Posts Tagged Mixing

Okt 13 2017

BHS-Sonthofen: Mixers from Bavaria on the roof of the world

Mixing hydro dram concrete: Twin-shaft batch mixers deployed 3,700 m above sea level

BHS-Sonthofen: Mixers from Bavaria on the roof of the world

The six BHS-Sonthofen mixers are located in the building holding the batcher that feeds aggregates

Six twin-shaft batch mixers of type DKX 6.0 delivered by BHS-Sonthofen are producing the concrete needed to build the main embankment of the Dagu hydro dam undergoing construction near the Tibetan city of Zangmu. The construction site is located 3,700 m above sea level, making this the most elevated site ever for employing mixers from BHS. BHS-Sonthofen specially modified the mixers to meet the challenges they are facing at this extreme altitude.

The first two mixers of type DKX 6.0 started producing the first batches of concrete on 12 July 2017. Two months later, Sinohydro No. 9 Engineering Company commissioned four more units. The mixers will produce approximately three million tons of roller compacted concrete (RCC) over the course of the dam“s construction, which is scheduled for completion in 2019. The complete facility, which comprises six mixers, is dimensioned to produce 160,000 m³ of hardened concrete per month.

The mixers are equipped with a coarse-grain mixing unit for processing grain sizes up to 160 mm, as is typical in hydro dam construction. This mixer type has proven its worth in numerous installations across the globe.

About 6 m³ of hardened concrete are discharged per batch at a rate of up to 48 cycles per hour, resulting in a total yield of up to 288 m³ of hardened concrete in one hour. The cycle times are short due to the intensive mixing of the concrete and the extra-large rotary valves at the underside of the mixing trough, which significantly speed up the discharge process.

Given the vast amount of concrete that needs to be processed, BHS-Sonthofen reinforced the mixing troughs with a tougher version of its 28-mm „Optilong“ wear tiles. The service life of these tiles is nearly twice as long as the diamond-shaped tiles commonly used in construction projects. The variable hardness of the individual tile rows ensures uniform abrasion across all wear zones.

BHS-Sonthofen even accounted for the remote location of the construction site: In order to prepare the machines for a potentially unstable grid, the company used special motor couplings. The hydrodynamic turbo couplings reduce mechanical as well as electrical load peaks. Thanks to this property, they have proven ideal for use in locations with critical grid fluctuations.

Also, since high-altitude air does not extract as much heat from the electric motors, BHS-Sonthofen equipped the mixers with special motors that feature type „H“ insulation.

The sheer remoteness of the construction site posed yet another challenge. The construction site in Tibet is nearly 4,000 km from Tianjin near Beijing, which is where BHS-Sonthofen“s Chinese subsidiary is situated. It took 20 days to transport the mixers across this distance.

The project:

Once completed, the Dagu dam will be 126 m tall with a dam crest measuring 385 m. The power plant will generate 640 MW of hydro energy.

The dam is part of a major project undertaken by the Chinese government to provide the eastern parts of the Tibetan Autonomous Region with electricity, all the way to remote villages. Multiple hydro dams are damming up the Yarlung Tsangpo, the Earth“s highest river. It crosses Tibet from west to east and continues through India, where it is called Brahmaputra.

About BHS-Sonthofen GmbH

BHS-Sonthofen GmbH is an owner-operated group of companies in the field of machinery and plant engineering based in Sonthofen, Germany. The company offers technical solutions for mechanical process technology, concentrating primarily on mixing, crushing, recycling and filtration. BHS-Sonthofen has a global presence, with more than 350 employees and several subsidiaries.

The Mixing Technology division produces batch and continuous mixers and offers the full range of process technology services for mixing applications. The twin-shaft batch mixer, which is considered a global benchmark in the concrete industry, is a key product.

Building companies use the mixers first and foremost to produce transport, precast, high-performance and hydro dam concrete or concrete paving blocks. BHS mixers are also highly suited for mixing dry mortar, cement and sand-lime products or for processing clay-and-rock mixtures.

They are widely used for processing mineral mixes, landfill substances, fly ash, dusts or other bulk materials, or for the conditioning of sludges and the production of suspensions. The latter is often done in the context of backfilling mines or depositing mineral waste.

For further information, please visit: www.bhs-sonthofen.de

Company-Contact
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
Phone: +49 8321 6099-231
E-Mail: press@bhs-sonthofen.de
Url: http://www.bhs-sonthofen.de

Press
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
Phone: +49.241.89468-24
Fax: +49.241.89468-44
E-Mail: reinhardt@vip-kommunikation.de
Url: http://www.vip-kommunikation.de

Jan 27 2017

BHS-Sonthofen Appoints New Mixing Division Sales Manager for U.S. Site

Mixing technology for concrete

BHS-Sonthofen Appoints New Mixing Division Sales Manager for U.S. Site

Mike Kerins, the new Mixing Division Sales Manager at BHS-Sonthofen Inc. in Charlotte, North Carolin

Mike Kerins is the new Mixing Division Sales Manager at the American subsidiary BHS-Sonthofen Inc. based in Charlotte, North Carolina. BHS-Sonthofen has appointed him to further strengthen the sales team, which has quadrupled the number of mixers installed in North America since 2011. Moreover, BHS is now offering its customers the option to carry out material and field tests at their own facilities by providing laboratory mixers on a rental basis from the Charlotte location.

