Sutco RecyclingTechnik GmbH
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- Offer Profile
- EFFICIENT RECYCLING IS
BENEFICIAL FOR YOUR COMPANY AND THE ENVIRONMENT. DOUBLE PROFIT.
The Sutco RecyclingTechnik GmbH is one of the worldwide largest and most
successful manufacturer of treatment and sorting systems for waste
We have been committed to environmental protection and recycling for more
than 35 years.
Using the know-how from more than 480 implemented plant solutions, we can
give you comprehensive and individual advice on all areas of treatment
Planning. Design. Production. Installation. Commissioning. Service.
Maintenance. All from one company.
EFFICIENT RECYCLING IS BENEFICIAL FOR YOUR COMPANY AND THE ENVIRONMENT. DOUBLE PROFIT.
Environmental policy requests and promotes efficient and environmentally friendly recycling: Almost no landfill - but useful recycling - is not only a requirement but the order of the day, if long-term success in the market is aimed at.
MUNICIPAL & HOUSEHOLD WASTE
CUSTOM MADESORTING- AND TREATMENT PLANTS. MODULE SYSTEM - CUSTOM MADE
Household waste is waste which is collected in a mixed and unsorted manner.
Approx. 250 kg of household waste is generated in the European households per capita every year.
Household waste mainly contains materials such as:
- Organic waste (garden and kitchen waste)
- Mineral substances
- Rubber and others
Sutco household waste sorting and/or treatment plants are designed according to the customer’s specifications.
Using the throughput, the composition of waste and the customer's objectives, Sutco can prepare an suitable concept: Plants with mainly manual solutions which can be extended up to fully automatic systems. Thanks to the excellent sorting equipment, Sutco systems can achieve a high output of material fractions from household waste. Using trommel screens, magnetic technology, ballistic separators and near-infrared devices (NIR) and/or manual sorting processes, the material is sorted to form different fractions.
SUBSTITUTE FUEL AND GENERATION OF BIOGAS.
The material (metal, cardboard, plastics etc.) which is sorted out is subjected to further processing or is converted to substitute fuel which is processed by a shredder to form a marketable fraction. The organic fraction; which was screened before, is further treated by the Sutco composting process. The material can be prepared as a landfill cover or as a substitutive fuel in a dried condition. In addition, the material may also be converted to new energies together with our partners. Biomethanation processes can be used to produce biogas which is converted to electrical power by a combined heat and power unit.
5-STAGE-MODEL HOUSEHOLD WASTE
SORTING- AND TREATMENT PLANTS. MODULE SYSTEM - CUSTOM MADE
The modular concept of the Sutco RecyclingTechnik GmbH domestic waste management concept is adapted to the specific customer requirements and is used according to the flow throughput, the waste composition and the goal of the customer. The right technique creates alternative energy sources.
HOUSEHOLD WASTE CONCEPT IN 5 DIFFERENT MODULES
With its 5-stage-model household waste, Sutco offers sorting and treatment plants from manual sorting to semi-automatic to fully automatic systems. Thanks to the reliable sorting technology, the Sutco systems achieve a high yield of recyclable fractions from household waste.
Planning, design, manufacturing, assembly and aftersales - a turnkey solution.
- Module 1: Simple type with manual sorting
- Module 2: Semi-automatic system
- Module 3: Automatic sorting plant
- Module 4: Automatisc sorting plant with biological treatment
- Module 5: Waste to energy
SUTCO® SORTING- AND TREATMENT PLANT – THE RIGHT SOLUTION FOR EVERYONE.
SORTING AND TREATMENT OF COLLECTED AND MIXED MUNICIPAL SOLID WASTE
- with manual system
- with semi-automatic system
- with a fully automated system
BIOLOGICAL STABILIZATION AND COMPOSTING
- with the dynamic system BIOFIX & WENDELIN
- with the tunnel system
- with static system
SUTCO®-TECHNOLOGY FOR DOMESTIC WASTE PROCESSING OFFERS:
- Inexpensive alternatives for thermal disposal
- Take account of regional differences of waste
- Recycling income by clean separation and baling of recyclables
- RDF/SRF for recovery
- Composting to stabilize and use
- Fermentation for power generation
- Minimization of the deposit (remaining amount)
PRODUCTION OF SUBSTITUTE FUELS (SRF/RDF)
TREATMENT PLANTS FOR REFUSE DERIVED FUEL (SRF/RDF)
Substitute fuel or secondary fuel is fuel which normally consists of high-calorific waste The waste used for the production of substitute fuel may come from households, industry and trade.
