32
RESEARCH KOMPTECH GOES DANISH PRACTICE CONCENTRATED RDF POWER PRACTICE JØRGEN NESTOR POWERS UP magazine 1/2013
| Date post: | 06-Apr-2016 |
| Category: |
Documents |
| Upload: | thomas-hohenadler |
| View: | 228 times |
| Download: | 2 times |
RESEARCHKomptech goes Danish
pRACtiCEconcentrateD rDF power
pRACtiCE
Jørgen nestor powers Up
magazine 1/2013
A-8130 Frohnleiten, Kühau 37 | T +43 3126 505 0 | [email protected]
The rest is in the brochure. And at www.komptech.com.
Incredibly tough: The Terminator direct
Shaken, not stirred: The Ballistor
THE RDF PROS.
A fine thing: The Rasor
Stationary single-shaft shredder for pre-shredding with direct drive
Stationary post-shredder for RDF
Stationary ballistic separator
Sverker Rosdahl’s investment has paid off
Publisher: Komptech GmbH, Kühau 37, A-8130 FrohnleitenT +43 3126 505 - 0, F +43 3126 505 - 505, [email protected], www.komptech.comEditors: Andreas Kunter, Joachim Hirtenfellner, Martin WellacherLayout & graphics: Alexandra GauglPhotos: Komptech GmbHFrequency: periodically
CONTENTSPracticEWELL PREPARED FOR THE RDF MATCHHow Slovakia’s t+t company is meeting a lot of goals with Komptech’s RDF line – a team report. 4
iNtErViEWTHE EARTH IS HEATING UPKarl Rose is one of the world’s most respected climate experts. He paints a gloomy picture of the future. 6
PracticEICING ON THE CAKELayering it on with the Terminator - a special recipe in Boone County, Iowa. 8
PracticEONE GOOD TURN DESERVES ANOTHERThe MBT in Myslenice is one of the most advanced in Poland, and is reducing the burden on regional landfills. 10
KOMPtEcH iNSiDEWITH THE POWER OF THE SUNEach year Komptech generates over 205 MWh of power with the new solar array on the roof of its Slovenian plant. 12
KOMPtEcH iNSiDEBELLA ITALIACompagnia Generale Trattori S.p.a. (CGT):Off to new horiizons with a new sales partner. 13
BUSiNESSAN INVESTMENT THAT HAS PAID OFFIn Halmstad in southern Sweden, Sverker Rosdahl has taken Komptech´s largest stationary trommel screen into profitable operation. 14
rESEarcHDANISH INSTITUTE RESEARCHES FOR KOMPTECHTurning forestry waste into an industrial heating briquette - cooperative research between the Danish Technological Institute and Komptech. 16
iNNOVatiONGREETINGS FROM THE AXTORA machine goes on tour and brings home a wealth of new experiences. 18
iNNOVatiONPRODUCT SPOTLIGHT: THE AXTORSix reasons why the Axtor is the best machine in its class. 20
BUSiNESSREFINERY TO GOAndreas Zeller talks about his plans for the future, and why it’s important to get your hands dirty sometimes. 22
PracticEISRAELI PIONEERSThree partners had a vision, and within five years built one of the largest composting operations in the world in the Jordan valley. 24
PracticEMORE MUSCLEJørgen Nestor and his new Crambo Heavy Duty. More hp for more profit – an interview. 26
PracticEA LEARNING JOURNEYA 25-person delegation of British organic waste specialists visited Austria and took lots of good ideas back home with them. 28
LEttErS tO tHE EDitOrQ & AKomptech has answers to urgent questions about service and technology. 30
Title picture:Jørgen Nestor powers up
22
24
14
6
Andreas Zeller and his “refinery to go”
Compost OR, Israel’s compost pioneers
Karl Rose about the future
TECHNOLOGY FOR A BETTER ENVIRONMENT 03
A-8130 Frohnleiten, Kühau 37 | T +43 3126 505 0 | [email protected]
At the t+t plant in Slovakia, a team of Komptech machines is ready to face any challenger.
04 PRACTICE
RDF stands for Refuse-Derived Fuel. Figuratively speaking, it’s the ball that goals are made with. If you can make high-quality RDF, you win - or at the very least, you can do good business. The t+t company in Žilina, Slovakia has taken an RDF plant into operation with a strong team of machines that can stand up to any contender. All wear green, and all are from Komptech: Terminator, Flowerdisc, Multistar, Ballistor, Rasor. From
mixed household waste they create a premium RDF - no easy matter for standard machines, but no problem at all for these top-shelf Komptech players.
CONCRETE CUSTOMERThe main customer for the premium RDF is a company called ecorec, which delivers it to the Holcim cement works in Rohožník. ecorec also takes the recycling fraction, consisting of
the rolling materials from the Ballistor (PET, HDPE, heavy items).
HIGHLY MOTIVATEDA good match takes team spirit and top players. t+t is a motivated and visionary player in the Slovakian waste business. Founded 20 years ago and headquartered in Žilina, it employs 185 people, made revenues of 8 million euros in 2011, and operates extensive waste collection
weLL prepareD For the rDF game
TERMINATOR
FLOWERDISC MULTISTAR
RASOR BALLISTOR
THE KOMPTECH TEAM
TERMINATORSingle-shaft pre-shredder
Max. throughput 50 t/h
the five pros in the Komptech rDF team
Company: t+t as
Location: Žilina, Slovakia
Commissioning: 15 December 2011
Annual throughput: 40,000 tonnes
Hourly throughput: 23 tonnes
Employees: 7
Website: http://t-t.sk
FACTS
PRACTICE 05
services, two landfills, and now a refuse-derived fuel plant. It started as a successor to “Žilina Technical Services” and is today the majority owner of a PPP together with the City of Žilina that provides landscaping and city cleaning services. The company takes in 40,000 tonnes of mixed household waste each year from about 100 municipalities in northern Slovakia, as well as schools, hospitals, supermarkets and restaurants. The disposal fees they pay cover the costs of processing the waste. The main customer is the City of Žilina. With a population of 85,000, this university and industrial city is the metropolis of northern Slovakia.
PIONEERS TEAM UPTwo years ago, two pioneering companies got together here - t+t and Komptech. Their shared vision of modern resource and waste management led them to team up, and they quickly planned, built and commissioned the Žilina RDF processing facility. Now, in Dolný Hric ov a Terminator 3400 S, Flowerdisc, Multistar 2-SE, Ballistor 6300 and Rasor 5400 run twelve hours a day to
turn customers’ household waste into products t+t can sell at a profit. Plant director Juraj Hollý and manager Miloš D urajka together bring 50 years of experience to bear.
MEETING UP AT A MATCHThe companies have also met, if not on, then certainly at the playing field. Markus Maierhofer of Komptech’s Sales department is an amateur footballer. He and Vladimir Solokovský, Board Chairman of t+t and a fan of MSK Žilina, got together at a European Cup game of Slovakia’s national champion side. Their shared professional interest is matched by shared personal interests. What does Vladimir Solokovský associate with Komptech? “The Terminator is your top player. It best shows what Komptech is all about.”
BAD TIMES FOR LANDFILLSThe new facility means slimmer pickings for landfills in Slovakia. Landfill space is already scarce, and in any case landfilling untreated waste is increasingly seen as an environmental problem, even though it is not yet prohibited in this country.
THE KOMPTECH TEAM
FLOWERDISCDisc screen
Max. throughput 50 t/h
MULTISTAR 2-SEStar screen machine
Max. throughput 30 t/h
BALLISTORBallistic separator
Max. throughput 60 t/h
RASORPost-shredder
Max. throughput 10 t/h
the five pros in the Komptech rDF team
But pressure from Brussels to comply with the European landfilling directive, and the introduction of a landfill tax, will make it easier for t+t to turn its pioneering role into a profitable one. Currently the cost of processing cuts into profits, and landfilling is still cheaper than treating waste.
THE NEXT STEPBut t+t is already planning the next step - biological treatment downstream from the RDF processing plant in Dolný Hric ov. This vision will make the company even better.
Žilina
BratislavaSlovakia
HuNGARY
CZECH REPuBLIC
POLAND
AuSTRIA
ROMANIA
uKRAINE
Director Juraj Hollý and manager Miloš D urajka are enthusiastic fans of the Komptech team.
06 INTERVIEW
Karl Rose is Senior Fellow of the World Energy Council, London, and heads the development of global energy scenarios for 2050.
Photo: Fischer
INTERVIEW 07
the earth is heating UpEconomics research Karl Rose considers climate goals unreachable. He predicts a four-degree rise in temperature and a doubling of energy consumption, and considers the actions of individuals to be the key to a sustainable economy.