BHS-Sonthofen has appointed Mike Kerins to further capitalize on the continually increasing acceptance of BHS mixers in North America. Kerins has over 10 years of experience in the concrete industry through his time with CEMEX and Pavestone and certifications from the American Concrete Institute (ACI), the National Ready Mixed Concrete Association (NRMCA), the North Carolina Department of Transportation (NCDOT), and the South Carolina Department of Transportation (SCDOT). Kerins has managed the design, start-up, operation and quality control of plants throughout the US. He graduated magna cum laude with a B. Sc from Clarion University of Pennsylvania.

Kerins will provide customers with expert technical consulting on all topics concerning BHS mixing technology. He will also draw upon his expertise to oversee tests with laboratory mixers that customers can rent from BHS to run trials at their own facilities.

At BHS-Sonthofen Inc., Kerins will support project management in ensuring even shorter delivery times for mixers and spare parts in the United States.

Dennis Kemmann, the Managing Director of BHS-Sonthofen GmbH, has the following to say of Kerins: „Mike is a recognized specialist who knows his way around concrete plants and construction sites. He has familiarized himself with all different kinds of mixers over the course of his career. We are happy that he has chosen to come on board with BHS-Sonthofen and bring his wealth of expertise to the table.“

Ever since BHS-Sonthofen Inc. established the Mixing Division in 2011, the company has successfully established the German mixers on the American market. For instance, twin-shaft batch mixers make up the lion“s share of the 220,000 m³ of in-situ concrete required to construct the New NY Tappan Zee Bridge. They are also producing tens of thousands of cubic meters of concrete for the bridge“s precast structural elements, some of which weigh over 300 tons. BHS-Sonthofen single- and twin-shaft batch mixers are also becoming increasingly popular for use in dam stabilization projects and for conditioning backfill material in mining applications.

Mike Kerins“ contact information:
-Tel.: (+1-704) 845-1190
-E-mail:michael.kerins@bhs-sonthofen.com

About BHS-Sonthofen Inc. (USA)
BHS-Sonthofen Inc., based in Charlotte, North Carolina, was founded in 1998 as the first BHS-Sonthofen subsidiary in order to address the growing demand for BHS filtration technology in North America and provide local customers with in-depth support. Since 2011, BHS-Sonthofen Inc. has also been responsible for selling mixing technology in North America and started selling recycling technology in the region in 2015.

The Mixing Division established in 2011 supplies single- and twin-shaft batch mixers for continuous and batch operation. The sales team consults North American clients on selecting and dimensioning plants, guaranteeing quick service all the while. Alongside an extensive warehouse for spare and wear parts, the Charlotte site is also home to laboratory mixers available on a rental basis to companies interested in carrying out their own material and test mixing.

BHS-Sonthofen Inc. is also a certified member of the Concrete Plant Manufacturers Bureau“s (CPMB) Mixer Manufacturers division.

About BHS-Sonthofen
BHS-Sonthofen GmbH is an owner-operated group of companies in the field of machinery and plant engineering based in Sonthofen, Germany. The company offers technical solutions for mechanical process technology, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers and offers a full range of process technology for mixing applications. The twin-shaft batch mixer, which is considered a global benchmark in the concrete industry, is a key product.

For further information, please visit: www.bhs-sonthofen.de

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Jun 16 2016

BHS-Sonthofen supplies the largest indexing belt filter in the company“s history

Extraction of reusable substances from plant waste: New plant makes several process stages superfluous.

BHS-Sonthofen supplies the largest indexing belt filter in the company"s history

The BHS indexing belt filter during final assembly at the beginning of 2016 at the Sonthofen plant.

BHS-Sonthofen has received the order from an American customer to supply an indexing belt filter for extracting reusable substances from plant waste. With a filter area of almost 90 m², the type BF 350-255 filter plant is not only the largest plant that BHS has ever built, but it is also one of the most efficient of its kind in the world.

The indexing belt filter of type BF 350-255 will process up to 5,000 kg of fibrous plant waste hourly, extracting recoverable liquid components generated in a previous production process. The filtrate is used for the manufacture of basic chemicals, while the remaining solids, which could not previously be used, are reprocessed.

During project planning, the customer had initially envisaged a multi-stage process with a sequence of consecutive screening and filtration steps and with the solids being resuspended several times. The proposal from BHS-Sonthofen to use an indexing belt filter of type BF with a single process step convinced the customer, however. Not only is the process much simpler, but it also concentrates the reusable substances to a greater extent. This means that less energy is required for extracting the substances at a later stage in the process.

As part of the treatment process, the plant waste is first suspended in water. To ensure that the reusable substances dissolved in this can be extracted as effectively from the solid as possible, BHS implements a multistage counter-current wash process in the filter plant. This allows the filter to achieve a very good washout quality, thereby significantly increasing the concentration of the dissolved reusable product in the liquid. The BHS indexing belt filter of type BF 350-255 extracts approximately 10 percent more recoverable materials than conventional procedures.

Moreover, the operating costs are lower because the indexing belt filter requires about 30 percent less water than the multistage process. This also results in considerably lower investment costs as no multiple cascades of stirring tanks and filters are required. As the entire filter plant is much simpler in design than conventional plants, it ensures a high operational reliability. At the same time, maintenance costs are significantly lower in comparison to conventional plants.

After receiving the order in December 2015, BHS supplied the filter plant in spring 2016. Commissioning is planned for autumn 2016.

Background: The BHS indexing belt filter of type BF

The indexing belt filter is a continuously operating, horizontal vacuum filter that allows for reliable and gentle separation of sedimentation solids from suspensions. The filter medium is a circulating belt, which moves forward in cycles.

