3R 15/200 Industrial Shredder for Waste to Energy

What we are most proud of is bringing Italian technology to the world. The raw power of our shredders, combined with the meticulous design we put into custom projects, form a unique combination increasingly sought after by companies from every nation specializing in the processing and disposal of industrial waste and materials.

For us at SatrindTech, there is nothing better than when our expertise and know-how are requested where shredding requirements become more serious and pressing. In addition to our standard products, we are able to offer customized solutions for the most extreme shredding needs.

The system we present today was installed in China, in Jiangsu Province, a highly populated area that represents one of the country’s economic engines. The project is the result of collaboration with a local engineering company, which assisted our specialists at a cement plant: the shredded material will be used as a combustion aid for the kiln in the cement production cycle according to the waste to energy principle.

What we installed in China is a system of considerable power, designed for intensive use and compatible with various materials that also compose large objects. The installation work was a true engineering challenge, but we are extremely satisfied with the result.

The heart of the system consists of a 3-shaft industrial shredder model 3R 15/200 with 150 kW that delivers a power output of 200 HP. The shredder is equipped with 5-1 tooth blades with 50 mm thickness and material selection screens with 100 mm holes.

The system is mounted on a support frame equipped with walkways connected to a large primary hopper. The latter is divided into chambers separated by automatic gates and is connected to a secondary discharge hopper, also closed by a gate.

The shredder’s operation is controlled by a Siemens PLC management system, which represents the nervous system of the plant.

The PLC (Programmable Logic Controller) is accessible through three different interface modes:

• Directly near the machine through a convenient touch display installed on the electrical panel.
• Remotely: the PLC is connected with a very long cable to a remote room, the DCS (Distributed Control System). This allows, thanks to the Profibus communication protocol, management of the shredder from one of the site’s control rooms, eliminating the need for constant operator presence near the system.
• Remote assistance: a gateway module equipped with SIM and UMTS antenna is connected to the PLC, allowing SatrindTech technicians to connect remotely to intervene on the PLC software. We can thus monitor, without leaving our offices, the correct operation of the system, manage any anomalies, and make periodic modifications in the form of upgrades and updates.

The machine we installed in China, as we have just described it, is designed for the industrial shredding of packaged textiles and garments, empty metal drums, and standard 200-liter IBCs with frames. These waste materials and scraps, once shredded and reduced to minimize their volume, will undergo a controlled combustion process inside the cement plant to fuel combustion in the cement mixture firing process in the kiln, reducing costs and decreasing environmental impact: this is the waste to energy principle in action.

Given the complexity and significant size of the entire system, it was necessary to configure the entire system to simplify future maintenance operations as much as possible. The shredder is, in fact, extractable from its housing with the aid of a winch. By releasing the grinding body from the hopper above, it can slide on special rails and be extracted for blade sharpening or their replacement in due time. Given the uniqueness of the system and the complexity of its implementation, a considerable part of the project also involved the release of technical documentation on the product’s specifications and operation.

The distinctive feature of this installation consists of the sophisticated sealed gate opening and closing system. The system, in fact, handles hazardous waste: each chamber opens and closes in an automatic cycle with nitrogen insufflation. This prevents contact of the material to be treated with oxygen, preventing the risk of fires and explosions.

The excellent result in the installation and commissioning of the system is the result of successful collaboration with the Chinese partner. SatrindTech supplied the heart of the machine, namely the grinding body, together with the related hydraulic power units and the electrical panel through which to control them, also remotely via cable, through the Profibus protocol, as well as remotely under remote assistance. The SatrindTech team handled, during the design phase and on-site, all engineering phases, while, regarding the construction of all metalwork, our partner worked locally, scrupulously following all our instructions.

The installation of the custom 3R 15/200 industrial shredding system in the Far East represents for the company not only a technical and commercial success, but a project we will remember with great pleasure in the years to come. Considering only the final result, one risks, in fact, forgetting the best aspect of our work, namely the collaboration between experts of different backgrounds and cultures toward a common goal.

SatrindTech’s philosophy is, in fact, not simply to export shredders and technical solutions, but also an innovative work style that allows us to give our best regardless of the nation and context in which we operate.