technical sheet - recoquip · accidentally some softer steel parts with a maximum thickness of 20...

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CABLEBOX

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TECHNICAL SHEET



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After having a lot of success with our large-scale recycling lines throughout the world, MTBhas decided to answer the newest market requirements by developing a more modestdimensional system. Furthermore, in order to facilitate its integration and use, ourengineering department has put a great emphasis on building an user-friendly solution.

Consequently, the standard version of our line if now available as a “PLUG-N-RUN” model,and the whole process has been fitted into reinforced customized containers. Once on-site,the boxes only have to be positioned and connected together to get started.

Despite its smaller size and footprint, our new CABLE BOX system features all the sameadvanced design as our greater process and will make it possible to treat lower quantity onthe most effective way.

by



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SCOPE OF SUPPLY

The whole line is able to process between one and two tons of cables per hour. All thesefigures should be reached in normal conditions. The capacity may change depending onthe actual metal content of the cables, the regulation on the line and the maintenancemade on the equipment (wear of the blades).

The final end product depends directly on the mix of cables to be treated. A normalcapacity is considered around 40% copper countenance.The final size is normally 6 mm on big copper, 4.5 mm on fine copper, but can also bebigger or smaller (minimum screen size is 3.5 for specific telecommunications wires).

Capacity of the system

The front step of the process being a 90kW BDR 1245 shredder, this will grant the line thepossibility to treat a wide range of materials as long as it is accepted by the shreddertorque:

• Non-reinforced cables up to 1.5 inch diameter (40 mm) will be shredded with noproblem. Slightly bigger cables could also be accepted with gentler feeding.

• Automobile wires, both removed manually and clean, as well as dirtier packageremoved by automatic sorters (ICW from ASR).

• Pre-cut Non-Ferrous metals chips such aluminum scraps or radiators.

• Pre-cut electronic scraps.

Specification of the products to be processed by the CABLE BOX:



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Using slots

Can be used in inside temperatures from –15°C to + 40°C and a medium hygrometry of 65%.24 hours a day, seven days a week.The effective working time of the machines is above 90% (maintenance).If we consider six working days per week, the number of working hours per year could be: 24 x 6 x 52 x 90% = 6.740 hours

Fluids connections

The main box should be connected to the air box (third container) in which is incorporated the dust filtration system. The filter is connected to a compressed air system for the automatic cleaning system of the filter bags. The compressor is included in the air box.

In order to facilitate the maintenance and cleaning operations, we are offering in option to put inlets of compressed air in the system. This will be very useful to allow the use of pneumatic tools.

Qualification level of the employees

Number of needed operator to feed the crane: 1

Number of needed operator to oversee the line and to remove the output product: 1

Number of needed technician to secure the maintenance: 1 (part time task)

Usage limits

The BDR 1245 does not accept heavy and /or metallic parts. It is limited to receive accidentally some softer steel parts with a maximum thickness of 20 mm.

Sound level

The sound level depends directly on which materials are shredded. The medium level is80 dB at one meter away when the machine is empty. During the process the sound levelmay reach 105 dB at one meter away.Ear protections are required for the operators.NB : ear protections and soundproof panels are not included in this offer.

Electrical power

About 375 kW for the line, including dust filtration system.The electrical consumption of the machine is roughly 70% of the installed power.

Operational conditions

GENERAL DATA



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I) Shredding and granulating unit: SHRED’BOX

❑ The shredder BDR 1245 is directly fed in cables by crane (or a dosing conveyor). Themachine is equipped with a screen positioned under the rotor and easilyinterchangeable (an hour in average) which determines the size of the output material.

❑ The product then goes successively through two granulators BAT 845 to be reducedinto the final wished size. A vibrating extractor positioned under the first BAT, then anincorporated screw conveyor under the second one allow to collect the stream (flow)and to transfer it to the following machine. A new innovating design of tip-up screensupport offers an easy access to replace rapidly the screen (20 minutes in average).

This primary phase is in a 40’ container composed of reinforced sections around the shredder’s hopper as well as on its front to protect the sides against the impacts made by the crane and the cables. Moreover, many openings have been included to allow a simple access for the control and maintenance.

CABLE BOX PROCESS

II) Sorting unit: SORT’BOX

Once the final granulometry is reached, the separation phase can start. Combining the use of different types of screens and air density tables, it is possible to obtain two copper fractions (fine and big copper), a mix of non-ferrous flakes (connectors) and to extract the plastic particles.

