standard equipment: the following standardized components
TRANSCRIPT
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
Material of Construction : Stainless steel
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.
Mainly consisting of:
Executed as screw conveyor
Screw housing prepared for vacuum filter
2 screws, cylindrical, double‐flighted
Drive by geared motor, approx. 7,5 kW
Screw speed adjustable by frequency inverter
Load and speed indication on the panel
Seal air for shaft penetrations
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.
Mainly consisting of:
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.
Mainly consisting of:
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
Seal air for shaft penetrations
Circumferential side seals
Water cooling of press rollers
3.2.5 Hydraulic Unit
The hydraulic unit generates the required compacting pressure.
Mainly consisting of:
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.
Mainly consisting of:
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.
Mainly consisting of:
Drive by geared motor, approx. 5,5 kW
Rotor speed adjustable by frequency inverter
Rotor diameter 250 mm
Working length 600 mm
Screen insert to be finally determined
Seal air for shaft penetrations
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.
Mainly consisting of:
Drive by geared motor, approx. 5,5 kW
Rotor speed adjustable by frequency inverter
Rotor diameter 250 mm
Working length 600 mm
Screen insert to be finally determined
Seal air for shaft penetrations
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
Material of Construction : Stainless steel
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.
Mainly consisting of:
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
Drive Power : approx. 4,0 kW
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
Conveying Length : approx. 2,2 m
Total Length : approx. 3,5 m
Material of Construction : Stainless steel
Drive Power : approx. 1,5 kW
3.5.5 Trough Screw Conveyor
For collecting undersize material from the screening machine. Executed as trough
screw conveyor.
Technical Data:
Diameter : DN 250
Conveying Length : approx. 2,6 m
Total Length : approx. 4,6 m
Material of Construction : Stainless steel
Drive Power : approx. 1,5 kW
3.5.6 Belt Conveyor
For collecting final material from the screening machine. Executed as closed system
with dedusting nozzle.
Mainly consisting of:
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
Material of Construction
‐ Belt : EP 400/3
‐ Housing : Stainless Steel
Drive Power : approx. 1,5 kW
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
3.5.8 2‐Way‐Valve
For decision of return of oversize back to CVF or back to bucket elevator.
Two proximity switches for positioning control left and right
Technical Data:
Diameter : DN 200
Operating : pneumatically
3.5.9 Flow Detector
For detecting of oversize material in order to check process and equipment
performance.
Technical Data:
3.5.10 2‐Way‐Valve
For discharging of oversize material in case a higher flow of material will be
detected or foreign materials are inside the loop.
Two proximity switches for positioning control left and right
Technical Data:
Diamater : DN 200
Operating : pneumatically
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
Operating : pneumatically
3.6.2 2‐Way‐Valve
For change over from one to the other container.
Two proximity switches for positioning control left and right
Technical Data:
Diameter : DN 200
Operating : pneumatically
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
Material of Construction
‐ 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
Material of Construction
‐ Housing : Stainless steel
‐ Blades : Spring Steel
Drive Power : approx. 0,75 kW
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).