Compact System For Secondary Fuels
% Maximum flexibility
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 non-
standard 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.
concerning fuels to be used
% Limited space requirements
% Reliable conveyor
equipment
% Low energy consumption
% Simple safety technology
% Low operating costs
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 Docking station with screw-
discharge system conveyed live bottom bin

Weighfeeder

M Conveyor
M line

M
Troughed belt conveyor

Rotary piston blower

Blow-through rotary feeder

Module Description
Delivery Site

Function

The secondary fuels are supplied on semitrailers in the Technical Data

form of loose products. Any vehicle type conforming to the
local Road Traffic Regulations may be used. % Bottom plate:
- Asphalt or concrete
The delivery surface is to be designed for a minimum of
two vehicles so that the system can be operated in % Dimensions:
alternating or parallel mode. - Length: 13,500 mm
- Width: 5,000 mm
The semitrailer backs into the docking station. The trailers - Ground slope: < 2%
are properly positioned with the aid of guide tubes and tyre
limit stops. % Hydraulic unit (for walking floor):
- Twin-unit equipped with oil sump
Fitting close with the semitrailer's outline, the lateral rubber - Hydraulic pipes with double jacket
aprons of the docking station accomodate different vehicle
widths and heights. This helps to keep the delivery site % Dimensions:
clean. After opening the rear doors inside the docking - Length: 1,750 mm
station, unloading can take place. - Width: 1,150 mm
- Height: 850 mm
The tractor is now no longer required. The ready
semitrailers assume the function of a silo. % Power consumption: 2 x 7.5 kW

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.
 Delivery Site With Docking Stations

Docking Station

Function Technical Data

For reception of the secondary fuels, normally two % Steel plate construction mounted on IPE supports
parallel docking stations are available ensuring with ground clearance
continuous fuel supply. % Four feed screws per station
% Rubber apron sealed vehicle reception
The individual cabins are fitted with a sealing system % Prime coat approx. 12 µm
designed to adjust to the semitrailer's degree of
unloading. This helps to keep the environment clean. % Dimensions (per station):
The docking stations are equipped with a photocell - Length: approx. 4,000 mm
hopper level control system cycling the upstream - Width: approx. 2,240 mm
walking floor live bottom. - Height: approx. 4,400 mm

The feed screws mounted in stations transport the % Weight (per station): approx. 2,500 kg
secondary fuel discharged from the semitrailer to the
adjacent troughed belt conveyor. % Power consumption (per station): 2.2 kW

Depending on the selected feed rate, the four feed Options:

screws are controlled in pairs for alternating operation,
so good fuel prefeeding and uniform discharge of the
docking station are ensured.
% 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

The docking station screws feed the secondary fuel into % Steel construction supported on floor beams
the lateral inlet holes of the troughed belt conveyor.
% Transport via individually tensioned roller chains
Driven by revolving chains on both sides, drag plates
pull the feed material over the rising conveying trough % Totally enclosed to prevent dust escape
to the weighfeeder's inlet shaft.
% Prime coat: approx. 12 µm
The conveyor chains are driven jointly via a sprocket % Feed rate: max. 60 m³/hr
shaft arranged in the upper belt strand. Two chain % Conveying speed: 0.5 m/sec
tensioners mounted in the lower belt strand ensure safe % Height of lift: approx. 2,000 mm
chain running.
% Dimensions
- Length: approx. 4,500 mm
- Width: approx. 1,000 mm
- Height: approx. 2,500 mm

% Weight: approx. 800 kg

% Power consumption: approx. 3.0 kW

Options

% Special constructions in other RAL shades

 Weighfeeder, MULTIDOS type

Weighfeeder, MULTIDOS type

Function Technical Data

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

Blow-through Rotary Feeder

Function Technical Data

Mounted flush with floor level below the weighfeeder's % Steel plate construction supported on IPE supports
discharge chute, the rotary feeder accommodates the with ground clearance
material discharged from the weighfeeder in its % Stuffing box shaft seals
chambers. % Rubber or metal chamber seals (exchangeable)
% Chain drive
The fuel stored in every rotary chamber is discharged % Prime coat approx. 12 µm
by force and blown through the conveyor line to the
burner. % Filling funnel: 800 x 230 mm
% No. of chambers: 6 – 12 chambers
Every rotary feeder is tailored to the specific project. % Rotary feeder rate: max. 100 m³/hr
The chambers surface cross-sections are tuned to the % Rotor speed: 14 rpm
associated blower rate. This type of sizing reduces the % Blow-through line connector: DN 70 –200 mm
escape of air across the feeder inlet.
% Dimensions (as a function of feed rate)
Depending on the composition of the secondary fuel, a - Length: approx. 1,500 mm
rubber- or metal-sealed variant can be installed. The - Width: approx. 1,500 mm
seals can be inspected through the inspection flap on - Height: approx. 1,050 mm
the weighfeeder discharge and serviced, if necessary.
% Power consumption: approx. 5.5 kW
Rotary Piston Blower

Function Technical Data

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.
% 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: approx. 1,500 mm

- Width: approx. 1,300 mm
- Height: approx. 1,600 mm

% Electrical consumption: approx. 22 kW as a

function of type

Pneumatic Conveyor Line

Function Technical Data

The conveyor line transports the fuel blown out of the % Sections
rotary feeder chambers directly to the burner. - Steel pipe St 35, seamless to DIN 2448
- DN 70 – 200
Air quantity, run length and pipe diameter are selected - Prime coat approx. 12 µm
in accordance with the particular project so optimal
material transport without line deposits is obtained at % Bends
minimal abrasion of the pipe inner wall. - 90° radius
- Steel pipe St 35, seamless to DIN 2448
The line must be arranged horizontally and/or - DN 70 – 200
vertically. Pipe bends have to be reduced to the - Prime coat approx. 12 µm
absolute minimum. Pipe lengths below 100 m enable
the highest economic efficiency of the system. % Pipe joints
- Flanges to DIN 2631
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
Electrical Control

Function Technical Data

Designed in accordance with the German VDMA/VDI
regulations, the electrical control system is installed in a
control cubicle. All switching gears required for open-
and closed-loop control and fusing of the units installed
are included. The lead to the control cubicle is mounted
in the factory.
% 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

The setpoint (feed rate in t/hr) is entered on the central % Control cubicle dimensions:
control panel. All other units are controlled or switched - Length: approx. 1,200 mm
as a function of the set feed rate. Upon start of the - Width: approx. 500 mm

BV-D2145GB XBS 05.0901. We reserve the right to discontinue or change specifications or designs at any time without notice or obligation.
system, a sound signal is produced before the blower - Height: approx. 2,000 mm
or rotary feeder starts operating.
% Weight: approx. 500 kg
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 % Customized design
instrumentation section for commissioning, evaluation % Coupling to host system
and monitoring. % Additional queries and evaluations
% Top coat in other RAL shades
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.

Measuring and Process Systems

SCHENCK PROCESS GmbH A cooperation between
D-64273 Darmstadt SCHENCK PROCESS GmbH
Phone: +49 (0) 61 51-32 10 28
and Energieberatung Hess GmbH
Fax: +49 (0) 61 51-32 11 72
E-Mail: sales2.process@schenck.net
www.schenck-process.net