Each time the cloth stops, the filtrate is sucked downwards. Then the vacuum is switched off to release the filter cloth, which can now be moved forward. The filter cake forms on top of the belt and can undergo further treatment by washing (co-current or counter-current), reslurrying, steaming, extraction, vacuum drying or pressing. During this process, the filtrates can be recovered individually from each vacuum tray and further processed without any cross-contamination. The filter cake is discharged at the discharge roller. The cloth is cleaned as the belt returns.

The design of the BHS indexing belt filter allows continuous, even feeding of the suspension via distribution devices, which also spread the solids gently. The filter cake formed by gravity and vacuum is not subject to any mechanical forces during transportation or further treatment. This makes the indexing belt filter suitable for pressure-sensitive solids as these can be processed without grain particle breakage.

About BHS-Sonthofen GmbH

BHS-Sonthofen GmbH is an owner-operated group of companies in the field of mechanical and plant engineering, based in Sonthofen (Germany). The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling, and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Filtration Technology division manufactures machines and plants for mechanical solid/liquid separation using pressure or vacuum filtration. Key applications are processes in the chemical and pharmaceutical industry, the plastics industry, as well as for energy and raw material extraction.

For further information, please visit: www.bhs-sonthofen.de

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Mrz 18 2016

bauma premiere: Mixing high-abrasive material with minimum abrasion

Mixer for the sand-lime brick industry: New twin-shaft batch mixer with rubber provides low-cost mixing.

bauma premiere: Mixing high-abrasive material with minimum abrasion

The first twin-shaft batch mixer in the new DKXK variant for producing sand-lime bricks.

At bauma 2016, BHS-Sonthofen is introducing a new generation of twin-shaft batch mixers of type DKXK that features a rubber trough specially designed for producing sand-lime bricks. This new type of batch mixer features particularly low wear to the trough – an important factor when processing abrasive mixtures such as sand-lime bricks.

The new DKXK version that BHS has developed for the proven twin-shaft batch mixer is optimally adapted for producing sand-lime bricks. This new innovation allows this industry to take advantage of BHS-Sonthofen twin-shaft mixing technology. The results are homogeneous mixing, short mixing times and low wear. The intensive mixing process also utilizes a high percentage of the lime used in each mixture, which in turn produces a very dense packing mixture.

The first mixer in this new generation – which has a 2,300-liter capacity – will start operations in February 2016 in Baden-Baden (Germany) as the main mixer upstream of the reactor. Since 1971, the client has been operating a BHS-manufactured twin-shaft batch mixer of similar design that they are now replacing with a more powerful state-of-the-art unit.

Sand-lime bricks are made of sand mixtures containing a high silicate, quicklime and water content. This material is highly abrasive. Considerable wear occurs in previously used conventional mixing systems such as intensive mixers. The reason so much wear occurs is because the fine sand acts like sandpaper on the mixing tools and on the mixer’s trough wall.

BHS has therefore specifically developed the DKXK type of mixer for producing lime mixtures as an alternative version to the world’s proven DKX type of twin-shaft batch mixer. Instead of a steel trough with a lining made of wear tiles, BHS builds their sand-lime brick mixer with a rubber mixing trough that pulsates when mixing, thus effectively preventing sticky mixing material from caking. This reduces blade and trough lining wear as well as reduces the engine’s power consumption.

This solution has long proved itself as one of BHS’s very reliable single-shaft continuous mixers. DKXK can optionally equip the mixing blades with Widia (tungsten-carbide) plates, which significantly increases service life.

The new DKXK mixer variant offers several advantages when compared with the intensive mixers that have been used in the sand-lime brick industry until now: In contrast to the circular motion of other mixing systems, the three-dimensional mixing principle of the twin-shaft batch mixer produces a more intensive exchange of material. This results in shorter mixing cycles with the effect of a lower energy consumption. In addition, the mixer requires less maintenance because wear parts are easy to replace.

This is another reason why the twin-shaft batch mixer by BHS-Sonthofen is an economical alternative for producing sand-lime brick mixtures.

In the future, BHS-Sonthofen will offer the DKXK twin-shaft batch mixer for the sand-lime brick industry with a filling volume ranging from 1,000 to 6,500 liters.

Background: Twin-shaft batch mixers of the DKX series

The twin-shaft batch mixers from BHS-Sonthofen have a mixing mechanism whose arms, which are in the form of an interrupted spiral, are arranged on two counter-rotating mixing shafts. They generate a circular, three-dimensional movement with intense material exchange in the turbulent overlap area of the two mixing circuits. Counter paddles on the shaft ends redirect the entire material, so that it is repeatedly returned to the mixing process.

They achieve a higher mixing effect than comparable single-shaft or intensive mixers as all the material is constantly in movement even at low speeds – and at significantly lower energy consumption.
In contrast to other mixer systems, twin-shaft batch mixers can be filled to a much higher level, so that they are more compact with the same throughput. Thus in new-build plants the mixers score points with their small dimensions. Moreover in case of retrofit and plant modifications in existing installations a more powerful mixer can be installed.

About BHS-Sonthofen

BHS-Sonthofen is an owner-operated group of companies in the machinery and plant engineering field, based in Sonthofen, Germany. The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers with single and twin-shaft technology and offers a full range of process technology for mixing. The spectrum extends from conventional applications in the concrete industry for transport, precast, dam or high-performance concrete and the mixing of dry mortar, cement, mineral mixes, landfill construction materials or other bulk materials to the conditioning of sludges, the production of suspensions or applications in mining.

