Page 23 - Hub-4 Magazine ISsue 64

Recycling
MRF’S
machinery choices. The machines installed by STADLER at this plant included one PPK and two STT2000-8 ballistic separators, two trommel screens, 12 NIR (near-infrared) optical sorters, nine material bunkers, three magnets, two eddy current separators, six sorting conveyors, and two
balers, as well as dust-extraction and HVAC.
In Phase 2, STADLER’s in-house project
management team is forwarded a Project Handover which contains detailed information relating to the contract and customer requirements. With this information, the in-house designers create a detailed 3D design of the plant. Because this design shows the complete steel supporting structures and walkways, the client is given a complete overview of the plant and STADLER can conduct an Access, Lifting and Maintenance review (ALM) along with the client. The ALM looks at accessing, lifting and maintaining key components such as drive motors. Carrying out the ALM during the design phase eliminates the need to modify steel work once the installation has been completed. Once the layout has been approved by the client, drawings are submitted for the start of manufacture and supplier equipment is ordered. Electrical information is passed on to STADLER’s in-house electrical team, where electrical panels are manufactured, and operating programmes written.
The third phase is installation, typically involving a combination of machinery from STADLER and other manufacturers, which STADLER project-manages on-site. All installation activities are carried out by STADLER employees holding all necessary health and safety and training qualifications.
Phase 4 is ‘cold’ commissioning of the plant without material. During this phase, the STADLER commissioning team is introduced to the project and carries out various activities such as testing the different modes of operation, pre-setting frequency invertors, making final adjustments on supplier equipment, and training staff members. ‘Hot’ commissioning is performed shortly afterwards with an agreed volume of input material. During this process STADLER assesses the areas that are critical for material flow, checking if transition points need to be optimised and if all machinery is operating according to specifications. Once these criteria are met, STADLER then runs the plant with the contracted throughput as stipulated by the client.
Finally, Phase 5 is Performance Testing and Take Over. An independent contractor is appointed to
verify the performance of the plant and to ensure that all contractual requirements are met. STADLER personnel are still on-site during this phase, to assist the client with day-to-day operations and clarify any queries the independent
contractor may have regarding material analysis. Following the performance testing, the results
are summarised and presented to the client in a final Take Over Report. Upon confirmation of this report, an Acceptance Certificate is signed by STADLER and the client.
Throughout these phases, all design, manufacturing, installation, commissioning and performance testing utilises STADLER personnel with the exception of the independent contractor. Keeping all activities in-house streamlines efficiency by ensuring less interface management.
As a result of this replacement, the new facility now has the capacity to sort 17 tonnes per hour of mixed recyclable material, producing fractions of news and pams, mixed paper, cardboard, HDPE, PET, mixed plastics, film, non-ferrous and ferrous materials, and scrap metals. One key strategy, removing cardboard from the process as soon as possible (with a STADLER PPK unit located after the first pre-sort cabin) has significantly benefited the rest of the line. Capacity has been raised from 65,000 to 75,000 tonnes per year.
The improvements achieved by this modernisation project and many others like it, and the growing number of new turn-key MRFs built by STADLER, are essential steps in the journey towards creating a circular economy. And at the same time as benefiting the environment, they are enhancing each plant’s commercial competitiveness.
www.hub-4.com Sept/October 2020 - Issue 64
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