COMPLETE PET RECYCLING PLANT NEW

Complete  used PET Recycling plants new

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Quotation and delivery scope of a new PET bottle recycling plant on behalf of STF GmbH. The quotation includes a PET bottle recycling plant for used PET bottles pressed into bales. The result of the processing is PET flakes, cleaned, separated, and packed into big-bags, ready for sale. The gained light fractions are a Polyolefine (PO) flakes mixture packed into separate big bags.

TECHNOLOGICAL PROCESSING DESCRIPTION

1. Material input / requirement

The equipment consist of a feeding conveyor, the bale release with hydraulic pressing slide gate, followed by a combination of conveyor belts. In the bale opener, the bales of pressed bottles are separated after removal of the tension wires. A magnetic separator removes any contained, magnetisable particles of the input material. A dosing screw guarantees a continuous material flow to the separator. The capacity of the plant is determined by continuous modulation of the screw rotating speed. The sorting station is made up of a sorting belt and a platform construction. It is possible to have up to 4 persons sorting the material. Provisions for discharging chutes for the sorted out materials are available. The conveyor speed is continuously variable and a remote control for the material (used PET bottles) supply is installed. An ascending belt conveys the bottles to the cutting mill/ crusher.

2. Comminution / crushing and rough cleaning

A crusher cuts up the material and by addition of water, a good crushing with cleaning effect is achieved. The complete interior of the crusher chamber and knives are lined with wear resistant material (Hardox). The stator knives as well as the support of the stator knives are exchangeable. The cut up material is fed into a friction cleaner. In the friction cleaner the washing water is separated from the plastic. A fan carries the material into the separating stage 1. The cleansed washing water is returned to the crusher container.

  3. Preliminary Separating and Separating stage 1

3.1. Preliminary Separation

In the preliminary separation the ground PET and PO Flakes are separated from the fine particles contained in the grist, such as labels, paper, dust and other materials. The separation takes place in a perpendicular air separator. The material supply into the perpendicular air separator is done via a cyclone with star feeder. The PET and PO particles sink down and they are carried with a blower to the cyclone of he separating stage 1. The contained fine particles are sucked off above and blown into a waste container.

3.2. Separating stage 1

The separating plant consists of a stirrer and a separation tank. The material input to the stirrer tank is done via cyclone and a star feeder. With an agitator the plastic is stirred into the separation medium water. A pump carries the homogeneous mixture in a separation tank completely flooded with water. A special separating mechanism achieves a laminar decreasing flow, and the plastic particles are separated into rising and sinking layers. Decisive for the separating process is the difference in density of the particles to the density of the separating medium water. As PET has a higher density than water, all PET particles sink and are carried with a pump to the friction cleaner. All polyolefines (PE, PP etc.) have a density lower than the density of water and so these particles rise. They flow into the friction dryer. In the friction dryer and cleaner the water is separated from the material. A fan carries the dry material to the next station. The separating water is cleansed in a fibre separator and returned to the circulation tank of the separating stage 1.

4. Hot washing unit

4.1. Hot washing unit:

The hot washer operates with an upstream system. This can be flooded with water or with a medium of 2- 4 % caustic soda solution. The PET flakes are transported by parallel running, very slowly turning feeding screws. An optimal effect of the purification process is obtained by the increased retention time in the medium (upward separation of adhesive & dirt).

4.2. Friction cleaner

In a downstream friction cleaner the water with caustic soda solution is separated. Any adhering adhesives are removed by the produced friction. The washing water with the dissolved dirt parts is pumped to the fibre separator in the circulation tank of the hot washer.

4.3. fan : A fan carries the dried material to the hot washer.

4.4. Circulation tank with electric heating system

The circulation tank with heating system consists of: - Circulation vessel for water added to caustic soda - Heating tank with thermo oil (Type Mobiltherm 605) and electrical heating elements (approx. 250 kW) - Fibre separator approx. 1,8 kW

- Circulation tank approx. 2,2 kW. Water temperature and water level are controlled by suitable systems accordingly.

Optionally the lye concentration can be controlled automatically.