For more information, see www.bhs-sonthofen.de.

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Mrz 7 2016

BHS-Sonthofen: Creating value from overburden

Economical alternative to wet processing of clay-and-rock mixtures

BHS-Sonthofen: Creating value from overburden

The Combimix system of type DKXC in a CEMEX France treatment plant

The dry Combimix process developed by BHS-Sonthofen removes clay adhesions from screen waste produced in quarries and gravel pits. Operators report that they are able to convert more than 90% of contaminated feed material into salable rock grade using the Combimix system.
At the same time, the dry process significantly reduces water, energy and material costs.

Many quarries contain large quantities of material contaminated with clay that has not been possible to be processed economically up to now. Frequently, the material has to be dumped at considerable expense as mining overburden.

However, wet treatment is one method that allows this material to be used. Washing and subsequent water treatment as well as sludge disposal is extremely costly. The process often fails because many quarries lack access to the volumes of water required. Dry processing in conventional continuous mixers using quick lime is also been problematic because the retention times of the material in the mixer are so short that the clay cannot blend adequately with the lime.

The solution: Variable retention time

The patented BHS Combimix system developed by BHS-Sonthofen offers an economical alternative and its practical suitability has already been proven in several quarries. The basic principle has been known for years but it has not been possible to implement the system due to various limitations in mixing technology: Mixing clay with quick lime changes the properties of the clay, which can then be reliably separated from the rock.

For the first time, twin-shaft continuous mixers of type DKXC allow regulation of the retention time of the material in the mixer within broad limits. The clay has enough time to mix intensively with the lime and detach from the rock. The intensive movement of material during the mixing process also assists the cleaning process.

After screening, the feed material is so clean that it is no longer classed as waste and can be sold. Grains greater than 5 mm in diameter that are largely free of clay can now be further processed in the gravel quarry. Grains less than 5 mm in diameter form a lime/clay mixture that can be sold to the agriculture industry, for example.

Combination of batch and continuous mixers

The Combimix process is based on the combination of twin-shaft batch and continuous mixers manufactured by BHS-Sonthofen. Unlike traditional continuous mixers, the retention time of the mixture in the Combimix system can be regulated within broad limits – from less than 30 to more than 100 seconds.

BHS regulates the retention time via a gate on the underside of the mixing trough. The company is the only manufacturer that offers a trough with this design. Extracted material is replaced with an equivalent volume of feed material. Continuous measurements are taken during this process to monitor the weight of the mixer. The quick lime is metered by a screw conveyor inside the mixer according to the clay content in the feed material in a range of less than one or a maximum of five percent of the feed quantity.

Together with the long retention time, the established three-dimensional mixing principle of the BHS-Sonthofen twin-shaft mixer makes an important contribution to achieving good results: The lime is mixed intensively with the clay so that the treated clay reliably separates from the rock. Costs for supplying water, reslurrying, filtering and disposing of the slurry are no longer incurred because the material is treated dry.

BHS-Sonthofen manufactures different versions of mixer for throughputs between 85 and 1000 t/h. The grain size of the feed material can range up to 150 mm, depending on the mixer size.

Practical experience

BHS has installed the Combimix system in several quarries. One facility has been operating extremely successfully for several years in a quarry owned by the company Cemex based in France. Before the system was installed, more than 100,000 t of rock/clay mixture from the quarry had to be dumped every year. More than 90% of contaminated feed material is now sold as rock grade thanks to the Combimix system.

Jean-Serge Peret, plant manager at the Chateaubourg quarry owned by Cemex, is extremely pleased about the significant reduction in costs: „Before the mixer was installed, we had to break down 400,000 t of rock each year to obtain 300,000 t of salable material. The new procedure means we only require 330,000 t to achieve the same delivery quantity.“

Info: The benefits at a glance:

Compared with wet treatment:
-Processing of the entire material
-No introduction of moisture in the aggregates
-No wet screening, no sludge treatment
-No water consumption

Compared to conventional continuous mixers:
-Processing of the entire material
-Long retention time in the mixer
-Minimal consumption of quick lime
-High throughput
-Minimal wear

About BHS-Sonthofen

BHS-Sonthofen is an owner-operated group of companies in the machinery and plant engineering field, based in Sonthofen, Germany. The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers and offers a full range of process technology for mixing. The twin-shaft batch mixer, which is considered a global benchmark in the concrete industry, is an important product.

For more information, see www.bhs-sonthofen.de.

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Mrz 1 2016

IFAT premiere: New ball shaper for fine fractions containing metal reclaims more recyclable materials

Reclamation of recyclable materials from e-scrap, shredder residues and slag

IFAT premiere: New ball shaper for fine fractions containing metal reclaims more recyclable materials

BHS rotor impact mills of type RPMV/RPMX are high-performance crushers

At IFAT 2016, BHS-Sonthofen unveiled the new rotor impact mill of type RPMX for separating composite parts and shaping metals from recycling products such e-scrap, shredder residues (ASR) and slag into balls. The new RPMX is a further development of the established rotor impact mill of type RPMV and generates finer fractions from which recyclable materials can be reclaimed more effectively. It enables the efficient reclamation of materials such as stainless steel and cable strands, which were previously considered problematic.

The rotor impact mill of type RPMV is an established recycling machine used for separating composites, crushing brittle components and shaping ductile components into balls in a wide variety of applications. The new rotor impact mill of type RPMX from BHS-Sonthofen is a valuable addition to the existing range of systems for recycling residual materials.

