{"id":207,"date":"2013-11-26T17:07:26","date_gmt":"2013-11-26T16:07:26","guid":{"rendered":"http:\/\/www.alternativefuelinstallations.com\/?page_id=207"},"modified":"2013-12-04T11:49:09","modified_gmt":"2013-12-04T10:49:09","slug":"shredder","status":"publish","type":"page","link":"http:\/\/www.alternativefuelinstallations.com\/index.php\/modular-alternative-fuel-equipment\/preparation-and-conversion-of-waster-into-adf\/shredder","title":{"rendered":"Shredder"},"content":{"rendered":"

APPLICATION<\/h3>\n

Equipment designed for primary \u2013 secondary shredding of different types of resistant materials such like plastics, pruning, wood chips, animal biomass, textiles, aluminium, bronze, brass, and ferrous alloys of low mechanical resistance.<\/p>\n

FUNCTIONING AND PROCESSING<\/h3>\n

The shredding process starts with the introduction of the material to be treated into the hopper of the equipment. The hooper is equipped with a press moved by hydraulic cylinders, pressing the material towards the rotor of the shredder , in this way it is possible to shred whatever elements independent its geometry (bars, laminated rolls, planks, pallets ,boxes, etc…).<\/p>\n

\"Shredder\"Once the material has been introduced into the shredder chamber, it will be sheared and cut by the knives mounted on top of a robust rotor which rotates at medium speed. The points of these knives first pinch the material, drag it according to the rotation of the rotor and afterwards is torn apart by a difference of speed caused by the different position of the knives. The shredding of the materials is carried out by the shearing against other static knives positioned in the cutting jaw. This jaw is adjustable to compensate the wear of the cutting knives.<\/p>\n

The press is continuously pressing the material against the cutting rotor. When the motor consumption of the rotor is too high or too low (no material to be shredded), the press returns to the rear part of the hopper and preventing the entry of new material or preventing the rotor from a possible shearing with excessive torque. This movement will be controlled alternatively by a PID regulator and an adjustable timer.<\/p>\n

The reduction rate (output dimension of the material) is guaranteed by a constant distance between the mobile cutting knives and the stationary cutting knives. Once cut, the material rotates with the rotor and moving along the semi-circular screen which is situated at the bottom side of the rotor. When the material particles have reached their desired dimensions in the first shredding cycle, these fall through the holes of the screen, but if bigger than the desired dimensions, they will return to the shredding chamber, which process will be repeated until the material particles have reached their desired dimensions (the average time of a cycle is 0.5s therefore the shredding process will only take a few seconds).<\/p>\n

Finally the shredded and calibrated material falls into a screw base extractor where it will be conveyed to the next stage in the system.<\/p>\n

\"Shredder\"<\/a>\"Shredder\"<\/a><\/p>\n

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SHREDDING PROCESS<\/h3>\n
\"Shredder\"

The material to be shredded is pressed against the rotor of the shredder<\/p><\/div>\n

\"Shredder\"

The rotor cuts by shearing the material using the blade of the knife<\/p><\/div>\n

\"Shredder\"

The semi-circular screen around the rotor calibrates the output dimensions of the particles<\/p><\/div>\n

\"Shredder\"

The output particles present a very homogeneous dimension which facilitates its processing afterwards<\/p><\/div>\n

CONSTRUCTION<\/h3>\n

\"Shredder\"<\/a>A<\/strong>: Press driven by hydraulic cylinders
\nB<\/strong>: Rotor of shredder
\nC<\/strong>: Drive
\nD<\/strong>: Transmission
\nE<\/strong>: Multiplicator by gears
\nF<\/strong>: Knife holder + cutting knives
\nG<\/strong>: Adjustable stationary knives
\nH<\/strong>: Extraction screw for treated material<\/p>\n

CUTTING PROCESS<\/h3>\n

There is a wide variety of cutting processes for every kind of materials to be shredded, the most important parameters are the dimensions of the cutting blades, the shape of the cutting blades, the cutting angle of the cutting blades, cutting speed, etc…these parameters result in big differences which have led to the following cutting systems:<\/p>\n

\"Shredder\"

Integrated triangle<\/p><\/div>\n

\"Shredder\"

Cylindrical triangle<\/p><\/div>\n

\n
\"Shredder\"

Cylindrical rounded<\/p><\/div>\n

\"Shredder\"

Cylindrical rectangular<\/p><\/div>\n

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CHANGE OF THE KNIVES<\/h3>\n

An important aspect in all actual applications is the energetic efficiency, therefore the energy consumption of all equipment. The efficiency in the shredding process is created by a minimal torque of the main rotor, consequently we have to minimize the tangential forces of the cutting taking into consideration the following factors:<\/p>\n

    \n
  1. The cutting geometry should be adequate for the material to be shredded.<\/li>\n
  2. The cutting speed should be precise according to the production hours.<\/li>\n
  3. The cutting blades should be made of the proper material and should have the proper thermic surface treatment.<\/li>\n
  4. The cutting blades should be in good conditions.<\/li>\n<\/ol>\n

    For maintaining the cutting blades in good condition, an adequate maintenance is required which should be as simple as possible. For all SECON\/DSG shredders, this aspect has been perfectly studied and analysed. The solution is to make the cutting blades independent from the rotor so that they can be mounted in a reusable blade support in a way that these cutting blades can be used four times guaranteeing a very long lifetime. The automatic inspection door can be opened in a few seconds and allows an easy access towards the shredder chamber facilitating the maintenance process enormously.<\/p>\n

