PET recycling lines
complete PET recycling plants
OFFER No.: E 644 of a used Recycling Plant
for
PET-Bottles, Year 2004
Offer
Extents..............................................................................................
4
1
Technical Process Description
................................................................ .4
1.1
Material Introduction
..................................................................................................
4
1.3
Cutting and Pre-Cleaning............................................................................................
4
1.4
Air-Stream Separation Stage
......................................................................................
5
1.5
Separation
Stage.........................................................................................................
5
1.6
Hot Washing
Stage......................................................................................................
5
…2
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1.7
Post-Washing
Stage......................................................................................................6
1.8
PET-Flake Post-Processing
.........................................................................................
6
1.9
PET Filling
Station.......................................................................................................
6
1.10
PO Filling Station
.....................................................................................................
6
1.11
General Description and Operation of Circulatory Systems
............................... 7
1.12
General Description and Operation of Dispensing Station
.................................. 8
1.13
Electrical Installations
...............................................................................................
8
2
Technical Data:..........................................................................................
9
2.1
Material Introduction
..................................................................................................
9
2.2
Manual Sorting.............................................................................................................
9
2.3
Cutting and Pre-Cleaning..........................................................................................
10
2.4
Air-Stream Separator
Stage......................................................................................
10
2.5
Separation
Stage.........................................................................................................
10
2.6
Hot Washing
Stage.....................................................................................................
11
2.7
Post-Washing
Stage....................................................................................................
12
2.8
PET-Flake Post-Processing
.......................................................................................
12
2.9
PET Filling
Station.....................................................................................................
12
2.10
PO Filling Station
...................................................................................................
13
2.11
Circulatory Systems
...............................................................................................
13
2.12
Electrical Installations
...........................................................................................
14
2.13
Additional Data
......................................................................................................
14
3
Wear and Tear/ Spare Parts
.................................................................. 15
4
Customer Responsibility.........................................................................
15
5
WARRANTIES.......................................................................................
16
5.1
Production Warranty.................................................................................................
16
5.2
Process Warranty.......................................................................................................
16
5.3
Operation Warranty
..................................................................................................
16
5.4
Warranty Exceptions
.................................................................................................
16
6
INSTALLATION, STARTUP, AND FINAL INSPECTION............. 17
7
TERMS AND CONDITIONS OF PAYMENT.................................... 18
8
DELIVERY
DATE..................................................................................
18
9
VALIDITY OF OFFER..........................................................................
18
10
CUSTOMER
SERVICE.........................................................................
18
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Offer Extents
The offer includes a complete recycling plant, designed
for the processing of PET-bottles
from post-consumer collection that are pre-selected and
compacted to bales or
briquettes. The final products after processing are
cleansed, separated, and ready-to-sell
PET-flakes and PO-fractions, both packaged in Big-Bags
1 Technical Process Description
1.1 Material Introduction
The PET-bottles that are initially compacted in the
shape of bales or briquettes are
introduced into the bale breaker with the help of a
forklift after prior removal of the
packaging wire. Inside the bale breaker, the bottles
are untangled and fall into the
discharging screw that transports the bottles evenly to
the elevating conveyor belt. By
means of regulation of the rotational speed of the
screw, the plant throughput capacity
is determined. The elevating conveyor belt is equipped
with a non-magnetic area that
has a permanent magnet installed above it.
Ferromagnetic materials that are present
within the input are thereby removed from the plastics.
The elevating conveyor belt
moves the remaining materials to the manual sorting
stage.
1.2 Manual Sorting Stage
The sorting belt is located on top of a stage structure
that is designed to incorporate four
manual sorting stations. This stage is mounted in a way
that large sorting containers
can be located below where the selected materials are
introduced manually through
shoots. A wide-area detection coil is mounted below the
sorting belt and stops the
transport if any metallic materials are detected within
the stream. The selection
personal is thereby given the opportunity to remove
such materials manually and restart
the belt once this is done. The time-lapse due to
stopping and restarting of the sorting
belt is then compensated for by a dispensing bunker.