Across Europe, there is discussion of renewable fuels. Do we really need to choose between fuel and food?
KARL ROSE: No, that’s a much too narrow perspective. Whether or not Austria introduces renewable fuel has no effect on world hunger. But if fossil fuel were to be replaced with renewable fuel worldwide, it would be a different story.
Governments are holding to the Copenhagen climate goal of no more than two degrees global warming. Is that still realistic?
ROSE: We will most definitely not reach that goal. That would require tremendous political shocks or technology leaps that are not presently on the horizon.
What do you mean by political shocks?
ROSE: A planned economy that intervened to a massive extent in resource use. Like the “car free days” of the 70s. That is incompatible with our democratic way of doing things. We already have enough heated discussion if the vice-mayor of Graz does away with a few parking places at the train station.
And then there are the new middle classes in China and India...
ROSE: Yes. They have an enormous appetite for energy, and feed it mostly with coal. That will remain the case for decades, whether or not we
in Europe approve. But we need to use new technologies, like carbon dioxide scrubbing and storage. We need to make these technologies as cheap and widespread as possible, as quickly as possible.
How much global warming do you project?
ROSE: Our scenarios are horrific. By 2050 global energy consumption will double. I project three and a half to four degrees global warming, and that’s if everything goes well.
What will that mean?
ROSE: It’s difficult to predict, because the scenarios are hard to model. But perhaps it will be less apocalyptic than we assume.
Is it true that the economic crisis was the most effective climate protection measure thus far?
ROSE: Yes. A recession is actually the best thing that can happen for the climate. It sets the clock back 7 to 10 years, but then we have other problems. unemployment and lack of purchase power are not fun.
What can individuals do?
ROSE: Actions by individuals are the key to achieving a sustainable economy. It horrifies me that young people buy a new mobile phone every six months. That’s wasteful. We have made huge mistakes in our use of space and the way residences are spread out across the landscape. We
have to get people to move back into the cities. There are people who commute because they must, and those who commute because they can.
Laws are made more for those who commute because they can. If that weren’t the case, Austrian drivers wouldn’t get a tax writeoff for commuting.
ROSE: And, many tax-advantaged company cars are SuVs or other high-end vehicles. If I were in politics, that’s where I would start, because people will tolerate that.
With the kind permission of the Kleine Zeitung, Graz, Austria
In Austria, commuters get a tax deduction based on the distance between their residence and workplace. The deduction is applicable only if using public transport would take an excessive amount of time.
BACKGROUND
08 PRACTICE
icing on the caKethe Boone county Landfill team is proud of their new terminator Heavy Duty.
something it can’t handle the drum simply comes to a stop, instead of jamming and breaking down. That means no lengthy repairs or unplanned maintenance headaches.
FOCUS ON EASE OF MAINTENANCEScott also liked the way that the machine is designed to make servicing easy – just swing the side panel up and away, and everything is accessible.
“Our guys can work safe and standing up. There’s no crawling under the machine,” he said, adding that since the Terminator doesn’t jam and break down when it encounters something it can’t grind, “we’ve only had to open the panel four times in 3 months, and we never need to bring a torch.” According to Scott, the Terminator also gives comparable or even better uptime than conventional compactors, while cutting waste
Scott Smith, landfill administrator for Boone County, Iowa, is proud of his new Terminator 5000S Heavy Duty Edition by Komptech. It maximizes his landfill capacity, while minimizing downtime.
He had originally been looking for a replacement compactor when a friend at a nearby RDF plant alerted him to what Komptech grinders could do. Scott took a look, saw a demo, ran the numbers, and ended up convinced that a Terminator was the way to go.
Of key importance in his decision was the huge increase in uptime due to the low-speed grinding action. unlike a fast shredder, when the Terminator encounters
PRACTICE 09
the Boone county landfill handles municipal solid waste, c&D waste, and compatible commercial and industrial waste, all told about 100-150 tons per day. the planning district it serves is one of only two in iowa to meet the state’s goal of 50% waste diversion; currently it diverts 55% of waste through source reduction, reuse, and recycling; regrinding waste for rDF would boost that to 65%.
FACTS
Washington
Oregon
California
Nevada
Idaho
Montana North Dakota
South Dakota
Nebraska
CANADA
MEXICO
Kansas Missouri
Boone
Arkansas
LouisianaFlorida
Oklahoma
Texas
Minnesota
WisconsinMichigan
Illinois Indiana
Ohio
Pennsylvania
West Virginia
Kentucky
Tennessee
MississippiGeorgia
Alabama
North Carolina
South Carolina
Virginia
New York
MaineMassachusetts
Maryland
New Hampshire
Vermont
IowaWyoming
utah
Arizona New Mexico
Colorado
Komptech uSA Inc.
Rhode Island
Connecticut
New Jersey
Delaware
Komptech USa inc.Headquarters: Denver, USacEO: Marcel Vallen2011 revenues: > 15 million eurosNumber of distributors: 13 and rising
the terminator beats any waste compactor.
volume by half. For example, some of the waste that comes to the landfill is already baled and very tightly compressed. The compactor can’t really do much more to it, but the Terminator can open up and grind the bales to half of their previous volume. “On a bad day, we can reduce our total volume by 40%; on a good day we can reduce it by 60%,” said Scott. Adding it up, that means the landfill will be able to stay in operation 14 years longer than planned, without adding acreage. Since the landfill makes money every year it is in operation, this makes the Terminator a very profitable investment.
ICING ON THE CAKEIn addition, by grinding the waste into same-sized particles, the Terminator reduces the amount of cover dirt needed to just a third of what the landfill was using previously. At the end of every workday the landfill covers the waste with 15 cm of dirt, “and now I’m frosting a cake instead of using extra dirt to hold down mattresses and fill in around bales,” as Scott put it. He opted for a ferrous separator on the Terminator, which lets the landfill separate out and sell scrap metal for an additional revenue stream. He also has other ideas on how to maximize profit at the landfill. For instance, the landfill can now do brush and post-disaster grinding, which were formerly contracted out. Scott is also looking at regrinding waste for RDF. This way the landfill can fill the trucks which currently leave the landfill empty, for additional revenue.
10 PRACTICE
preparing For the FUtUreGood preparation and good decisions - the two key factors in managing a waste handling facility. Ewa Kęsek knows whereof she speaks.
“The most important things in managing this facility were the preparations and then the decisions we made. We looked for advice and chose consultants we could trust. Komptech is one of them,” says Ewa Kęsek, CEO of Zakład utylizacji Odpadow Sp. z o.o., the company that provides waste handling services for the city of Mys lenice in the Voivodeship of Lesser Poland. What was the most important decision? Kęsek: “Whether or not to go ahead with it.”
A QUESTION OF NEGOTIATION SKILLSEwa Kęsek, was entrusted with the waste handling for Mys lenice in 2007. At the time, that meant landfilling. But Ewa Kęsek had a plan. She knew about the waste handling requirements that resulted from Poland’s entry into the Eu, and repeatedly brought up the subject with the mayor. “We started with a budget of 500,000 Złoty (125,000 euros), and each week another million was added.
Finally we were at 47 million Złoty (12 million euros) and were able to start investing.” The decision was made for a mechanical-biological waste treatment system (MBT). Thanks to well-chosen advisers the city was able to do its own planning work. The system was tendered out, constructed and taken into operation. Since 1 April 2012 Komptech machines have been working with three sorting lines and a box composting system from Austrian supplier MuT.
Director Jerzy Podmokły and CEO Ewa Kęsek in front of the Komptech Mashmaster.
PRACTICE 11
preparing For the FUtUre
NEW BUSINESS FIELDSThe plant produces cleanly sorted recyclables, refuse-derived fuel for the cement industry and a landfill cover material. There are no tipping fees for these material streams, and the recyclables bring in revenues. Thanks to the Komptech Ballistor, an unusually clean ferrous fraction can be extracted from the rolling fraction. Currently it is selling for 175 euros per tonne, and higher amounts are paid for the hand-sorted PET, the foil and aluminium. “Sales of recyclables is its own business field for us. Currently we sell at daily spot prices, but we’re looking for long-term contracts,” reveals Jerzy Podmokły, Director of the Mys lenice MBT. The environment also profits, since not even half as much material as before goes to the new landfill. The success is visible.