5. Hot washing unit

5.1. Hot washing unit:

The material in the hot washer is washed by high turbulences, intensively. produced by an agitator.

5.2. Friction cleaner:

The washed material flows through the overflow of the washer into a friction cleaner. In the friction cleaner the washing water is separated. This carries the material to the following washer. The washing water with the dissolved dirt parts is pumped to the fibre separator of the circulation tank of the hot washer.

5.3. Circulation tank with electric heating system

The circulation tank with heating system consists of:

- Circulation tank for water added to caustic soda

- Heating vessel with thermo oil (Type Mobiltherm 605) and electrical heating elements (approx. 150 kW) - Fibre separator approx. 1,8 kW - Circulation tank approx. 2,2 kW Water temperature and water level are controlled by suitable systems accordingly. Optionally the lye concentration can be controlled automatically.

6. Follow-up washing unit

The follow-up washing unit with the friction cleaner and fan is identical in structure and in the function mode to the hot washer. The washing fluid in the following washer is not heated and does not contain chemicals.

7. Separating stage 2

The function mode of this separation stage is identical to the separation stage 1.

The PET flakes are released in a 2-step friction dryer from the separation water, and are dried intensively. A fan carries the thoroughly dried material to the aftertreatment fraction. All still remaining polyolefines (PE, PP etc.) contained in the material, are separated in the hot- and post washer, flow into the collecting tub of the 2-step friction dryer for PET, and are pumped with the separated water to the fibre separator of the cycle container of the post washing unit, and are clustered as waste.

8. Follow-up treatment heavy fractions (PET)

An air separator separates mainly PET dust from the grainy PET. A combination of vibration chute and drum magnet follows downstream. The vibration chute singularises the material and the drum magnet isolates magnetisable contamination. The PET flakes material falls on a further vibration chute, is singularised and trickles through the all-metal separator, whereby also NE-metals and high-grade steel parts are separated.

Optional: In the automatic separation system the PET flakes, cleaned from any metal, is separated in a further vibration gutter and trickles through a colour recognition separate plant. Pre-programmed coloured flakes are separated from the transparent material. In the all-metal separator and failed colour separator also small quantities of PET flakes are blown out. The material cleaned in this way falls into a fan funnel and is carried to the PET filling station.

9. Follow-up treatment light fractions (Polyolefine - PO)

The PO obtained in the separation stage 1 is mainly separated from foils in the air separation. The grainy PO is carried with a fan to the PO (Polyolefine) filling station.

10. / 11. Filling station PET and PO (Polyolefine)

The filling station consists of a base frame with a platform, two suspension devices for big-bags, holding construction for cyclone and cell wheel sluice and a pneumatically switch.

12. General description and function of the circulation system

The plant has 3 separate circulation systems: Crusher / friction cleaner separating stage 1 / friction cleaner PET and friction dryer PO, Post washer / friction cleaner / separating stage 2 / 2-step friction dryer.

Each circulation system consists of: Storage tank; Cycle pump; Fibre separator lower discharge for sediment material.

The circulation pump transports the cleaned water from the storage tank to the respective plant component (see layout).

From the collecting tub of the friction cleaner or friction dryer the dirty circulating water is pumped back to the storage tank.

The dirty water, separated by the friction cleaner and friction dryers from the respective circulation systems, is pumped to the associated fibre separator. In the fibre separator foreign substances (fibres, fluff, general dirt, etc.) are removed, and the water flows to the storage tank. The collected material on the sieve deck of the fibre separator is thrown into a waste conveying screw and transported to the waste press. From the underflow of the storage tanks a defined quantity water (appr. 1,5 – 2,5 m³/h) including sediments is pumped in a water treatment unit for subsequent treating. Depending upon the resulting water quality it can be returned into the processing plant. For the post washer and separation stage 2 it is expressly recommended however to supply fresh water( 2 – 3 m³/h).

13. OPTIONAL: Water treatment unit

The water treatment plant is a separate unit, which can work independently of the recycling plant. Thus in low operating times of the recycling plant it is possible to clean the complete industrial water.

