DIALOG Issue 09/2010 (pdf-File) - Rehart GmbH

DIA LOG
The Newsletter for Customers & Partners of the REHART-GROUP
Issue 9/2010
Environmentally Friendly and Highly Efficient
Archimedean screw turbines for small volumes of water are on the rise
Baiersdorfer Mühle, Baiersdorf
The compact systems for
the development of “small
hydropower stations” are the
Archimedean screw turbines
of tomorrow. The previously
unused potential of smaller volumes
of water can now be developed
very cost-effectively.
Hydropower is one of the most
significant sources of renewable
energy. The existing potential in
the sector of “small hydropower
stations” is far from being comprehensively
developed – REHART is
a pioneer in this field…
Continued on page 2
Separation of hard and soft materials
from plastic bulk
The limits of cleaning and energetic considerations
of the various systems for the field of clay blocks.
An effective cleaning
of plastic raw materials
is possible thanks to the
targeted positioning of the
cleaning machine. Technical
innovations also create
advantages. The patented
rSE system (rotation-shear
effect) combines the advantages of a classical
screen filter mixer with the mechanical components
of a clay cleaner.
The cleaning of plastic raw materials remains a
current topic, be it due to impure raw materials in
the pit such as roots, quartz, pyrite, chalk, basalt or
due to additives which do not possess the required
characteristics. The consequences of these impurities
are reductions in quality such as chalk prob-
lems and problems in firing (roofing tiles, facing
bricks, clay blocks) or complications in the shaping
process due to jams in the tip (clay block area).
Continued on page 3
DEAr rEADEr,
the economic crisis is behind
us and we are pleased that
we have been able to manage
these uncertain times so
effectively. After having faced
the challenges of the recent
months, we are now looking forward with new motivation.
We are carried forward by, amongst other
things, our successful optimization in the brick
industry. Our customers are profiting to a high degree:
they will be saving 600,000 euros in energy
costs every year.
In times of economic tension, measures for the
more efficient use of existing resources are gaining
in significance. We are integrating our know-how
in the field of energy generation with hydropower.
Our developments achieve particularly high
degrees of efficiency in the segment of so-called
“small-scale hydropower”. It is precisely this sector
that we are covering with our Archimedean screw
turbines.
With these innovations, we are sustainably shaping
not only the future of our company, but most
importantly, the future for a clean environment.
Our developments make a significant contribution
to CO 2 reduction.
Best wishes,
Klaus Schülein
Chief Executive
TABLE OF CONTENTS
P. 02: Environmentally Friendly
and Highly Efficient
P. 02: Certification of the REHART GmbH
P. 03: nanoseal – New Impact Resistant
Adhesive
P. 03: Separation of hard and soft materials
from plastic bulk
P. 04: Continuation of separation of hard and
soft materials from plastic bulk
P. 04: 25 Years of Rehart – 25 Year Employees
P. 04: Legal Notice

Continued from the Title Page Environmentally Friendly and Highly Efficient – Archimedean screw turbines for small volumes of water
are on the rise
With new innovations, REHART has made possible
the profitability of small heads between
one and eight meters with volumes of water
between 500 liters/sec up to 10,000 liters/sec.
REHART has developed systems for these sources
of “small hydropower stations” which provide
an outstanding alternative to other methods.
The peerless competence of REHART is no coincidence:
years of experience in the construction
of Archimedean screw pumps for sewage treatment
plants has allowed the company to develop
the technological advancements which first
make the innovations for hydropower possible.
It was only a small, albeit decisive, step for the
company from the “Archimedean screw pump”
to an Archimedean screw turbine.
At the forefront with production methods: As
compact systems, the Archimedean screw turbines
are assembled in the factory. This reduces
the expenses during installation onsite to a minimum.
This makes the investment a cost-effective
alternative for many areas of application.
The “Renewable Energy Law” of the European
Union entered into force in 2009.
Head H (m)
power output
Water flow Q (m3 /s)
Water flow up to 10.000 l/s Efficiency up to 85 %
Head up to 10 m Output up to 500 kW
Diagram for the use of Archimedean screw pumps.
New Certifications of the rEHArT GmbH
Quality Management and Credit Rating
REHART was certified according to the guidelines
of ISO 9001-2008 in 2009. This fulfills the
requirements for meeting the needs of customers
for large orders as well as ready-to-use
systems. The monitoring audit in 2010 confirmed
the path taken to improve the processes as well
as the quality progress achieved.
The former largest compact system worldwide. The screw has a diameter of 3.6 meters and a blade length of 8.5 meters.
120 KW is generated with 6,000 liters of water per second. Standing in front of it are chief executive Klaus Schülein, sales
engineer Matthias Reinhardt and technical director Gerhard Wolff (from left to right).
It regulates the compensation for green electricity.
The demand for Archimedean screw turbines has
increased hugely at home and abroad since the
compensation for electricity fed into the grid for
Archimedean screw turbines has been adjusted
to that of other renewable energies such as biogas,
wind power and solar energy.