This 20’ container including the sorting process has two swinging doors offering a complete lateral access on both sides of the system.We also positioned two magnetic separators along the line in the objective to remove the ferrous inserts.



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KEY ADVANTAGES

➢ Custom-made MTB concept

➢ Compliances security norms

➢ Compact turnkey system

➢ Rapid and easy installation and startup

➢ Duplicated robustness of our large scale installations

➢ Perfectly appropriated for difficult waste

➢ High quality of output products

CABLE BOX PROCESS

BDR 1245 BAT 845 BAT 845STMO STMO (optionnal)

STMO T600TAM 700T600TAM700

SHRED’BOX

SORT’BOX



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The exact composition and output will be adjusted based on the given waste into our line.

Those fractions may be listed according to the following categories:

❑ Fine copper❑ Big copper (potentially mixed with other heavy metals)❑ Concentrated flakes (coming from connectors)❑ Ferrous inserts❑ “Re-run” fraction meant to undergo a second pass (copper/aluminum/plastic wires;

isolated intentionally)

RADIATORS OPTIC FIBERFAIRY LIGHTS ACSR

COPPER/ALUMINUM GLASS FIBER/PLASTICSCOPPER/PLASTICS ALUMINUM/STEEL

RECYCLED PRODUCTS

INPUT PRODUCTS

OUTPUT PRODUCTS

CABLES

MISCELLANEOUS

COPPER

FINE COPPER BIG COPPER CONNECTORS PLASTICS FERROUS

VERSATILITY CABLE BOX



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BDR COMPACT SHREDDER

The BDR 1245 shredders are extremely robust andpowerful despite their smaller size. Those machinesfeature all of the same advanced design as our reinforcedlarger shredders, but have been purposely built for moremodest dimensional work. Those shredders willefficiently reduce a large number of scraps down to sizesbetween 10 and 100 mm depending on the screen sizeused.Specially treated alloy steel cutting blades can be turnedfour times to ensure a sharp cutting edge and long bladewear life.MTB designs all equipment, works to minimize downtimeand to guarantee very low operating costs. This designbrings our shredders to be the reference in the market.

Compact shredders

Technical Data BDR 945 BDR 1245 BDR 1645

Power 75 HP / 55 kW 125 HP / 90 kW 175 HP / 132 kW

Length of the rotor 900 mm 1,200 mm 1,600 mm

Diameter of the rotor 380 mm 416 mm 482 mm

Rotor rotation speed 150-200 RPM 140 -180 RPM 120 -170 RPM

Weight 5 T 7.5 T 13 T

Quantity of fixed blades 6 6 8

Quantity of movable blades

18 18 24

Blades dimensions 28 x 56 x 150 28 x 56 x 195 28 x 56 x 195



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Robustness and reliability

• As an operator itself, MTB is aware thatoperating cost can have a significantinfluence on the installation’ viability andhas developed its machines to enable thesimplest and cheapest maintenancepossible. All the parts subject to wear(blades, knife holders, wear plates etc.) havevery simple inexpensive geometric forms.

• The BDR possess fixed and mobile identicalblades. For operators, there is therefore onlyone reference of knife to manage. Moreover,these blades are parallelepiped and can beused many times by being turned oversuccessively.

• To guarantee optimum performances overtime, it is vital to be able to adjust the gapbetween the mobile blades and the stator tomaintain it at a correct value. This operationcan be complex depending of the shredder’sarchitecture. Thanks to its experience as anuser, MTB clearly made the choice ofsimplicity and efficiency.



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Advantages

• The knives of the stator are mounted two by two on a support and thanksto a simple pushing screw system accessible even when the machine isclosed. It is very easy to adjust the gap to the ideal level of each knifeholder independently.

• When the shredding capacity increases or when slightly more difficultparts reach into the cutting chamber, the shredder must be able to getover these “sticking points” without jamming (production loss). Inertia iscreated on many machines simply by the rotation of large rotors (up to 1m); MTB has made a radically different choice, as it is true that the loadedmass generates inertia, this one depends essentially from the repartitionand the distance of the mass in relation to the rotation axis. The shredderhas a rotor of modest size (around 400 mm depending on the models) buthe has on the other hand a flywheel (up to 1 ton and of 1,3 m ofdiameter). Hence with a lower loaded mass, the inertia generated is finallyup to three times more important. The weight/power ratio is thenoptimized.

