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CompostingMethod for composting organic waste

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The Task aT hand

The aim of composting is to decompose organic substances as efficiently and odourlessly as possible and to convert them into stabile, plant-compatible humus substances with the intention of producing a qualitatively high product within a rotting period that is as effective and as short as possible, and with emission levels that are as low as possible. We at Komptech have been working intensively on this for more than 15 years. The result of close collaboration with experts in the fields of natural science, agriculture and mechanical engineering are composting products and solutions that, when tailored to their on-site conditions, guarantee a maximum in ecological and economical efficiency.

One-stop supplierThe services offered range from the requirements of an agricultural composting site with tractor-pulled turner and mobile drum screen, right up to large-scale plants with pre-treatment, closed rotting technology and treatment of the end product. The product quality attainable, and hence also the range of applications, is essentially determined by the starting material. Komptech provides the necessary expertise and the appropriate machine and system technology for all applications so as to be able to generate a recyclable product for the purposes of resource preservation and the closing of material cycles.

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Biowaste

Agricultural waste

Household waste

Residual waste

Green waste

Bush cuttings

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experTise

Sewage sludge

Manure

The following technologies are generally used from raw material to end product:

Treatment By shredding, mixing and, where required, screening, a blend is produced that is as free as possible from contraries and is optimised for the rotting process.

Rotting processThe decomposition and conversion process, performed by microorganisms, is controlled from outside by ventilating, mixing and watering.

Final processingScreening and wind sifting guarantee compost with a homogenous particle size and free of contraries.

Komptech GmbhKomptech is a leading international technology supplier of machinery and systems for the mechanical and biological treatment of solid waste and for the treatment of biomass as a renewable energy source. Komptech’s product portfolio includes more than 30 different machine types, enabling the company to be active in the fields of solid waste processing and biomass treatment.With its products, Komptech covers the major process steps of modern waste processing and biomass treatment, namely shredding, screening/separation and composting. Modular construction offering different performance categories simplifies combinations for complete systems.Always a focus: Innovative technology and solutions that maximise customer benefit.

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Composting

TreatmentThe process steps in the treatment phase include the separating of contraries and conditioning for the subsequent rotting process. This process is undertaken in a roofed area with or without walls depending on the input material and local conditions. This process can also be conducted outside for purely green waste composting.Associated with the shredding process for material exclusion and homogenisation is the separation of contraries, or non-compostable fractions. Contaminated input materials such as bio-waste can be effectively freed of contraries using disc separators or star screens. Defined mixing or addition of different materials is achieved with a batch mixer.

Rotting processThe input material and the associated limiting factors also decide for the rotting process whether it is conducted closed, i.e. in an indoor part of the system, or open as windrow composting.

process cycle

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Green wasteBiowasteHousehold waste

Treatment: Shredding, screening, mixing Sewage sludge

Closed intensive rotting

Windrow composting: Triangular windrows

Contraries Mobile screening technology Stationary screening technology

Contraries

Wind sifting

Green waste Shredding

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Processing technology:Shredding, screening, mixing The CRAMBO shredder brings the material down to a defined particle size. MULTISTAR star screens and FLOWERDISC disc separators separate off contraries and non-compostable fractions. A defined mixture is attained by using the MASHMASTER batch mixer.

Final processing:Screening, wind siftingThe broad spectrum of drum screens, MULTISTAR star screens and HURRIKAN wind sifters includes the right machine for any requirement. Professional compost spreaders in the MEGAFEX family output finished compost.

Open/closedrotting methodTurning machines with practical size graduations are available for open windrow rotting under the product name TOPTURN.If the requirement is for a closed system, tunnel composting systems are used in cooperation with an experienced partner.

The first phase of the rotting process, intensive rotting, often takes place in a closed system with ventilation and outlet air conditioning. The subsequent post-rotting process can then be laid out as open windrow rotting with mobile turning technology. The rotting process is generally complete after 8-12 weeks.