14. General description and function of the dosing station

The dosing station is a compact unit and consists of several dosing pumps. These pumps injects the antifoaming agents, washing intensifier, and the concentrated caustic soda into each circulation systems.

15. Electro technical equipment

The controls of the complete plant are installed in the main control cabinet. Any important information is indicated in the instrumentation (current consumption, revolutions, flow rate, etc.). Warnings and disturbances are signalled. All necessary operating and controlling elements are placed in the doors of the control cabinet for easy repair, service, and individually adjustable.

TECHNICAL DATA / plant Components and equipments.

(1.1.) Bale belt for bale release

belt length: 7.800 mm x conveying width: 1.310 mm - actuation capacity: 2,2 kW rotation speed: regulated by frequency converter; Bale recognition sensor: transmitter/receiver

(1.2.) Bale release BW

total length: 3.170 mm x total width: 2.370 mm x total height: 3.120 mm

actuation capacity: 1 x 30 kW; 1 x 15 kW; 1 x 7,5 kW – Hydraulic

(1.3.) Conveyor belt

belt length: 7.000 mm x conveyor width: 800 mm x actuation capacity: 2,2 kW - rotation speed: 49 rpm

(1.4.) Magnet UMP 70 120 T

total length: 2.000 mm x total width: 2.754 mm x total height: 3.050 mm - actuation capacity: 2,2 kW

(1.5.) Feeding screw dosing

total length: 4.770 mm x total width: 1.700 mm x total height: 1.800 mm - actuation capacity: 2 x 1,5 kW

rotation speed: regulated by frequency converter; rotations monitored: with two sensors filling level monitor: transmitter/receiver

(1.6.) Sorting belt with sorting platform

belt length: 7.000 mm, conveying width: 800 mm

actuation capacity: 2,2 kW; rotation speed: 26 rpm

(1.7.) Ascending belt to the crusher

conveying length: 10.500 mm x conveying width: 800 mm - actuation capacity: 2,2 kW - rotation speed: 49 rpm

Comminution / crushing and rough cleaning

(2.1.) Crusher KSM 800-1530

rotor diameter: 800 mm x working width: 1.530 mm x number of rotor blades: 5 x number stator blades: 2

actuation capacity: 132,0 kW - 1,1 kW – for hydraulic power pack

(2.2.) Friction cleaner FR 800-2000 with base frame, collecting tank and pump, (2.4.) fan and pipeline

total length: 2.690 mm x total width: 1.800 mm x total height: 2.190 mm - actuation capacity: 37,0 kW

rotation speed: 1.450 rpm - fan MFT 45/350: 7,5 kW - conveyor pumps: pump to sieving machine 3,1 kW

Preliminary separating

(3.3.) Air separator with (3.1.) cyclone and (3.2.) cell wheel sluice and (3.4./3.5.) fan

total length: 1.500 mm x total width: 1.500 mm x total height: 6.100 mm - cell wheel sluice: 0,55 kW

fan MFT 45/350: 2x7,5 kW

Separating stage 1

Stirrer tank with (3.1) cyclone, (3.2) cell wheel sluice and separating tank

total length: 5.000 mm x total width: 2.120 mm x total height: 5.650 mm - cell wheel sluice: 0,55 kW

(3.3) Stirrer tank EB 1900-2220

Stirrer: 4,0 kW - Pump: 2,0 kW

(3.4) Separating tank TB 1900-3445

Pump: 3,1 kW - electro-pneumatic valve block: (5-fold) - air pressure: 6 bar (connection) - set operating pressure appr. 4,5 bar

(3.5.) Friction cleaner for PET with base frame, collecting tank and pump, (3.7.) fan and pipeline

total length: 2.690 mm x total width: 1.800 mm x total height: 2.190 mm - actuation capacity: 37,0 kW

rotation speed: 1.450 rpm - fan MFT 45/350: 7,5 kW - pump to sieving machine: 3,1 kW

