REDWAVE - a division of BT-Wolfgang Binder GmbH

Recycling - Waste Treatment - Sorting Plant for 100.000 Tonnes of Residential Waste - Video

This waste processing plant built by REDWAVE consists of two separate units. The ‘EKOREFINERY’ plant is for initial processing of the household waste and the PLASTICS SORTING plant is for sorting and recovery of plastics.

The two plants are housed in separate buildings, which are connected to each other by a bridge with a conveyor belt. Another conveyor bridge leads to the intake bunker of the existing power plant.

In the ‘EKOREFINERY’ plant the household waste is received and is put through a set of initial separation steps. First it is shredded, then it passes through a number of processing stages including sieving, wind sifting and extraction of metals. At this stage the following fractions have been created:

• Light materials (paper, cardboard, plastics, …)
• Heavy materials (wood, diapers, shoes, …)
• Organics
• Ferrous metals
• Nonferrous metals

The heavy materials are transferred to the existing power plant, via one of the two conveyor bridges to be used as fuel. The metal fractions are sold to outside customers.

The light fraction essentially consists of plastics and paper, and is transferred to the plastics sorting unit for further processing. In this plant, the fraction is separated into the different plastic fractions (PP, HDPE, PET, LDPE and mixed plastics). First the input material is separated into 2D and 3D fractions. Then the targeted plastics are recovered by REDWAVE sorting machines and another stage of metal extraction is performed.

As well as the light fraction recovered from general household waste, the plastics sorting unit also sorts separately collected plastic waste (SCPW) into pure plastic types. This material is delivered to a separate section of the PLASTICS SORTING unit and is fed into the sorting process after the necessary initial steps of opening sacks and sieving, and is handled in a different shift than the material from the EKOREFINERY.

The reject material from the plastics sorting unit is put through another shredding stage and prepared for use as fuel. The sorted plastic and metal fractions are sold to outside recycling companies for further processing.

Optionally, the recovered plastic fractions can be further refined by passing through a washing process, additional shredding and extrusion. This results in regranulate which is ready for reforming into recycled plastic products.

The throughput of the EKOREFINERY plant is 35 tonnes of household waste per hour; thus around 100,000 tonnes are processed annually. The plant is operated in two shifts. The plastics sorting unit has an intake of 12 tonnes per hour when processing the light fraction from the EKOREFINERY, and 4 tonnes per hour when sorting the separately collected plastic waste. The unit is run in three shifts, with two shifts processing the material from the EKOREFINERY whereas the third shift is dedicated to the SCPW fraction.

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