Editorial 1 Product News 2 The new Lindner Polaris Lindner News 3 Sutco UK and ALBA Nordbaden trust in Lindner quality Technology 4 Calciner firing of refuse derived fuels Polaris Day 2016, Klagenfurt Austria Dear Ladies and Gentlemen! Once again, I am very pleased to be sending you our Transform newsletter with all the latest news from Lindner and I am particularly delighted to be able to introduce you to our new universal shredder, Polaris an innovation by Lindner. This shredder allows you in just a single step to turn untreated solid, industrial and commercial waste into RDF fractions that can be fired in a calciner in the cement industry or used in fluidised-bed combustion in thermal power plants. We recently hosted the first Polaris Days in Klagenfurt, Austria, which gave us the opportunity to present this new shredding solution to an international audience. I m very happy to report that it was a great success. Read on to find two examples of how the new Polaris will be used by ALBA Nordbaden and SUTCO UK to produce refuse-derived fuels at low cost and high performance and continue their successful business relationship with Lindner Recyclingtech. However, the purpose of this newsletter is not only to inform you about Lindner Recyclingtech and our innovative products, but also to show you how you, too, can benefit professionally from our revolutionary technology and expertise. On that note, we would like to draw your attention to our exclusive expert article: Dr Klaus Diller and Dirk Lechtenberg will give you a unique insight into calciner firing, technical processes and material requirements in modern waste management. Best regards, DI Manuel Lindner
PRODUCT NEWS POLARIS SINGLE-SHAFT SHREDDER FROM LINDNER OPTIMIZES THE ONE-STEP PROCESSING OF RDF Providing enormous shredding power, Lindner s universal Polaris single-shaft shredder has been developed specifically for the one-step processing of untreated household refuse as well as industrial and commercial waste. The Polaris 2200 and 2800 are two new single-shaft shredders from Lindner that have been optimized for the cost-efficient, single-step shredding of untreated household refuse as well as industrial and commercial waste. A typical application area is the processing of refuse-derived fuel (RDF) that is used instead of fossil fuels in calciners of cement factories or in thermal power plants. Because the Polaris shredders run at a particularly low speed and with correspondingly high torque, their knives cut the input material with enormous power, as required by the single-step process. Type 2200, with a feed opening of 4090 x 3000 mm and a rotor length of 2115 mm, shreds, for example, up to 22 t of commercial and industrial waste per hour. The Polaris 2800, with a feed opening of 4779 x 2370 mm and a rotor length of 2805 mm, achieves a volume of up to 32 t/h. Depending on the choice of screens, the final grain sizes are between 50 mm and 120 mm. With its cutting principle and automated pusher system control, Lindner s single-shaft shredder technology ensures constant output with uniform grain size. Every individual component of the system is noted for the robustness that is typical of Lindner products. This begins with the solid chassis and the powerful, highly reliable asynchronous motors with nominal outputs of 200 kw (Type 2200) and 2x 132 kw (Type 2800). The two-step belt drive that has proven so successful with Lindner shredders, transmits the very high torque to the rotor. If non-shreddable extraneous material turns up, the integrated sliding clutch brings the machine reliably to a standstill. The large hydraulic maintenance flap and doors offer convenient access, for example to replace the six or eight easy-to-handle screen modules or to rotate the knives that can be used on four sides.
PRODUCT NEWS Ideal for application-optimized RDF With the development of the Polaris single-shaft shredder, Lindner is supporting the trend towards the optimum processing of RDF to ensure that it is coordinated to the scheduled application. This enables the system to function cost-effectively and with maximum efficiency. Companies that process refuse-derived fuels for captive use thus have the possibility to make their production more cost-efficient. The rugged, low-maintenance Polaris shredder also makes it possible for customers who process waste to market it as RDF to achieve higher margins. Stefan Scheiflinger-Ehrenwerth, Product Manager at Lindner Recyclingtech, says: When processing waste into RDF, high throughput and low shredding costs per ton are even more important than in other industrial processes. This applies especially to the processing of refuse-derived fuels for use in a calciner. At the same time, the system must be able to shred untreated and in some cases bulky waste in a single process step to grain sizes of 80 mm and less. This makes particularly high demands on the design of the shredder deployed for this job. With the new Polaris, we comply precisely with these demands. It is proving in practice to be an energy-efficient system that functions reliably and, if necessary, is easily accessible for cleaning and maintenance work and thus enables consistently high productivity. The market has welcomed the concept of shredding untreated waste in a single process step. Scheiflinger-Ehrenwerth continues: Since we presented the new Polaris for the first time at IFAT in May 2016, we have sold an average of one machine a month. And, before the year is out, we will see a whole number of new orders. Depending on the input material, the relatively coarse shredded material produced by the new Polaris shredders has an average calorific value of 15 to 18 MJ per kg, and is thus ideal for the calciner. In comparison, the use of RDF as a secondary fuel in the main combustion chamber of cement factories, where temperatures of up to 2,000 C can be reached, makes different demands on the properties of the RDF. Here, two-step systems from Lindner are still the first choice. Consisting of a Jupiter pre-shredder, a separating unit and a Komet post-shredder, they produce an optimum shredded material with a defined grain size of less than 35 mm. Pilot application proves cost efficiency The Austrian waste disposal company, KAB Kärntner Abfallbewirtschaftung (www.kab. co.at), which operates equipment for the production of refuse-derived fuels at the very highest technical standard, was one of the first processors to gain practical experience with the new Polaris. Says Managing Director Werner Bleiberger: Our company wanted to take advantage of the economic advantages of the single-step shredding technology. In the search for a modern, high-performance system, our attention was drawn to Lindner. They loaned us a first prototype of the Polaris to test for around a year. Over this period, the system proved its efficiency, reliability, low maintenance and maintenance friendliness very impressively indeed. Lindner s uncompromising commitment to maximum quality and the shredder s successful implementation in practice were convincing arguments for us.