(3.8.) Friction dryer for PO with base frame, collecting tank and pump, (3.10.) fan and pipeline

total length: 2.690 mm x total width: 1.804 mm x total height: 2.190 mm - actuation capacity: 22,0 kW

fan MFT 45/350: 7,5 kW - pump to sieving machine: 3,1 kW

Hot washer

(4.3.) Hot washer with (4.1.) cyclone and (4.2.) cell wheel sluice and (4.5.)friction

cleaner with base frame, collecting tank and pump, (4.7.) fan and pipeline

total length: 3.220 mm x total width: 2.280 mm x total height: 2.700 mm - hot water washer: 3x0,18 kW

cell wheel sluice: 0,55 kW - filling level measurement: pressure sensor

Temperature control with safety disconnection (safety thermostat) - friction cleaner: 37,0 kW

fan MFT 45/350: 7,5 kW - pump to sieving machine: 3,1 kW

Circulation tank with electric heating system

(4.4.) Heating tank with (4.4.1.) fibre separator

heating elements: 250 kW - fibre separator: 1,8 kW - circulation pump: 2,2 kW

Hot washer

(5.3.) Hot washer with (5.1.) cyclone and (5.2.) cell wheel sluice and (5.5.) friction cleaner

with base frame, collecting tank and pump and pipeline

total length: 4.775 mm x total width: 1.820 mm x total height: 3.595 mm - cell wheel sluice: 0,55 kW

stirrer: 22,0 kW - friction cleaner: 37,0 kW - filling level measurement: pressure sensor

conveying pumps: pump to sieving machine 3,1 kW

Circulation tank with electric heating system

(5.4.) Heating tank with (5.4.1.) fibre separator

heating elements: 150 kW - fibre separator: 1,8 kW - circulation pump: 2,2 kW

Post washer

(6.1.) Post washer and (6.2.) friction cleaner with base frame, collecting tank and pump, (6.4.) fan and pipeline

total length: 4.775 mm x total width: 1.820 mm x total height: 3.595 mm - stirrer: 22,0 kW - friction cleaner: 37,0 kW - fan

MFT 45/350: 7,5 kW - filling level measurement: pressure sensor - conveying pumps: turbo pump to friction cleaner 3,1 kW

Separating stage 2

consisting of:

Stirrer tank with (7.1.) cyclone, (7.2.) cell wheel sluice and separating tank

total length: 5.000 mm x total width: 2.120 mm x total height: 5.650 mm

(7.3.) Stirrer tank EB 1900-2220

stirrer tank: 4,0 kW - Pump: 2,0 kW

(7.4.) Separating tank TB 1900-3445

Pump: 3,1 kW - electro pneumatic valve block: (5-fold) - air pressure: 6 bar (connection) - set operating pressure appr. 4,5

bar

(7.5.) 2-stage friction dryer for PET with base frame, collecting tank and pump, (7.7.) fan and pipeline

total length: 7.420 mm x total width: 2.900 mm x total height: 3.940 mm - actuation capacity: 1 x 37 kW / 1 x 30 kW - pump

to sieving machine 3,1 kW - fan MFT 45/350: 7,5 kW

After treatment heavy fractions

consists of:

PET air separator

(8.1.) cyclone

(8.2.) cell wheel sluice: 0,55 kW

(8.3.) air separator KF20: 1,5 kW

(8.4.) discharged air cyclone

(8.5.) fan TRL 55: 4,0 kW

PET - Flakes after separation

(8.6.) cyclone

(8.7.) cell wheel sluice: 0,55 kW

(8.8.) vibration chute: 2 x 0,7 kW

(8.9.) magnet drum: 0,37 kW

(8.10.) vibration chute: 5,0 kW

(8.11.) all metal separator: 1,0 kW

(8.12.) Optional: vibration chute: 5,0 kW

(8.13.) Optional: failure colour separation: 1,0 kW

(8.14.) fan TRL 55: 4,0 kW

After treatment light fraction

PO air separator

(9.1.) cyclone

(9.2.) cell wheel sluice: 0,55 kW

(9.3.) air separator: 1,5 kW

(9.4.) discharged air cyclone

(9.5.) fan TRL 55: 4,0 kW

PET Filling station

(10.3.) PO Filling station with (10.1.) cyclone and (10.2.) cell wheel sluice

cyclone

cell wheel sluice: 0,55 kW

pneumatic switch:

big-bag filling station

PO Filling station

(11.3.) PO Filling station with (11.1.) cyclone and (11.2.) cell wheel sluice

cyclone

cell wheel sluice: 0,55 kW

pneumatic switch:

big-bag filling station

Circulation systems with waste press

3 circulation tank

each consists of: (12.1.) – (12.10.)