The gap between the grinding tools and the anvil ring on the new machines is much smaller: The gap width is only 5 mm. In combination with higher circumferential speeds, they generate finer fractions and intensify the ball-shaping effect, whereby a much higher proportion of materials is reclaimed than before.

One application example is the disaggregation and shaping of wires and strands into balls. Previously, conventional sorting systems were not able to separate these wires and strands because long thin parts evaded the separation process in air separator tables or non-ferrous separators. The RPMX compacts and shapes individual parts into balls so that they can then be separated cleanly. The machine is also suitable for handling pure cable fractions.

The „Zurik“ fraction of mixed shredder residues containing between 30 and 85% metal (predominantly stainless steel but also copper and aluminum) can now be efficiently separated into individual components after being processed in the RSMX.

The technology in detail

The input material is fed into the machine from above by means of the central input tube. When it hits the cover plate of the rotor, it is accelerated outwards by the centrifugal forces and falls into the grinding gap between the horseshoe-shaped impact hammers and the anvil ring. Here, it is struck by the impellers and thrown against the outer wall. The material passes from top to bottom all the way through the gap between the impact hammers and the stationary ribs on the anvil ring. During this process, it is highly stressed by impact, shock and shearing forces that cause the composite parts to separate. The brittle components are crushed while multiple stresses shape the ductile components into balls. The material leaves the rotor through the gap between the rotor and the anvil ring and falls downwards through the two discharge chutes.

The new rotor impact mill from BHS-Sonthofen is available in two versions: the RPMX 1116 with a diameter of 1.10 m, eight impact hammers and a maximum drive power of 200 kW, and the larger RPMX 1516 with a diameter of 1.50 m, twelve impact hammers and a maximum drive power of 315 kW.

Pre-shredding

Object fractions between 300 and 500 mm in size are pre-shredded by an BHS Rotorshredder of type RS, which generates fractions smaller than 30 mm suitable for the rotor impact mill. Before the material can be further processed in the RPMX, an air sifter removes any potentially harmful components.

Background: BHS rotor impact mills

Also known as „ball shapers“ in the industry, the BHS rotor impact mills from the RPMV series are high-performance crushers with a vertical shaft for applications in the recycling industry. The ring-shaped rotor is fitted with horseshoe-shaped hammers. In combination with the toothed anvil ring, this unique impeller rotor is able to selectively crush composite parts.

Materials that have different physical properties are separated from one another in the machine and entangled materials are singled out. At the same time, the machine shapes the ductile metals into balls and cleans them. In the subsequent process steps, they are much easier to separate than elongated metal parts, which can become entangled and matted.

About BHS-Sonthofen

BHS-Sonthofen is an owner-operated group of companies in the machinery and plant engineering field, based in Sonthofen, Germany. The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS-Sonthofen has a global presence.

The Recycling Technology division offers a wide range of machines and systems for the recycling industry. The product spectrum covers the processing of brittle-hard waste materials such as electronic waste, slag, shredder residual fractions etc., as well as resilient materials such as tires, cables, and refuse-derived fuels.

For more information, see www.bhs-sonthofen.de.

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Dez 4 2015

BHS-Sonthofen strengthens its presence in Turkey

Recycling, mixing and crushing technology in Turkey: New subsidiary is the product of a long-standing business relationship.

BHS-Sonthofen strengthens its presence in Turkey

The General Manager, Ramazan Ergin (left), and the National Sales Manager, Alper Sahin in Istanbul

BHS-Sonthofen has founded BHS-Sonthofen Turkey Makina Sanayi Ltd. Sti. in Turkey in October with its corporate headquarters in Istanbul. The company enables BHS to offer its customers expert advice at the local level at the gateway between Europe and Asia. The newly founded subsidiary is a joint venture which has developed from a long-standing business relationship with DTR Industries.

The foundation of the new subsidiary means that BHS will be able to meet the increasing demand for the recycling, mixing and crushing technology products from Sonthofen on the Turkish market.

A number of machines and installations have been in operation in these segments for several years in Turkey, e.g. for processing slag and mixing concrete, as well as crushers for the production of chippings and sand.

The corporate headquarters is located in Istanbul, within sight of Sabiha Gökcen airport. Ramazan Ergin is the General Manager of BHS Turkey; he will continue as General Manager of DTR Industries, a company which also represents other German machine manufacturers in Turkey. Ergin has known the machines of BHS for a long time. High-quality advice is guaranteed from the very first day, owing to the expertise he has acquired in dealing with them. Alper Sahin is the National Sales Manager for Turkey. He knows the recycling industry inside and out from his job at a company in the sector, where he worked for several years.

Dennis Kemmann, the General Manager of BHS-Sonthofen GmbH, sees enormous potential in Turkey: „We have noticed a constantly growing awareness of the importance of recycling reusable materials and environmental protection in Turkey: Many local authority areas are investing in waste recycling. There is also a large market for scrap. The construction industry is experiencing dynamic growth, which not only creates a growing demand for concrete mixers but also for cement. We are supplying systems for this market which enable refuse-derived fuels to be used to a high degree.“

Address and contact data of BHS Turkey:
BHS-Sonthofen Turkey Makina Sanayi Ltd. Sti.
Yenisehir Mah. Sumbul Sok. No: 8/1/113
34912 Pendik – Istanbul / Turkey
Phone: +90 216 9092-490
Fax: +90 216 9092-492
e-mail: turkey@bhs-sonthofen.com

About BHS-Sonthofen

BHS-Sonthofen is an owner-operated group of companies in the machinery and plant engineering field, based in Sonthofen, Germany. The company offers technical solutions for mechanical process engineering, concentrating primarily on mixing, crushing, recycling and filtration. With more than 350 employees and several subsidiaries, BHS Sonthofen has a global presence.