LINDNER NEWS SUTCO UK OPTS EXCLUSIVELY FOR POLARIS AND KOMET FOR A MAJOR CONTRACT Sutco RecyclingTechnik GmbH is one of the world s largest providers of processing plants for a diversity of waste types. With over 460 references around the globe, in the course of its more than 30-year history, the company has established a successful reputation in the waste management industry. Via four subsidiaries in Poland, the UK, Spain and South America, the plant builder seeks to create an efficient, closed-loop economy worldwide by means of effective recycling, which is available on a one-stop-shopping, turnkey basis. For a current project, the Sutco subsidiary in the UK has opted exclusively for innovative Lindner technology in the form of three Polaris 2800 and two Komet 2800 universal shredders, which are to be integrated into diverse, planned applications. For this major contract, the Polaris 2800 will reduce roughly pre-sorted wastes to <75 mm in a single operation. In this regard, machine continuity and availability play an extremely important role. Marco Egger, Klaus Mildner, Gerd Tischner, Stefan Scheiflinger-Ehrenwerth Sutco sees another significant advantage of the high-tech Polaris as emanating from the shredder s throughput capacity and uncomplicated maintenance. Indeed, Klaus Mildner, the Sutco UK Managing Director, says that the choice of this single-shaft shredder was relatively straightforward: The machine offers a simple and very robust design in tandem with extremely easy maintenance. This is just what is needed in the waste management area, as the greater the simplicity, the higher the availability. In addition, we were also convinced by Lindner s flexible service, which even at weekends offers quick and professional, on-the-spot assistance in technical matters. POLARIS 2800 IN OPERATION FOR THE PRODUCTION OF HIGH-QUALITY RDF AT ALBA NORDBADEN GMBH For the past thirty years, ALBA Nordbaden GmbH in Karlsruhe has been a reliable partner to commercial, retailing and industrial companies for all types of waste disposal. Its highly modern recycling systems and handling facilities offer comprehensive service for every branch, situation and refuse type. For the production of high-quality RDF, ALBA employs a Polaris 2800, a universal shredder, which in particular stands out due to its excellent throughput capacity, straightforward maintenance and the size of the output material. Joachim Wunsch, ALBA s Operational Excellence Manager, explains why his company selected a Lindner shredder as follows: We were convinced by the performance of the Lindner Polaris in practice. We were able to observe the machine Alba Nordbaden GmbH in action over an extended period and were quite simply impressed.
TECHNOLOGY CALCINER FIRING OF REFUSE DERIVED FUELS Alternative or refuse derived fuels (RDF) are mainly fired in kiln burners, preheater or calciner kilns. Of the greatest importance in this regard is homogenous fuel quality consisting of two-dimensional parts. Alternative fuel for the kiln burner has to be free of disruptive fractions (e.g. metals, stones, glass), which might cause problems in the feeding equipment or the burner itself. Alternative fuel for the main burner has to possess the following dimensions: Kiln burner fuel characteristics Grain size...<35mm, non-3-dimensional Calorific value...>4,500 kcal/kg Density... >60 kg/m 3 <200 kg/m 3 Moistrure content... <15% The calorific value must amount to at least 3,500 kcal/kg and preferably more than 4,500 kcal/kg. Whatever the case, fuel combustion is largely dependent upon moisture, physical properties, particle sizes, chemical composition and homogeneity, which in secondary fuels fluctuate considerably. Calciner fuel characteristics Grain size...<100mm, Calorific value...>3,500 kcal/kg Density... >100 kg/m 3 <200 kg/m 3 Moistrure content... <20% The homogenous composition of chemical and physical parameters, especially particle sizes and distribution, is also imperative for a calciner. However, in the calciner, the calorific value of the fuels can be lower with the result that even CV fractions with a minimum of 2,500 kcal/kg can be used. Most significant is a homogenous grain size. From a technical standpoint, the design principles used by suppliers of calciners and other equipment are similar or comparable. What are important, as they also apply to other feed points in the rotary kiln, are the product characteristics of the RDF, temperature and residence times. The residence times of the alternative fuels and the size of the feed can both increase in line with the dimensions of the calciner. However, the generalisations often made when discussing the utilisation of alternative in a calciner, such as feed sizes of 50-80mm, are only rarely correct. Basically, the particle size of the alternative fuels must be selected in such a way that a consistent burnout within the calciner is possible. The fuel particles may neither be fed into the kiln inlet with the meal stream, nor conveyed with the gas stream into one of the upstream cyclones. Otherwise the cold stream of meal-rich suspension and the hot combustion flue gas stream run parallel to each other and owing to their differing densities, require a long residence time for mixing. In order to avoid problems such as accumulations and blockages, process deterioration can be prevented by either the careful design of the feed location and the injection technology, or increased pre-treatment of the alternative or RDF to produce a finely ground, homogenous grain size. Using such homogenous feeding, depending upon the chemical parameters, RDF substitution rates of above 65% have become standard. Moreover, substitution rates of above 90% have been reported for large kilns with a highly voluminous calciner design and long retention times. (c) Dirk Lechtenberg & Dr. Hansjörg Diller