A COMPACT PLANT FOR A BIG JOBThe compact dimensions of the facility are obvious at a glance. Just two halls were built next to the new
landfill section, but these two halls handle 30,000 tonnes of household waste annually from Mys lenice and its surrounding area. With Terminator, Ballistor, Multistar and Mashmaster, Komptech supplied the core machinery for the mechanical processing, as well as a Topturn for turning the windrows. Naturally there was opposition to Ewa Kęsek´s plans. Some neighbours were afraid of what the changes might mean, but ultimately they could not prevail against the many benefits of the latest waste handling techniques. “The strong vision of this new era in waste handling in Poland has established itself,” says Ewa Kęsek, adding a crisp “I finish what I start.” It’s something that could also be said of Komptech.
Company: MBA Mys lenice of Zakład utylizacji Odpadow Sp. z.o.o.
Location: Mys lenice, Poland
Throughput: 30,000 t/year (one shift) 60,000 t/year (two shifts)
upfront cost: 47 million Złoty (12 million euros)
Commissioning: 1 April 2012
Installed power: 1.2 mW
Employees: 50
Website: www.skladowisko.com.pl
FACTS
Mys lenice
WarsawaPOLANDGERMANY
CZECH REPuBLIC
AuSTRIASLOVAKIA
HuNGARY ROMANIA
uKRAINE
LITHuANIABaltic Sea
REPuBLIC OF BELARuS
Recyclables recovery in Mys lenice.
http://www.agrex-eco.pl/
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
��
��
�
● ANCONA tel. 071.727711 - fax 071.7108331
60027 Osimo, Via A. Volta 15Loc. Aspio Terme - Zona Ind.le
● AOSTA tel. 0165.77481 - fax 0165.765192
11020 Quart, Località Amerique● AREZZO tel. 0575.394.1 - fax 0575.356608
52100 Via P. Calamandrei, 305● BARI tel. 080.5861111 - fax 080.5322179
70026 Modugno, Zona Industriale S.S. 96 km. 118
● BERGAMO/BRESCIA tel. 030.657681
fax 030.6857215 - 25050 Passirano, Via S.Antonio, 4/B
● BOLOGNA tel. 051.6477.1 - fax 051.727450
40012 Calderara di Reno, Via Persicetana, 4
● BOLZANO tel. 0471.82451 - fax 0471.824590
39044 Egna, Via degli Artigiani, 14 - Zona Ind.le Sud
● CAGLIARI tel. 070.211271 - fax 070.240377
09030 Elmas, Via Sernagiotto Snc● CARRARA tel. 0585.50771 - fax 0585.55296
54031 Avenza, Via Aurelia, angolo Via Carriona
● CASERTA tel. 0823.583111 - fax 0823.824244
81025 Marcianise, S.P. 336 (ex Sannitica) km. 21,035
● CATANIA tel. 095.7498111 - fax 095.291047
95030, Zona Industriale C.da Palma● COSENZA tel. 0984.831611 - fax 0984.402532
87036 Rende, Zona Industriale C.da S. Valentino
● CUNEO tel. 0172.63801 - fax 0172.691464
12045 Fossano, Via Torino, 57● FIRENZE tel. 055.88604.1 - fax 055.8860428
50041 Calenzano, Via G. Zanella, 11● FOGGIA tel. 0881.680405 - fax 0881.680404
71100 Zona Industriale C.so del Mezzogiorno km. 3
● GENOVA tel. 010.7236.1 - fax 010.750767
16163, Via Lungo Torrente Secca, 64 rosso
● IMPERIA tel. 0184.46461 - fax 0184.464646
18018 Taggia, Regione Periane snc● LIVORNO tel. 0586.9440.1 - fax 0586.941606
57017 Stagno, Via Aurelia● MILANO tel. 02.923641 - fax 02.92364430
20061 Carugate, Strada Provinciale 121● PADOVA tel. 049.873371 - fax 049.633509
35030 Sarmeola, Via della Provvidenza, 151
● PALERMO tel. 091.8633101 - fax 091.8690220
90044 Carini, S.S. 113 km. 281,5● PARMA tel. 0521.615227- fax 0521.656663
43010 Fontevivo, Quartiere Romitaggio, 21
● PERUGIA tel. 075.9880124 - fax 075.9880125
06089 Torgiano, Loc. Pontenuovo - Via Kennedy, 3
● PIACENZA tel. 0523.7626.1 - fax 0523.760706
29010 Gragnano Trebbiense, Loc. Noce, 8
● POTENZA tel. 0971.485519 - fax 0971.485525
85050 Tito Scalo, Zona Industriale di Tito
● RIMINI tel. 0541.623473 - fax 0541.623589
47822 Santarcangelo di Romagna, Via del Pino, 5
● ROMA tel. 06.82601 - fax 06.8260358
00137, Via Nomentana, 995● SASSARI tel. 079.2637401 - fax 079.260609
07100 Zona Industriale Predda Niedda Strada n. 18
● SONDRIO tel. 0342.493802 - fax 0342.493794
23010 Colorina, Loc. Piani della Selvetta
Via Nazionale, 620● TERAMO tel. 085.946541 - fax 085.9462123
64025 Scerne di Pineto, Via Piane Vomano
● TORINO tel. 011.8963511 - fax 011.8963556
10036 Settimo T., Via Leinì, 130● TREVISO tel. 0422.724166 - fax 0422.724168
31027 Spresiano, Via Marmolada, 8● UDINE tel. 0432.85071 - fax 0432.853408
33019 Tricesimo, Via S. Giorgio, 15● VERCELLI tel. 0161.2951 - fax 0161.295226
13100, Via Torino, 45● VERCELLI Divisione Energia tel. 0161.290300
fax 0161.290370 - 13100, Via Ettore Ara, 1
● VERONA tel. 045.825041 - fax 045.8201179
37066 Sommacampagna, Via dell’Agricoltura
CGT SpA Direzione Generale: MILANO - 20090 Vimodrone - Strada Statale Padana Superiore, 19 - tel. 02.274271 - fax 02.27427554
Filiali di Vendita, Nuovo e Usato, Noleggio e Assistenza Tecnica
[email protected] | www.cgt.it | 800-827134
12 KOMPTECH INSIDE
Slovenia has up to 2300 hours of sunshine a year - at the top of the European charts. So for CEO Sonja Rajh it only made sense to install a huge solar power array on the roof of the new factory building in Ljutomer when Komptech expanded its facility there.
Komptech CEO Josef Heissenberger, Farmtech CEO Sonja Rajh and Project and Production Manager Franz Jantscher with the new solar array.
With 927 modules of 205 watts output each, the array has a rated output of over 190 kW. “This lets us generate about 205 megawatt hours of current per year, saving almost 160 tonnes of CO2,” said project leader Franz Jantscher.The investment costs were about 320,000 euros. The array was put up by a Slovenian company, Pro-Sigma d.o.o., and went into operation in late 2012.
FACTS
Farmtech d.o.o.Activity: Component manufacture for Komptech and production of agricultural machinesLocation: Ljutomer/SloveniaCEOs: Sonja Rajh, Franz Jantscher, Borut KapunEmployees: 265Total production space: 11,200 m2
Machines produced per year: 1500
“We want to play an active role in the transition to renewables,” said Komptech CEO Josef Heissenberger in explaining the motivation for this flagship project. “So the installation of a new solar array was just another logical step.” But that’s not all - as part of next year’s expansion of the Frohnleiten facility, the company plans to replace its existing gas furnace with a modern chip-fired heating plant.