Normally, industrial waste and bulky waste mainly contain
- Composite packagings
All these materials have a high calorific value. Using advanced treatment technology, a fuel (so-called co-incineration) is produced for the cement, lime and power station industry or even as a sole fuel in SF substitute fuel power plants.
After pre-crushing the material is screened, then separated by the wind sifter and followed by a separation of ferrous and non-ferrous metals with a subsequent NIR separation (near infrared separation). The material may be post-crushed again. Frequently, the material is pelletized until its use or can be filled into containers and/or stored in bunkers.
MECHANICAL-BIOLOGICAL WASTE TREATMENT (MBT)
MECHANICAL-BIOLOGICAL TREATMENT PLANT (MBT)
The mechanical-biological waste treatment (MBT) is material-specific waste treatment which can be recycled from a material and energetic point of view.
The waste which is treated is refuse from households and companies (household waste or household-like industrial waste and green waste).
The following waste fractions can be produced during the treatment process:
- Waste for material recovery
- Waste for energetic recovery
- Waste for thermal treatment
- Waste for biological treatment and subsequent landfill
THE OBJECTIVES OF MECHANICAL-BIOLOGICAL WASTE
- Reduce the volume of the waste to be dumped and thus preserve the required landfill volume.
- Reduce the biological activity of the organic fraction in the household waste such that as little landfill gas as possible can escape in an uncontrolled manne on the dumpsite.
- Minimize the harmful substances which may enter the groundwater together with the leachate.
Miscellaneous process steps treat the input material, e.g. the material is crushed for coarse primary sorting. It is then screened to divide the material to form several material flows, subjected to separation of ferrous and non-ferrous metals and, if required, to a manual sorting process to divide the fractions to coarse, medium and fine fractions. The coarse fraction contains film, paper, hard plastics, wood etc. which is separated from heavy and interfering material again. They will be disposed of separately.
This produces a highly calorific fraction which can be used as fuel in SF power plants. The fine fraction is conveyed to the biological section of the plant where the material is subjected to a further anaerobic treatment by a composting process, significantly reducing the organic substances.
WASTE TO ENERGY - REC&EN TECHNOLOGY
RECYCLABLES AND ENERGY FROM WASTE
Household waste is rich in organic ingredients and recyclable materials. They can be separated from the waste, and the organic fraction can be converted to profitable energy by fermentation.
WASTE TO ENERGY.
The scope of delivery for recovering recyclables and energy from waste (REC&EN Technology) includes an integrated recycling and energy recovery system for municipal solid waste (MSW). This system offers a variety of advantages and allows the collection of sorted recyclables for marketing as well as the generation of self-sufficient energy, and additionally maximizes the power and energy generation for sale.
THE MAJOR PARTS OF OUR EQUIPMENT ARE:
- Recovery of recyclables
- Substitute fuels
Sutco BIOFIX – row composting
Automatic, dynamic process. Estimated throughputs > 35,000 – 80,000 Mg/a
Sutco WENDELIN “the new generation”
Dynamic windrow process of large volumes, estimated throughputs > 80,000 Mg/a
Sutco tunnel composting
Static process, composting and/or drying of the input material
This is an alternative fermentation process which significantly improves the energy balance and the processing capacity of composting plants.
OTHER TREATMENT STEPS
- Slag preparation
- Baling units/bypass revision WIP
SORTING SYSTEMS FOR PACKAGING WASTE
In case of recyclable materials a distinction is made between the packaging waste identified by e.g. the Green Dot (Germany), Eco-Emballages (France), and in other 22 European countries, i.e. packing waste collected in bags, barrels or recyclable material containers as well as recyclable material collected by the communities or third parties entrusted with the collection.
This packaging waste is mainly
- Cardboard articles
- Lightweight packagings (packagings of plastics, metal and composites)
Sutco sorting systems separate this waste to recycle materials by mechanical and automatic sorting methods and to form fractions of them as well. Key units such as bag openers, trommel screens (sorting of material by size), wind sifters (separation by weight), ballistic separators (tabular-light and heavy-rolling), magnets and eddy current separators sort the packaging waste and use the near-infrared devices for fractioning.