The Mixing Technology division produces batch and continuous mixers and offers a full range of process technology for mixing. The twin-shaft batch mixer, which is considered a global benchmark in the concrete industry, is an important product.

The Crushing Technology division manufactures impact crushers and mills with vertical and horizontal shafts, which are used for processing mineral substances, e.g. in quarries, gravel works and mining.

The Recycling Technology division offers a wide range of machines and systems for the recycling industry. The product spectrum covers the processing of brittle-hard waste materials such as electronic waste, slag, shredder residual fractions etc., as well as resilient materials such as tires, cables, and refuse-derived fuels.

For more information, see www.bhs-sonthofen.de.

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Nov 17 2015

BHS-Sonthofen: BHS Australia established

Mixing, crushing, and recycling technology in Australia and Oceania: New joint venture begins with extensive product and application know-how.

BHS-Sonthofen: BHS Australia established

Geoffrey Lee, Business Development Manager for BHS Australia

BHS-Sonthofen has recently set up the joint venture BHS-Sonthofen (Aust) Pty Ltd in Australia and can now offer sales, professional consulting, and quick on-site service to its customers „down under“. The newly established company employs a service team of competent specialists, who have been familiar with BHS machines for many years, and is equipped with several test machines and a spare parts warehouse.

The demand for mixing, crushing, and recycling machines from BHS-Sonthofen in Australia is continuously increasing. BHS mixers in Australia, for example, have been instrumental in backfilling mines for many years. A number of BHS concrete mixers are also being used for major infrastructure projects in Australia. A prestigious example of this is the current „Barangaroo Development Project“ in Sydney, one of the world’s largest city renovation projects. Around 54 acres of downtown Sydney’s west harbor edge is set to be fully renovated by 2022.

In order to meet the increasing demand for consultation and service, BHS has collaborated with Gill Wedmore to set up the Joint Venture „BHS-Sonthofen (Aust) Pty Ltd“ with headquarters in Newcastle/New South Wales, which Wedmore will be heading as Chairman. Wedmore has been operating BHS-Sonthofen mixers for many years in his own company BFG Group Pty. Ltd.

BHS Australia will be actively marketing products for the mixing and crushing business sectors in Australia. BHS also sees great potential on the fifth continent in recycling waste material and scrap metal. A current example: A BHS Rotor Impact Mill of type RPM at a waste treatment plant in the state of New South Wales crushes used glass, which is used to replace sand as an aggregate for concrete. Sand is in short supply in the Sydney area.

Geoffrey Lee has been working as Business Development Manager for BHS Australia since August. He brings with him extensive knowledge of machine technology in mining, the construction industry, and recycling. BHS Australia sends out experienced employees with many years of machine expertise to perform the installation, maintenance, and repair work.

The company’s own spare parts warehouse near Newcastle allows it to drastically reduce delivery times. Moreover, its presence in Australia gives customers and interested parties a strong sense of security before making their investment decisions. They can now use test machines for trials in their own country.

Dennis Kemmann, Managing Director of BHS-Sonthofen GmbH, is convinced that the new joint venture will greatly benefit its customers in Australia. „BHS and Gill Wedmore are united by mutual trust which has been repeatedly affirmed over many years. The expertise that our Australian colleagues have developed in using our machines allows us to ensure that the advice and service provided will be at a very high level from day one – precisely what BHS is famous for.

About BHS-Sonthofen

BHS-Sonthofen GmbH, with headquarters in Sonthofen in Southern Germany, is an owner-operated group of companies in the field of machine and plant engineering. The company offers technical solutions in the field of mechanical process engineering, with a focus on mixing, crushing, recycling, and filtration. BHS-Sonthofen has a global presence with over 350 employees and a number of subsidiaries.

The Mixing Technology division produces batch and continuous mixers and offers the entire spectrum of process engineering for all mixing requirements. A major product is the twin-shaft batch mixer, which is regarded as a global benchmark in the concrete industry.

The Crushing Technology division produces impact crushers and mills with vertical and horizontal shafts that are used for processing minerals – such as those found in quarries and gravel pits and in the mining industry.

The Recycling Technology division offers a broad range of machines and plants for the recycling industry. The spectrum includes the treatment of brittle-hard waste materials such as electronic scrap, slag, shredder residue fractions, etc., and of elastic materials such as tires, cables, and fuels derived from refuse.

More information is available at www.bhs-sonthofen.de.
e-mail BHS Australia: info@bhs-sonthofen.com.au

Firmenkontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt
VIP Kommunikation
Regina Reinhardt
Dennewartstr. 25-27
52068 Aachen / Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
www.vip-kommunikation.de

Mrz 21 2014

BHS-Sonthofen: More than a million refrigeration units cost-effectively recycled

Rotorshredder proves its worth in mechanical crushing

BHS-Sonthofen: More than a million refrigeration units cost-effectively recycled

Internal view of the BHS Rotorshredder of type RS

The BHS Rotorshredder has proven its worth in practice in the mechanical crushing of refrigeration units at the recycling company H.J. Hansen A/S in Odense, Denmark. Since its commissioning, the machine has processed more than a million units. The appraisal after five years is highly positive: energy and wear-related costs are nearly half of those from other processes.

