INTEGRATED WASTE PLASTIC RECYCLING PROJECT PLASTICS RECYCLING.pdf · 2016-08-01 · 1. Waste sorting module 2. Waste plastic recycling module 3. Plastic injection and product manufacturing

Emek Mahallesi 29. Sokak No: 38/A Cankaya-Ankara-Turkey

Tel:+90.312.212 1281 Fax: +90.312.215 6065

[email protected] www.metan.com.tr

metan medical technical analytical instruments international trade & consultancy co., ltd

INTEGRATED WASTE PLASTIC RECYCLING PROJECT

We are herewith pleased to submit our “ WASTE PLASTIC RECYCLING SYSTEM “ proposal which consists of four stand alone modules :

1. Waste sorting module 2. Waste plastic recycling module 3. Plastic injection and product manufacturing module 4. PET recycling module

Each section is standalone unit can be operated with or without the other sections but all together propose a complete pilot waste plastic recycling project. Our main philosophy in designing the entire project and choosing the individual equipment has been to offer the best quality and robust equipment which would be operated easily for a long time without requiring big amount of service and parts requirement.

WASTE PLASTIC RECYCLING SYSTEM

1. GENERAL

The waste plastic recycling pilot project is consisted of four main stations:

1. Waste sorting unit 2. Waste plastic granulation unit 3. Plastic injection and product manufacturing unit 4. PET recycling unit

All of the above modules are autonomous and can be operated independently for different jobs to yield different products. But on the other hand, four units make a complete pilot project to work also in sequence to define a complete waste recycling project.

2.1. WASTE SORTING MODULE First of all, it is to be noted that a recycling and reuse project starts at the point of generation and the success of the entire project is entirely related to the success of waste segregation at the sources. For this purpose the waste sorting containers in different designs and shapes are to be used at the sources to separate different waste streams without polluting each other. The segregated waste streams are to be transported to different waste recycling stations for further recycling or re-use. In our case, the plastics are to be transported to the waste plastic recycling station either in bales or in containers, trucks, etc. or by any other shape and means.


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Whatever the success of segregation is, anyhow, at the station a further separation and waste sorting is required because not ant waste segregation at the source is 100 % successful. So, the plastic masses are to be dumped over a conveyor band to be sorted manually by normally 8-10 workers besides the conveyor band. Each of the workers is responsible for picking up and putting in a container certain sort of plastic. Finally, the waste is sorted to different plastic classes as Poly ethylene, ply propylene, PVC, PET, etc. Each sort is to be further treated in a different way. This job can also be done by highly sophisticated, fully automatic waste sorting machinery but in the countries where labor cost is relatively low and the budget for very sophisticated equipment is a little bit short, the manual sorting is the preferred way. And in fact, this way is, after a certain period of experience, the fastest, most economic and guaranteed way.


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2.2 WASTE PLASTICS RECYCLIN MODULE Plastic recycling is the process of making re-useable plastic raw material from plastic wastes. The process starts with the sorting of the waste plastics. Clean plastics are crushed and turned to granules. Waste plastics from garbage should be crushed, washed, dried and turn to granules in complete recycling lines. The line consists of these machines in order ; platform conveyor, crushing machine, washing basins, centrifuge, squeezing machines, storing units, agglomeration machine and granule extruder. After the granule cutting machine PE, PP, PS, LDPE, HDPE, ABS and PET materials are turned into re-useable granules. Waste plastics collected from garbage should be sorted and crushed in crushing machine. After turbo washed in centrifuges, they transferred into washing basins. Then they squeezed by squeezing machine and transferred to the silo by conveyor fan. Stored materials are transferred to the agglomeration machine by conveyor spiral and then to the extruder. In granule extruder plastics are melt and they cut into granules in granule cutting machine. Plastic recycling lines can be manufactured according to the raw material to be used and capacity. Recycling of waste plastics is highly important for environment and reduces the green house effect. Below given is the PE ( polyethylene ) or PP ( polypropylene) recycling systems with the functions and specifications of the individual units .