    \"Shredder\"\"Shredder\"<\/p>\n

    \"Shredder\"\"Shredder\"<\/p>\n

    \"Shredder\"\"Shredder\"<\/p>\n

    \n

    TECHNICAL SPECIFICATIONS<\/h3>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
    Dimensions input (width x length)<\/td>\n3050×1500 mm<\/td>\n<\/tr>\n
    External diameter including knives (1)<\/td>\n800 mm<\/td>\n<\/tr>\n
    Speed rotor rotation<\/td>\n250 rpm<\/td>\n<\/tr>\n
    N\u00ba of knifes<\/td>\n80\/160<\/span><\/td>\n<\/tr>\n
    Geometry of knives<\/td>\nTriangular\/Redonda\/cuadrada<\/span><\/td>\n<\/tr>\n
    Quality of knives<\/td>\nHardox-500\/600<\/span>\/650<\/td>\n<\/tr>\n
    Average superficial hardness of knives<\/td>\n500\/600<\/span>\/650 HB<\/td>\n<\/tr>\n
    Max. punctual hardness of blades<\/td>\n600\/700<\/span>\/800 HB<\/td>\n<\/tr>\n
    Distribution of the knives on the rotor<\/td>\nLineal<\/span> \/spiral\/lineal-espira<\/span><\/td>\n<\/tr>\n
    Diameter axle at max. flexo traction<\/td>\n300<\/td>\n<\/tr>\n
    Thickness rotor<\/td>\n80 mm<\/td>\n<\/tr>\n
    Quality rotor<\/td>\nUNE-F-1140<\/td>\n<\/tr>\n
    N\u00ba of stationary knives<\/td>\n12 uts in 6 jaws<\/td>\n<\/tr>\n
    Geometry knives<\/td>\nTriangular\/Redonda\/cuadrada<\/span><\/td>\n<\/tr>\n
    Quality knives<\/td>\nHardox-500\/600<\/span>\/650<\/td>\n<\/tr>\n
    Capacity of drive mechanism<\/td>\n160 Kw x 2 uts = 320 Kw<\/td>\n<\/tr>\n
    N\u00ba of installed motors<\/td>\n2 uts<\/td>\n<\/tr>\n
    Max. capacity admissible for shredder<\/td>\n440 Kw (2m x 220 Kw)<\/td>\n<\/tr>\n
    Type of transmission<\/td>\nPoleas dentadas<\/span> \/ Direct-drive<\/td>\n<\/tr>\n
    <\/td>\n<\/td>\n<\/tr>\n
    FORCES WITH MAX. CAPACITY INSTALLED<\/th>\n<\/tr>\n
    Max. torque of cutting<\/td>\n300 Kn<\/td>\n<\/tr>\n
    Average nominal force of cutting<\/td>\n2.000 N<\/td>\n<\/tr>\n
    Average max. force of cutting<\/td>\n5.600 N<\/td>\n<\/tr>\n
    Max. puntual force of cutting<\/td>\n167.500 N<\/td>\n<\/tr>\n
    <\/td>\n<\/td>\n<\/tr>\n
    FORCES WITH INSTALLED CAPACITY<\/th>\n<\/tr>\n
    Max. torque of cutting<\/td>\n14.5 Kn<\/td>\n<\/tr>\n
    Average nominal force of cutting<\/td>\n580 N<\/td>\n<\/tr>\n
    Average max. force of cutting<\/td>\n1.620 N<\/td>\n<\/tr>\n
    Max. puntual force of cutting<\/td>\n48.575 N<\/td>\n<\/tr>\n
    <\/td>\n<\/td>\n<\/tr>\n
    Press drive<\/td>\nBy hydraulic group<\/td>\n<\/tr>\n
    Opening\/closure drive of shredder chamber<\/td>\nBy hydraulic group<\/td>\n<\/tr>\n
    Capacity hydraulic group<\/td>\n9 Kw<\/td>\n<\/tr>\n
    Opening\/closure time hydraulic press<\/td>\n30 s<\/td>\n<\/tr>\n
    Max. pressing force<\/td>\n300.000 N<\/td>\n<\/tr>\n
    <\/td>\n<\/td>\n<\/tr>\n
    Passing screen<\/td>\n10<\/span>\/20\/30\/40\/50\/60\/70\/80\/90\/100<\/span> mm<\/td>\n<\/tr>\n
    Thickness screen<\/td>\n10\/15\/20\/30<\/span> mm<\/td>\n<\/tr>\n
    Geometry screen holes<\/td>\nCuadrado\/redondo\/<\/span>rectangular\/coliso<\/span><\/td>\n<\/tr>\n
    Quality screen<\/td>\nHARDOX-400\/500\/600\/650<\/span><\/td>\n<\/tr>\n
    Hardness screen<\/td>\n400\/500\/600\/650<\/span> HB<\/td>\n<\/tr>\n
    <\/td>\n<\/td>\n<\/tr>\n
    Production according to hardness and dimension of material to be processed<\/td>\n125-140m3\/h (1)<\/td>\n<\/tr>\n
    Mass<\/td>\n33.450 Kg<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n

    1) Depending on the material to be shredded, according to the dimensions of input and desired output, the type of knife and the dimensions and shape of the screen might change, and with all this, the output flow.<\/sup><\/p>\n

    ADVANTAGES<\/h3>\n