Evenly a screw conveyor
introduces the pre-selected materials into the mill
funnel.
1.3 Cutting and Pre-Cleaning
The cutting mill is essentially a wet-shredding and
cutting mill. With the help of adding
an abundant amount of water, the shredding process in
this stage provides a
combination of cutting and cleaning effects. The
machine interior is covered with a
highly wear-resistant material (Hardox). This interior
shielding, along with the stator
blade covers, is completely replaceable. During the
shredding process, 95% of all paper
labels are dissolved. Inside the frictional cleaner
unit, the washing water along with the
therein contained paper and dirt is separated from the
material to be processed and
pumped to the fibre-separator of the circulation
container #1. The material is
transported towards the air-stream separator #1 with
the help of a blower unit.
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1.4 Air-Stream Separation Stage
Within the vertical air-stream separator, the PET- and
PO-flakes are separated
From other materials contained in the mill output like
labels, paper, and dust.
The material transport into the air-stream separator is
done through a cyclone
with a rotary valve. The heavier PET- and PO-flakes
descend to the bottom and
are transported by another blower through the cyclone
of the separation stage.
The lightweight particles inside the air-stream are
vacuumed off the top of the
vertical air-stream separator and introduced into the
cyclone for waste.
The separation resolution can be adjusted via the label
blower setting.
1.5 Separation Stage
The separation stage consists of a stirring and a
separation container.
The material transport into the stirring container is
passed through a
cyclone with a rotary valve. With the help of a
stirring mechanism,
the plastic material is blended into the aqueous
separation medium.
A pump transports the homogenous mixture into the
separation
container where due to a laminar flow, the heavier
particles move towards the
bottom and the lighter particles towards the top of the
flow. The
principle behind this separation mechanism is the
difference in
density of the materials to be separated. While PET has
a higher
density than water and therefore sinks to the bottom of
the cont.
other polyolefin plastics like PP, PE, etc. and other
less dense
materials (with respect to water) float on top of the
medium.
The materials that are skimmed off the top of the
stream are
introduced into a frictional cleaner unit and then
transported via
blower to the PO filling station, whereas the heavier
PET from
the bottom is also introduced into a frictional cleaner
unit but
then transported to the next stage. With the help of
the
frictional cleaner units, the materials are separated
from the
washing medium and the dirt enriched medium pumped into
the fibre separator of the washing medium circulatory
system #2.
1.6 Hot Washing Stage
The hot washing stage utilizes a 4-5% caustic soda
solution as
washing medium. In order to maximize the cleaning
effect of this
stage, the washer units are heated by electrical heater
plates.
The temperature of the washing medium and its caustic
soda
concentration is automatically regulated by
programmable active
feedback control systems. Through a cyclone with a
rotary valve,
the PET-flakes are introduced into the heated screw
washer unit
wherein the material is transported through parallel
running,
low revolution screws. The extended processing time
within this
unit provides a maximum cleaning effect (separation and
dissolving
of adhesives and dirt). After the screw washer, the
material is
introduced into a heated turbo washer unit where it is
intensively
cleaned with the help of strong turbulences generated
by the
beater wheels contained. The frictional cleaner unit
that is
installed behind the turbo washer unit then separates
the
washing medium from the PET-flakes and removes
remaining
adhesives. The washing medium that is removed by the
frictional
cleaner unit is introduced into the fibre separator of
the circulatory
system #4. A blower unit transports the mostly dry
flakes into the
post-washer unit.
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1.7 Post-Washing Stage
Within the post-washing stage, the material is
intensively cleaned
from remaining caustic medium utilizing strong
turbulences
generated by the beater wheels contained. Introduction
is done
past a cyclone with a rotary valve. Via the washer
overflow, the
material is introduced into a twin frictional cleaner
unit where it
is mostly separated from the washing water within the
first stage
and dried within the second stage. The dried PET-flakes
are then
blown into the PET-Flake Post-Processing and the
washing
medium pumped into the circulatory system #3.