• When a solid part enters the cutting chamber accidentally, theconsequences can be serious if the machine has not been specificallydesigned for it. On standard machines with large cutting diameter,sudden blocking is usually not possible due to the inertia of the rotorleading to intense shocks in the chamber with breaking risks. In the BDRcase, a mechanical friction disk (clutch) has been installed between theflywheel and the rotor. If solid parts have been introduced, the rotor isblocked instantly (avoiding breakages) and the friction disk isolated itfrom the wheel which tends to be taken by its higher inertia. MTB’sunique shredder design gets the most out of rotating mass inertia withouthaving to cope with any undesirable effects in case of a problem.



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Technical layouts BDR 1245



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GRANULATORS

Thanks to its robustness and to his wide cuttingdiameter, the granulator BAT 845 owns a powerfulimportant cut. Extremely versatile, the BAT 845 is ableto granulate a large number of products previouslyripped apart in our shredders of type BDR down to asize of 3 mm.

This essential step allows to release the differentelements present in the input material and to obtain ahomogenous particle size to optimize the sortingprocess. Specially treated alloy steel cutting blades canbe turned four times to ensure a sharp cutting edge andlong blade wear life.

The easy blade adjustment and grid mount systemsminimize downtime for maintenance.

Heavy duty granulators

Technical Data BAT 845 BAT 1245

Power 115 HP / 75 kW 170 HP / 110 kW

Length of the rotor 800 mm 1,200 mm

Diameter of the rotor 610 mm 610 mm

Rotor rotation speed 300-400 RPM 300-400 RPM

Weight 7 T 9 T

Quantity of fixed blades 8 12

Quantity of movable blades 20 30

Blade dimensions 28 x 56 x 195 28 x 56 x 195



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Robustness and reliability

• These single shaft granulators robustand versatile allow to release differentelements to optimize the sorting phasesthanks to its five rows of mobile bladeseasily interchangeable and of anintegrated hydraulic screen lift.

• As well as on the BDR, all the partssubject to wear (blades, knife holders,wear plates etc.) have very simpleinexpensive geometric forms. Finally, itis really easy to replace and adjust themwhich provides lower amount of time ofmaintenance than on concurrentmachines.

• The MTB granulators possess fixed andmobile identical blades. For operators,there is therefore only one reference ofknife to manage. Moreover, these bladesare parallelepiped and can be used manytimes (3 or 4) by being turned oversuccessively. Those blades ensure from200 to 500 tons of production per edge.

• The material fed in the BAT is theshredded fraction in the BDR 1245 andfreed of steel particles.

GRANULATORS



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Advantages

• The blades used are inexpensive and can be turned over, which decreasesthe operational cost. It is quick replacing and adjusting them which offersinferior period of time of maintenance to the competing machines.

• Thanks to a simple pushing screw system accessible even when themachine is closed, it is very easy to adjust the gap to the ideal level ofeach knife holder independently.

• When the granulation capacity increases or when slightly more difficultparts reach into the cutting chamber, the granulator must be able to getover these “sticking points” without jamming (production loss). Inertia iscreated on many machines simply by the rotation of large rotors (up to 1m); MTB has made a radically different choice, as it is true that the loadedmass generates inertia, this one depends essentially form the repartitionand the distance of the mass in relation to the rotation axis. Thegranulator has a rotor of modest size (600 mm) but he has on the otherhand a flywheel. Hence with a lower loaded mass, the inertia generated isfinally up to three times more important. The weight/power ratio is thenoptimized.

• An optimization was brought up to change the fixed blades directlyadapted on the rising screen holder. Moreover it is not necessary anymoreto remove the vibrating extractor to change screen which reducesconsiderably the time of maintenance.

• The BAT 845 was optimized for its overload to equip the modular Boxsystems while keeping similar performances of treatment to its peers.

GRANULATORS



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Technical layouts BAT 845

GRANULATORS



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The MTB air density tables allow an easy and in-depth sorting of consistent size and shape ofgranulated materials that are different in terms of weight.The separation is a combination of an air fluidized bed and a sloping vibrating table. To avoidsignificant dust emission, the airflow is recovered by an extractor hood and then treatedthrough a dust collection system.MTB air density tables can be used to separate metals from plastics, or heavy metals from lightones.