Fine treatmentTo attain a product with uniform particle size, and to separate off any contraries still present, the compost is screened off using mobile or stationary screening technology. The screen overflow is fed back into the composting process as structure material after wind sifting. The particle size produced is based on the end use. It ranges from coarse compost fractions for use in agriculture to private households and gardens, to finely screened-off material as mixture components for garden and potting soil. For agricultural composting, the agricultural product line from Farmtech includes a broad range of general-purpose spreaders.

process sTages

Sewage sludge

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Composting - treatment

TreaTmenT

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Shredding and mixingPreparation of the raw material is the cornerstone for a success rotting process. The optimum particle size of the structure material is attained by the CRAMBO shredder. Mixing dry with moist components, components rich in nutrients with those low in nutrients and components with a stable structure with those with a weak structure provides an environmental condition in the raw material that is perfect for microorganisms. This process is performed using the MASHMASTER batch mixer or during the layer-wise build-up of the windrow using a wheel loader and subsequent stirring with a turner.

Removal of contrariesBecause the focus is on the generation of a usable product, contraries should be removed as best they can during preparation. This process is particularly important when compost is to be generated from mixed waste. In this case, over-sized particles (>60-100 mm) are separated from organic-rich undersized particles. A comprehensive range of screening technology - drum screens, star screens and disc separators - is standing ready for this task.

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key componenTs

Mobile/stationary shreddingOn the CRAMBO, particle size is adjustable with easily exchangeable screen baskets. Slow-running screws with cutters minimise the fine fraction and create resistance to contraries. Mobile machines are available on trailers, tracks and hook lifts. On the electric versions, the drive can be decoupled from the shredding process.

MixtureOn the MASHMASTER, four electrically driven screw shafts keep the material in an intensive mixing motion. Rugged tools on the screws provide fibrous shredding and homogenisation. With conveyor belt feed, automation with precise definition of the mixing ratio is possible with electronic scales.

Pre-screeningStationary technology is commonly used for pre-screening. Stationary drum screens are used in a wide array of applications and are available in many mesh sizes. Star screens can separate into three fractions in one operation and selectivity is retained, even for moist material. Disc separators are particularly robust against contraries.

Mobile machines Drive rating Throughput

Stationary machines – system technology Drive rating Throughput

Mobile shredderCRAMBO 3400 | 5000 | 6000 242 kW | 328 kW | 429 kW to 45 t/h | 60 t/h | 100 t/h

ShredderCRAMBO 3400 | 5000 | 6000 160 kW | 200 kW | 320 kW to 45 t/h | 60 t/h | 100 t/h

Drum screens 2255 | 2278 | 2290 | 2590 | 25120 18 - 37 kW 150 m3/h to 230 m3/h

Star screens2SE | 3SE 12-22 kW | approx. 50 kW to 250 m3/h

Disc separatorsFD40 | 80 | 150 16,5 - 22 kW to 40 t/h

Batch mixerMASHMASTER 1300 SE 150 kW to 55 m3/h

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Composting – rotting process

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Closed rotting: Rotting tunnelWhen composting the organic fraction from mixed waste, household waste or residual waste, the first rotting phase (often the entire rotting process) usually takes place in an enclosed system such as a rotting tunnel. Relevant parameters are used to determine the degree of decomposition and electronically controlled ventilation and watering ensure a perfect rotting process. Extracted air is treated in line with mandatory regulations.

Open rotting: Line windrowTurning of the rotting process is controlled when windrow composting pure green waste, when mixing with bio waste and sewage sludge, and for the maturation process of residual and household waste. A turning process using a TOPTURN improves ventilation and ensures stirring of the different rotting areas. The windrow is loosely stacked, has a triangular cross-section and helps itself to the necessary fresh air using the “chimney“ effect. The intensive mixing balances out moisture and nutrient differences, creating the perfect living conditions for microorganisms.

• Special roller shape with large diameter for best possible mixing

• Wheeled chassis for perfect traction or tracked chassis for mobility on unstable ground

• Simple transportation and easy access with pivotable cabin

• Side repositioning for optimal utilisation of space (option)

roTTing process

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key componenTs

Tunnel composting systemsThis is where the decomposition process takes place in rotting tunnels with electrically controlled ventilation and capture and conditioning of emissions. Material is generally fed automatically into the tunnel with conveyor belts. Wheel loaders and conveyor systems are used for discharge. Komptech offers the entire range of services, from the design phase to commissioning, in conjunction with WTT (Waste Treatment Technologies, NL), a leading international supplier of tunnel composting systems.