1.8 PET-Flake Post-Processing
The first stage of the post-processing is composed of a
vibrating
channel and a drum type magnet. The vibrating channel
consists
of two layers where the upper one is responsible for
straining the
oversize flakes and the lower one for spatially
separating the
flakes prior to magnetizing and separating remaining
ferromagnetic
materials. The grain type PET falls into another
channel
where its flow is further spaced out and introduced
into a
combinatory separator. This not only separates the PET
from
non ferromagnetic materials like stainless steel or
aluminium,
but also post-separates by color which minimizes errors
that
occurred in the manual selection stage. Smaller amounts
of
PET-flakes are also blown into the waste collector by
the
Combinatory separator. The clean material then falls
into a
blower funnel and is transported to the filling station
for PET.
1.9 PET Filling Station
The filling station consists of a structure designed to
hold two
Big-Bags at the same time. Above it, a dispensing and
storage
container is mounted that has a selective dual output
spout
aiming into a Big-Bag each. Sensors mounted to the
storage
container above control the level inside. Inside each
filling
funnel, sensors are mounted to control the filling
level of the
bags. Once a bag is full, the dual funnel switches to
fill the
other bag mounted which assures a continuous filling
operation. Additionally, the filling station contains a
pneumatic
vibrator unit, which maximizes the filling capacity of
each
Big-Bag by minimizing air gaps.
1.10 PO Filling Station
This station consists of a cyclone, a storage funnel, a
rotary
valve, and an operational stage with bag mount. Inside
the
filling funnel, a sensor is mounted that stops the
rotary
valve, once a Big-Bag is full. The operator then
replaces
the full Big-Bag with an empty one and restarts the
filling
process. Meanwhile this is done, the storage funnel
compensates for the stopped material flow without
overflowing.
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1.11
General Description and Operation of Circulatory Systems
The
plant consists of four separate circulatory systems:
Cutting
Mill
Separation
Stage
Heated
Washing Stage
Post-Washing
Stage
Circulatory
System of Cutting Mill:
Circulatory
container #1
Fibre
separator 1500
Circulatory
pump
Dirt
pump
Circulatory
System of Separation Stage:
Circulatory
container #2
Fibre
separator 1500
Circulatory
pump
Dirt
pump
Circulatory
System of Heated Washing Stage:
Circulatory
container #4
Fibre
separator 1000
Circulatory
pump
Circulatory
System of Post-Washing Stage
Circulatory
container #3
Fibre
separator 1000
Collecting
tank with overflow
Circulatory
pump
Transportation
pump towards circulatory container #2
Waste
press for dehydrate the waste from the fibre separator of the cutting
mill
circulatory
system.
The
circulatory pumps move the cleaned water from the circulatory containers
to the
specific
plant components (see layout).
The
dirty water separated by the frictional cleaner units is pumped onto the
specific
fibre
separators before it is re-introduced into the circulatory systems. The
foreign
materials
(dirt, fibre, adhesive chunks, etc.) are strained off and introduced
into a waste
press.
Some of the water (approx. 1.5 – 2.5 cubic meters per hour) are taken
out of the
circulatory
systems of the mill and separator systems and have to be treated by a
water
treatment
unit before re-introduced into the specific circulatory system. It is
strongly
recommended
to feed fresh water to the post-washing stage (2 – 3 cubic meters per
hour)
and the circulatory container #4.
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1.12
General Description and Operation of Dispensing Station
The
dispensing station consists of various pumps (membrane-type) that
introduce
controlled
amounts of anti-foaming agents, 50% caustic soda and detergents into the
specific
circulatory systems.
1.13
Electical Installations
Inside
of the main control box, the controls for the entire plant are installed
including all
important
gauges (power consumption, flow, and temperatures etc.) and warning
indicators.
All components can be individually controlled manually or through the
controls
software for maintainance or repair purposes.