The credit agency Creditreform
has assessed the
REHART GmbH as very positive,
making REHART an especially
reliable partner for
long-term business relations.
REHART has invested with
goals in mind and established
its own development
and competence team. Two
patents and a utility model
were protected within only
half a year.
An innovation is the European
patent registration for
the so-called “floating screw
pump”, meaning that the
Archimedean screw turbine
adjusts itself to the current water level, making
our systems even more efficient for many sites.
An additional patent is currently being registered:
this development will allow REHART to reduce the
sound emissions to 5 decibels below standard
plants. This means that REHART will be able to
supply Germany’s quietest Archimedean screw
turbines!
The results of our previous work are more than 35
installed systems and project studies with more
than 800 application options, which clearly verify
the high profitability of the REHART Archimedean
screw turbines. – Innovation for the future … and
for you!
Contact Partner:
Mr. Georg Zeiler
Project Manager - Hydropower
Systems
Cell: +49 (0) 170 919 54 31
georg.zeiler@rehart.de

nanoseal TB Flex S – The New Impact resistant Adhesive
rEHArT is excited to present a new kind
of adhesive with a high degree of impact resistance:
TB Flex S. This was developed on
the basis of shock absorbing polymers, from
which it receives its special strength which
prevents it from breaking due to impacts or
blows. Its extremely high resistance to aggressive
biomasses and organic materials
allows many areas of application.
This provides us with an especially suitable solution
for mechanical engineering, construction
and maintenance. Adhesives are increasingly
being used in these fields as an alternative to
welding, soldering, screw connections, et cetera.
The requirements for this are very high – TB Flex
S fulfills these and allows faster, more flexible
and more reliable work.
The new adhesive TB Flex S has proven itself in
practice with numerous examples. It has been
used on ceramic molds and ceramic cladding
in cyclones, mills and similar constructions and
used to seal or set pump and plant parts subject
to high mechanical and/or chemical stresses.
What are the properties of the new adhesive?
A sufficient amount of plastic raw material must be
present. The machine technology does not distinguish
between hard foreign bodies and hard mass.
This applies both to the separation of hard materials
and soft materials. This defines the application
limits of a separation machine. For this reason, it is
urgently necessary that an additional plasticization
take place prior to the separation process. The
foreign bodies do not need to be distinguished between,
as the entire concept of separation must be
dealt with differently here.
Hard materials should, if possible, be separated at
the beginning of the preparation as these are largest
here, meaning that they are easiest to touch
and do not need to be ground any further. Soft materials
can separated most easily directly before the
shaping process as the greatest degree of plasticization
exists here.
The Separation of soft materials:
In our experience from recent years, the separation
of soft materials has been best accomplished
by the use of the cleaning machine near
the shaping. When using the cleaning machine
between the preparation and the sump or sump
shaping, it is preferable that the machine is posi-
TB Flex S is a two-component
adhesive which is putty-like
after mixing. It is drip proof up
to 1 cm in layer thickness and
can be spread flush. Another
advantage: it can be molded as
desired within ca. 30 minutes.
The material then dries without
shrinkage. It contains no
solvents. TB Flex S is unique
for its high impact resistance. If
an epoxy coating is struck from
behind with a hammer, for example,
it will crack and flake.
This is not the case with TB
Flex S – even after many blows from a hammer
which deform the sheet metal. This is especially
remarkable as TB Flex S has a high hardness of at
least Shore-D 70.
TB Flex S and its unique properties were, of
course, subject to intensive laboratory tests. It
was important that the high adhesive properties
remained high even after storage in typical media.
Continued from the Title Page Separation of hard and soft materials from plastic bulk
tioned directly in front of the vacuum aggregate.
In this manner, the greatest number of impurities
are separated prior to shaping, especially
the dry material which has accumulated during
the preparation process.
The goal must always be to clean the mass with
the highest degree of plasticity. The influence of
the dried mass is also minimized by the positioning
of the cleaning machine before the shaping
process.
Two separation aggregates have proven themselves
for this type of separation:
• The Screen Filter Mixer
• The Clay Cleaner
The Screen Filter Mixer:
The screen filter mixer system builds upon a
double shaft mixer with standard mixer shafts
where the mass is pressed through a transverse,
replaceable screen. In the event of dirtying
and wear of the screen, a clean screen section is
pushed in front of the discharge screw conveyor
transversely. One of the advantages of the screen
filter mixer is a good opportunity to thoroughly
mix the mass with simultaneous plasticization
TB Flex S is not broken after being struck from behind. Standard epoxy adhesive
is broken.
Even after multiple weeks of storage in 30%
caustic soda, propanol or diluted hydrochloric
acid, outstanding results were achieved. The
application options are so diverse that they can
almost certainly solve any construction prob-
lem you may
have.
Contract Partner:
Mr. Friedrich Hornung
Sales Advisory Service
Welding and Composite
Technology
Cell: +49 (0) 171 632 81 49
friedrich.hornung@rehart.de
with steam or water. An economic cleaning with
screen holes up to 5 mm is possible with a standard
screen filter mixer..
