Standard Equipment: The following standardized components

Standard Equipment:

The following standardized components will be used and have been

considered in this specific quote:

Drives SEW

Hydraulics HAWE, OTTO

Vacuum Pumps BUSCH, RIETSCHLE

Safety Switches ELOBAU, SCHMERSAL

Gap Sensor SCHREIBER

Level Switch VEGA

Pressure Transmitters WIKA

Pneumatics FESTO

Control Cabinets RITTAL

Bearings SKF or FAG

Raw Material Feed

3.1.1 Buffer Silo

Cylindrical silo with conical outlet and fixation supports, top with raw

material feed nozzle, dedusting nozzle, man hole DN 500 and nozzle for level

sensor

Weighing devices for continuous control of level inside buffer silo

Level sensor for overfilling detection

6 pcs. 2“ pipe collars at the circumferential of the conical outlet in order to

retrofit air systems in case of discharge problems.

Technical Data:

Required Volume in cylindrical area : approx. 10,5 m³

(5.000 kg/h / 2 / 0,275 kg/l) + 15%

Total Volume : approx. 14 m³

Diameter : approx. 2,5 m

Cylindrical Height : approx. 2,2 m

Material of Construction : Stainless steel

3.1.2 Bin Activator

The diameter has been chosen quite big in

comparison to the diameter of the buffer silo.

Flexible compensator at the inlet

Discharge cone with integrated material release plate

Vibration by means of two unbalanced drives

Technical Data:

Diameter: approx. 1,8 m

Material of Construction: Stainless steel

Drive Power: approx. 2 x 0,55 kW

3.1.3 Slide Gate Valve

Manually operated shut off system for maintenance purposes only. Installed at the

outlet of the discharge bottom. With proximity switches for control of positioning.

Technical Data:

Diameter of Opening : 250 mm

Height : approx. 290 mm

Operating : manually by crank handle

Material of construction : Stainless Steel

3.1.4 Discharge Dosing Screw

As dosing system for controlled feed of battery mass on top of roller compactor.

Executed as tube screw conveyor.

Technical Data:

Diameter : DN 250

Conveying Length : approx. 3,8 m

Total Length : approx. 4,3 m


Drive Power : approx. 3,0 kW

3.2 Roller Compactor

3.2.1 CVF‐ Stirrer

The CVF‐Stirrer is equipped with a double chamber for feed of raw material (main

chamber) and recycle of undersize material (second chamber).

The second chamber at the same time serves to deaerate the raw material. Both

product streams are mixed in the CVF‐Screw.

Mainly consisting of:

Hopper with cover, volume approx. 1.250 / 450 liter

Equipped with a horizontal stirrer (in both chambers)

Drive by geared motor, approx. 2,2 kW

Cover plate with required connecting nozzles

Suction nozzle

Seal air for shaft penetrations

Level probe

3.2.2 CVF‐ Feed Screw

The feed screw unit de‐aerates the raw material and transports it into the

nip area of the press rollers.


Executed as screw conveyor

Screw housing prepared for vacuum filter

2 screws, cylindrical, double‐flighted


Screw speed adjustable by frequency inverter

Load and speed indication on the panel


3.2.3 CVF‐ Vacuum

The machine is equipped with a vacuum station. By means of the vacuum at the

screw feeder housing outlet, the flow behavior of the product into the roller gap is

positively influenced.


Vacuum pump as dry‐ running pump, approx. 0,25 kW

Filter insert for screw housing

Safety filter

Vacuum indication on panel in bar

3.2.4 Roller Unit PP 500 x 500

In the roller unit the compaction of the raw material is effected.


Drive by 4 geared motors, approx. 37 kW each

Roller speed adjustable by frequency inverter

Load and speed indication on the panel

Roller gap measuring

Roller gap control

Double‐ sided roller bearings, easy access

Roller surface grooved and knurled

Roller diameter = 500 mm

Roller width = 500 mm

Max. compacting pressure = 48 kN/cm roller width

Adjustable scrapers

Sample port for flakes

Suction nozzle


Circumferential side seals

Water cooling of press rollers

3.2.5 Hydraulic Unit

The hydraulic unit generates the required compacting pressure.