HIGH-QUALITY SECONDARY RAW MATERIALS.
Thanks to the qualitative combination of the equipment used the Sutco sorting systems achieve a high degree of purity and thus allow the marketing of exactly sorted fractions which can be sold well as high-grade secondary raw materials.
COMMERCIAL AND INDUSTRIAL WASTE (C+I)
SORTING SYSTEM FOR COMMERCIAL WASTE
Commercial waste is residual waste from business enterprises and institutions. This waste has a high fraction of valuable resources for the worldwide raw material industry.
Sutco commercial waste systems have a high degree of automation and can sort recyclable materials such as
- Non-ferrous metals
- Ferrous metals
Using miscellaneous key units such as trommel screens, magnetic separators, ballistic separators and NIR separators, Sutco Recycling Technik can provide uniquely separated flows of material.
Manual sorting equipment is used to sort polymers, paper and film again to provide optimal quality. In addition, this plant technology makes sure that other input material (such as construction site waste and bulky waste) can be treated, if required.
In addition to the production of pure recyclable material, our treatment technology is also designed for producing substitute fuels which can be generated positively by near-infrared equipment.
WASTE PAPER AND CARDBOARD
SORTING PLANT FOR WASTE PAPER AND CARDBOARD
The purer the paper can be returned to the paper industry, the more valuable it is. This means that the more primary fibres are replaced with secondary raw material from waste paper, the more favourable it is for the paper industry since less water, energy and raw materials must be used.
WASTE PAPER … VALUABLE RAW MATERIAL.
To achieve a high degree of purity of the paper, the sorting process must ensure high reliability and productivity.
Here, the separation of non-paper ingredients are at issue such as
as well as the production of defined paper grades.
- plastics etc.
Sorting may be perfomed manually or semi-automatically. The collected paper mixture is sorted to form several fractions in individual process steps. The deinking products, cardboard and mixed paper are fed or dosed to the individual sorting unit via a moving floor. Sorting is performed by screens to obtain coarse and fine material, and advanced optical detection systems classify the goods before they pass a manual product check in a final step. In this way high-grade waste paper qualities are produced.
COMMINGLED WASTE (MRF)
TREATMENT PLANT FOR COMMINGLED WASTE (MRF)
This is a semi-automatic sorting systen for dry recyclable material, especially for the UK market. The following input materials are understood as dry recyclable material:
- Paper & cardboard
- Mixed plastics
- Non-ferrous tins
- Residual material
After a manual pre-sorting process screening is by screens to form different fractions which subsequently receive a maximum of recyclable material in a sort-separated manner, partially produced by NIR equipment. The separated recyclable material is then processed by baling presses for transport.
MIXED BUILDING DEBRIS
SORTING PLANT FOR CONSTRUCTION AND DEMOLITION WASTE
Mixed construction site waste is a mixture of mineral and non-mineral materials,
e.g. mixtures of
- packaging materials
- plastics etc.
The mineral materials contained e.g. In bricks, tiles, wall debris, stone, concrete etc. as well as special waste such as bitumen roofing felt, asbestos cement, paint, varnish etc. are excluded.
The material which cannot be recycled is separated from the recyclable material from this mixed construction site waste, and the recyclable fractions are fed separately to circulation. Recyclable products of high quality, the preservation of landfill areas and the protection from hazardous waste are major benefits.
SLAG AND BOTTOM ASH FROM INCINERATION
BOTTOM ASH TREATMENT AND MOBILE BOTTOM ASH TREATMENT.
Slag or ash is residual material from combustion processes in power stations or from waste incineration plants. Slags from WIPs are particularly significant for the protection of the environment.
PREPARATION OF SLAG.
Waste incineration produces about 250 - 350 kg of slag from every ton of waste. This waste is - like the waste itself - of an extremely different composition with respect to the content of mineral substances, iron scrap, water and heavy metals.
Prior to the further use of the WIP grate ash must be treated and stored such that it complies with the quality requirements of the intended later utilization.
In most cases the slag is conveyed from the WIP to the treatment plant via conveying equipment. There, it is pre-stored for an integration of air CO2 for at least one day. Then, the slag is sieved and crushed . Iron scrap and non-ferrous metals such as aluminium, copper and brass are separated from the slag and will be re-used in metallurgical facilities as raw material. Unburnt rests will be processed and removed in a classifier.