Ljutomer
Ljubljana
SLOVENIA
AuSTRIA
GERMANY
ITALY
CROATIA
HuNGARY
BOSNIA-HERZEGOVINA
Adriatic Sea
with the power oF the sUn
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
��
��
�
● ANCONA tel. 071.727711 - fax 071.7108331
60027 Osimo, Via A. Volta 15Loc. Aspio Terme - Zona Ind.le
● AOSTA tel. 0165.77481 - fax 0165.765192
11020 Quart, Località Amerique● AREZZO tel. 0575.394.1 - fax 0575.356608
52100 Via P. Calamandrei, 305● BARI tel. 080.5861111 - fax 080.5322179
70026 Modugno, Zona Industriale S.S. 96 km. 118
● BERGAMO/BRESCIA tel. 030.657681
fax 030.6857215 - 25050 Passirano, Via S.Antonio, 4/B
● BOLOGNA tel. 051.6477.1 - fax 051.727450
40012 Calderara di Reno, Via Persicetana, 4
● BOLZANO tel. 0471.82451 - fax 0471.824590
39044 Egna, Via degli Artigiani, 14 - Zona Ind.le Sud
● CAGLIARI tel. 070.211271 - fax 070.240377
09030 Elmas, Via Sernagiotto Snc● CARRARA tel. 0585.50771 - fax 0585.55296
54031 Avenza, Via Aurelia, angolo Via Carriona
● CASERTA tel. 0823.583111 - fax 0823.824244
81025 Marcianise, S.P. 336 (ex Sannitica) km. 21,035
● CATANIA tel. 095.7498111 - fax 095.291047
95030, Zona Industriale C.da Palma● COSENZA tel. 0984.831611 - fax 0984.402532
87036 Rende, Zona Industriale C.da S. Valentino
● CUNEO tel. 0172.63801 - fax 0172.691464
12045 Fossano, Via Torino, 57● FIRENZE tel. 055.88604.1 - fax 055.8860428
50041 Calenzano, Via G. Zanella, 11● FOGGIA tel. 0881.680405 - fax 0881.680404
71100 Zona Industriale C.so del Mezzogiorno km. 3
● GENOVA tel. 010.7236.1 - fax 010.750767
16163, Via Lungo Torrente Secca, 64 rosso
● IMPERIA tel. 0184.46461 - fax 0184.464646
18018 Taggia, Regione Periane snc● LIVORNO tel. 0586.9440.1 - fax 0586.941606
57017 Stagno, Via Aurelia● MILANO tel. 02.923641 - fax 02.92364430
20061 Carugate, Strada Provinciale 121● PADOVA tel. 049.873371 - fax 049.633509
35030 Sarmeola, Via della Provvidenza, 151
● PALERMO tel. 091.8633101 - fax 091.8690220
90044 Carini, S.S. 113 km. 281,5● PARMA tel. 0521.615227- fax 0521.656663
43010 Fontevivo, Quartiere Romitaggio, 21
● PERUGIA tel. 075.9880124 - fax 075.9880125
06089 Torgiano, Loc. Pontenuovo - Via Kennedy, 3
● PIACENZA tel. 0523.7626.1 - fax 0523.760706
29010 Gragnano Trebbiense, Loc. Noce, 8
● POTENZA tel. 0971.485519 - fax 0971.485525
85050 Tito Scalo, Zona Industriale di Tito
● RIMINI tel. 0541.623473 - fax 0541.623589
47822 Santarcangelo di Romagna, Via del Pino, 5
● ROMA tel. 06.82601 - fax 06.8260358
00137, Via Nomentana, 995● SASSARI tel. 079.2637401 - fax 079.260609
07100 Zona Industriale Predda Niedda Strada n. 18
● SONDRIO tel. 0342.493802 - fax 0342.493794
23010 Colorina, Loc. Piani della Selvetta
Via Nazionale, 620● TERAMO tel. 085.946541 - fax 085.9462123
64025 Scerne di Pineto, Via Piane Vomano
● TORINO tel. 011.8963511 - fax 011.8963556
10036 Settimo T., Via Leinì, 130● TREVISO tel. 0422.724166 - fax 0422.724168
31027 Spresiano, Via Marmolada, 8● UDINE tel. 0432.85071 - fax 0432.853408
33019 Tricesimo, Via S. Giorgio, 15● VERCELLI tel. 0161.2951 - fax 0161.295226
13100, Via Torino, 45● VERCELLI Divisione Energia tel. 0161.290300
fax 0161.290370 - 13100, Via Ettore Ara, 1
● VERONA tel. 045.825041 - fax 045.8201179
37066 Sommacampagna, Via dell’Agricoltura
CGT SpA Direzione Generale: MILANO - 20090 Vimodrone - Strada Statale Padana Superiore, 19 - tel. 02.274271 - fax 02.27427554
Filiali di Vendita, Nuovo e Usato, Noleggio e Assistenza Tecnica
[email protected] | www.cgt.it | 800-827134
Milano
Genova
Padova
Treviso
Bologna
Ancona
Perugia
Arezzo
FirenzeLivorno
CarraraRimini
Teramo
Cosenza
Palermo
Catania
Potenza
Bari
FoggiaCaserta
Roma
Cagliari
Sassari
BolzanoSondrio
Aosta
Torino
Cuneo
Imperia
Piacenza
Parma
Verona
BerganoVercelli
udine
KOMPTECH INSIDE 13
Based in Milan, the company is Caterpillar’s general representative in Italy, and has an accordingly dense network of locations across the country. “The Komptech brand is already well-established in Italy, and Komptech is recognized as the most innovative. What was missing was a broader, full-coverage sales and service organisation that could make use of the existing potential and successfully go up against the current market leader Cesaro Mac Import,” said CSO Josef Imp of the reason for the decision.
“CGT is a sales partner who brings exactly this to the table, and is also very interested in getting more deeply involved in environmental technology,” he continued. “As the CAT sales organisation, the company is definitely in a position to make good use of the considerable potential synergies, from the CAT engines used in Komptech’s mobile machines to the same customer segment for CAT handling machines in disposal companies.”
These facts speak for themselves, and encourage both partners to hope that by joining forces they can substantially grow Komptech’s share of the Italian market in the coming years, with above-average profit opportunities for both companies. We’re looking forward to seeing it unfold.
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
�
��
�
�
�
�
�
�
�
�
�
�
�
��
�
�
�
�
● ANCONA tel. 071.727711 - fax 071.710833160027 Osimo, Via A. Volta 15Loc. Aspio Terme - Zona Ind.le
● AOSTA tel. 0165.77481 - fax 0165.765192 11020 Quart, Località Amerique
● AREZZO tel. 0575.394.1 - fax 0575.35660852100 Via P. Calamandrei, 305
● BARI tel. 080.5861111 - fax 080.532217970026 Modugno, Zona Industriale S.S. 96 km. 118
● BERGAMO/BRESCIA tel. 030.657681fax 030.6857215 - 25050 Passirano, Via S.Antonio, 4/B
● BOLOGNA tel. 051.6477.1 - fax 051.72745040012 Calderara di Reno, Via Persicetana, 4
● BOLZANO tel. 0471.82451 - fax 0471.82459039044 Egna, Via degli Artigiani, 14 - Zona Ind.le Sud
● CAGLIARI tel. 070.211271 - fax 070.24037709030 Elmas, Via Sernagiotto Snc
● CARRARA tel. 0585.50771 - fax 0585.5529654031 Avenza, Via Aurelia, angolo Via Carriona
● CASERTA tel. 0823.583111 - fax 0823.82424481025 Marcianise, S.P. 336 (ex Sannitica) km. 21,035
● CATANIA tel. 095.7498111 - fax 095.29104795030, Zona Industriale C.da Palma
● COSENZA tel. 0984.831611 - fax 0984.40253287036 Rende, Zona Industriale C.da S. Valentino
● CUNEO tel. 0172.63801 - fax 0172.69146412045 Fossano, Via Torino, 57
● FIRENZE tel. 055.88604.1 - fax 055.886042850041 Calenzano, Via G. Zanella, 11
● FOGGIA tel. 0881.680405 - fax 0881.68040471100 Zona Industriale C.so del Mezzogiorno km. 3
● GENOVA tel. 010.7236.1 - fax 010.75076716163, Via Lungo Torrente Secca, 64 rosso
● IMPERIA tel. 0184.46461 - fax 0184.46464618018 Taggia, Regione Periane snc
● LIVORNO tel. 0586.9440.1 - fax 0586.94160657017 Stagno, Via Aurelia
● MILANO tel. 02.923641 - fax 02.9236443020061 Carugate, Strada Provinciale 121
● PADOVA tel. 049.873371 - fax 049.63350935030 Sarmeola, Via della Provvidenza, 151
● PALERMO tel. 091.8633101 - fax 091.869022090044 Carini, S.S. 113 km. 281,5
● PARMA tel. 0521.615227- fax 0521.65666343010 Fontevivo, Quartiere Romitaggio, 21
● PERUGIA tel. 075.9880124 - fax 075.988012506089 Torgiano, Loc. Pontenuovo - Via Kennedy, 3
● PIACENZA tel. 0523.7626.1 - fax 0523.76070629010 Gragnano Trebbiense, Loc. Noce, 8
● POTENZA tel. 0971.485519 - fax 0971.48552585050 Tito Scalo, Zona Industriale di Tito
● RIMINI tel. 0541.623473 - fax 0541.62358947822 Santarcangelo di Romagna, Via del Pino, 5
● ROMA tel. 06.82601 - fax 06.826035800137, Via Nomentana, 995
● SASSARI tel. 079.2637401 - fax 079.26060907100 Zona Industriale Predda Niedda Strada n. 18
● SONDRIO tel. 0342.493802 - fax 0342.49379423010 Colorina, Loc. Piani della SelvettaVia Nazionale, 620
● TERAMO tel. 085.946541 - fax 085.946212364025 Scerne di Pineto, Via Piane Vomano
● TORINO tel. 011.8963511 - fax 011.896355610036 Settimo T., Via Leinì, 130
● TREVISO tel. 0422.724166 - fax 0422.72416831027 Spresiano, Via Marmolada, 8
● UDINE tel. 0432.85071 - fax 0432.85340833019 Tricesimo, Via S. Giorgio, 15
● VERCELLI tel. 0161.2951 - fax 0161.29522613100, Via Torino, 45
● VERCELLI Divisione Energia tel. 0161.290300fax 0161.290370 - 13100, Via Ettore Ara, 1
● VERONA tel. 045.825041 - fax 045.820117937066 Sommacampagna, Via dell’Agricoltura
CGT SpA Direzione Generale: MILANO - 20090 Vimodrone - Strada Statale Padana Superiore, 19 - tel. 02.274271 - fax 02.27427554
Filiali di Vendita, Nuovo e Usato, Noleggio e Assistenza Tecnica
[email protected] | www.cgt.it | 800-827134
Italy is one of the largest waste markets in Europe. With significant unresolved public waste disposal challenges, especially in the south, there is much potential for development in the coming years. Renewable energy is also gaining importance in Italy. For this reason, Komptech has decided to leverage this potential with a new partner, Compagnia Generale Trattori S.p.a. (CGT).
