JWC - Sewage Grinders Brochure

www.jwci.co.ukMM-JWCIMuffin MonsterFamily of GrindersMini Monster® For low flow, buildings and small pump station applications the Mini Monster is a reliable grinder in a small package. It grinds wastewater to eliminate costly pump problems and sewer back-ups.Muffin Monster® Troublesome solids are now easier than ever to reduce with the Muffin Monster dual-shafted grinder. Its low speed, high-torque design shreds tough solids that typically cause sewer problems. With over 20,000 installations the Muffin Monster is legendary for protecting pumps and keeping the wastewater flowing.Macho Monster For big solids reduction projects the Macho Monster has the power to keep up with huge slugs of material. It utilizes larger cutters, shafts and motors than the Mini or Muffin Monster ranges.Features & BenefitsDual Shafted Grinder• Capable of grinding a wider variety of solids than single shafted machines or macerators• High torque allows the grinder to handle rocks, sticks, clothing, plastics, bedding and more without jamming Ease and Flexibility of Installation• Adapts to existing pipeline or channel applications with little or no modification to piping or channel• In-line unit incorporates a quick-change cutter cartridgeCartridge Seal Assembly• High pressure capability – 6 bar• No seal flush required and no packing gland to adjustHigh-Flow Side Rails• Increases flow rate and decreases head loss• Deflects solids into the cutting chamberCompact, Efficient Design• Cutter and reducer design allows the use of small, energy efficient motors – 2.2 to 7.5kW• Compact units fit in small spacesAutomated PLC Monitoring and Controls• Auto load sensing and reversing reduces motor trips, protects system and eliminates need for manual check-ups*All units Atex certified Grp11 cat 2Open channel unitIn-line unitJWC InternationalPerformance Capability – Open Channel ConfigurationModel Flow Ratem3/hHead Drop mmNet WeightApprox. kgMaximum Dimensions - mmA (IP55) A (IP68) 20002-DI 18 80 102 912 1215Flow based on optimum channel conditions • Consult factory for final analysis of application • Drive dimensions are a maximum based on a unit with a 1.5 kW drive • Extended drive shafts are available on request.Mini MonsterModel 20000Motor: Standard 1.5 kW; 0.75kW optionalFlow rate: In-line: 60 m3/h Open Channel: 18 m3/hPressure: 6 bar (working)Weight: In-line: 125 kg Open Channel: 102kgCutter size: 120mm diameterRemovable Cutter CartridgePerformance Capability – In-Line ConfigurationModel Flow Ratem3/hrPipelineSize-mmPressure Drop (Bar)Net Wt. kgMaximum Dimensions - mm Flange Dimensions - BS EN 1092A (IP55) A (IP68) B C D20000-D100 60 100 0.07 125 944 1236 180 19 (M16) 8In-Line unit typically installed prior to suction side of pump • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 1.5 kW drive.In-Line Configuration Open Channel ConfigurationMini Monster installed in a pump station In-line Mini Monster In-line Mini Monster Easy to remove cutter cartridge203 MAXØ250 MAX410DØ x ØCØ100 N.B.B PCD36295215330120A¾ B.S.P. Drain PlugsAØ250 MAX203 MAX298240 38114 33095215210Muffin MonsterModel 30000Performance Capability – Open Channel ConfigurationModelFlow Ratem3/hHead Drop mmNet WeightApprox. kgMaximum Dimensions - mmA (IP55) A (IP68) B C30005-0008 76 241 168 1202 1306 203 49530005-0012 111 343 186 1307 1411 305 60030005-0018 168 444 211 1456 1560 457 74930005-0024 228 495 236 1602 1706 609 89530005-0032 334 546 263 1799 1903 813 109230005-0040 454 597 295 2002 2106 1016 1295Flow based on optimum channel conditions • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 4 kW drive • Extended drive shafts are available on requestPerformance Capability – In-Line ConfigurationModel Flow Ratem3/hrPipelineSize-mmPressure