MECHANICAL TREAMENT BEFORE INCINERATION/POWER STATION
PRE-SORTING FACILITY BEFORE THERMAL TREAMENT
During the delivery of the waste and the pre-treatment of the municipal waste to be treated thermally, the upstream plant complies with the special requirements for the check, pre-sorting, crushing and homogenisation. The household-like industrial waste and the product-specific commercial, household and/or residual waste and bulky waste are correspondingly treated before they are fed to the waste bunker.
The Sutco plant ensures a uniform utilization and working temperature by feeding inputs constantly. The results are, among others, an opimization of the incineration process, a reduction of harmful substance peaks in the flue gas and a reduction of operational faults caused by hot/cold hearths. A clean solution.
TREATMENT OF WOOD
Treatment of biological mass by e.g. wood treatment plants for the production of wooden beams and pellets.
Sutco provides plants for the treatment of wood. The wood is crushed, dried and processed to provide wooden chips and pellets.
SORTING PLANT FOR MATTRESSES
Since dumpsites are scarce for the waste industry, Sutco develops mattress sorting systems which allow the parts of mattresses to be sorted and separated.
In a series of mechanical and manual steps foamed material, fibres and metals are separated and stored for recycling or re-use.
LINE-COMPOSTING SYSTEM BIOFIX
BIO-WASTE COMPOSTING PROCESS BIOFIX
The Biofix system processes biodegradable waste in anautomated and dynamic process to recycle it into a highquality compost or produce landfill material complying with the legal requirements, laid down in the various directives.
Thanks to its modular design, different biological waste can be treated separately. Starting with two bins, an expansion of the number of bins is possible. Even the length of the bins is flexible. Normally, a length of approx. 48 m is used. Plants of up to 50,000 Mg/a and more can be implemented.
WINDROW COMPOSTING SYSTEM WENDELIN "THE NEW GENERATION"
COMPOSTING PROCESS WENDELIN "THE NEW GENERATION"
Wendelin has been designed for the use in composting halls and for the treatment of green waste, biowaste and organic waste from MBT including an optional addition of fermentation residues. A humid warm climate prevails in the composting hall.
The input material may be screened by max. 80 mm perforations. In some cases the parts may have approximately 150 mm.
MAXIMUM WINDROW LENGTH
The maximum turning width of Sutco Wendelin is approx. 23 meters. To maximize the efficiency of the plant, the primary windrow length should be equivalent to the maximum turning width.
Depending on the material composition, the SUTCO Wendelin turning capacity is up to 260 cubic meters per hour.
ADVANTAGES OF THE SUTCO WENDELIN
- Material-dependent turning capacity of up to 260 m3/h
- Support structure, handrails and grates of non-rusting material
- Where admissible, the screws are made of stainless steel
- Steel parts according to C5-I corrositivity category
- Teeth on the bucket wheel are made of resistant low-wear Hardox steel
- Wheel bucket and teeth mounted by screwed connection
- The conical surface within the bucket wheel is lined with Hardox steel
- The deflection rollers of the inclined belt are on oil-lubricated bearings
- Bearing units of the travel drive are with automatic lubrication
- Chute lined with a wearing plate
- Energy supply as well control lines are run through energy chains to the bridge, trolley and reversible belt
- To prevent an extreme contamination of the energy chains, they are protected by a cover
- Short cable routes by a re-positioning of the terminal boxes
- Cabling of the machine by LAPPKABEL Ölflex Robust
- Pre-installation of the conduits for corrosion control
- Energy chain route made of 1.4571
TUNNEL COMPOSTING SYSTEM
SCOPE OF SUTCO SERVICES.
Design, execution planning as well as hall component, delivery and installation of the machine equipment, composting tunnel, areation and water equipment, cleaning of exhaust air, commissioning and trial operation.
The waste to be treated is generated from household waste. The waste is crushed and screened in the customer’s mechanical treatment plant (MTP). The screen overflow > 80 mm is freed of ferrous and nonferrous metals by a ferrous and non-ferrous separator and is fed to a loading process as a fraction with a high calorific value (HCV). The iron is largely separated from the fine fraction < 80 mm by a ferrous separator. After that, the material is fed to the intensive composting system.
