Turn key installations for plastics recycling

Third Generation Washing and Regeneration Plant

Video shows a recently installed regeneration plant for LDPE / HDPE

General description of process

The process is designed according to the following criteria:

Optimal quality of the intermediate product (densified material) in order to assure a first class regranulate
Maximum productivity and minimum energy consumption
Automation where ever possible or useful
Budget: depending on capacity 10,000 t/year to 15,000 t/year about 1.7 - 2.0 Millions Euro ex works Italy

The designation of components follows the layout*)

* ) For viewing of the layout and planning samples the Plug-in WHIP!-Plug-in is needed. You can download the program free-of-charge from Autodesk under http://www.autodesk.com/whip. After the downloading WINDOWS must be restarted.

The Loading Conveyor (1) of the Guillotine has sufficient storage capacity to allow for the simultaneous loading of different bales (e.g. film with a content of Stretch or bales of different quality). Thus already in this phase a good mix of materials can be obtained. Die Guillotine (2) pre-cuts the material and thus augments the capacity of the shredder. Following a Fe-separator and a visual control concerning major stones can be provided, to protect the blades of the shredder. Optionally for Agro-film a Prewashing / Sievetrommel (4) can be provided. The Shredder (6) [Client's supply] with a grid of about 50 mm shreds the material to the required size for the washing plant.

After the shredder the material is conveyed by means of a scraper conveyor (8) to the Turbowash (9). The Turbowash (9) is a horizontal centrifuge with a closed drum. The material is washed an rinced with a high quantity of water. Paper, dirt and adhesions are removed and exit with the water. The machine has a proper water circuit. The photo shows the rotor of the Turbowash with the removable wear plates. The rincing water exits thru the sieve.

From the discharge of the Turbowash the material passes through a drained auger to the loading system of the Swim-Float-Tank (13). The material is, by means of submerged augers, pressed beneath the surface of the water, which avoids the effect of the surface tension that might cause some heavy material to float and thus reducing the decanting effect. By means of this system a considerable improvement of the separation effect was obtained.
Horizontal drums with vanes, together with the water current, convey the material along the water surface. The sinking fraction PS, PET, PVC goes to the bottom and is removed by 2 bottom scraper conveyors. PE und PP pass at the end of the tank over an edge and enter into a auger (12) which discharges the material to the loading auger of the centrifuges.
The Swim-Float-Tank (13) is of stainless steel, as are also all other components in contact with the water. The rotation of the drums can be adjusted individually the regulate the capacity of the tank.

The photo shows the discharge system type "swan neck" for the sinking fraction. It consists of 2 bottom scraper conveyors. The conveyors come in no contact with the water surface, thus avoiding that any floating material is removed unintentionally. Again the recovery rate for Polyolefines is improved by this means.
After the discharge from the tank the floating fraction is moved by means of a drained auger (15)to the 2 Dynamic Centrifuges (16), where it is dried to a residual humidity of ca. 3 - 5% for the densifying process. The material passes thru a decompression cyclone (17) to the Storage Silo (19) of the Densifier (21). The Densifier (21) increases, due to thermal and friction action, the density of the material to about 0,45, thus making it perfectly suitable for the subsequent production of finished products such as regranulate or tubes or other.

The Extruder is fed from the Densifier. It processes the material to high-quality granulate. The material is stored in Mixer Silos for sale. The granulate can be sold directly or worked to valuable final products.

Video shows a typical Agrofilm plant in operation

OCI GmbH

Baarerstrasse 95

CH 6301 Zug, Switzerland

Tel +41 81 3531685 / Fax +41 81 3535109

navarini@navarini.com

Distributor for:

Officine Meccaniche Costarelli s.r.l., Perugia (I)

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The Loading Conveyor (1) of the Guillotine has sufficient storage capacity to allow for the simultaneous loading of different bales (e.g. film with a content of Stretch or bales of different quality). Thus already in this phase a good mix of materials can be obtained.	Die Guillotine (2) pre-cuts the material and thus augments the capacity of the shredder. Following a Fe-separator and a visual control concerning major stones can be provided, to protect the blades of the shredder. Optionally for Agro-film a Prewashing / Sievetrommel (4) can be provided.	The Shredder (6) [Client's supply] with a grid of about 50 mm shreds the material to the required size for the washing plant.


The photo shows the discharge system type "swan neck" for the sinking fraction. It consists of 2 bottom scraper conveyors. The conveyors come in no contact with the water surface, thus avoiding that any floating material is removed unintentionally. Again the recovery rate for Polyolefines is improved by this means.	After the discharge from the tank the floating fraction is moved by means of a drained auger (15)to the 2 Dynamic Centrifuges (16), where it is dried to a residual humidity of ca. 3 - 5% for the densifying process. The material passes thru a decompression cyclone (17) to the Storage Silo (19) of the Densifier (21).	The Densifier (21) increases, due to thermal and friction action, the density of the material to about 0,45, thus making it perfectly suitable for the subsequent production of finished products such as regranulate or tubes or other.


The Extruder is fed from the Densifier. It processes the material to high-quality granulate.	The material is stored in Mixer Silos for sale.	The granulate can be sold directly or worked to valuable final products.