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TECHNICAL FEATURES

PLASTIC GRANULATOR (100) and CONVEYOR

CONVEYOR Carries material to the crushing machine by 2,2 KW motor and conveyor belt system. 10 mm thick, rubber belt is used. PLASTIC GRANULATOR (100) Rotor blades : 110x25x500 6 pcs (2 pcs x 3 rows) Number of fixed blades : 110x25x500 4 pcs (2 pcs x 2 rows) Rotor length : 1000 mm Rotor blade length : 500 mm Rotor diameter : Ø650 Rotor shaft speed : 650 rpm Blade material : DIN 2379 ( AISI D2 ) Motor power : 90 kW 1500rpm Screen Hole Diameter : 20 & 70 mm Cooling system : Water-cooled ball bearings Safety switches : 1 pcs Capacity : 500 - 600 kg/h Made of heavy-duty steel and sheets, completely by gas welding manufacture. Horizontal profiles in the funnel prevent the material from deflecting back during the first breaking. Heavy-duty type bearings easily absorb the crushing impacts. Power is transferred to the rotor via the B-type V belts in the safety shelter. Crushing Machine is designed to allow automatic opening closing of the body via the hydraulic unit in order to prevent

wasting time for replacing the blades. In order to extend the lifetime of the blades and increase the product of the crushing process, the rotor and fixed blades are

made of DIN 2379 material and heat-treated at 58 HRC temper. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates. SCREW CONVEYOR


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Ø 250 x 4000 mm dimensions. Made of DKP iron sheet material. 4 KW motor is used. SINK – FLOAT TANK

It is used for separating floating plastics (PE, PP) from heavy plastics and contaminants like mud, stone, metal. 4000 x 1000 x 1500 mm effective dimensions. Internal screw (Ø200 mm) transfers heavy objects and mud which sunk in the pool to discharge screw. Discharge screw (Ø200 mm) transfers the sunk materials out of pool. 5 pcs of mixer track, each powered by individual engines. Made of AISI 304 stainless steel. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates. Ø250x3000 HORIZONTAL CENTRIFUGE


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Ø250 x 3000 mm effective length. Maximum cleaning ability with special rotor and rotor wings design. 7,5 KW 1000 rpm engine. Strong engine – shaft connection with gear system. Made of AISI 304 Stainless material. FILM DEWATERING MACHINE 75

Processes ~500 - 600 kg per hour proportional to the system capacity. Has 75 KW motor power. YRM 2545 extruder type gearbox is used. Squeezes the washed film material mechanically and reduce the humidity rate to 5 – 7%.


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By reducing humidity level to 5-7%, operation time of agglomeration machine for each batch is reduced. Made of heavy-duty steel and sheets, completely by gas welding manufacture. By mounting the screw to the gearbox at the back and to a thrust bearing at the front of the machine, lifetime of the machine is extended. Film Dewatering Machine is environmentally protected with the protection panels in order to prevent any danger arising around the machine for a number of reasons. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate, GOST-R and CE certificates.

VERTICAL CENTRIFUGE

Vertical Centrifuge is used for dewatering rigid flakes. Humidity rate of the flakes will be reduced to 2-3%. 5,5 KW 1500 rpm vertical spiral motor. 2.2 KW 1000 rpm input spiral motor. Ø250 mm rotor. Perforated screen with Ø2 mm holes. Vertical Centrifuge bearings are selected to be durable for high speed and load. Made of AISI 304 quality stainless steel material. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates.

STORAGE SILO ABOVE AGGLOMERATOR

Made of DKP iron sheet. Is used for film or hard material storage. 10 m3 storage volume. Double spirals for transferring material. Dust collecting system is included.


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AGGLOMERATION MACHINE Ø 130

Agglomeration machine dries dewatered plastics with the friction occurred between rotating and fixed blades under high speed. Tank body size is Ø130 cm. Body sheet thickness is ~12mm. Made of heavy-duty steel and sheets, completely by gas welding manufacture. Has an approximate capacity of 500 - 600 kg per hour. 132 kw 1500 rpm main engine. Discharge lid is opened pneumatically. 1 pc rotating track, 6 pcs rotating track blades and 7 pcs fixed blades. The power is transferred to the rotor via B type V belts within the safety shelter. System was designed in order to enable replacing the V belts, which would broke off for various reasons, easily and without wasting time. The lifetime of the existing bearing systems are improved after the research and development. Control panels, electrical power units and power cables comply with all safety specifications and CE standards. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates. SCREW CONVEYOR WITH BASIN

It is used for conveying material to extruder hopper without using manpower. 3 KW screw gearbox, 2,2 KW mixer gearbox. Manufactured around 4000-4500mm size. Made of iron sheet.