2
Technical Data:
2.1
Material Introduction
Bale
Breaker
Power:
45 kW
Length:
5500 mm
Width:
2200 mm
Height:
3200 mm
Discharging
Screw
Screws:
2
Power:
1.5 kW
Speed
31.5 rpm
Elevating
Conveyor Belt
Length:
7000 mm
Power:
2.2 kW
Speed:
49 rpm
Over-belt
Magnetic Separator
Length:
2000 mm
Width:
2754 mm
Height:
3050 mm
Power:
2.2 kW
2.2
Manual Sorting
Sorting
Belt
Length:
7000 mm
Width:
800 mm
Power:
2.2 kW
Detection
Coil PT: 800 mm TB
Speed:
variable
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Dosing
Hopper
Length:
6295 mm
Width:
1130 mm
Height:
2280 mm
Power:
2.2 kW
Elevating
Conveyor Belt
Length:
10000 mm
Width:
800 mm
Power:
2.2 kW
Speed:
49 rpm
Cutting
Mill KSM 800-1530
Rotor
Diameter: 800 mm
Working
Width: 1530 mm
Quantity
Rotor Blades: 5
Quantity
Stator Blades: 2
Power:
132 kW
Hydraulic
Pump 1,1 kW
Frictional
Cleaner with Base Frame, Collector with Pump, Blower, and Pipe
Length:
2690 mm
Width:
1800 mm
Height:
2190 mm
Power:
37 kW
Blower
MFT 45/350: 7.5 kW
Pump:
2.0 kW
2.4
Air-Stream Separator Stage
Vertical
Air-Stream Separator with Cyclone, Rotary Gate, and two Blowers with
Pipes
Length:
1500 mm
Width:
1500 mm
Height:
6100 mm
Gate:
0.75 kW
Blowers:
7.5 kW each
2.5
Separation Stage
Stirring
Container with Cyclone, Rotary Gate, and Separation Container
Length:
5000 mm
Width:
2120 mm
Height:
5650 mm
Gate:
0.75 kW
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Stirring
Container EB 1900-2282
Stirrer:
4.0 kW
Pump:
2.0 kW
Separation
Container TB 1900-2282
Pump:
2.0 kW
Electro-Pneumatic
Valve: 5-way
Air
Pressure (Connection) 6.0 bar
Working
Pressure 4.5 bar approx.
Frictional
Cleaner Unit for PET with Base Frame, Blower, and Pipe
Length:
2690 mm
Width:
1800 mm
Height:
2190 mm
Power:
30 kW
Blower
MFT 45/350: 7.5 Kw
Frictional
Cleaner Unit for PO with Base Frame, Blower, and Pipe
Length:
2690 mm
Width:
1804 mm
Height:
2190 mm
Power:
22 kW
Blower
MFT 45/350: 7.5 kW
Pump:
3.1 kW
2.6
Hot Washing Stage
Heated
Coil Washer with Cyclone and Rotary Gate
Length:
6295 mm
Width:
1130 mm
Height:
2280 mm
Power:
2.2 kW
Heaters:
200 kW
Gate:
0.75 kW
Temperature
Controlled by Thermostat
Heated
Washer with Cyclone, Rotary Gate, and Frictional Cleaner Unit with Base
Frame,
Blower,
Pump, and Pipe
Length:
4775 mm
Width:
1820 mm
Height:
3595 mm
Stirrer:
22 kW
Heaters:
259 kW
Gate:
0.75 kW
Frictional
Cleaner: 30 kW
Pump:
2.0 kW
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2.7
Post-Washing Stage
Post-Washer
with Cyclone and Rotary Gate
Length:
4775 mm
Width:
1820 mm
Height:
3595 mm
Stirrer:
22 kW
Gate:
0.75 kW
Pump:
2.0 kW
Dual
Frictional Cleaner Unit with Base Frame, Collection Tank with Pump,
Blower, and Pipe
Length:
7420 mm
Width:
2900 mm
Height:
3940 mm
Power:
30 kW each
Blower
MFT 45/350: 7.5 kW
Pump:
3.1 kW
2.8
PET-Flake Post-Processing
Cyclone
with Gate: 0.75 kW
Vibrating
Channel with Strainer 2.3 kW
Drum-Type
Magnet 0.37 kW
Blower
TRL 55: 4.0 kW
System
Requirement to the Customer:
Pressurized
Air, 8-10 bar, approx. 3000 l/min, dry and free from dust and oil
2.9
PET Filling Station
Dual
Filling Station with Expulsion Coils, Storage Container, and Cyclone
Expulsion
Coils: 1.1 kW each
Pneumatic
Vibrator
Filling
Level Sensors for Detection of Container and Bag Levels