Front, left to right: Josef Imp (CSO Komptech), Josef Heissenberger (CEO Komptech), Lino Tedeschi (CEO CGT), Vincenzo de Benedectis (Managing Director CGT)Rear, left to right: Christian Kulmer (Komptech Area Sales Manager Italy), Ewald Konrad (Senior Area Sales Manager Komptech), Paolo Vivani (Earthmoving General Manager), Andrea Elli (Earthmoving Marketing Manager)
14 BuSINESS
an investment that has paiD oFFThe 25/120 is Komptech’s largest stationary drum screen. In early 2012, the first Swedish customer took delivery of one. Stena Recycling Production Manager Sverker Rosdahl reports on how the machine has worked out so far.
Stena Recycling in Halmstad, Sweden had clear requirements for a new screener - high throughput and high reliability. The company needed a new trommel to handle “difficult” media. After detailed research of the products on the market, Sverker Rosdahl determined that Komptech machines met his requirements. Together with Daniel Carlberg of Pon Equipment,
Sverker rosdahl is doing good business with his new trommel screen.
Komptech’s Swedish representative, he visited Komptech to take a closer look at some of them.
FOUR FRACTIONS IN ONE PASSFinally, he decided on a stationary 25/120 trommel screen. The numbers stand for 2.5 meters drum diameter and 12 meters drum length. What clinched the deal was the ability to screen out four
fractions in one pass. The machine sorts out non-ferrous metals for recycling. “Our input material is difficult, because it has wires and cables in it. So we ordered the machine with anti-dirt bars to prevent the material getting stuck in the holes. It has worked very well and so far we have not had to clean the drum once,” emphasizes Sverker Rosdahl.
BuSINESS 15
an investment that has paiD oFF
THE STENA GROUP
The Stena Sphere Group was founded in 1939 and is one of the largest family companies in Sweden. It consists of three subsidiaries, Stena AB, Stena Sessan AB and Stena Metall AB. All told, these three companies employ about 19,000 people, and in 2009 made revenues of around 5.6 billion euros, for a pre-tax profit of about 200 million euros. Environment and recycling are the group’s fastest-growing business categories and are handled by Stena Metall AB, headquartered in Göteborg with 250 locations in Scandinavia. In recent years, there has been a major emphasis on research and development, with cooperative efforts with well-known Swedish universities (Göteborg, Linköping, Lund, Kalmar).Sverker Rosdahl is Production Manager at the facility in Halmstad in southern Sweden.
www.stena.com
FROM TWO TO ONE, FROM FOUR TO TWOThe new Komptech 25/120 trommel screen replaces two older machines, and has significantly improved Stena’s operations in Halmstad. “The screen has an incredible capacity and meets all our expectations. It let us switch from four shifts to two shifts, with the same output as before. The investment has absolutely paid off,” says Rosdahl, proud of his decision.
LESS NOISEIn addition to high capacity, Sverker Rosdahl also mentioned the operational safety of the drum, thanks to the four separate electric motors. “An additional requirement we had was that the new screen be environmentally sound, including low noise and dust emissions. Here again the new Komptech is significantly better than its predecessors.”
Screen model Length Diameter Max. throughput
1845 4500 mm 1800 mm 120 m3/h
2055 5500 mm 2000 mm 160 m3/h
2255 5500 mm 2200 mm 190 m3/h
2278 7800 mm 2200 mm 230 m3/h
2290 9000 mm 2200 mm 250 m3/h
2590 9000 mm 2500 mm 275 m3/h
25/120 12000 mm 2500 mm 300 m3/h
Stockholm
SWEDENFINLAND
LITHuANIA
LATIVIA
ESTONIA
NORWAY
DENMARK
GERMANY POLAND
Atlantic Ocean
Arctic Ocean
Baltic Sea
Gulf of Bothnia
Halmstad
16
Joint research on the use of forestry waste as fuel - the 1300 km between Frohnleiten, where Komptech is based, and Stenderup, home of the Pelletizing Test Center of the DTI (Danish Technological Institute), presented no obstacle. The Danish researchers confirmed the validity of the idea, and together with Komptech developed the process for making the new fuel. Previously the input material was left in the forest or composted. Today, with the help of the newly developed process, it can replace fossil fuels.
It takes the form of an industrial briquette and has an energy density of 3.6 MWh/m³. It’s ideal for coal-fired power plants looking for a renewable fuel for co-firing. The energy density of fuels has a huge influence on their transportation costs and thereby on their radius of use. Wood chips only have 0.7 MWh/m³, making them unsuitable for long-distance transportation, but this new briquette has five times that energy density, and 15 percent higher than conventional pellets - and pellets are already shipped from North America
to Europe for co-firing in coal power plants. The market is growing rapidly, since power plants can save CO2 certificates by co-firing wood with coal.
AWAY FROM OIL, GAS AND COALKomptech is researching in new directions. Inspired by our customers and motivated by their visions, the company is trying new approaches to meet future Eu rules. In few areas are the goals as ambitious as they are with renewable energy, where regulations calls for 20 percent of the Eu’s energy needs to be covered by
DANISH INSTITUTE RESEARCHES FOR KOMPTECH
A new biomass fuel has been developed in a unique cooperative effort between the Danish Technological Institute and Komptech. Woody material that was heretofore unusable can now replace coal in power plants.
RESEARCH
The DTI is recognised as a world leader in the conditioning of woody fuels.
RESEARCH 17
renewable energy in eight years, by 2020. That means moving away from petroleum, gas and coal, and to sun, wind, water and last but not least wood. Feverish research is underway in every area in order to meet this goal. Komptech is also researching and extending its biomass expertise.
THE PROJECT TEAMTo complete the development project, Komptech formed a project team consisting of six partners: Naturgut GmbH, Andritz AG, the Danish Technological Institute, KWB Kraft und Wärme aus Biomasse GmbH, KCO Cogeneration and Bioenergy GmbH (Kohlbach) and Komptech.
THE INPUT MATERIALThe new process increases the amount of biomass that can be used for energy as opposed to composting. undersizes from forestry residue are a by-product of biomass harvesting in the relevant European markets. It has a relatively moderate ash content, which is beneficial for the new preparation process. This undersize material can now be turned into industrial briquettes.
DANISH INSTITUTE RESEARCHES FOR KOMPTECH
THE PROCESSThe material first goes through a star screen at the finest setting, then a conveyor dryer and compressing machine (briquette press or pellet press). That’s all there is to it. Compared with conventional wood pellets, the new briquettes show no peculiarities that standard techniques cannot handle. Georg Payer of Kohlbach said “This fuel can be used in Kohlback’s furnaces without problems. It burns great!” This despite the fact that the visible pine needle content would seem to indicate problems with the ash melt properties and emissions; however, these do not arise.
CONCLUSIONS Komptech recommends making briquettes instead of pellets. At 3.6 MWh/m³ the attainable specific energy density is higher than with pellets, while briquettes are incomparably easier to make than pellets. It can further be expected that the wear on the briquetting machine is lower, since there is less contact surface per material volume. We expect that this process will make it possible to use another 25 percent of fresh forestry residue material for industrial briquettes.
COAL POWER PLANTS, HERE WE COME!