ADVANTAGES OF THE TUNNEL COMPOSTING SYSTEM.
- The automatic input process piles up the material loosely and windrows it for the composting process optimally in the tunnels without any additional compaction by a wheel loader.
- Minimum power consumption for ventilation by open ventilation basements.
- Low cleaning expenses by small conical nozzle openings in the aeration floor and open ventilation basement.
- Operation of the intensive composting process without waste water possible; the process water from the input material leaves the system through exhaust-air cleaning.
- Pressurized ventilation ensures optimum aeration of the material and removes deposits in the ventilation nozzles.
- Good control of the process by small self-contained units in the tunnels.
ORGANIC WASTE PRESS WATER DIGESTION BIOPV
Digestion of a liquid phase pressed out of organic waste in biofilm reactors
THE NEW DIGESTION PROCESS COMBINES COMPOST AND BIOGAS.
Sutco Recycling Technik GmbH has developed a new digestion technology BioPV (organic waste press water digestion) as an alternative digestion process which significantly improves the energy balance and the processing capacity of composting plants.
Sutco Recycling Technik GmbH succeeded in achieving a maximum gas yield from the liquid phase pressed out organic waste with lowest technical efforts during the development of their new digestion process BioPV (organic waste press water digestion). With this technology organic ingredients from the biowaste as a liquid phase are digested and pressed out in biofilm reactors for generating biogas.
BIOGAS AND COMPOST.
Up to now, mainly dry digestion plants have be used for the energetic use of the organic substances contained in organic waste. However, these processes achieve a high biogas yield but require considerable efforts and expenses for the treatment of the digestion rest to provide a quality-based and marketable compost. The conditioning and drying of the digestion rest requires a high energy consumption for that.
Contrary to that, Sutco could largely avoid digestion rests to be disposed of externally with their BioPV. Here, digestion is performed in parallel to the composting process with the liquid phase separated from fresh organic waste. The digestion rest is run in a cycle and is only disposed of in case of excess water in the total plant.
Depending on the requirements and specific features of waste treatment, Sutco can manufacture and deliver miscellaneous units of its own. The size of a waste processing company does not matter. Our engineers will customize the currently required components to suit the inventory.
Sutco developed the trommel screen as a major plant component for advanced treatment plants. It is designed for the crea - tion of different particle fractions, the breakdown of agglomerates and the homogenization of material.
Trommel screens are used for screening a wide range of materials such as: slag, mixed construction waste, cardboard-paper, plastics, wood etc. The generation of 2 to 4 sieve cuts and throughputs of up to 160 t/h are possible.
- Generation of Different particle fractions
- Disintegration of agglomerates
The trommel body installed in an inclined fashion is the core of the trommel screen. The body is equipped with six changing plates for each screen shot over the circumference. Depending on the sizing, the trommel body may comprise 4 to 6 screen shots. The trommel body is supported on two turned races. Depending on the requirement, several screen fractions may be generated by a trommel screen. The built-in equipment (stopper, accelerator) can be used to influence the screening result.
The screen perforation may optionally be designed as round or rectangular perforations, with wrapping protection in case of round perforation as well. Together with the races the trommel body is supported by a total of 4 rollers with vulkollan linings. The rotary movement of the trommel body is generated via one or two rollers which are driven by geared motors. The rollers are bolted to the base frame.
An axial pressure roller exerting pressure against one race prevents the trommel body from an axial movement caused by the rotation and trommel inclination. The base frame stands on supports dowelled to foundations.
The box feeder is designed for accepting, buffering and metered feeding of biological waste and greencut, organic production residues, waste paper and plastic waste.
The decompacting unit available as an accessory consists of one to two decompacting rolls. The rolls loosen up the biological waste and make sure that the material is uniformly fed to the downstream treatment plant.
Dosing feeder of robust design for mainly feeding biological waste and greencut. Discharge is performed by a drag chain conveyor. Feeding is by a wheeled loader.
- Feeding of Biological Waste
- Feeding of Greencut
- Feeding of Structured material
ADVANTAGES OF THE SYSTEM
Box and drag chain conveyor of robust design. The tensioning spindle for the tensioning bearing is on the outside, so the chains can be tensioned during operation without removing the chains.