2.10
PO Filling Station
Single
Filling Station with Storage Funnel, Gate, and Cyclone
Blower
TRL 20: 4.0 kW
Gate:
0.75 kW
Filling
Level Sensors for Detection of Funnel and Bag Levels
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2.11
Circulatory Systems
Milling
Circulatory System with Circulatory Container, Fibre Separator,
Circulatory Pump,
and
Sump Pump
Length:
2720 mm
Width:
2120 mm
Height:
5960 mm
Strainer
Size: 1500 mm
Power:
3.0 kW
Circulatory
Pump: 2.0 kW
Sump
Pump: 2.2 kW
Separation
Stage with Circulatory Container, Fibre Separator, Circulatory Pump, and
Sump
Pump
Length:
2720 mm
Width:
2120 mm
Height:
5960 mm
Strainer
Size: 1500 mm
Power:
3.0 kW
Circulatory
Pump: 2.0 kW
Sump
Pump: 2.2 kW
Heated
Washing Circulatory System with Circulatory Container, Fibre Separator,
Circulatory
Pump, and Sump Pump
Length:
1940 mm
Width:
1420 mm
Height:
4300 mm
Strainer
Size: 1000 mm
Power:
1.0 kW
Circulatory
Pump: 1.5 kW
Sump
Pump: 2.2 kW
Post-Washing
Circulatory System with Circulatory Container, Fibre Separator, and
Circulatory Pump
Length:
1940 mm
Width:
1420 mm
Height:
4300 mm
Strainer
Size: 1000 mm
Power:
1.0 kW
Circulatory
Pump: 1.5 kW
Collecting
Tank with Pump to Circulatory Container 2
Length:
1500 mm
Width:
755 mm
Height:
700 mm
Circulatory
Pump: 1.5 kW
Waste
Press Power: 3.0 kW
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2.12
Electrical Installations
Plant
control is achieved by combining precision logical control systems (SPS)
with
power
electronics. All necessary controls and indicators are mounted in front
of the
plant
control box.
Operational
Modes: Automatic
Manual/
Service Mode
ON-/OFF-Switches
and Emergency Shut-Off Switches are strategically positioned
throughout
the plant.
2.13
Additional Data
Overall
Power Consumption: approx. 1.0 MW
Air
Pressure: approx. 8.0 bar
Freshwater
Consumption w/o Regeneration approx. 2-3 m³/ h
Water
Regeneration approx. 1.5-2.5m³/ h
3
Wear and Tear/ Spare Parts
Various
machine elements are subject to wear and tear. A detailed list thereof
is
included
in the plant documentation. By design, the recommended spare part
contingent
is minimized utilizing identical machine elements like bearings and
motors
for
several plant components. Since we operate this type of recycling plant
ourselfs, our
knowledge
will benefit your site by minimizing the recommended stock of spare
parts.
All
wear and tear parts can be replaced individually.
4
Customer Responsibility
To
complete the plant detailed in this offer, the customer must provide the
following:
·
Wear and tear parts / spare parts in accordance with the list attached
·
Ventilation of plant building
·
Electrical energy, water, and air pressure supply at designated points
on site
·
Air Compressor
·
Sharpening equipment and tools for blade servicing and replacement
·
Lifting equipment for unloading, transport, and installation of
equipment
30
ton crane
7.5
ton forklift
Machinists,
welders, and electricians that are in charge of future maintainance
·
Machines, tools, and equipment necessary for service work
·
Building structure and foundations according to final layout
·
Noise proofing and other safety-related installations (fire-proof doors,
etc.)
