Promeco SpA

Promeco SpA

- Model RDF Series - Auto Shredded Waste Plants (ASW)

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Promeco has engineered a system for the production of RDF (refuse derived fuel) from ASR automotive shredder residues.Vehicles at the end of their life are, after remediation (removal of fluids, oils, fuels, batteries), demolished. About 75% of the material components of the vehicle is recovered. In particular, the destruction and demolition/crushing of vehicles allows to recover the metal components.

What remains, called ASR (automotive shredder residues), is a mix of materials including plastics (PE, PVC, PP), elastomers (rubbers, chloroprene, ABS) resins (PU, PA, epoxides, styrene compounds), cellulosic materials (textile, paper, wood), minimal residual metals (Cu and Fe in particular) and others (glass, paints, ceramics).

To date, the ASR were mainly destined to landfilling. However, the prevailing policy within the European Union is to minimize and, if possible, completely avoid the use of landfill as a means to dispose of waste. Recently adopted European regulations (Directive 53/2000 on the ELVs, End-of-Life Vehicles), require that, from 2015, 95% (by weight) of a motor vehicle components and materials has to be recovered, conceding that only 5% is sent in landfills.

As the materials from ASR can be the basis for RDF of excellent quality, PROMECO has engineered a system that, starting from the ASR, allows to obtain a RDF in briquettes, which can be used as fuel replacement in facilities such as incinerators, cement kilns, etc.

Characteristics of the input material

  • Auto shredded waste (waste from cars demolition)
  • Maximum input size: about 50 to 60 mm.
  • Negligible presence of metals and absence of inert materials with a diameter less than 10 mm.
  • Optimum particle size of about 40-50 mm, easily achieved with a pre-grinding.
  • Max humidity up to 20-23% depending on the characteristics required for the briquettes / pellets.

Characteristics of the finished product

  • Briquettes: diameter 70-90 mm, length 250 mm, depending on the used matrix;
  • Residual moisture: <5%
  • PCI: about 10000 kcal / kg
  • Treatment capacity: installation, up to 18 tons / h (each machine up to 3 tons / h) (Depending on the composition of the material input)
  • Requested area: approx. 58 mx 56 m (excluding storage of raw material and finished product)

Description of the process

The material to be treated, pre-shredded, is stockpiled in a storage area. By means of a mechanical shovel, is placed in the hopper (Pos 1). From there, a conveyor belt (Pos 2) feeds a rotating sieve (Pos 3).The underscreen fraction is composed of  hard and abrasive materials (mainly glass and inert), unfit for the RDF production. The overscreen fraction, mainly consisting of plastics and rubber, is collected by belt conveyors (Pos 4.5) and sent to a temporary storage hoppers (Pos 6).  The flow is then collected by other belt conveyors (Pos 7, 12) and sent, after separation of ferrous (Pos 8) and non ferrous metals (Pos 9), to a distribution system (Pos 13) feeding the briquetting lines, based on the densifier/agglomerator PROMECO PES - Promeco Extruder System.  Metal fractions (ferrous and nonferrous) are removed by conveying belts (POS 8A, 10,11) to storage container.  The Promeco Extruder System (Pos 14) receives the material to be treated in a feeding hopper. From here, two augers feed the material to a vibrating table, which optimizes the flow to the PES extrusion chamber. In the extrusion chamber the material is subjected to high friction and pressure, generated by the rotating screw mixers, and is then pushed through an extrusion matrix (Pos 14A), which determines the shape and size of the product. The molten profile coming from the matrix is pushed along a stabilization track in a cutting system (Pos 15), which regulates the briquettes according to the specific length and shape desired. The briquettes are then taken by conveyor belts (Pos 16,17,18) and sent to a container.

The process generates heat and steam. The latter, along with possible dust, is collected by an exhausted air suction system and, if needed, sent to an air treatment system. The hoods sucking air to treat are located above the extruder feeding system and over  the stabilization track.

The control system (Pos 20) is equipped with PLC and inverter for the main engines, that require speed adjustment. The system is controlled by multiple control panels placed close to the different phases.

The plant can operate with 3 employees per shift, and in both automatic and manual mode.

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