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Compact System For Secondary Fuels

% % % % % % Maximum flexibility concerning fuels to be used Limited space requirements Reliable conveyor equipment Low energy consumption Simple safety technology Low operating costs

Application The Compact System For Secondary Fuels is designed to generate a continuous mass flow from combustible recycling products of the most diverse nature. Fitted with large cross-sections, the conveyor equipment can handle flakes, fibres, plastic shredders as well as compounds. The system is primarily used for the feeding of fuels into rotary cement kilns. The feed rate for this application is typically between 1 and 10 t/hr.

Equipment The system comprises: % Docking stations with live bottom bin for semitrailers with walking floor % Troughed belt conveyor % Weighfeeder with nonstandard features % Blow-through rotary feeder of special design % Rotary piston blower % Pneumatic conveyor line % Measuring, control, and supervisory electronics for continuous operation The design is protected by utility model registration and patent.

Function The fuel is supplied on semitrailers. Via the integrated walking floor, the fuel is fed into the live bottom bin of the docking stations. The screws feed the fuel into the troughed belt conveyor which supplies the weighfeeder. The weighfeeder feeds the fuel into the rotary feeder and determines the conveying speed of the upstream live bottom bin.

BV-D 2145GB

Schematic Diagram Semitrailer with walking floor discharge system Docking station with screwconveyed live bottom bin



Conveyor line

Troughed belt conveyor


Rotary piston blower

Module Description Delivery Site Function The secondary fuels are supplied on semitrailers in the form of loose products. Any vehicle type conforming to the local Road Traffic Regulations may be used. The delivery surface is to be designed for a minimum of two vehicles so that the system can be operated in alternating or parallel mode. The semitrailer backs into the docking station. The trailers are properly positioned with the aid of guide tubes and tyre limit stops.

Blow-through rotary feeder

Technical Data % Bottom plate: - Asphalt or concrete Dimensions: - Length: - Width: - Ground slope:


13,500 mm 5,000 mm < 2%


Fitting close with the semitrailer's outline, the lateral rubber aprons of the docking station accomodate different vehicle widths and heights. This helps to keep the delivery site % clean. After opening the rear doors inside the docking station, unloading can take place. The tractor is now no longer required. The ready semitrailers assume the function of a silo. A stationary hydraulic unit drives the semitrailer's walking floor system during unloading. The hydraulic pipes come with a double jacket ensuring any leaked oil returns into the oil sump. This reduces the risk of soil contamination through leaking hydraulic oil.

Hydraulic unit (for walking floor): Twin-unit equipped with oil sump - Hydraulic pipes with double jacket Dimensions: - Length: - Width: - Height: Power consumption:

1,750 mm 1,150 mm 850 mm 2 x 7.5 kW


Delivery Site With Docking Stations

Docking Station Function For reception of the secondary fuels, normally two parallel docking stations are available ensuring continuous fuel supply. The individual cabins are fitted with a sealing system designed to adjust to the semitrailer's degree of unloading. This helps to keep the environment clean. The docking stations are equipped with a photocell hopper level control system cycling the upstream walking floor live bottom. The feed screws mounted in stations transport the secondary fuel discharged from the semitrailer to the adjacent troughed belt conveyor. Depending on the selected feed rate, the four feed screws are controlled in pairs for alternating operation, so good fuel prefeeding and uniform discharge of the docking station are ensured. Technical Data % % % % % Steel plate construction mounted on IPE supports with ground clearance Four feed screws per station Rubber apron sealed vehicle reception Prime coat approx. 12 µm Dimensions (per station): - Length: - Width: - Height: Weight (per station):

approx. 4,000 mm approx. 2,240 mm approx. 4,400 mm approx. 2,500 kg

% %

Power consumption (per station): 2.2 kW

Options: % % % % % Roller gate on reception opening Special seals on reception opening Suction system in station Expansion to four stations Top coat in other RAL shades

Troughed Belt Conveyor

Troughed Belt Conveyor Function Technical Data Steel construction supported on floor beams Transport via individually tensioned roller chains Totally enclosed to prevent dust escape Prime coat: Feed rate: Conveying speed: Height of lift: Dimensions - Length: - Width: - Height: Weight: Power consumption: approx. 12 µm max. 60 m³/hr 0.5 m/sec approx. 2,000 mm

The docking station screws feed the secondary fuel into % the lateral inlet holes of the troughed belt conveyor. % Driven by revolving chains on both sides, drag plates pull the feed material over the rising conveying trough % to the weighfeeder's inlet shaft. % The conveyor chains are driven jointly via a sprocket % shaft arranged in the upper belt strand. Two chain % tensioners mounted in the lower belt strand ensure safe % chain running. %

approx. 4,500 mm approx. 1,000 mm approx. 2,500 mm approx. approx. 800 kg 3.0 kW

% %

Options % Special constructions in other RAL shades

Weighfeeder, MULTIDOS type

Weighfeeder, MULTIDOS type Function The material is discharged from the troughed belt conveyor into the weighfeeder's infeed hopper. The weighfeeder controls the docking station feed screws and the walking floor discharge system in a networked control loop. The weighfeeder is specially designed and equipped for the feeding of light bulk solids (bulk density < 0.2 kg/cm³). In addition, special skirt boards guide the material and prevent its lateral escape between the belt and limitation. A segmented belt scraper ensures good belt cleaning. % The weighfeeder is completely enclosed and can be equipped with a suction system in accordance with the characteristics of the material fed. The discharge hood is fitted with an inspection flap permitting weighfeeder and rotary feeder below to be serviced. % Technical Data For % % % % % % % % % general data, see Spec Sheet BV-D2080. Special variant for light bulk slids Special belt, continuously vulcanized Automatic belt tensioning and tracking station Belt slip monitoring Mechatronic design Feeder drive with integral frequency converter Integrated weighing electronics, DISOCONT type Fieldbus for serial data exchange Dimensions (as a function of feed rate): - Axle spacing: approx. 2,700 mm - Belt width: approx. 800 mm - Height: approx. 730 mm Weight: Power consumption: approx. approx. 800 kg 1.5 kW