·
Designation of safety supervisor
·
Wall and ground channelling for wiring installations
·
Plant component and electrical installation other than specified in
contract of
purchase
·
Everything that is not listed in contract of purchase
…/13
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5
WARRANTIES
5.1
Production Warranty
PET-bottles,
compacted to bales or briquettes from post-consumer collection,
preselected:
max.
1400 kg/h input
5.2
Process Warranty
The
PET-bottles originate from post-consumer collection and are pre-selected
automatically
or manually.
5.3
Operation Warranty
The
manufacturer extends the warranty for a period of 6 months from the date
of initial
startup
in customers factory. Warranty for electronic parts according to our
supplier.
5.4
Warranty Exceptions
The
warranty is not extended on wear and tear parts, static and dynamic in
nature like
seals,
liquids, and blades, or parts that are damaged due to improper use,
service or
repair
without prior notification of the manufacturer. Due to technological
advance, the
manufacturer
claims the right to change components included in this offer without
prior
notice
(the plant as well as the components thereof conform with EU regulations).
In
addition to all of the above, our “general delivery and warranty
conditions” are valid
unless
otherwise specified.
6
INSTALLATION, STARTUP, AND FINAL INSPECTION
Plant installation and start-up are not included in the
offer given. Transportation costs
(air or ground), lodging, accommodation and food will
be billed separately.
The installation of the complete plant and initial
start-up thereof will be performed by
specialized personnel of the manufacturer and billed
according to actual costs.
The testing phase after completion of the installation
begins with the start-up of
individual plant components and ends with the fine
tuning of the entire plant to
guarantee the desired operation. When this is completed,
the warranty term described
in the contract begins. Upon delivery of the
operational plant, all necessary
documentation (operating manuals, spare parts list,
etc.) will be delivered to the
designated operator.
At the end of the testing period, a final inspection/
revision of the entire plant operation
will be performed to check permanent performance. As a
result thereof, a final
inspection protocol will be created and signed by both
installation team and customer.
The final test-run will be performed by the technicians
designated by the customer with
the help of specialized personnel from the manufacturer.
All necessary connections,
structures, piping, media, etc. that is necessary for
the installation as specified have to
be provided by the customer prior to initial start-up.
Minor flaws in our installation or components thereof
that do not impede production
may not be considered reason to postpone final
inspection and will be rectified
immediately. If any major flaws should occur that are
reason enough to not start
production, the final inspection will be postponed to a
later date (with all problems
solved as soon as possible) that is negotiated in
agreement of both manufacturer and
customer. The legal terms and conditions come into
effect as with final inspection if the
customer begins production despite minor flaws or does
not give reasonable time to the
manufacturer to rectify the situation before final
inspection or does not provide the
necessary conditions (customer side) for final
inspection within 60 days from the initial
start-up.
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7
TERMS AND CONDITIONS OF PAYMENT
See
payment condition.
8
DELIVERY DATE
Delivery
shall be completed approximately two months after clarification of all
technical
details,
offer received, and demonstration of guarantee of payment, or according
to
prior
agreement.
9
VALIDITY OF OFFER
This
offer is valid for a period of one month total from the date it is given.
The
manufacturer explicitly reserves the right to change components in type
or version,
due
to the technological advance or improvement.
In
addition, all the manufacturer´s terms of delivery are valid unless
otherwise stated.
Subject
to prior sale and errors in technical data
10
CUSTOMER SERVICE
Upon
purchase, a free-of-charge training to the customer´s designated
personnel will be
offered
at a similar PET recycling plant at the factory located in Aicha v.
Wald.
The
customer is solely responsible for transportation, lodging, food, etc.
for his own
personnel.
The amount of staff to be trained and the extent of the training period
is
specified
upon signing of the contract of purchase
Delivery
condition : ex works, load in Truck or Container
Payment
condition :
50
percent by order, balance after start up in suppliers factory or by
irrevocable
and
confirmed letter of credit checked from our bank against presentation of
shipping documents.
Subject
to prior sale and errors in technical data!
Installation
at customers factory by our technicians on customers charge.
Charges
for flights, accommodation and catering are not subject of the price and
will be invoices
separately.