Tank with hydraulic pump and all necessary valves and instruments,

approx. 2,2 kW

2 hydraulic cylinders with the necessary piping and hoses

2 accumulators

Operating pressure max. 350 bar

Compacting pressure infinitely adjustable between the limits,

pressure kept constant during the compacting process

Pressure indication via manometer in bar

Pressure indication on panel in bar or kN/cm

3.2.6 Oil Lubrication System for roller bearings

Not needed after final discussion with bearing manufacturer.

3.2.7 Flake Crusher

After compaction, the flakes are pre‐crushed on the flake crusher.


Crusher shaft with cam discs

Drive by geared motor with fix speed, approx. 3,0 kW

3.2.8 Technical Cabinet

The technical cabinet is positioned near the roller compactor.

The following devices are installed in the cabinet:

Vacuum pump

Hydraulic unit

Compressed air unit

Cooling water

HMI with protection cover in the front door

The pipe connections between compactor and cabinet (1 x hydraulic,

1 x vacuum, 1 x compressed air, 2 x cooling water) will be executed as hoses and

belong to our scope of supply. Max. distance 5 m.

The dimensions of the technical cabinet are 600 x 2.000 x 500 mm (WxHxD)

including a plinth of 100 mm. Material of construction: mild steel, painted

RAL 7035.

3.2.9 Options

Re‐cooler

The cooling water for the rollers can be run in a closed circuit through a re‐cooling

unit, thus avoiding a constant water consumption. The cooling unit has a mild steel

housing of 560 x 1.000 x 710 mm and can be located near the machine. It is

equipped with pump, tank and all necessary hose connections.

Water consumption (once): approx. 50 l.

3.3 Granulation

3.3.1 Pre Granulators

The pre‐crushing step is effected by two Rotor Fine Granulators RFG 250 DL with a

screen insert approx. 2,5 times bigger than the final grain size. The diagonal screen

design developed by Alexanderwerk grants an especially careful size reduction of

the product as well as a perfect usage of the working surface.



Rotor speed adjustable by frequency inverter

Rotor diameter 250 mm

Working length 600 mm

Screen insert to be finally determined


1 pressure reducer for both pre granulators

3.3.2 Fine Granulators

The fine granulation step is effected by four Rotor Fine Granulators RFG 250 DL to the

final grain size. The diagonal screen design developed by Alexanderwerk grants an

especially careful size reduction of the product as well as a perfect usage of the

working surface.



Rotor speed adjustable by frequency inverter

Rotor diameter 250 mm

Working length 600 mm

Screen insert to be finally determined


1 pressure reducer for four pre granulators

3.3.3 Purge Air Control

Positioned in a stainless steel control cabinet for installation close to the

granulators. With pressure reducer and 6 solenoid valves for activating of purge air

for each granulator.

3.4 Screening

3.4.1 Screening Machine

For separation of final material from oversize and undersize material.

High performance screening machine.

Not moving screening machine. Just the screen mesh will be activated by

beating bars which will be operated by electromagnetic vibration heads.

Doubledeck execution.

Tensioning of screen mesh in axial direction by spring packages.

With inlet hopper, upper part of outlet hopper, overflow hopper.

Top cover for inspection of screen mesh.

Exhaust air pipe with connection flanges on both sides.

Electromagnetic vibration heads covered by shrouds for reduction of noise.

Electrical controls for installation close to the screening machine. Intensity

and cleaning cycles can be adjusted. Interaction with overall control system

by potential free contacts.

Stainless steel cabinet for integration of electrical controls and positioning

close to the screening machine. At the inside of the door a table will be

placed where the operators have to sign all changes and reasons for the

operating parameters of the screening machine.

Technical Data:

Dimensions : approx. 2,9 x 4,6 m

Drive Power : approx. 3,52 KW


3.5 Transport Systems

3.5.1 Continuous bucket conveyor

The vertical transport of the pre‐crushed flakes on top of the building will be

realized with an continuous bucket conveyor in C execution.