PROPERTIES OF THE INDUSTRIAL BRIQUETTE
The industrial briquette has an energy density of 3.6 MWh/m³ and a heating value of 4.7 kWh/kg. It is ideal for coal power plants needing a renewable fuel for co-firing. Wood chips only have 0.7 MWh/m³, making them unsuitable for long-distance transportation, but this new briquette has five times that energy density and 15 percent higher than conventional pellets. The dimensions are 75 mm diameter and 50 mm length. The water content is <10%, as is the ash content.
FACTS
The Danish Technological Institute is a self-owned, non-profit institution that develops, implements and disseminates technology-based knowledge for the Danish and world business sectors. It works in close collaboration with leading Danish and international research and educational institutions on development projects which are of use to society. The DTI also carries out consultancy and standardisation services, which contribute to a dynamic and harmonious development of society. Its most important task is to ensure that new knowledge and technologies can be quickly converted into value for its clients, in the form of new or improved products, materials, processes, methods and organisations. The DTI works with new and established companies, individually and in groups, on new ways to enhance technological and management restructuring and efficiency, in industry as well as in leading ancillary sectors.
Sønder Stenderup Copenhagen
DENMARK
SWEDEN
POLAND
NORWAY
GERMANY
North Sea
Baltic Sea
President: Søren Stjernqvist
Year founded: 1906 by Gunnar Gregersen
Revenues in 2011: EuR 132 mill.
Revenues from R&D: EuR 33 mill.
Employees in 2011: 953, whereof 876 academics
Website: www.dti.dk
Bella Italia!
18 INNOVATION
The Axtor is a universal high-performance chipper for green cuttings and wood. Says Komptech. To make sure it is familiar to all interested parties, our demo machine travelled the length and breadth of Europe.
Six countries, six jobs, one machine. Or, what a demo unit goes through in just a few weeks.
USED WOOD, FINELY CHOPPED Location: Kent (UK)Date: 20 June 2012The British used wood market demands a finer granulation than most. The Axtor’s output was at first too coarse, and customers were distinctly “not amused” by the many overlengths. After some rummaging in the tool box, the Axtor’s bite was made tighter, and it was fitted with a special used wood screen basket and new, solid free-swinging teeth. Now it chews its food much more thoroughly.
READY FOR COMPOSTINGLocation: South HollandDate: 10 august 2012The input material properties are extremely important in composting, we were told by the operator of a Dutch tunnel composting facility for green cuttings and organic waste. The Axtor knows this, and when working in shredder mode with free-swinging teeth it delivers a consistent output material without destroying the structures that are critical for ventilation. Demonstrating its chipping ability the very next day is another matter, but not really a problem, since conversion from shredder to full chipper mode doesn’t take more than three hours.
Toate cele bune
Cheers!
greetings From the aXtor
Bella Italia!
INNOVATION 19
LIKE IT WAS MADE FOR BARKLocation: Baden-Württemberg (D)Date: 22 august 2012Several tests have already shown that the Axtor is well suited to chopping bark. Now we have confirmation, from one of Germany’s largest producers of decorative bark and mulch, that it is the ideal machine for the task. With fixed teeth it creates the ideal chip shape, whether the bark is wet or dry, and with a throughput of 250 m³/h it is also extremely economical to operate.
BUON APPETITO FOR THE LEFTOVERSLocation: Friaul-Julian Venetia (i)Date: 05 July 2012In Italy, energy wood plantations make an important contribution to renewable energy. The stumps and rootstocks that are left behind after the harvest can also be chipped into a useful biomass fuel if you have a tough machine like the Axtor. The huge feed area makes it easier, as does the active intake system that dependably pulls bulky items in for chipping.
Grüße aus D
eutschland!
Servus Österreich!
Dag allemaal!
greetings From the aXtor
OVERLENGTHS UNWELCOME Location: Styria (a)Date: 12 September 2012“Thou shalt have no fines nor overlengths” - the first commandment of good chip quality. Especially when overlengths can clog furnace feed systems. The heating plant operator, in this case a large industrial operation in Austria, wanted 40 x 40 mm for the formerly coal-fired plant he is converting to use wood. Throughput OK, screen analysis OK, order OK?
HOT TIMES IN ROMANIALocation: piatra Neamt (rO)Date: 18 July 2012Over 40°C in the shade, dust all over everything, and chipping without letup. No fun for man or machine. But extreme conditions like this let us know where the limits are, and supply valuable information for developments and improvements. For instance, now we know how to seal dust out of the Axtor, and how to protect it from heat stroke.
20 INNOVATION
proDUct spotLight: the aXtor
01
02
05 Man and machine
A colour display clearly shows all functions and the operating status.Colour-coded graphics help the user quickly locate the right controls for each function. The optional remote control has all the functions needed to control the machine.
The feeder specs are impressive - 1.6 m wide and 1 m high, fed by what is probably the best intake system in this machine class. The combination ofhorizontal and vertical feed rollers and a wide sectional steel belt ensure activeintake into the machine, even with bulky green material.
At over 2 m wide and up to 6 m long (7.5 m for the semi-trailer version), the movable feed hopper can accept thebulkiest items from the biggest shovels or grippers, without blockages.
Huge feed area
Active feed
INNOVATION 21
proDUct spotLight: the aXtor
AXTOR 8012
Drive
Engine / Power: CAT ® C18 / 570 kW / 780 HP
Material feed
Feed table L x W (mm): Trailer: 6000 x 2100 Semi-trailer: 7500 x 2100
Feeder opening H x W (mm): 1000 x 1610 (with vertical feed rollers 2100)
Shredding unit
Drum diameter x drum width (mm): 1250 x 1630
Tools: 108 pieces free-swinging tools or 36 pieces fixed tools
Drum rpm: 730 (shredder mode) or 400 (chipping mode)
Dimensions
Transport dimensions L x W x H (mm): Trailer: 10600 x 2550 x 4000 Semi-trailer: 11535 x 2550 x 4000
Working dimensions L x W x H (Conveyor belt 35°, mm): Trailer: 15000 x 2550 x 4700 Semi-trailer: 16455 x 2550 x 4700
Weight, dependent on equipment (t): Trailer: ~ 26.0 Semi-trailer: ~ 30.0
Throughput (dependent on material)
Throughput performance (m3/h): up to 400
In shredder mode, there are three freeswinging tools in each tool mount, for 108 tools on the drum. In chipper mode, thereis a fixed blade holder in each position that can take chipper or shredder blades. Conversion takes about an hour.
The fixed holder can turn on its shaft, but is held in position on the drum by a shear bolt. In the event of a large contrary, the shear bolt breaks and the holder swings into the drum body, preventing additional damage in the shredding area.
04 Contrary-safe in chipper mode
Designers and service technicians worked together on the Axtor right from the start, to give it easy maintenanceaccess few other machines can match. The Axtor is the only machine anywhere to combine an underfloor engine, swingoutscreen basket, easily accessibleshredding chamber and individual mounting of tools on the drum.
Easy maintenance0603 Shredding
or chipping
22 BuSINESS
QUALITY
Andreas Zeller has built a refinery. It’s small, compact, and mobile when it needs to be. With it, he makes renewable fuel from local raw materials, for local customers.
The green refinery is on the outskirts of Mutterstadt (Germany). unlike its fossil counterparts with their steel gantries, smokestacks and gas flames, it basically consists of a shredder and a screener. The raw material is not fossil but “freshly grown”, in the
form of brushwood, logs, rootstocks and untreated used wood, all of which absorbs as much CO2 when it grows back as it gives off when burnt. It is harvested locally, mostly from landscaping, and it is also used locally - instead of being piped thousands of kilometres through unstable regions, it is trucked short distances to area heating plants.
ZELLTHERM CUSTOM QUALITYThanks to a certain stubbornness, the Zeller company has grown to become an established regional vendor in a
relatively short amount of time. It supplies power plants as well private customers within a 100 kilometre radius with customised Zelltherm brand fuel. Zeller can tailor the grain, heat value, ash content and ultimately the price to individual customer needs. “We sell customers exactly the fuel that makes the best business sense for their system. There is no point in making top grade when it’s not needed for good combustion, and when it costs too much in the long run,” says Andreas Zeller confidently.
Fuel Fuel Zelltherm G100 Heating oil Natural gas
State Solid Liquid Gaseous
Energy content in kWh 10 kWh 10 kWh 10 kWh
Weight in kg 3.8 kg 0.860 kg 0.840 kg
Volume in litres 15 Liter 1 Liter 1000 Liter
Price per kWh 1.4 cents 10.45 cents 8.62 cents
CO2 emissions per kWh neutral 263 g 198 g
10 kWh is the energy required to heat 860 litres of water by 10 C°.
refinery to go
From green cuttings, shrub cuttings, untreated used wood, energy wood, forestry residue and rootstocks, the Zeller company makes customised fuel under the Zelltherm brand. Zelltherm is CO2-neutral, economical, and keeps value creation in the local area.
andreas Zeller and his new star screen, which can process up to 200 cubic metres of green and shrub cuttings to renewable fuel every hour.