The ballistic separator is an aggregate used to separate one input material stream into two or three fractions. The big advantage of the ballistic separator in comparison to other separating devices is the combination of the sorting method in weight, dimension, density and form. By means of the single-stage main aggregate the material stream is separated into two main fractions, as there are „rolling heavy fraction“ (stones, wood, tins, massive plastic parts etc.) and „flat light fraction” (foils, textile, paper, cardboard, fibrous products etc.) Depending on the paddle perforation, a third screening fraction according to its grain size is also possible.
FIELD OF APPLICATION
- Sorting of light packaging material and classification of polymer fractions.
- Screening and Seperation of contraries in plants used for the treatment of substitute fuel.
- Material Stream Seperation as a first step of Seperation within the mechanical Biologiacal treatment of residual waste.
- Post classification of the Biologically treated fraction before dump garbage.
The basic principle is based upon rotating paddles being situated parallel to each other. The complete ballistic separator is constructed with the possibility of angle adjustment. Depending on the case of application, the paddle surfaces are closed or designed with given perforations and structure of carriers. Due to the adjustment of the angle of inclination and the sturcture of carriers the separator is adaptable to the input material.
The application possibilities of the separator for heavy materials are very versatile and a quick integration into different huge and small plant configurations is possible. Due to the varying and simple adjustment possibilities the separator for heavy materials is adaptable to the input material.
The Sutco disc screen provides another technology for presorting cardboard (cartons) and paper. The use of the disc screen allows sorting processes by up to less than 60% of personnel - an economic aspect which pays. Another great advantage is the fact that large pieces of material are eliminated and the personnel is thus relieved. Also, the Sutco disc screen disentangles the remaining material and thus leads to an increase in the sorting quality.
- Section steel construction of welded design
- Axles with slip-on discs / spacers
- Drive supported by induction-hardened chain wheels
- Triangular disc for disc screen fine plastic
- Elliptical disc screen for coarse plastic
- Hexagonal plate for industrial waste and wood from Hardox 500
Material to be conveyed: Cardboard, paper
(industrial waste and wood)
Screen width and length: Design according to the required throughput
Motor power: 7.5 kW for the coarse disc screen per cascade,
5.5 kW per cascade for the fine disc screen per cascade
The Sutco apron conveyors are designed for feeding and transporting large and heavy materials. The robust design allows heavy materials such as stones, mixed construction waste, bulky waste, industrial waste etc. to be charged. Apron widths of up to 3000 mm and throughputs of up to 500 t/h (depending on the material) are possible.
- transport of household waste
- bulky waste
- steel scrap
- industrial waste
- mixed construction debris
The base frame consists of a folded and screwed modular steel sheet structure. Accessories such as pull cord switches, standstill detectors, dust covers, suction hoods and subbelt covers can be attached. A system perforation in the steel sheets allows a subsequent installation of these parts. In addition, numerous inspection openings are provided for maintenance and repair.
This unit has especially been developed for an air-supported separation of tabular-light and heavy materials and is used for EBS (substitute fuel) production - and for DSD (Duales System Deutschland) sorting of household waste as well. Throughputs of up to 20 t/h are possible. The 5 main adjustment positions ensure an exactly defined separation. Since the air moves within a closed circuit, only a small filter surface is required for cleaning the excess air volume.
- Separator for heavy parts
- automatic Seperation of light and and heavy recyclable material
- protection od downstream units (e.g. crushers) by Separating bulk material
The material to be classified is conveyed to the separation chamber by an acceleration belt whose speed can be adjusted. An air flow whose volume and direction can be adjusted flows through the discharge parabola immediately after leaving the belt conveyor, transporting large-surface particles with a low weight to the rear area of the classifier where they settle on the light-material collection belt and are conveyed out of the classifier together with it.
Heavy and massive parts fall onto the heavy-material collection belt in the front area of the classifier. The separating cut between heavy and light material can be adjusted according to the requirements by the separating vertices which can be adjusted by a motor. The required air flow is generated by a radial fan. To keep the air flow to be dedusted as low as possible, the air blown into the rear part of the separation chamber is sucked again by a radial fan, i.e. operated in a circulation air mode. A part of the sucked air is delivered to a dedusting unit so that the separati- on chamber is kept under vacuum and an escape of dust is largely prevented.