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Ø 150 GRANULE EXTRUDER – SIDE FEED –

Ø150 mm main screw, L/D: 36. 4140 material is used for the production of the main and side feeding screw and barrel. Screw and barrels are made to have 58-60 HRC

temper by induction process. Lifetime of bimetallic screw is extended by a special hard welding which is applied on the screw pitches. The chassis of the Granule Extruder Machine is made of ~8 mm sheets. Depending on the material to be used, the capacity of Granule Extruder Machine is around 500 - 600 kg per hour. The hazardous gases and chemicals within the material are removed by absorbing with the vacuum system and the gas that forms after

this process is cleaned of all hazardous elements in compliance with the European Standards and considering the human health. Granule Extruder Machine has three centers main and three centers side feeding gearboxes. All gearboxes and engines are Turkish made. 160 KW main engine, 30 KW side feeding engine are used. Both engines are controlled by Fuji inverter. Ø300 mm, single plate screen changer with two filtration zones is used. 4 KW hydraulic oil unit compatible with the screen changer. If the screen is not cleaned in the proposed period, the pressure sensor alarm system is activated to notify the concerned personnel of

the situation. The ceramic heaters and isolated special protection sheets used for the Granule Extruder Machine provide 20% electrical savings, and

additionally the initial operation time of the machine is reduced from 1.5 – 2 hour to minimum level. Different regions are allowed to be adjusted for different heat levels by the fans on the Granule Extruder Machine. Mixer tracks in the side feeding unit silo prevent material jamming. Direct connection of main drive and gearbox saves energy. System is controlled by Fuji PLC. Control panels, electrical power units and cables comply with all safety specifications and CE standards. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate, GOST-R and CE certificates


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PELLETIZER 260

Spiral motor : 3 KW 900 rpm Cutting head motor : 3 KW 1500 rpm (inverter controlled) Water circulation motor and pump : 4 KW 5,5HP Water transfer motor and pump : 2,2 KW 3HP Heater power : 6 KW Total electrical power : 18,2 KW Machine body : CRNI 304 stainless Track blade : 2 pcs ( 2379 material ) Granule Cutting Machine performs vertical hot surface cutting as hot round granules. Has track blades and a die that are easy to replace thanks to its movable body components. BLOWER It is used for pneumatic transport. Adequate for the system capacity.

GRANULE STORAGE SILO Made of DKP sheet. Silo volume is 2 m³.


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The plastic beads are the final products which are stored and packaged for marketing.

2.3 PLASTIC INJECTION AND READY TO SELL PRODUCT MAKING MODULE The plastic materials above recovered are used by many industries without to be used in food packaging in direct contact with food.


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Here in this project, an plastic injection machine of 3m m3/h capacity is offered. As two different products, moulds for food transport cases and bucket making moulds are offered. Of course different moulds are added according to the preference.


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2.4 PET RECYCLING MODULE

The PET bottles are recycled to Pet flakes which further can be used for manufacvture of various products.

TECHNICAL FEATURES

PRE-WASHING TROMMEL

High pre-washing effect with water. Ø500 x 4000 mm trommel dimensions. Parts facing water are made of AISI 304 stainless steel.

CONVEYOR

Carries the material to the crushing machine by 1,5 KW motor and conveyor belt system.


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10 mm thick, rubber belt is used. PLASTIC GRANULATOR (100) - WET

Rotor blades : 110x25x500 10 pcs ( 2 pcs x 5 rows ) Number of fixed blades : 110x25x500 4 pcs ( 2 pcs x 2 rows ) Rotor length : 1000 mm Rotor blade length : 500 mm Rotor diameter : Ø750 Rotor shaft speed : 650 rpm, Blade material : DIN 2379 ( AISI D2 ) Motor power : 90 kW 1500rpm Screen Hole Diameter : 12 – 16 mm Cooling system : Water-cooled ball bearings Safety switches : 1 pcs Output Capacity : 500 kg/h

Made of heavy-duty steel and sheets, completely by gas welding manufacture. Horizontal profiles in the funnel prevent the material from deflecting back during the first breaking. Heavy-duty type bearings easily absorb the crushing impacts. Power is transferred to the rotor via the B-type V belts in the safety shelter. Crushing Machine is designed to allow automatic opening closing of the body via the hydraulic unit in order to prevent wasting time for

replacing the blades. In order to extend the lifetime of the blades and increase the product of the crushing process, the rotor and fixed blades are made

of DIN 2379 material and heat-treated at 58 HRC temper. 1 set of spare blades and 1 screen is included as spare part. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates.


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SCREW CONVEYOR

Adequate for the system capacity: Ø 250. Made of DKP iron sheet material. 4 KW motor is used. PET SEPARATION TANK

~ 4000 x 1000 x 1500 mm effective dimensions. Internal spiral Ø300 mm 2 pcs, transfers PET material. Upper spiral Ø200 mm, transfers the flowing material (PE, PP) out of the tank.