Sour
ce: Ö
ster
reic
hisc
her B
iom
asse
-Ver
band
, LW
F (D
),
Zelle
r Gm
bH (D
)
BuSINESS 23
“Transparency is our philosophy. We take prospects, for example the mayor of a town with a heating plant, to see our operation and show them exactly how we make the fuel and what we make it from. We supply the material for a test phase, and if everything turns out as promised, we’ve gained a new customer.” The range of services extends from straightforward fuel sales to heat contracting, including operation of the heating plant and a guaranteed fuel supply.
DESIRE AND REALITYEverybody talks about getting away from fossil fuel. But it’s easier said than done. Biomass heating and power plants face tough competition from conventional power plants backed by gas and oil giants that are not going to just fade away. The price pressure is often passed along to suppliers of renewable fuels. Andreas Zeller knows all about it: “Biomass heating plants can only pay a certain maximum rate for fuel. If the price of gas sinks they come under pressure and look around for cheaper fuels. What’s more, the fuel market is very flexible, not to say opaque. Different fuel grades, seasonal surpluses and shortages, and the many middlemen just make it confusing.” To cope with this dynamic situation, Andreas Zeller has invested in a modern screening system.
ONE SCREEN - FOUR FRACTIONSThe heart of the system is a new Multistar star screen, painted bright yellow. It is fed by upstream shredder via an intermediate hopper, which allows the addition of other material. The Multistar separates into four fractions: Fines for composting, two fuel fractions with different grain, and woody oversizes which go back for re-shredding. Electronic conveyor scales give precise data on output, which Andreas Zeller can access remotely at any time. His motto is “it has to pay”, and he regularly examines volume flows and material streams to adjust his system and processes for the optimum economy. He likes the way the screening system gives him to the flexibility to do that. “I can respond to different material properties or new customer requirements instantly just by changing the screen cuts. You can’t do that with trommel screens.”
THE BOSS GETS HIS HANDS DIRTYAndreas Zeller spends a lot of time at a desk, but that doesn’t prevent him from regularly doing hands-on work. “When I help with the maintenance on a machine or operate a wheel loader a couple of hours loading the star screen, it lets me know what really works versus what only works on paper.” He’s always had this close contact with his machines - for as long as he
FACTS
The Zeller company is a recycling and container service provider for the Rhine and Vorderpfalz region, as well as a leading manufacturer and vendor of biomass fuels. At the heart of its biomass production is a new Multistar 4 SE star screen.
www.zeller-recycling.de
can remember, the family business was the determining factor. “Home and business were one and the same, and when I was little I would drive my go-kart around among the containers. Later, before I went to school I would often turn our compost windrows in the morning and then show up at school smelling of compost, which not every teacher thought highly of.”
Sometimes during a quiet moment he reflects on what he has accomplished at a young age - turning what was originally a container service into a broadband recycling operation, and entering the challenging field of biomass energy. Andreas Zeller is convinced that it will be of enormous importance to his business, and to the future environment.
Mutterstadt
Berlin
GERMANY
AuSTRIA
SWITZERLAND
FRANCE
NETHERLANDS
BELGIuM
CZECH REBuBLIC
DENMARK SWEDEN
POLAND
Baltic Sea
North Sea
24 PRACTICE
Three partners are revolutionising waste management in Israel. In the middle of the Jordan valley, within just a few years one of the world’s largest composting operations has taken shape.
In Tuvlan in the Jordan valley, Daniel unger, Jacob Abraham and David Reiner formed Compost OR in 2007. At that time the company handled 4000 tonnes of sewage sludge and 1000 tonnes of green waste each month on about 4 hectares of land. Since then the area has tripled and the throughput quintupled to 20,000 tonnes per month, giving 12,000 cubic metres of valuable compost for agriculture.
THE MAGIC FORMULA: 24/7The plant runs 24 hours a day, seven days a week. Ten employees make it possible. Fresh greenwaste is piled up, and a frontloader dumps sewage sludge on that to create a triangular windrow. A Topturn mixes the windrow evenly and shapes it to measure five metres wide and two metres high. The windrow is then turned once a week by the Topturn for four to six weeks. The temperature inside the windrow reaches up to 70 degrees centigrade, evaporating the excess moisture and disinfecting the material. At the end of the process a high-value compost is obtained. This is screened by a Mustang electric trommel, and then cured for 30 to 60 days in a pile.
HIGH ENVIRONMENTAL STANDARDSDuring the curing process, independent licensed laboratories test it to make sure that it contains no bacteria or pathogens. Since Israel’s standards for wastewater are among the world’s highest, the heavy metal concentration in the material is generally very low, and the finished compost can be used on fields without any problems.
BIG PLANSThe three Compost OR partners have big plans. Starting in 2013 they want to get into decontamination, and have added another seven hectares to make room for it. The idea is to clean up soil contamination with oil or fuel. A Topturn X67 would keep the aerobic process working.
israeLi pioneers
One of the world’s largest composting plants is located in the Jordan valley.
PRACTICE 25
israeLi pioneers
In the next few years the company also plans to build enclosed rotting halls with exhaust air scrubbers, in order to be able to process any kind of organic waste. Here again Komptech will have a major role to play.
A SUCCESSFUL PARTNERSHIPThe partnership with Komptech has expanded as the company has grown. The experienced Compost OR team has tried out machines from several other manufacturers, but ultimately keeps returning to Komptech. The first Topturn X53 turned in over 8000 operating hours before it was replaced by a new one. The Mustang E also has over 8000 hours under its belt.
With this positive experience, the company will continue to work with Komptech in the future. Because experts only stand to learn from each other...
Compost OR is a private company belonging to three partners. Daniel unger, a mechanical engineer by training, is CEO. David Reiner is operations manager. Jacob Abraham, a civil engineer by training, is responsible for legal issues as well as the expansion plans. The three partners have extensive experience in the development, planning, construction and management of landfills, reloading stations and composting facilities. The Tuvlan facility handles organic waste from Haifa, Karmiel, Nahariya, Netanya, Ramat Gam and Raanana.
http://www.compostor.co.il/len/
Jacob abrahamDavid reinerDaniel Unger
the Mustang E ensures a quality substrate.
Tel Aviv
Jerusalem
ISRAEL
LEBANON
SYRIA
JORDAN
WESTBANK
GAZA
EGYPT
Death Sea
Sea of Galilee
Mediterranean Sea
Tovlan
26 PRACTICE
The Danish biomass industry is enjoying good times. Right in the middle of it is Klintholm director Jørgen Nestor. We asked him if more horsepower means more profit.
What does Klintholm I/S do at present?We are a waste company jointly owned by six municipalities on the island of Funen. We treat waste from nearly 200,000 residents. At Klintholm we crush and screen C & D waste, screen contaminated soil, and last but not least turn greenwaste, roots and stumps into biomass.
You recently bought a Crambo 5000 HD-version – what do you use it for?All the greenwaste generated at the six municipalities we work for is collected and transported to our site. First of all we shred it in order to reduce the volume. By doing that we save space – we actually reduce it to 1/3 of the original volume of the waste. Naturally it also has to be shredded, since our biomass customers have certain size requirements.
Our new HD version performs extremely well, particularly with roots and stumps.
At Klintholm you used to work with an “ordinary” Crambo 5000 – why did you upgrade to the HD version?We were definitely happy with our old Crambo 5000, which was built on a trailer chassis. But our new Crambo 5000 HD is built on a “Track Fast” chassis, and it really makes a great difference when we do onsite jobs on muddy and slippery ground. In addition, our new HD machine is stronger than the old Crambo 5000 we used to have, since it has more horsepower. More muscle means higher capacity in the shredding business – it’s as simple as that! Another nice feature is the larger gearbox and the armoured shredder rollers – now we don’t have to do repair welds on the rollers for a very long time.
What does the extra capacity mean to you?We are happy that we have managed to achieve an additional capacity of
more mUscLe
approximately ten percent with the new HD version compared to the old Crambo 5000. It means that we can finish our shredding jobs faster and get on to the next jobs. And our customers are pleased too. At Klintholm we bill by the hour, so now we're able to shred the same amount of biomass at a lower price.
What does the mobility mean to you?Mobility is of great importance for us, since most of the shredding jobs are on-site at our customers’ transfer
Klintholm director Jørgen Nestor.
the crambo can pile the material up to four metres high.
