Special reduction plant shreds bulky steel shavings whilst simultaneously recycling the adherent oil

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1 Recycling of soiled waste Special reduction plant shreds bulky steel shavings whilst simultaneously recycling the adherent oil (1 st of April 2013) Until now, bulky steel shavings covered with oil have, in the most part, simply been disposed of, thus wasting valuable resources. In order to avoid this, the company GEZE GmbH searched for a method of reducing the volume of the shavings and simultaneously recovering the oil adhering to them for re-use. The company Erdwich Zerkleinerungssysteme GmbH developed a plant for this purpose, which reduced the soiled steel shavings, centrifuged them and finally fed them to a swarf container. The oil removed by the centrifuge was cleaned and re-fed to the production system. A further challenge was the very limited space available and the need to tailor the plant to fit in in such a way that access could be secured to the servicing area. We have made it a priority for us to continually improve the ecology of our products and production processes and to use resources responsibly, explained Kasim Yörük, project leader in Leonberg for GEZE, a world leading provider of door, window and security technology. Until now, the steel shavings, soiled with oil, were disposed of in the conventional manner into a steel scrap container in order for them to be recycled. Compact packing was not achievable because of the volume of the steel shavings. That was the reason the company turned to the experts for waste shredding, Erdwich. The requirement was to build a plant capable of reducing steel shavings or discharging problem materials such as off-cuts from bars of size mm by mm which it may contain. Erdwich installed the drum shaving reduction plant TSZ 1500S. We chose this plant as the solution because it features a hydraulically driven problem material gate with a large angle opening, guaranteeing a problem free discharge of problem materials, explained Richard Adelwarth, project leader with Erdwich. Also, the feed drum, with a capacity of 1.5 m³ is big enough that no delays arise and feeding in parallel during busy periods is made possible from standard swarf containers via the platform on site.

2 With a capacity of 1500 litres, the TSZ 1500S is mainly used for automatically processing voluminous and bulky swarf. With the aid of an inclined stirring arm integrated into the rotating feed drum, the material is fed slowly and steadily to the cutting gear. The rotational speed of the drum can be set using the control panel to suit the kind and form of material being processed. The heart of the plant is the Erdwich single shaft shredder, M600/TSZ S. It recognizes the presence of foreign bodies and overloading of the machine automatically. Should this occur, it moves the stator blade bar aside and simultaneously a flap is opened through which the foreign material is ejected. After the flap has been closed again and the stator blade bar repositioned, the reduction process of the plant resumes automatically. The volume reduction and the removal of problem material was, however, not the only goal set for the new plant: For many of our machines oil is used as a lubricating coolant. For reasons of resource preservation and economy we set ourselves the goal to recover the oil component of the steel shavings, said Yörük. After the removal of the problem material, the oil covered shavings are reduced and transported to a centrifuge via a hinged apron conveyor, where the lubricant is spun out. Thereafter, the centrifuged shavings, with a maximum limit of 3 % residual liquid content, are transferred via another apron conveyor, to a container where they are spread using a rotating chute, Adelwarth explained. The recovered oil is pumped over a magnetic roller, cleaned, then transported to an on-site collection container in the production area, continued Adelwarth. By the use of the plant, large quantities of oil, which had previously been disposed of, have been recovered and re-fed to our machining production. Thus, the plant makes an important contribution to resource conservation within the realm of our environmental protection activities, added Yörük. Throughput of 300 kg per hour for 15 shifts per week In addition, attention was paid to minimizing the cleaning and maintenance times, because of the constrained physical access limitations of the plant. Over and above this, the plant has

3 low noise, odour and dust emission, vibration protection and a low energy requirement. This was important for GEZE for reason of environmental policy and for reasons of economy, as the intention was to use the plant on a 3 shift basis, resulting in 15 shifts a week, and achieve a throughput of 300 kg per hour. Through the reduction process the waste density of the shavings was approximately doubled. Thus it was possible to reduce the container size significantly whilst maintaining the container replacement interval. The ERDWICH plant has been in operation at GEZE since December The system meets our safety and quality standards. Thanks to the low waste volume and the oil recovery the company is able to save money on a daily basis the investment costs remained within the economic framework and it was possible to execute the development extremely rapidly, concluded Yörük. Background As one of the global leaders in the provision of systems for door, window and safety engineering, GEZE GmbH has been a leading influence in its trendsetting developments. These developments are being continually furthered in their own technology centre. The name GEZE is representative of innovation and the highest of quality in products, processes and services. GEZE offers a wide ranging of products for automatic door systems and door techniques, glass systems, smoke and heat extraction plants (RWA), safety systems and also window and ventilation technology products. The company Erdwich Zerkleinerungssysteme GmbH was founded by Johann Erdwich in 1972 as a mechanical engineering and metal construction company. Presently, 35 persons are employed. The three core businesses of the company for machine and plant engineering are split into the fields of recycling and re-processing of materials, destruction of hazardous waste of all kind and shredding of refuse for volume reduction. In the segment of recycling plants for refrigerating devices, Erdwich GmbH ranks globally under the top three companies.

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5 Graphical material: Picture-ID: Anlage_Schnee.jpg Caption: A specially tailored shredder system has recently begun to make the disposal and recycling of steel shavings and steel remnants easier, thus enabling the saving of time and money at the same time as protecting the environment. Source: GEZE GmbH Picture-ID: Anlage in Action.jpg Caption: As a result of the size reduction the density of the waste steel shavings is approximately doubled. With the same interval between the exchange of containers, the container size could be considerably reduced. Source: GEZ GmbH Picture-ID: Platzmangel.jpg Caption: The space available for the plant installation was very limited, which was the reason why the plant had to be individually tailored whilst also securing adequate access to the servicing area. Source: Erdwich

6 Picture-ID: Späne.jpg Caption: The plant from Erdwich reduces the soiled steel shavings and centrifuges them before they are fed to a swarf container. The oil separated in the centrifuge is cleaned and returned for use in the production. Source: Erdwich Picture-ID: Durchsatz.jpg Caption: The centrifuged swarf, which must contain not more than 3 % residual moisture, is distributed in a container by means of a hinged apron conveyor and a rotating chute. Source: Erdwich Further information for readers/observers/sales prospects: Erdwich Zerkleinerungssysteme GmbH Johann Erdwich, Managing Director Kolpingstr 8, Kaufering, GERMANY Tel.: +49(0) , Fax: +49(0) infoline@erdwich.de Internet: GEZE GmbH Reinhold-Vöster-Straße 21-29, Leonberg, GERMANY Tel.: +49(0) , Fax: +49(0) Internet: Further information for editorial staff Pressebüro Beatrix Gebhardt-Seele Leonrodstraße 68, München, GERMANY Tel.: +49(0) , Fax: +49(0) pressebuero@gebhardt-seele.de Internet: Reprint free of charge provided the source is stated, specimen copy requested