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Has 1 piece of mixer paddle. 2 pcs. 4 kw internal screw engine, 25 rpm gearbox. 1 piece 2,2 kw mixer engine, 30 rpm gearbox. 1 piece 2,2 kw upper screw engine, 30 rpm gearbox. Total installed capacity is 12.4 KW. Tank is made of 3 mm thick AISI 304 material; carrying legs are made of 40x60x2 painted iron profile. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates.

Ø250x3000 HORIZONTAL CENTRIFUGE

Ø250 mm x 3000 mm dimensions. Perfect cleaning ability with special rotor design. 7,5 KW 1000 rpm spiral motor. Made of 3 mm thick AISI 304 Stainless material. Ø1200 HOT WASHING TANK

It is used for cleaning dirt on PET material like glue, oil in continuous system. It is completely made of AISI 304 stainless steel. 4 kw discharge screw engine, 11 kw mixer engine. Double layer technology for heating. (hot water is required) Ø1200 mm x 1300 mm dimensions.


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Total installed capacity is 15 kw. Automatic caustic soda solution intake by the help of level control system. (Caustic acid and hot water solution should be prepared separately)

Ø450 DYNAMIC CENTRIFUGE

Dynamic Centrifuge is used for dewatering rigid flakes. Humidity rate of the flakes will be reduced to 1%. 22 KW 1500 rpm vertical spiral motor. 2.2 KW 180 rpm input spiral motor. Ø450 mm rotor. Perforated screen with Ø2 mm holes. Dynamic Centrifuge spiral bearings are selected to be durable for high speed and load. Made of AISI 304 quality stainless steel material. Our machines have TSE, Warranty Certificate, After Sales Compliance Certificate and CE certificates. BLOWER

7,5 kw blower. Adequate for the system capacity.

SILO

Made of DKP iron sheet. Silo volume is 3 m³.


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2.5 DATA STORAGE AND PROCESS MANAGEMENT MODULE ( if required, can be added by defining different sub-modules ) ,

If required, the above plants can be installed at the same location and the process parameters, data storage, technical and financial report keepings tec. Are kep in an intelligent software . The details are to be determined according to the requirements. 3 REQUIREMENTS AREA : ( height : 10 m ) WASTE SORTING MODULE: 500 – 600 M2 WASTE PLASTICS RECYCLIN MODULE: 1000 -1200 M2 PLASTIC INJECTION MODULE: 300 M2 PET RECYCLING MODULE : 1000 M2 DATA STORAGE AND PROCESS MANAGEMENT MODULE : 100 M2 POWER: WASTE SORTING MODULE: 100 KW WASTE PLASTICS RECYCLIN MODULE: 500 kW PLASTIC INJECTION MODULE: 200 kW PET RECYCLING MODULE: 500 kW DATA STORAGE AND PROCESS MANAGEMENT MODULE: 20 kW WATER: WASTE PLASTICS RECYCLIN MODULE: 50-100 M3/DAY PLASTIC INJECTION MODULE: 50-100 M3/DAY MANPOWER ( 2 SHIFTS PER DAY ) WASTE SORTING MODULE: 10


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WASTE PLASTICS RECYCLIN MODULE: 10 PLASTIC INJECTION MODULE: 2 PET RECYCLING MODULE: 10 DATA STORAGE AND PROCESS MANAGEMENT MODULE: 2 CONCLUSION. The above project proposal is JUST AN EXAMPLE AND THE MODELS AND SPEFIFICATIONS ARE SUBJECT TO CHANGE for an integrated waste plastic recycling project which covers many modules. Of course such an integrated project by all means makes an excellent recycling application and not only is an environmentally sound project but also a profitable investment which generates money depending on the country’s local market conditions. The first module, waste sorting module can be expanded to packaging waste sorting module. Each module can be installed and operated independently and autonomously but the integration is also possible. The final project proposal can be given according to your specific requirements. Thank you for your consideration and best regards

Dr. Cemal Kaldirimci (Chemical Engineer) Founder, Managing Director


Tel:+90.312.212 1281 Fax: +90.312.215 6065



Documents

INTEGRATED WASTE PLASTIC RECYCLING PROJECT PLASTICS RECYCLING.pdf · 2016-08-01 · 1. Waste sorting module 2. Waste plastic recycling module 3. Plastic injection and product manufacturing