Triangular windrow turnersAt Komptech, professional turning machines for the processing of line windrows bear the name TOPTURN. Characteristic features of the TOPTURN X family are the generously dimensioned turn roller with perfect mixing properties, the solid telescopic frame and a hydraulic chassis, with either wheel or track drive. The pivotable cabin combines easy access from the ground with a perfect view in the working position. Optimal space utilisation is achieved by deploying the side repositioning option.

System technology – system construction

for system sizes from upwards of 15,000 tons per year

TOPTURN 300 Tractor with 45 kW required to 500 m3/h

TOPTURN 3500 G 112 kW / 152 HP to 1000 m3/h

TOPTURN X53 242 kW / 330 HP to 3500 m3/h

TOPTURN X60 242 kW / 330 HP to 3500 m3/h

TOPTURN X67 328 kW / 446 HP to 4500 m3/h

Stationary machines – system technology Drive rating Throughput

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Composting – final processing

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The compost is screened off to attain a product with a consistent particle size and to separate off any contraries still present (clingwrap, stones, etc.). Komptech has a wide range of mobile and stationary screening machines for this process stage. A technological difference can be made between drum screens and star screens.

Drum screensFrom the hopper to the drum – on mobile drum screens, everything is designed for high operational demands. Extremely rugged hopper design, straight line travel control of the hopper belt and automatic fill level control for the screen drum ensure smooth operation. Working with the electrically driven versions is particularly energy efficient. On stationary screen machines, drums up to 2.5 m in diameter and up to 12 m in length are used. The screening process is performed either with a screen drum with a fixed hole size or with a flexible system comprised of a core drum with exchangeable screen segments.

screening, drum screens • Broad product range for any performance requirement

• Large bandwidth of screen hole sizes, mobile: 5-80 mm stationary: 10-300 mm

• Selection of drive on mobile machines (MAXX, MUSTANG) diesel-hydraulic, diesel-electric or mains operation

• Stationary solutions with precise tailoring to the locality

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key componenTs

Mobile drum screensIn the mobile sector, the entry level products are the JOKER and PRIMUS. Following on from them are the MAXX and MUSTANG screen machines, ideal for use on mid-sized to large-scale compost sites. Their rugged structure and high-performance components make them suitable for almost any screen application and represent professional solutions for contracting companies. At the top end of the range is the MAGNUM – with a performance familiar only from the stationary sector.

Stationary drum screensThe stationary drum screen systems are true workhorses. Direct-drive heavy-duty supporting wheels provide quiet drum operation and, thanks to the perfect degree of efficiency, reduce energy consumption and noise emissions. The variable machine configuration in regard to sub- structure, servicing accessibility, enclosure and drive simplify tailoring to on-site conditions. Many options are also available for the screen drum, such as a special carrier drum with exchangeable screen segments.

Mobile machines Drive rating Throughput

Stationary machines – system technology Drive rating Throughput

JOKER 16,5 kW to 35 m3/h

PRIMUS 38 kW to 70 m3/h

MAXX (MAXX E) 62,5 kW (48 kVA) to 120 m3/h

MUSTANG (MUSTANG E) 70 kW (48 kVA) to 160 m3/h

MAGNUM 97 kW to 200 m3/h

Drum screens2255 | 2278 | 2290 | 2590 | 25120 18 - 37 kW 150 m3/h to 230 m3/h

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Composting – final processing

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In addition to the proven drum screens, star screens also provide convincing performance in the composting sector.

Star screensScreening is always in season with MULTISTAR star screens. High throughput and selectivity are retained, even with variations in moisture content and the various states of rotting. This is because the screen units are continually cleaned by the patented CLEANSTAR cleaning system.Separation into three fractions (two fractions on the M2, L2 and 2-SE) takes place in one operation – with wind sifting and Fe separation on request. Options such as wind sifting, magnet separation and separation of the rolling fraction ensure quality compost free of contraries. The screen section is infinitely variable over a wide range depending on the screen deck configuration selected (coarse, medium, fine and finest screen). The electric drive (diesel generator on mobile versions) and the intelligent controller with self-explanatory visual controls allow ease of working without high power costs.