Drop (Bar)Net Wt. kgMaximum Dimensions - mm Flange Dimensions - BS EN 1092A (IP55) A (IP68) B C D E F G30004T-B100 102 100 0.04 250 1425 1529 718 489 238 180 19 (M16) 830004T-B150 159 150 0.08 254 1425 1529 718 540 264 240 23 (M20) 830004T-B200 216 200 0.15 258 1425 1529 718 591 289 295 23 (M20) 1230004T-B250 352 250 0.08 256 1717 1821 1010 692 313 355 28 (M24) 1230004T-B300 512 300 0.11 367 1717 1821 1010 794 336 410 28 (M24) 12In-Line unit typically installed prior to suction side of pump • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 4 kW drive.Specifications: 50mm hex shafts; 2.2 kW motor standard; 25:1 reducer; tungsten carbide face seal cartridgesCutter size: 120mm diameter cutters Seal max working pressure - 6.0 barIn-Line ConfigurationOpen Channel ConfigurationØ250 MAXA272 MAXØF x GE P.C.D.387 C292220137BD298216178Ø350 MAX272 MAX13798B CA220Performance Capability – Open Channel ConfigurationModel Flow Ratem3/hHead Drop mmNet WeightApprox. kgMaximum Dimensions - mmA (IP55) A (IP68) B C40000-0018 204 203 533 1704 1816 457 76840000-0024 341 406 619 1882 1994 610 94640000-0032 477 457 708 2050 2162 813 1114Flow based on optimum channel conditions • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 7.5 kW drive • Extended drive shafts are available on requestPerformance Capability – In-Line ConfigurationModel Flow Ratem3/hrPipelineSize-mmPressure Drop (Bar)Net Wt. Maximum Dimensions - mm Flange Dim. - BS EN 1092kg A (IP55) A (IP68) B C D E F G40002-18B300 316 300 0.24 690 1704 1815 895 768 273 410 28 (M24) 1240002-24B300 727 300 0.08 805 1882 1994 895 946 273 410 28 (M24) 1240002-24B400 909 400 0.12 860 1882 1994 1099 946 321 525 31 (M27) 1640002-24B450 1152 450 0.20 950 1882 1994 1200 946 346 585 28 (M24) 2040002-32B500 1431 500 0.25 1184 5080 2162 1302 1114 381 650 34 (M30) 20In-Line unit typically installed prior to suction side of pump • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 7.5 kW drive.Macho MonsterModel 40000Specifications: 64mm hex shafts; 7.5 kW motor standard with 5.5 kW optional; 35:1 reducer; tungsten carbide face seal cartridgesCutter size: 190mm diameter Seals-Max. working pressure: up to 6.0 BarPerformance Capability – Open Channel ConfigurationModelFlow Ratem3/hHead Drop mmNet WeightApprox. kgMaximum Dimensions - mmA (IP55) A (IP68) B C30005-0008 76 241 168 1202 1306 203 49530005-0012 111 343 186 1307 1411 305 60030005-0018 168 444 211 1456 1560 457 74930005-0024 228 495 236 1602 1706 609 89530005-0032 334 546 263 1799 1903 813 109230005-0040 454 597 295 2002 2106 1016 1295Flow based on optimum channel conditions • Consult factory for analysis of application • Drive dimensions are a maximum based on a unit with a 4 kW drive • Extended drive shafts are available on requestIn-Line Configuration Open Channel ConfigurationØ350 MAX306 MAXAC502E P.C.D.ØF x G152410D279B 502373C114A152410306 MAXØ350 MAX279Ø340B0.000.050.100.150.200.250 10 20 30 40 50 60 700 36 72 108 144 180 216 25230004T-1208(200 mm)30004T-1204(100 mm)30004T-1206(150 mm)0.000.100.200.300.400.500 20 40 60 80 100 120 140 1600 72 144 216 288 360 432 504 57630004T-2412(300 mm)30004T-2410(250 mm)6Model 30004T-12Flow rate (m3/h)Flow rate (l/s)Model 30004T-24Model 30005Head drop (mm)Pressure drop (mm)Flow rate (m3/h)Flow rate (l/s)Flow rate (m3/h)Flow rate (l/s)Pressure drop (mm)Flow Curves020040060080010000 20 40 60 80 100 120 140 1600 72 144 216 288 360 432 504 57630005-003230005-004030005-002430005-001830005-001230005-0008Mini Monster installed in a pump stationRAWSEWAGEHdown=150mm10% DS 8% DS 6% DS4% DS2% DS10% DS8% DS6% DS4% DS2% DSHdown=250mmHdown=350mmHdown=450mmHdown=550mmHdown=650mmHdown=750mmHdown=850mmHdown=950mmHdown=1050mmRAWSEWAGEFlow rate (m3/h)Flow rate (l/s)Head drop (mm)Flow rate (m3/h)Flow rate (l/s)Pressure drop (mm)Flow rate (m3/h)Flow rate (l/s)Pressure drop (mm)Model 40000Model 40000-32Model 40000-180.000.050.100.150.200.250.300.350.400.450 50 100 150 200 250 300 350 400 4500 180 360 540 720 900 1080 1260 1440 162040000-3220(500 mm)02004006008000 20 40 60 80 100 120 140 1600 72 144 216 288 360 432 504 57640000-003240000-002440000-00180.000.050.100.150.200.250.300.350 50 100 150 200 250 300 3500 180 360 540 720 900 1080 126040000-2412(300 mm)40000-2416(400 mm)40000-2418(450 mm)Flow CurvesHdown=150mm10% DSRAW SEWAGE8% DS6% DS4% DS2% DS10% DSRAW SEWAGE8% DS6% DS4% DS2% DSHdown=250mmHdown=350mmHdown=450mmHdown=550mmHdown=650mmHdown=750mmApplicationsIndustry Mini Monster Muffin Monster Macho Monster Application NotesBuildings / ResortsMore powerful than grinder pumps. Prevents sewer overflows and messy pump rebuildsPump Stations Stainless steel guide rails make installation and retrieval easy Screenings Improves washing and compacting of screened solidsSludge / Scum Cleaner, stronger and longer lasting than maceratorsBelt Press / CentrifugeGrinds a wide variety of solids, including rocks and rags, to protect dewatering equipmentJails / Prisons Over 2,000 grinders installed in correctional facilities worldwideHospitals / Nursing HomesShreds large solids including rags, pads, clothing and dangerous medical wasteFood / Fish ProcessingSample grinder installations: fish, slaughterhouse scraps, spoiled food destruction, wash water channels, manure tanksPulp / Paper Installed in sludge systems, pulp lines and wastewater plantsHeavy IndustrialRefineries, hazardous waste processing, obsolete inventory destruction, recyclingConsult factory for additional application assistance and approval.Photo GalleryIn-line Muffin Monster In-line Macho MonsterMuffin MonsterIn-line Muffin MonsterMuffin Monster in fish processing plant Muffin Monster in pump stationMuffin Monster in pump stationMuffin Monster in prisonUnit 15, Daneside Business ParkRiver Dane RoadCongleton, Cheshire CW12 1UNPhone: +44 1260 277047Fax: +44 1260 277557jwci@jwce.comMM-JWCIwww.jwci.co.uk© JWC Environmental. United States patents may apply: 4,919,346; 5,060,872; 5,320,286; 5,333,801; 5,354,004; 5,478,020; 5,505,388; 5,593,100; 6,176,443; 6,332,984; 7,073,433;7,080,650; 7,081,171; RE37,349; RE37,550E; 10/131,040. Additional and foreign patents pending. (MM-JWCI-06)Features and OptionsCutters• Range of cutter options maximize grinding efficiency• Special: 3-tooth fish grinding cutter• Custom: extra-hard carburized cutters, stainless steelCustom Frames• Frames attached to pump sump wall• Grinder support base, subchannel, overflow bar racks and other frame configurations available Scrapers*• Fixed steel scrapers increase material throughput and help cutters clean-out faster.High Flow Side Rails• Slotted side frames to increase flow capability and reduce headloss• Helps keep sand and grit in suspension• Increased component serviceabilityHigh-tech Controllers• PLC based controllers to ensure maximum grinding ability, minimum stoppage and maximum electrical/mechanical component protection• Optional enclosures: Eexed Zone 1 (flameproof) available on request Note: Warranty invalid if JWCI controller or similar approved is not usedMotors• Electric motor: 1.5, 2.2, 4, 5.5, 7.5 kW• ATEX explosion proof electric motor: 2.2, 3.7, 7.5 kWExtended Motor Shaft• Longer drive shaft puts motor above the highest water level. Available in 150mm up to a maximum of 3.0m.Hex Seal Cartridges• High pressure capability – 6 bar• No seal flush required and no gland packing to adjustHardened steel cuttersCustom frameExclusive: high-flow side railsOptional Scrapers* Open channel units. Not available on Mini Monster Units.Hex seal cartridgeExtended motor shaft