The heavy fraction comes out at the frontof the table while the light fraction isevacuated at the back of the table thanksto the integrated cross screw conveyor.The hood of the table must be connectedto the main aspiration system.

The machine is delivered with thefrequency inverters allowing to adjust theparameters.

Technical Data T 600x1200 T 1000x1500

Power 11 HP / 7 kW 22 HP / 14 kW

Table length 1,200 mm 1,500 mm

Table width 600 mm 1,000 mm

Weight 1 T 1.5 T

Aspiration air flow 6,500 m3/h 13,000 m3/h

Air density tables T 600 x 1200

AIR DENSITY TABLES



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AIR DENSITY TABLES



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SIEVING TABLES

MTB sieves are used for the final separation of the productand carry out a size-segregation.The screen is changed very easily within few minutes thanksto the rapid clamping system.The bigger parts will run on top of the screen while thesmaller inserts will fall through the screen and be evacuatedon the side of the machine.

Sieving tables TAM 700

Technical Data TAM 700 TAM 850

Power 1 HP / 0.75 kW 3 HP / 2.2 kW

Sieving length 1,300 mm 2,300 mm

Sieving width 650 mm 800 mm

Weight 1 T 2 T



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MAGNETIC SEPARATORS

We placed several magnetic sorters within the processdesigned to extract the steel particles contained in thestream.Those permanent neodymium magnetic pulley are made ofa non-magnetic casing that turns around a magneticsegment.The first magnetic separator is an “extraction” design usedmainly to remove the ferrous metals of bigger size that arethe most reactive to the magnetic field. This one is locatedat the exit of the shredder.

The other units that are placed after the granulator(optional) and the air density table are designs to be incontact and produce a magnetic field more intense tocatch the smaller size and weaker magnetic fractions inorder to finalize the extraction task.

Magnetic drums TAP / STMO

Technical Data STMO300*600

Power 0.8 HP / 0.55 kW

Pulley length 600 mm

Pulley diameter 300 mm



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In order to keep a line design offering a quick and easy installation, the dust filtration systemhas specifically been studied to be put in an independent container. The third container calledAir’Box only needs a simple connection to the other main containers to be functional.This one is clamped on top of the sorting container.Due to various and hazardous types of materials that are likely treated in the recycle line, it isreally important to install a certified anti-explosion ATEX system.

Dust exhausts are located all along the installation to catch the dust efficiently and to thenguarantee the most possible favorable working conditions.The air density tables hoods are also linked to the main pipe line in order to evacuate the airstream used to make the sorting of materials on fluidized beds.

The air full of dust, textile and light diverse waste goes through a cyclone before reaching themain filter.

DUST FILTRATION SYSTEM

View of the 10’ container Series of cyclonesIndoor explosion vents

Each solid component will fall down of the cyclone due to gravity and will be evacuated via airproof rotary valve. Some screw conveyors positioned under the valves will collect this solidcontent and will bring it to the Air’Box extremity. It will be then evacuated from the air proofrotary valves and will fall inside the 10’ container located under the Air’Box.

The air stream which passed the cyclone stage will finally be treated by the filter. A system ofhanging cartridges inside this cavity will catch the residual dust whereas the clean air beenreleased into the atmosphere.

Thanks to the integrated compressor, the cartridges are automatically cleaned up (declogging)by compressed air knives often blown inside each part.

Technical Data SFU 25

Power 115 HP / 86 kW

Capacity 25,000 m3/h



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Indoors explosion vents

The indoors explosion vent guarantees safe explosion venting in production halls in case thisunlikely situation happens.The flame gases are instantly extinguished inside the vent by efficient cooling. This product isdesigned for plant components that are at risk of dust explosions just like the Air Box.

This type of vent provides a perfect protection of the surrounding area. Neither heat, dusts nor adangerous pressure wave emerge from the vessel - everything stays in the vent. It also reduces thenoise levels and integrates signaling unit for reliable monitoring.

It comes in a package of two indoor explosion vents to add to the Air Box.