• Separation into 2, 3 or 4 fractions with one machine and in one operation

• High throughput with precise selectivity with the CLEANSTAR system

• High degree of flexibility by changing particle size within seconds

screening, sTar screens

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key componenTs

Mobile star screens The semi-mobile EASYSTAR star screen unit is the entry level product for mobile star screen technology. The MULTISTAR M3 represents the right solution for mid-sized sites. The MULTISTAR L3 is used if more performance is required. Ease of use and high-grade components make it perfect for continuous operation on large sites. The MULTISTAR XL and XXL are at the top end of the mobile range. They have been designed as high-performance machines for large sites.

Stationary star screensStationary MULTISTAR star screen systems leave no customer requirement unaddressed. The machines range from the MULTISTAR 2-SE star screen system (an easily integratable solution by virtue of its compact design) to the MULTISTAR 3-SE and 4-SE screen systems. The modular design tailors perfectly screen decks, feed metering container, wind sifter, stone separation and magnet separation to the separation job at hand, generating up to 4 fractions in one operation.

Mobile machines Drive rating Throughput

EASYSTAR 12 - 27,5 kW to 150 m3/h

MULTISTAR M3 | M2 48 kVA | 48 kVA to 120 m3/h | 100 m3/h

MULTISTAR L3 | L2 60 kVA | 44 kVA to 180 m3/h | 150 m3/h

MULTISTAR XL | XXL 60 kVA | 100 kVA to 250 m3/h | 400 m3/h

Star screen2SE | 3SE 12-22 kW | approx. 50 kW to 250 m3/h

Stationary machines – system technology Drive rating Throughput

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Composting – final processing and output

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Screening at the end of the rotting process generates a usable fraction and a screen overflow. This is again perfect for use as structure material. Use of these woody fractions as biomass fuel is also conceivable, provided however that as many spurious contraries as possible (mainly light material such as clingwrap) have been removed.

Wind sifterThe HURRIKAN and HURRIKAN S wind sifters from Komptech are a benchmark in this sector. The patented pressure-suction process ensures extremely effective separation of the lightweight fraction from the screen overflow. In the first step, material is separated off by a pressure blower. In the second step, the lightweight material is drawn off by a powerful extractor fan. This, together with the optimal adjustments to material properties, ensures an excellent degree of selectivity. The quality of the recyclable over-sized particles can be improved further still by using magnet separation and separation of rolling fractions.

• High throughput with over 90% selectivity

• Optimal adjustments to material properties

• Mobile wind sifter can be combined with virtually any commercially available screen machine

• Available as mobile versions with integrated diesel unit (option) or as electric stationary variants

Wind sifTing

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key componenTs

Wind sifters HURRIKAN wind sifters are available as mobile and stationary variants. The mobile machine is easy to transport, quickly deployed and with a generator, also independent of power supply. The wide feed chute enables the combining with virtually any commercially available screen machine. For wind sifting, the stationary HURRIKAN unit has extremely compact dimensions and can therefore be easily integrated into a system chain. For both variants, there is a powerful S version with an enlarged suction section.

Compost spreaderThe controlled discharge of fertilizer is a prerequisite for responsible agriculture. The MEGAFEX from Farmtech guarantees uniform spreading. Many years experience in agricultural engineering, combined with expertise gained in custom machine construction, have resulted in a general-purpose spreader with the highest performance in all conditions. The machine is also easy to use. The sprung hitch (top or bottom), the hydraulic supporting foot, the lift axle and the electro-hydraulic remote control from the tractor ensure work is relaxing.

Mobile machines Drive rating Throughput

Stationary machines – system technology Drive rating Throughput

Wind sifter HURRIKAN 48 kVA to 40 m3/h

Wind sifter HURRIKAN S 60 kVA to 60 m3/h

Compost spreader MEGAFEX LOAD CAPACITY Load capacity 1400 | 1700 | 2000 85 kW | 100 kW | 120 kW 15,2 m3 | 16,2 m3 | 20,7 m3

Wind sifter HURRIKAN | HURRIKAN S 28 kW / 47 kW to 40 m3/h | 60 m3/h

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Technology for a better environment

Komptech GmbHKühau 37A-8130 Frohnleiten[t] +43 3126 505 - 0[f] +43 3126 505 - 505[e] info@komptech.com

www.komptech.com

Komptech UK Ltd.Forge End, Lodge Farm, Kineton, Warwickshire, CV35 0JH[t] +44 1926 64 29 72[f] +44 1926 64 29 71info.uk@komptech.com

We reserve the right to make technical changes due to ongoing development. E-06-2009