rpm% Blow-through line connector: DN 70 –200 mm

% Dimensions (as a function of feed rate)- Length: approx. 1,500 mm- Width: approx. 1,500 mm- Height: approx. 1,050 mm

% Power consumption: approx. 5.5 kW

Rotary Piston Blower

Function

The amount of air required for pneumatic conveying ofthe material from through-blow rotary feeder to kiln isgenerated by a rotary piston blower with integratedpulsation reducer.

The constructional conception of this kind of blowerascertains high mechanical and volumetric efficiency atultimate reliability and operating safety.

The rotary piston blower is dimensioned and integratedinto the system in accordance with the project. Theblower is mounted in a noise insulating housing.

Technical Data

% Blower with 3-wing-type piston% Sound reduction through pulsation degradation by

means of two pre-intake channels cast into thepressure side of the cylinder

% Housing of GG20, ribbed and air-cooled% Shafts and pistons (C45N) forged of a single piece% Control gears of 16 Mn Cr5E% Overhung drive via V-belts% Elastic mounting bases

% Prime coat: approx. 12 µm

% Rotary piston blower dimensions:

- Length: approx. 1,500 mm- Width: approx. 1,300 mm- Height: approx. 1,600 mm

% Electrical consumption: approx. 22 kW as afunction of type

Pneumatic Conveyor Line

Function

The conveyor line transports the fuel blown out of therotary feeder chambers directly to the burner.

Air quantity, run length and pipe diameter are selectedin accordance with the particular project so optimalmaterial transport without line deposits is obtained atminimal abrasion of the pipe inner wall.

The line must be arranged horizontally and/orvertically. Pipe bends have to be reduced to theabsolute minimum. Pipe lengths below 100 m enablethe highest economic efficiency of the system.

To protect the system from kiln faults, an explosioncheck valve has been installed.

Technical Data

% Sections- Steel pipe St 35, seamless to DIN 2448- DN 70 – 200- Prime coat approx. 12 µm

% Bends- 90° radius- Steel pipe St 35, seamless to DIN 2448- DN 70 – 200- Prime coat approx. 12 µm

% Pipe joints- Flanges to DIN 2631

Options:

% Bends with cast basalt linings% Top coat in other RAL shades

Electrical Control

Function

Designed in accordance with the German VDMA/VDIregulations, the electrical control system is installed in acontrol cubicle. All switching gears required for open-and closed-loop control and fusing of the units installedare included. The lead to the control cubicle is mountedin the factory.

The setpoint (feed rate in t/hr) is entered on the centralcontrol panel. All other units are controlled or switchedas a function of the set feed rate. Upon start of thesystem, a sound signal is produced before the bloweror rotary feeder starts operating.

The fill degree of the docking stations is monitoredelectronically and cyclically starts the hydraulics of thewalking floor system on the semitrailer to be loaded.

The weighfeeder is equipped with a DISOCONTweighing electronics complete with additionalinstrumentation section for commissioning, evaluationand monitoring.

Information on actual value, daily totals, etc. can becalled up. Interfacing with a host system is alsopossible.

A PLC system monitors and controls all systemcomponents. This enables the individual system tooperate in automatic mode so that no manual operatorinterventions are required.

The system control is equipped with a power switch.

In case of emergencies, the complete system can beshut down with the use of Emergency Stop switchesaborting the entire conveying function and immediatelyclosing the rotary closure on the kiln.

Technical Data

% Steel plate control cubicle, two-wing type% Designed in accordance with VDMA/VDI

regulations% Surface powder-coated to RAL 7032% PLC control (SIEMENS S7)% Fieldbus for serial data exchange

% Control cubicle dimensions:- Length: approx. 1,200 mm- Width: approx. 500 mm- Height: approx. 2,000 mm

% Weight: approx. 500 kg

Options:

% Customized design% Coupling to host system% Additional queries and evaluations% Top coat in other RAL shades

Measuring and Process SystemsSCHENCK PROCESS GmbHD-64273 DarmstadtPhone: +49 (0) 61 51-32 10 28Fax: +49 (0) 61 51-32 11 72E-Mail: sales2.process@schenck.netwww.schenck-process.net

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A cooperation betweenSCHENCK PROCESS GmbHand Energieberatung Hess GmbH