DUST FILTRATION SYSTEM



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Our new Cable Box design includes the following parameters:

❑ The main unit with the IP55 protection index, equipped with SCHNEIDER components❑ Electrical supply 3P + PE, SLT : TN-C, 400V - 50hz (adapted to local standards) ), ICC Max= 25

kA❑ Control done by a touch screen fixed on the board door❑ The shredder and granulators are driven via soft starters❑ The complete line is entirely automatic (SCHNEIDER ELECTRIC)❑ Level sensors will allow to send information to the crane operator and the automatic

deviation of the stream if necessary❑ Movable remote control equipped with potentiometers are installed next to each air density

table❑ The main control cabinet is fixed on anti-vibration dampers

ELECTROTECHNICAL

One of the main advantages of our Cable Box is that it is delivered entirely pre-wired and readyto be connected to the transformer. Consequently the period of time usually dedicated to theelectrical connection and to the control of the connections is totally eliminated which representsin average several weeks of work.

Each motor as well as the main control cabinet equipped with a touch screen are alreadyconnected to the main electrical board.

A quick wired system will allow to link all the containers electrically together.

In order to provide evaluations on the machine’s functioning and toassist to optimize the line’s functioning, sensors are incorporated togive a permanent temperature follow up of the equipment. Twosensors located at the exit of each granulator are constantlychecking that the heat of the product is not too high which couldlead to the melting of materials and then lead to an immediate stopof the line. Consequently, those measures regulate automatically thestream of the product via the stoppage of the conveyors feeding andby sending a visual signal to the operator of the crane.

Temperature detection



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INSTALLATION

Project management, installation and start up

MTB designed this system in order for the installation, assembly and start up operations to bethe simplest possible. One of our project managers will be in close contact with the customerduring the whole project timeframe to provide him with all technical datas and to prepareefficiently the installation and the assembly of the boxes on site.

This installation step includes four days on site two technicians who will ensure the arrival ofthe containers until the start up of the system with a round trip ticket and associated expenses.

NB: the lifting equipment will need to be available on site before the technicians’ arrival. Thepower should also be ready and our electric board will need to be connected to thetransformer once the connection of the boxes is done.

On top of electrical connection requiredbefore our trainer arrives on-site, it is alsorequested for the internet connection to befinalized at the same time.Indeed, this will allow remote trouble shootingas MTB electricians will be able to access thescreen, controls and PLC.

The internet connection needs to beavailable at the same location than the mainpower supply.



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The standard version of the compact shredder BDR 1245 comes witha 90 kW motor (120 Hp). MTB offers the possibility to increase thepower up to 110 kW (148 Hp) in order to give it more torque and tohandle tougher products (cables with big diameters, steel shieldedcables, ACSR, aluminum and copper radiators…)

BDR 1245 shredder motor upgrade

This device incorporated at the end of the BDR 1245 rotor, onthe flywheel opposite side, allows controlling that the rotor isrotating when the unit is in production mode.As soon as the sensor detects that the rotor has stopped,because of a jam for instance, it will automatically send a signalto the PLC to stop the shredder motor instantly.This way, any jam or problem in the cutting chamber would notget worth, and driving belts are protected against any damage.

BDR 1245 rotor rotating sensor

OPTIONS LIST

BDR 1245 hopper cover

In case the Cable Box is installed outdoors or partiallyoutdoors with the main input location unsheltered, it isnecessary to avoid the rain from coming into the systemwhen this one is not in use. This will limit the humidityinside the CABLE BOX that can disrupt the sorting stepand downgrade the quality of the products. MTB can thenprovide in option an hopper cover to put on top of theBDR designed to be easily handled with a grapple.



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Two magnetic separators are included in the standard process. An additional magnetic pulleycan be placed between the two granulators to extract the ferrous inserts before the productreaches the last granulator. Based on the input product and the ferrous content, it is reallyimportant to eliminate the ferrous metals step by step after each size reduction. Thanks to thisadditional magnetic pulley, the second granulator is better protected. The blades and thescreens benefit from a longer lifetime.

The material caught by the pulley is collected in an underneath compartment and transferredoutside of the Box via an integrated screw conveyor.

Additional magnetic separator

OPTIONS LIST

Hydraulic unit

The opening of the swinging doors on the Sort Box and the control of thescreen riser from the BDR 1245 can be operated by a dedicated hydraulicsystem. As a standard, those are controlled by oil tanks and manualpumps.