fibre separator filter size: 48”; 60”

actuation capacity: 1,8 kW

total length: 2.133 mm

total width: 4.900 mm

total height: 2.805 mm

flow pump: 2,0 kW

underflow pump 1,5 kW

(12.11.) Waste feeding screw

screw diameter: 300 mm

actuation capacity: 1,5 kW

(12.12.) Fibre separator

fibre separator filter size: 48”

actuation capacity: 1,8 kW

(12.13.) Waste press

actuation capacity: 3,0 kW

(12.14.) Water dike

pump: 1,5 kW

(14.) Dosing station

for de-foaming agent, caustic soda and washing additives for hot washer.

(15.) Electrical equipment

The control of the unit consists of a logical part in conventional contactor switching and the capacity controls.

All necessary operating and monitoring elements are on the front side of the control cabinets.

Mode of operation: - automatic operation

- locked manual operation

- repair operation

ON / OFF or EMERGENCY OFF switch on the relevant part of the unit.

Further details

total installed electrical capacity: appr. 1090 kW

air pressure: appr. 8 bar

fresh water consumption: appr. 2-3 m³/h

output to water treatment appr. 1,5-2,5 m³/h

CORRODABLE AND SPARE PARTS

Diverse machine parts are subject to corrosion. A detailed list of recommended spare parts will be handed over at the time of delivery. By construction the necessary spare parts used are as many as possible made up of identical components (e.g. bearings, motors, pumps, friction aggregates).

As these units are in use in our own recycling companies, it is possible for us to recognitions all constructions and in this way are able to minimise spare part storage, and to facilitate maintenance. All corrodible parts can be exchanged separately.

CUSTOMER DUTIES

For the completion of the quoted unit, please find a list of duties and equipment which must be provided by the customer:

· corrodible and spares parts, according to the suggested list, which are subject to special arrangement

· aeration and ventilation of the hall

· energy supply and distribution (electricity, water, pressurised air) up to the connection points marked in the layout

· electrical supply to the control cabinets

· compressor for the pressurised air supply

· sharpening machines and tools for the crusher blades

· assistance for unloading, transporting and erection for the installation in the customer's factory

· facilities, tools and devices for the maintenance of the unit

· building and bricklaying work and foundations for the installation of the unit according to the relevant layout

· noise protection and other safety systems (fire protection)

· naming of security administrator

· wall and floor channels for laying the installation pipelines

· unit installation and electrical wiring of each unit component, if not specified in our quotation

· everything not specifically mentioned in the order confirmation

GUARANTEE

Production guarantee

PET bottles, pre-sorted from post consumer collections, loose or pressed into bales: appr. 1.400 up to1.500 kg/h input

depend of bottle waste condition

Procedure guarantee

The PET bottles originate from post consumer collection and have been automatically or manually pre-sorted. No demands are made against the density of the bundles and briquettes.

Operating guarantee

For a period of 6 months from the date of initiation, however within 12 months from date of invoice, the seller furnishes the purchaser, but not his legal successor, a guarantee for the quoted machinery and units. The guarantee is to be understood and ends with the free-of-charge exchange or the free-of-charge repair of the parts, which are found to be unusable due to material faults or to construction. Apart from the exchange or repair, as listed above, the seller has no further commitment, the purchaser has no right to demand a cancellation of contract or compensation. The seller is not responsible for defects which arise from the customer's materials or projects. The seller is only responsible for defects which arise in spite of proper operation. The seller is not responsible for defects which originate after delivery. The guarantee does not cover any damage or breakage caused by natural wear and tear, careless maintenance, misuse of the machinery by the purchaser. The guarantee ends, should the purchaser not effect payment at the arranged time or should a machine or part of a machine be modified or repaired without prior approval from the seller. Warranty claims are only valid if faults or defects are reported to the seller immediately after being discovered by the purchaser.