Feed station

Vertical transport housing

Head station with support

Beltbucketchain (Gurtbecherkette)

Pendulum knocker

Discharge hopper

Dedusting nozzle

Sliding supports at the platforms

Technical Data:

Width of Buckets : approx. 350 mm

Length of Foot Section : approx. 5,6 m

Length of Top Section : approx. 1,1 m

Vertical Length : approx. 17,8 m

Material of Construction

‐ Housing : Stainless steel

‐ Buckets : Polyamid


3.5.2 Diverter Flap

For distribution of pre‐crushed flakes on one or two pre granulators.

Two proximity switches for positioning control left and right (in order to

have a signal for being able to stop one of the granulators)

Technical Data:

Diameter : DN 200

Operating : manually

3.5.3 2 Diverter Flap

For distribution of pre‐crushed granules on one or two fine granulators.

Two proximity switches for positioning control left and right (in order to

have a signal for being able to stop one of the granulators)

Technical Data:

Diameter : DN 200

Operating : manually

3.5.4 Trough Screw Conveyor

For collecting oversize material from the screening machine. Executed as trough

screw conveyor. With reduced speed for gentle conveying of oversize material.

Technical Data:

Diameter : DN 250





3.5.5 Trough Screw Conveyor

For collecting undersize material from the screening machine. Executed as trough

screw conveyor.

Technical Data:

Diameter : DN 250





3.5.6 Belt Conveyor

For collecting final material from the screening machine. Executed as closed system

with dedusting nozzle.


Drive station with discharge hood, drive pulley, pedestal bearings, bevel gear

drive, scrapers

Tensioning station with pedestal bearings, protection shroud

Instruments

Entire belt completely covered

Technical Data:

Belt width : approx. 500 mm

Length : approx. 7 m


‐ Belt : EP 400/3

‐ Housing : Stainless Steel


3.5.7 2‐Way‐Valve

For plant emptying of undersize material and dust.

Two proximity switches for positioning control left and right

Technical Data:

Diameter : DN 200

Operating : pneumatically


For decision of return of oversize back to CVF or back to bucket elevator.


Technical Data:

Diameter : DN 200


3.5.9 Flow Detector

For detecting of oversize material in order to check process and equipment

performance.

Technical Data:


For discharging of oversize material in case a higher flow of material will be

detected or foreign materials are inside the loop.


Technical Data:

Diamater : DN 200


3.6 Final Product Handling

3.6.1 Shut‐off Flap

As soon as one final product container will be full the shut‐off flap will be closed.

Once the diverter flap has reached the opposite position and the other final product

container can be filled the shut‐off flap will open automatically again. Shut‐offvalves

with proximity switches for positioning control.

Technical Data:

Diamater : DN 200



For change over from one to the other container.


Technical Data:

Diameter : DN 200


3.7 Dedusting System

3.7.1 Dust Filter

For dedusting of the entire plant system.

Rectangular pocket filter or bag filter

Discharge cone

Filter pockets or bags can be accessed from the side or the top of the filter

Level sensor as overfilling detection

4 pcs. 2“ pipe collars at the circumferential of the cone in order to retrofit air

systems in case of discharge problems.

Techncal Data:

Raw Gas Volume : approx. 7.500 Nm³/h

Raw Gas Temperature : approx. 40 °C

Filter Surface : approx. 125 m²

Filter Surface Load : 1,25 m³/m²/min

Compressed Air Consumption : approx. 30 Nm³/h

Cleaning Method : differential pressure or time control

Difference Pressure : 7 – 12 mbar

Allowable dust content clean gas : < 20 mg/m³ (guaranteed)

< 10 mg/m³ (expected)

Dimensions : depending on final choice

Height : depending on final choice


‐ Housing : Stainless Steel 1.4301 or 1.4541

‐ Filters : Polypropylene, antistatic

3.7.2 Ventilator

For generation of underpressure in the entire dedusting system.