PRACTICE 27
stations. From April to October we are constantly on the move, doing shredding at the six municipalities that jointly own Klintholm I/S.
Last year you bought a Cribus 3800 E trommel screen. Do you use it for cleaning the biomass?Yes, after the greenwaste, roots and stumps have been shredded by the Crambo 5000 HD we upgrade the biomass quality by screening it with the Cribus 3800 E. Obviously our customers don't want to pay for soil, stones and other impurities.
an unbeatable team: together, crambo and cribus produce a top-grade biomass fuel.
Power to spare - Heay Duty means 481 HP
We take pride in producing a biomass of high quality, and our Cribus 3800 E trommel screen helps us do that. It is also extremely cost-efficient since it is diesel-electric. Its diesel consumption is only around 5 litres per hour. For Klintholm, which produces green sustainable energy, it means a lot that we can work green.
Klintholm I/S on the Danish island of Funen in the Baltic is a pioneer in the Danish biomass business. Recently Klintholm added a Crambo 5000 Heavy Duty Edition shredder and Cribus 3800 E trommel screen to its machine park, to turn still more greenwaste into valuable renewable energy. Komptech’s Danish sales partner Aksel Benzin supplied those machines and all processing technology for Klintholm.
www.klintholm-is.dk
FACTS
FunenCopenhagen
DENMARK
SWEDEN
POLAND
NORWAY
GERMANY
North Sea
Baltic Sea
28 PRACTICE
a Learning JoUrneyTravel, it is said, broadens the mind. In July of last year Komptech invited a 25-person delegation from Great Britain’s Association for Organics Recycling to have a look at the waste business in Austria and Slovakia.
The uK has some distance to go if it is to meet European union requirements for reduction of the organic component in landfilled waste by 2020. Austria leads Europe in waste handling, and the British organic waste specialists came to get a personal impression of how things are done there.
NEXT STOP: LOBAU, AUSTRIAIn Lobau, the City of Vienna operates a composting plant that receives 150,000 tonnes of organic waste each year from the greater Vienna area. Since 1999 it has been transforming this waste into a valuable soil improver with the help of composting technology from Komptech. A total of 60,000 tonnes of compost leave the facility each year, some to area farmers, some as bagged compost shipped throughout Austria.The oversize fraction is sent to a nearby incinerator. This type of waste handling is already important in the uK and will become more so in future.
the UK specialists also visited a bioenergy plant.
FIRST STOP: MALACKY, SLOVAKIAKomptech built a renewable fuel processing plant in Malacky in 2010. The facility handles 23 tonnes of waste per hour and transforms it into a high-quality fuel. Consisting of several Komptech machines, the plant was of interest to the visitors because this kind of waste treatment is still in its infancy in Great Britain. More can be expected in the coming years.
Learning 1: The plastic recovered from mixed solid waste at waste to energy facilities is a useful fuel resource of high calorific value.
Learning 2: This vast site relies on a straddle windrow turner to oxygenate, thoroughly mix and hydrate particles in the windrows. Such turners have the potential to maximise the biodegradation rate and minimise the formation of odours, yet diseconomy of scale and other factors seem to result in little use of this kind of machinery in the uK.
PRACTICE 29
a Learning JoUrney
WASTE TREATMENT IN THE UK TODAYThe European landfill directive (1999/31/EG) requires Great Britain to reduce the organic component of landfilled material by 50 percent by 2013, and by 65 percent by 2020, both compared with the amount landfilled in the benchmark year 1995. By 2010 the uK had achieved a reduction of only 39 percent. The “Waste Strategy” (in England) and the “Zero Waste Policy” (in Scotland, Wales and Northern Ireland) require that by 2010 a total of 30 percent of household waste be recycled or composted. By 2015 this needs to be increased to over 50 percent.
With many new ideas and impressions, the delegation returned to the island nation.
MAKES THE BEST OF WASTE: THE FROHNLEITEN MBTThe mechanical-biological treatment facility in Frohnleiten near Graz, Austria, was one of the largest projects in the history of Komptech. Here, a biological treatment stage processes 65,000 tonnes of organic residue each year, which it gets from a mechanical treatment plant in Graz. The material is biologically stabilised in a building which hosts 13 in-vessel tunnels and the stabilised organic material is then sent to landfill. The higher-calorific material is separated out and burned in an incineration plant. Systems of this type will also help the uK to meet European regulations.
GAS FROM FOOD?Finally, at Bioenergie GmbH in Marchfeld near Vienna the visitors had a look at a wet anaerobic digestion plant. Each year it processes 15,000 tonnes of organic waste, specifically restaurant waste, over-aged food and grocery store waste, some of it still packaged. The food and liquid biowastes are broken down into gas which is then used as a fuel in a district heating plant. After anaerobic digestion, the solids are separated from the liquid and then composted. Here too, all of the machinery used for preparing the waste was supplied by Komptech. At present, anaerobic digestion is being especially encouraged and promoted in Great Britain, and many plants will come on line in the next several years.
MalackyVienna
Frohnleiten
BratislavaAUSTRIA
SLOVAKIA
ITALY
BOSNIA-HERZEGOWINA
CROATIA
SLOVENIA
CZECH REBuBLIC
GERMANY
POLAND
HuNGARY
ROMANIA
SERBIA
SWITZERLAND
Adriatic Sea
Learning 3: The system here minimises the use of mobile vehicles, benefitting from initial MSW sorting and shredding at a pre-treatment facility.
Learning 4: This well thought-out facility links the digestion and composting processes by diverting some food waste solids and post-digestion separated fibre to composting. With resource efficiency in mind, the design engineer had the foresight to use process water to get food waste out of its packaging.
30 LETTERS TO THE EDITOR
Q & aCustomers have questions - Komptech’s specialists have answers.
How can I get more biomass out of green cuttings? And is there any news on fuel consumption and energy efficiency?
Asked by telephone
We’ve been getting this question more and more recently. To get more biomass out of green cuttings we developed the Bio-Basket XL, a screen basket with wide mesh and biomass cutters. It offers distinct advantages: up to 40 percent higher throughput with up to 40 percent lower specific fuel consumption, and considerably higher fuel yield. All of our customers who use it are very happy with it. For the Crambo we also have a new change system for the screen basket cartridge, which can be installed and removed simply, as a single unit. This lets users change screens very quickly, regardless of how dirty they are. For even higher energy efficiency, Komptech is currently working on a new drive for the Crambo which will let it work much more efficiently. We’ll present the machine at the start of 2013.
HEINZ LEITNER, CEO KOMPTECH FROHNLEITEN, ANSWERS:
I saw a mobile variant of the Stonefex on the Komptech website. Will a stationary version of the machine also be offered?
Question placed by online contact form.
BERND THIELEPAPE, CEO KOMPTECH OELDE, ANSWERS:
LETTERS TO THE EDITOR 31
Komptech employee packing spare parts.
The Stonefex was developed for electric drive, so it’s a great fit for stationary systems. A stationary variant was taken into consideration during the concept phase of the mobile Stonefex. We’ve installed the first such system in England, and the customer is very satisfied. In other words, yes, we have solutions for stationary use.
Machine reliability is of course very important for users, since downtime costs money. In recent years the availability of customer service and spare parts has become a priority, as processes involve more and more machines.More and more, we are being compared with construction machinery manufacturers like Caterpillar and Liebherr, or agricultural machine makers like John Deere and Fendt. Customers expect that parts required for functioning will be available in less than 24 hours. We are meeting the need through our staff’s high level of commitment and a completely revised logistics system.For example, all machine parts are marked with their importance for functioning. High-importance parts must be in stock in sufficient quantity in the markets so that they can be sent overnight. To facilitate this, they are stored ready to ship.
I’m in a market that is distant from Komptech, so spare parts availability is very important to me. What are Komptech’s replacement parts logistics like?
Asked at IFAT, May 2012
MANFRED HARB, GROUP SERVICE MANAGER, ANSWERS:
The new Bio-Basket XL for more biomass fuel.
The Stonefex is now also available in a stationary version.
the worLD is getting greener.
Screening with a star:The Multistar
Of course we´re not the only people helping to make the world a greener place. But we´re still very proud of our solutions for handling waste and biomass!
Pure design:The Topturn
Drum-roll:The Cribus
The universal genius:The Crambo
Provides for fresh wind:The Hurrikan
A real bigmouth:The Axtor
The end of the stone age:The Stonefex
Incredibly tough:The Terminator
Nicer chipping:The Chippo
Kühau 37, A-8130 Frohnleiten | T +43-3126 505 0 | [email protected]