Caveat emptor

Corrodible parts such as seals, fluids, blades as well as all static and dynamic wear parts which are directly subjected to the influences of the processing material or whose defects are caused by contamination due to misuse of the work instructions, bad maintenance, changes and repair work carried out by the customer without written consent from the seller are excluded from the guarantee.

In the course of technical improvements the seller maintains the right to chain quoted equipment (the complete unit

and all unit parts are in accordance with EG guidelines). For the rest our „general conditions for supply and service“ are valid.

INSTALLATION, START-UP AND APPROVAL

The costs for installation and start-up of the complete plant are not included in the price.

The installation of the unit accomplished by the technical personnel of the supplier and is including start-up the subject of achievement of the supplier. The account takes place according to the actual expenditure considering the costs of assembly service (enclosure). The test phase begins with the trial run of the unit components and ends with the adjustment of the complete unit, in order to fulfil all guaranteed parameters. The trial period and training of customer's staff starts now. At the end of the trial period, a final run under constant operation of 24 hours/day will be run for a period of 3 days. As a result an approval protocol of the unit will be issued which is to be signed by both contractual parties. The final run is to be carried out by the customer's staff and 3 STF engineers will be of assistance. Thus the start-up of the entire plant took place and starting from date of start-up begins the guarantee period to run. A documentation of all unit parts (operating documentation, spare parts list) will be handed over at the begin of the start-up. They have all up to the beginning of the acceptance for the enterprise of our delivery article necessary connections, supply and disposal pipelines and operational funds to produce respectively to make available. Smaller lack of our delivery article, which do not have effects on the production flow, do not prevent the acceptance. They are processed at short notice. With from us to representing production-preventing lack the acceptance is repeated at a time which can be specified by agreement. We will manufacture an acceptable condition immediately. The legal effects of the acceptance are considered as occurred, even if you – begin with presence of smaller lack – start with commercial production, or an opportunity do not give us to process about still existing lack of remainder at business-usual times or if within 60 days starting from start-up the for your part did not create you to furnishing conditions for acceptance.

Additional Information

Input Flow

Component:

Amount:

PET Max. 1,400 Kg / hour

Pre-sorted, to bales or briquettes pressed PET bottles from post consumer collection

Output Flow

Component:

Amount approx.:

PET Flakes 75 – 80 % (approx. 1050 Kg/h.)

PO ( Polyolefine PP & PE) 6 (approx. 85 kg/h.)

Labels / Paper 0.8 – 1.0 % (approx. 14 kg/h.)

Waste from grinder circuit

(mainly paper of labels,

residual moisture: approx.

35%)

10 %

“waste” from the remaining

circuits (mainly plastics

abrasion)

2 %

The declarations on the distribution of the output of a PET bottles recycling plant are only experience values from the production at STF GmbH own plants. These values are to regarded as reference values, as the composition depends on numerous factors. Particularly , the following factors are decisive.

·  configuration of the plant

·  size and weight of the bottle

·  nature of the labels

·  impurities in the input

Consumption / Discharge

electrical power:

per hour, approx.:

per Kg bottle:

Installed electrical power 1093 kW

Approx.65 percent effective electrical

consumption for input capacity of

1400 kg waste bottle

710 kW

0,51 kW

Electrical consumption for 1 Kg clean

PET flakes

710 kW : 1050 kg

per Kg flakes

0,67 kW

water consumption, approx.:

fresh water supply 2.0 – 2.5 m³ / h

Waste water (water for water treatment) * 1.5 – 2.0 m³ / h

loss 0.5 m³ / h

* The amount and quality of the processing water depends on the quality of the input and the desired quality of the output.

Considerably, the choice of chemicals has an impact on the sewages quantity and quality.

air, approx.:

consumption 3000 - 7000 l / min *

required compressor size 8000 l / min

required pressure 8 bar

* Depending on the quality of the input material