Throttle flap with manual adjustment

Compensators on suction and pressure side, with guiding plates

Dampers for installation of ventilator

Technical Data

Pressure Difference : approx. 36 mbar

Volume : approx. 9.000 Bm³/h

Temperature : ca. 40 °C

Drive Power : approx. 11 – 18,5 KW

3.7.3 Police Safety Filter

Installed between the dust filter and the ventilator. To avoid dust outlet to

atmosphere once a filter inside the dust filter got damaged. Filter equipped with a

differential pressure measurement in order to detect an increase of resistant.

3.7.4 Silencer

For reduction of noise level at chimney exit over the roof.

Slotted silencer (Kulissenschalldämpfer)

Installed at the pressure side of the ventilator

Transition pieces

Supporting structure (if necessary)

Reduction of noise level to < 85 dB(A)

3.7.5 Rotary Valve

As a discharge seal of dust filter.

Technical Data:

Diameter : approx. 275 mm


‐ Housing : Stainless steel

‐ Blades : Spring Steel


3.7.6 Dedusting Pipe System

Complete piping system with throttle flaps at the dedusting points, including:

Rising pipe from roller compactor to dust filter with additional junctions to

other dedusting points

Transition piece for inlet of dust filter

Clean gas pipe from dust filter to ventilator

Clean gas pipe from ventilator to silencer

3.8 Chutes, Pipes, Frames

As listed below:

Pipeline from dosing screw conveyor to CVF

Transition chute between roller compactor and bucket elevator

Outlet chute of bucket elevator

Piping system from bucket elevator to pre‐granulators

Inlet chutes of pre‐granulators

Outlet chutes of pre‐granulators

Piping system from pre‐granulators to fine‐granulators

Inlet chutes of fine‐granulators

Outlet chutes of fine‐granulators

Oversize outlet chutes of screening machine

Piping system for oversize material back to CVF or back to bucket elevator

Final product outlet chute

Piping system for final product to belt conveyor

Piping system for final product from belt conveyor to container systems

Undersize outlet chutes of screening machine

Piping system for undersize material back to CVF or plant emptying

Piping system for dust from star feeder of dust filter back to CVF

Frame for pre granulator

Frame for fine granulators

`

3.9 Electric Control System

3.9.1 Basic controls for Roller Compactor and Granulators

Controls and their components have been carefully chosen in order to grant the

maximum availability of the machine.

The complete controls are installed in a cabinet which should be placed near the

machine (max. distance 50 m). Separate cabinets for MCC and PLC. Cabinet

dimensions approx. 800 x 2.100 x 600 mm for PLC and approx. 4.800 x 2.100 x 600

mm for MCC. Cabinet in standard execution, powder coated, protection class IP 54.

Allen Bradley PLC connected to Simatic Touch‐Panel MP 377, which will be installed

in the technical cabinet, will provide process control and monitoring.

The PLC‐I/O subsystem is equipped with all necessary I/O to control and monitor

both MCC and control system field devices included in our scope of supply.

Power section (MCC) in standard execution, with power distribution and main

switch. Equipped with all necessary switchgear such as power contactors, motor

protection switches, fuses and variable frequency drives (VFD’s) as described in our

scope of supply.

The status of the compacting plant (running/fault messages, with message log) as

well as the load of various assorted drives will be shown on the HMI.

Communication from PLC to VFD’s is managed by Ethernet.

Software:

Operator Panel

The operator surface of the machine is based on WinCC Flexible. Panel language is

English.

Access Control

An access control for the operator panel of the machine is installed. Access control

means that only authorized persons within their responsibility have access to the

operator panel (enter name and password). Each user belongs to a user group with

defined access rights into the system. This avoids unauthorized changes or the start

of non‐cleared process steps. A member of the user group of operators can start

and stop the machine. In order to modify machine parameters, however, you have

to be a member of a superior level in the production management. The highest

access level is the super‐ user who can create users and define their affiliation to

the different user groups (roles).

Documents

Standard Equipment: The following standardized components