In order to simplify the cleaning and maintenance operations, it is possible to install a setof electrical plugs for portable devices as well as a compressed air network to usepneumatic tools. This option includes the connections from the electric board, theconnections from the compressor in the Air Box, the related wires or piping as well as a setof inlets located throughout the system.

Maintenance tools assistance option



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OPTIONS LIST

Each output fraction from the system is automatically transferred onthe sides of the Cable Box. Each dedicated container supplied by theclient (or offered as an option) must be located under each outputlocation to collect the products.

MTB offers an optional conveyor package that will transport eachoutput fraction further away from the main equipment allowing abetter handling of the output flows. Those conveyors also givegreater clearances under the discharged materials so that larger binsor sacks can be used.

Two options of conveyor packages are offered:- A pack of three screw conveyors intended for the transfer of fine

granules, connectors and of the plastic flow.- A pack of two screw conveyors equipped with magnetic head

drums intended for the transfer of fine granules and connectorsand a screw designed for the plastic flow.

Each option will include a wireless remote allowing the control at adistance of the conveyors in order to ensure their stops and alsoallowing the quick replacement of the contenants without any leak.

Different lengths of conveyors are available on demand to matchspecific heights of containers, but the standard package includesconveyors of 2.5m.

Conveyors pack option

MTB offers in option an additional screening step for the plasticsstream to reproduce the same process that the lines with largerscales. This stage is used to retrieve the fine residual copper in thegranulated plastics which have a similar reaction on the tables due totheir weak density.

To retrieve the copper, MTB uses a two stages sieving process. Thefirst sieving table isolates the larger plastic fraction and dischargesitself in an independent container. The second sieving table isequipped with an even finer mesh to retrieve the copper dust.

This package includes two screening tables TAM 700 as well as ascrew conveyor to unload the main plastic fraction. It is also possibleto select TAM 850 screening tables of a more important dimension.

We recommend in every instance a specific cover to protect theplastic sieving step.

Plastic screening option



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Dust dumpster option

Container 10 drums –4 crates option

OPTIONS LIST

Metallic dumpster located inside the 10’ container intended for the collection of dust comingfrom the cyclones installed in the Air Box. The quick connection system paired with thepresence of a manual guillotine hatch allows the removal of this bin without any spill ofmaterial. This dumpster has openings and securities specially adapted to its handling by aforklift.

The automatic opening system of the drop-bottom skip bin via a manual lever allows theoperator to empty the product without stepping down from the forklift. This way, he stays safewithout finding himself under a smokescreen when emptying the bin.

This package of ten drums and four metalliccrates adjusted to the heights of products’exits allows an optimal packaging of theoutput fractions.

The custom made forklift rings of the drumsmake possible the unloading of the materialsthrough the revolving of the forklift’s forks.



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Production optimization option

Crane operators training option

Production training option

OPTIONS LIST

Once the Cable Box is installed and started, the production itself may begin. MTB offers a support toguide the operators on their first few days. This will be the opportunity to ensure that the rightprocedures are implemented, the production be the most performant possible thanks to optimumadjustments of the machines and that the maintenance operations are learned.

This option includes four days on site for a MTB process specialist with a round trip ticket andassociated expenses.

In order to improve the skills and knowledge of the operators, our specialist has the possibility toprovide additional training sessions. The fact to extend the presence of our specialist on site willallow him to perform an in-depth teaching as well as providing customized specifications linked tothe different production configurations that could be met by the client.

It is also possible to get this option after several weeks or months of production to assure an optimaluse of the system on average term.

This option includes four days on site for a MTB process specialist with a round trip ticket andassociated expenses.

Feeding the CABLE BOX is a critical step that will determine the capacity of the system. Also, even ifthe task seems easy for the crane operators, it is important that the persons in charge of feeding theproducts in the MTB process receive a personalized training. This training will make sure that thecrane operators make the most of the CABLE BOX capabilities' and will teach them how to avoidfeeding problems.

This option includes three days on site for a MTB crane operator with a round trip ticket andassociated expenses.

Plug package for TBF connection

In order to ease the incorporation of a bin feeder in front of the Cablebox, it is possible to get theentire package already prepared.

This package includes all electrical components into the control panel and onto the container wall, aswell as cables, wiring and PLC integration.

technical sheet - recoquip · accidentally some softer steel parts with a maximum thickness of 20...

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