In 2007, H.J. Hansen A/S, one of the largest recycling companies in Denmark, planned the construction of a new plant with the capacity to recycle approximately 200,000 household refrigeration units, constituting a large part of Denmark“s annual yield. The units were to be recycled in single-shift operation, according to material type and in an environmentally friendly and cost-effective manner. From the start, H.J. Hansen had the goal of processing at least 100 units per hour – nearly twice as many as was usual in the recycling industry.

Its favorable experience in the crushing and disaggregation of mixed electrical waste led H.J. Hansen to order a BHS Rotorshredder of type RS 3218. This machine was the largest Rotorshredder built thus far and was the first for crushing refrigeration units.

With a diameter of 3,200 mm and a height of 1,800 mm, the working chamber can handle refrigeration units measuring up to 1,000 x 1,200 x 2,000 mm (W x D x H) and weighing up to 100 kg. This means that even large refrigerator-freezer units are crushed in one step, without the need for pre-crushing.

Once the components made of glass or wood, plastic films, electric cables, condensers, mercury switches, and compressors have been manually removed, a conveyor belt feeds the refrigeration units into the working chamber of the Rotorshredder. The chamber contains rotating hammers fastened to a high-speed vertical shaft. The Rotorshredder crushes the units through impact, punching and shear forces.

The solids are automatically sorted into ferromagnetic and non-ferromagnetic parts (predominantly aluminum and copper), plastics and polyurethane foam. The blowing agents released during crushing as well as the separated PU foam are disposed of entirely in accordance with the pertinent regulations.

Positive results

The plant has been in continuous single-shift operation since 2008 and has worked more than 8,000 hours to date. It still meets all the requirements defined at the start of the project, and does even more: it currently processes around 140 units – or approximately 6.8 tonnes – per hour. This corresponds to an average crushing time of 25 seconds per unit. The authors know of no other plant which achieves a higher throughput rate.

A test of 1,000 units carried out by a Swedish supplier of scrap refrigeration units in 2013 confirmed the plant’s performance, both in terms of compliance with permitted CFC emissions as well as the quality of the accurately separated final products.

Low costs

The excellent crushing performance and short processing time result in a very high degree of energy efficiency and therefore low energy costs. The average electrical power requirement is only 120 kW. This results in a specific energy consumption of only 18.5 kWh per tonne.

The wear-related costs are also extremely low in comparison to other crushing machines: they are less than three euro per tonne. Moreover, maintenance costs are low. As they do not cut but rather function by force of impact, the rotating hammers do not need to be adjusted or sharpened. Only a daily visual inspection is necessary.

Summary

With this plant, H.J. Hansen and BHS-Sonthofen have proven that refrigeration units can be recycled safely and inexpensively with the Rotorshredder. Due to the Rotorshredder“s low operating costs, H.J. Hansen can run the entire plant not just economically but also profitably.

Outlook

The Rotorshredder of type RS 3218 can crush up to 150 refrigeration units per hour. In three-shift operation, it could thus achieve a much higher performance of approximately 3,250 refrigeration units per day, and more than 800,000 units per year.
With an expanded sorting facility, it is also possible to process electrical and electronic waste (WEEE) in the same plant as the refrigeration units.

The IC process

For the treatment of gases in the refrigeration units, BHS has recently developed the IC process, a new technology for treating refrigeration units containing CFCs or hydrocarbons.

The central machine in this process is once again the BHS Rotorshredder. The refrigerants and blowing agents that are recaptured during the process undergo thermal-catalytic conversion and are completely transformed into harmless substances such as water vapor, carbon dioxide and dilute acids or saline solutions. Beyond this, the process allows for major cost savings.

The IC process also has major advantages in terms of efficient energy use: pentane, which is used increasingly in modern refrigeration units, has a substantial energy content and can thus assist the thermal treatment of the gases, up to the point of thermally self-sufficient operation. Compared to conventional plants, the process achieves remarkably large cost savings.
Bildquelle:kein externes Copyright

About H.J. Hansen A/S

The H.J. Hansen Group is a family-owned group of companies, with roots stretching back six generations. The company was established in 1829 as a grocery shop in Odense, Denmark and since then has developed into an international supplier of high-grade materials – in particular metals. The core business is the conversion of recyclable materials into marketable products.

The shredder plants in Odense and Hadsund process up to one million tonnes of scrap with a maximum thickness of 16 mm per year. The plant has a capacity of more than 250 vehicles per hour. The final product is ferritic scrap with a purity of 99 percent, which can then be re-melted. H.J. Hansen also sells metals and plastics for other recycling applications.

The plant in Odense processes white goods such as refrigerators and freezers and has a capacity of more than 1,000 units per day in single-shift operation. In Trollhättan, Sweden, H.J. Hansen operates a granulation plant for cables.

About BHS-Sonthofen GmbH

BHS-Sonthofen GmbH, headquartered in Sonthofen in Southern Germany, is an owner-operated group of companies in the field of machine and plant engineering. The company offers technical solutions in the field of mechanical process engineering, with a focus on mixing, crushing, recycling and filtration. With over 300 employees and a number of subsidiaries, BHS-Sonthofen has a global presence.

The Recycling Technology division offers a broad range of machines and plants for the recycling industry. The spectrum encompasses the treatment of brittle-hard waste materials such as electronic scrap, slag, shredder residue fractions, etc. or of elastic materials such as tires, cables and refuse-derived fuels.

For more information, visit www.bhs-sonthofen.de.

BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de

Jan 21 2014

AMNI shredding machines for recycling applications

Treatment of all kinds of materials: Shredding technology rounds off BHS-Sonthofen“s product range

AMNI shredding machines for recycling applications

Managing Director Dennis Kemmann (right) together with Udo Becker

BHS-Sonthofen has acquired all technical designs and documents, patent rights and trademark of the recycling technology division of AMNI Maschinenbau GmbH in Iserlohn (Germany) following its insolvency, effective from December 12, 2013. This has allowed BHS – a company known to date in the recycling sector for crushing by means of impact and shearing technology – to expand its product range into shredding technology using cutting tools. BHS thus now covers the full range of crushing and shredding technology for both brittle and elastic materials. At IFAT 2014, the company will unveil the rotor shears and granulators acquired from AMNI and upgraded by BHS.

AMNI manufactured rotor shears and granulators of various sizes for numerous customers for the treatment of electronic waste, tires, cables, refuse-derived fuels and other materials. They are robust and easy to maintain, and have a number of patented features as well.

For BHS-Sonthofen, this attractive acquisition rounds off its existing product range, as the company from Sonthofen has until now offered recycling machines exclusively based on impact and shearing technology. These machines crush the bulky input material and also achieve a selective disaggregation of composite materials. With rotor shears and granulators, BHS now also manufactures machines which are suitable for recycling elastic materials. These include domestic, industrial and commercial waste, cables, and car and truck tires – extending even to tires for construction machinery with a diameter of up to 3 m. The machines are also able to handle paper and cardboard, for example books or files, as well as wood and textile waste.

Since December 2013, Udo Becker, head of the former recycling technology division of AMNI, has been in charge of the further development and manufacture of the BHS shredding machines as Business Development Manager in Sonthofen. He is responsible for ensuring continuous support for operators of rotor shears and granulators. The maintenance and repair of existing plants and the supply of spare parts to former AMNI customers will be carried out by the BHS service team from now on.

Dennis Kemmann, Managing Director of BHS-Sonthofen, sees an important addition to the company“s range with this new product segment: „We can now offer all commercially available crushing and shredding processes in the field of recycling with our own machines. Each technology has specific advantages depending on the application. This is the ideal solution for many input materials, for example for mixtures of different materials. For the selective crushing of brittle-hard materials, we will continue to implement impact and shearing technology, and the rotor shears and granulators will shred the predominantly elastic materials. The advantage for our customers is clear: regardless of the material to be recycled, we offer the optimal solution from a single source.“

The proven VR rotor shears – now upgraded by BHS – are mostly used for pre-shredding at the beginning of each recycling process. They are equipped with two shear shafts which rotate at approx. 18 rpm. The machines are designed for a throughput rate of between 6 and 30 tons per hour.

The NG series granulators are used for granulating and separating composite materials as well as for the secondary shredding of difficult or large-volume materials – for example electronic waste and non-debeaded tires. Compared to the rotor shears, the shear shaft rotates significantly faster, at up to 420 rpm. With their high-torque drive and large inertia masses, the granulators develop very high shredding forces.

The technology in detail

Rotor shears
In addition to a good cutting performance, high availability was at the fore in the development of the machines: the housings consist of a one-piece, extremely robust and warp-resistant welded steel construction. The cutters are hard faced, allowing them to achieve a remarkably long service life. The scrapers can be replaced individually.

The two industrial gear units, which drive the rotor shafts in opposite directions, are torque-buffered. This relieves the load on the shear shafts and drive components if solid extraneous materials enter the machine. In case of overload, a current-based reversing control system protects the machine from damage.

The quick-change system for the shear shafts also contributes to short standstill times. Owing to the bearing shell bridging system, the shafts of the rotor shears can be exchanged within just four hours. This task now takes less than 20 percent of the time previously required.

The control system has a modem for remote maintenance. It can also be equipped with an electronic consumption optimizer, which balances the power, torque and current requirements. In this way, only the power that is actually required at any given time is developed – energy costs decrease and the plant functions much more economically.

Granulators
The granulators shred pre-crushed or pre-treated input materials. The NG series machines are single-shaft granulators in which a rotor equipped with fly cutters shreds the materials on the counter-blades of the stator. The rotor is equipped with a belt flywheel and can be controlled within a speed range from 0 to 420 rpm.

Special design features ensure excellent cost-effectiveness and durability. These include the extremely robust, external rotor bearings, the modular stator with blade segments which can be individually adjusted, and wear compensation with linear advance of the stator blades. In addition, the hydraulically retractable sieve can be exchanged simply without the need to dismantle the discharge equipment.

BHS-Sonthofen at IFAT (May 5 to 9, 2014 in Munich):
Hall B2, booth 339/444

About BHS-Sonthofen

BHS-Sonthofen GmbH, headquartered in Sonthofen in South Germany, is an owner-operated group of companies in the field of machine and plant engineering. The company offers technical solutions in the field of mechanical process engineering, with a focus on mixing, crushing, recycling and filtration. With over 300 employees and a number of subsidiaries, BHS-Sonthofen has a global presence.

For more information, visit www.bhs-sonthofen.com.

Kontakt
BHS-Sonthofen GmbH
Roland Schmid
An der Eisenschmelze 47
D-87527 Sonthofen, Germany
+49 8321 6099-231
press@bhs-sonthofen.de
http://www.bhs-sonthofen.de

Pressekontakt:
VIP-Kommunikation
Regina Reinhardt
Süsterfeldstrasse 83
52072 Aachen, Germany
+49.241.89468-24
reinhardt@vip-kommunikation.de
http://www.vip-kommunikation.de