The Clay Cleaner ZAR System Krüger with Manual
Stop
The clay cleaner system builds upon a 1-screw
concept with a counter-rotating basket. The
function for the separation of soft materials is
not limited to separation alone: fibers of excessive
lengths which have been trapped in the
screen holes of the basket are reduced in size
and thus can no longer interfere with production.
The amount of waste material is further
reduced thanks to this property. It has been demonstrated
that no automatic loss is necessary
during the separation of soft materials. A manual
stop is wholly sufficient.
The remaining fibers, fiber clumps as well as metal
and plastic parts can be disposed by the cyclic opening
once or twice per week via the manual seal.
A cleaning is possible up to a screen opening of 2.5
mm. The mixing in the machine is low even if a cer-
Continued on Page 4

Continuation Page 3 Separation of hard and soft materials from plastic bulk
tain homogenization
effect is achieved
from the peeling of
the bulk from the
screw.
The Screen Filter
Mixer “RSE”
The comparison of
both machine types
over a longer period
indicates that
the clay cleaner has better values in
terms of energy utilization. This is because
the bulk is not merely pressed
through a screen but instead peeled
from the screw with an additional
shear effect. We have attempted to
transfer this effect, even if to a lower
extent, to the screen filter mixer. The
approach is to set the bulk in forward
motion in a rotation which will then
shear with a previously activated star
screen. The first machines with this system were
delivered in 2007 and an improvement was obvious.
The equipping of an existing screen filter
mixer with the now patent-protected RSE system
achieved an improvement of 15-20%. Screens
with 4 mm screen holes can also be used with this
system.
A comparative table shows the various properties
and values of the individual machines. In
this comparison, the SFM1000 screen filter mixer
was compared with the ZAR560 clay cleaner.
This demonstrated that the mixing properties of
Hartmut Dietrich is the first employee to be
honored for twenty-five years of service. His
career began at the Schnelldorfer Maschinenbau
GmbH, which has belonged to the REHART
GROUP for 23 years. He worked here as a specialist
for the regeneration of parts subject to
wear for the brick industry and achieved independence
for the department. He has been active
from the very beginning of the main plant in
Ehingen. As department head, he is responsible
for internal maintenance including all procurement.
In addition, he is responsible for the division
“Regeneration of Replacement Parts” for
Comparison of the Separation Methods
SFM 1000 ZAR560 SFM 1000 RSE
Mixing Properties ++ – ++
Option to
Introduce Water ++ – ++
and Steam
Screen Holes mm Min 5 x 30 Min 2.5 x70 Min 4 x 30
Capacity to/h 40 50 48
Power Used kW 90 55 90
With Screen Holes mm 5 x 30 2.5 x 70 5 x 30
Specific Power kWh/to 2.25 1.1 1.875
the screen filter mixer and especially the option
to introduce water and steam allowed a setting
directly between preparation and shaping.
When using a clay cleaner, an excellent prior
plasticization of the bulk is to be noted. The optimal
placement here is in the bypass between
the screen rotary feeder/mixer and the vacuum
aggregate. The possible screen holes speak for
themselves,
as does the
specific energyconsumption.
Contact Partner:
Dipl. Ing. Mr. Thomas Kloft
Plant Director
Cell: +49 (0) 171 210 24 99
kloft@petersenservice.de
Award for Hartmut Dietrich
for 25 Years in the rEHArT GrOUP
the technical ceramic and porcelain industry.
This exemplary personal resilience reflects the
brand names
of the REHART
GROUP, namely
continuity.
rEHArT GmbH
regenerate
Spare Parts
Mechanical Engineering
Wear Protection Systems
Special Coatings
Acid Protection
Hydropower
Archimedean Screw Pumps
Industriestraße 1 • D-91725 Ehingen
Phone +49(0) 9835/9711-0
Fax +49(0) 9835/524
info@rehart.de • www.rehart-group.de
PetersenService GmbH
Mechanical Engineering
Spare Parts Service
Assembly
Maintenance
Used Machines
Kreuztaler Straße 7 • D-57250 Netphen
Phone +49(0) 271/77235-0
Fax +49(0) 271/77235-50
mail@petersenservice.de • www.rehart-group.de
Tribotec GmbH
Wear Protection Systems
Welding Technology
Spare Parts Service
Special Coatings
Acid Protection
Hydropower
Archimedean Screw Pumps
Brunnenstraße 1 • D-07950 Staitz
Phone +49(0) 36622/79066
Fax +49(0) 36622/79068
info@tribotec-staitz.de • www.rehart-group.de
Legal Notice
Published by and responsible for content:
REHART GmbH, D-91725 Ehingen.
Concept and text: www.lehanka.de
REHART GmbH, Industriestr. 1,
D-91725 Ehingen, phone +49(0) 9835/9711-0
www.rehart-group.de