Options: % % % % Suction system with bio filter Electrical equipment in control cubicle Top coat in other RAL shades Belt scrapers

Blow-through Rotary Feeder

Blow-through Rotary Feeder Function Mounted flush with floor level below the weighfeeder's discharge chute, the rotary feeder accommodates the material discharged from the weighfeeder in its chambers. The fuel stored in every rotary chamber is discharged by force and blown through the conveyor line to the burner. Every rotary feeder is tailored to the specific project. The chambers surface cross-sections are tuned to the associated blower rate. This type of sizing reduces the escape of air across the feeder inlet. Depending on the composition of the secondary fuel, a rubber- or metal-sealed variant can be installed. The seals can be inspected through the inspection flap on the weighfeeder discharge and serviced, if necessary. % Technical Data % % % % % % % % % % % Steel plate construction supported on IPE supports with ground clearance Stuffing box shaft seals Rubber or metal chamber seals (exchangeable) Chain drive Prime coat approx. 12 µm Filling funnel: No. of chambers: Rotary feeder rate: Rotor speed: Blow-through line connector: 800 x 230 mm 6 – 12 chambers max. 100 m³/hr 14 rpm DN 70 –200 mm

Dimensions (as a function of feed rate) - Length: approx. 1,500 mm - Width: approx. 1,500 mm - Height: approx. 1,050 mm Power consumption: approx. 5.5 kW

Rotary Piston Blower Function The amount of air required for pneumatic conveying of the material from through-blow rotary feeder to kiln is generated by a rotary piston blower with integrated pulsation reducer. The constructional conception of this kind of blower ascertains high mechanical and volumetric efficiency at ultimate reliability and operating safety. The rotary piston blower is dimensioned and integrated into the system in accordance with the project. The blower is mounted in a noise insulating housing. Technical Data % % Blower with 3-wing-type piston Sound reduction through pulsation degradation by means of two pre-intake channels cast into the pressure side of the cylinder Housing of GG20, ribbed and air-cooled Shafts and pistons (C45N) forged of a single piece Control gears of 16 Mn Cr5E Overhung drive via V-belts Elastic mounting bases Prime coat: approx. 12 µm

% % % % % % %

Rotary piston blower dimensions: - Length: - Width: - Height: approx. 1,500 mm approx. 1,300 mm approx. 1,600 mm approx. 22 kW as a function of type


Electrical consumption:

Pneumatic Conveyor Line Function The conveyor line transports the fuel blown out of the rotary feeder chambers directly to the burner. Air quantity, run length and pipe diameter are selected in accordance with the particular project so optimal material transport without line deposits is obtained at minimal abrasion of the pipe inner wall. The line must be arranged horizontally and/or vertically. Pipe bends have to be reduced to the absolute minimum. Pipe lengths below 100 m enable the highest economic efficiency of the system. To protect the system from kiln faults, an explosion check valve has been installed. Options: % % Bends with cast basalt linings Top coat in other RAL shades Technical Data % Sections - Steel pipe St 35, seamless to DIN 2448 - DN 70 – 200 - Prime coat approx. 12 µm Bends - 90° radius - Steel pipe St 35, seamless to DIN 2448 - DN 70 – 200 - Prime coat approx. 12 µm Pipe joints - Flanges to DIN 2631



Electrical Control Function Designed in accordance with the German VDMA/VDI regulations, the electrical control system is installed in a control cubicle. All switching gears required for openand closed-loop control and fusing of the units installed are included. The lead to the control cubicle is mounted in the factory. The setpoint (feed rate in t/hr) is entered on the central control panel. All other units are controlled or switched as a function of the set feed rate. Upon start of the system, a sound signal is produced before the blower or rotary feeder starts operating. The fill degree of the docking stations is monitored electronically and cyclically starts the hydraulics of the walking floor system on the semitrailer to be loaded. Options: The weighfeeder is equipped with a DISOCONT weighing electronics complete with additional instrumentation section for commissioning, evaluation and monitoring. Information on actual value, daily totals, etc. can be called up. Interfacing with a host system is also possible. A PLC system monitors and controls all system components. This enables the individual system to operate in automatic mode so that no manual operator interventions are required. The system control is equipped with a power switch. In case of emergencies, the complete system can be shut down with the use of Emergency Stop switches aborting the entire conveying function and immediately closing the rotary closure on the kiln. % % % % Customized design Coupling to host system Additional queries and evaluations Top coat in other RAL shades Technical Data % % % % % % Steel plate control cubicle, two-wing type Designed in accordance with VDMA/VDI regulations Surface powder-coated to RAL 7032 PLC control (SIEMENS S7) Fieldbus for serial data exchange Control cubicle dimensions: - Length: approx. 1,200 mm - Width: approx. 500 mm - Height: approx. 2,000 mm Weight: approx. 500 kg


Measuring and Process Systems SCHENCK PROCESS GmbH D-64273 Darmstadt Phone: +49 (0) 61 51-32 10 28 Fax: +49 (0) 61 51-32 11 72 E-Mail:

A cooperation between SCHENCK PROCESS GmbH and Energieberatung Hess GmbH

BV-D2145GB XBS 05.0901. We reserve the right to discontinue or change specifications or designs at any time without notice or obligation.