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<strong>Creating</strong> <strong>The</strong> <strong>Future</strong><br />

Machines Plants Process solutions


UNI-CUT®UC rotary shears<br />

endlessly versatile in pre-granulation<br />

>>> Page 6<br />

High-performance<br />

UNI-CUT®UG granulators<br />

For individual grain sizes from 8 to 100 mm<br />

>>> Page 6<br />

UNI-CUT®CC<br />

CableCutter<br />

the specialist for all cable waste<br />

>>> Page 8<br />

UNI-CUT®USM<br />

cutting mills<br />

the perfect cut<br />

for small grain sizes<br />

>>> Page 8<br />

Machine technology<br />

UNI-CUT®AC<br />

AlphaCutter<br />

single-shaft pre-shredder<br />

for difficult materials<br />

>>> Page 10<br />

the diversity of the <strong>MeWa</strong> range of<br />

machines is aligned to the requirements<br />

for the size reduction of different<br />

types of waste. as a single<br />

machine or integrated in complete<br />

plant solutions, recycling machines<br />

from <strong>MeWa</strong> have already proven<br />

their worth more than 1000 times.<br />

Hammer mills<br />

UNI-CUT®UHM<br />

effective purification<br />

>>> Page 17<br />

UNI-CUT®SB<br />

<strong>The</strong> patented<br />

UNI-CUT®QZ<br />

Querstromzerspaner<br />

Perfect in separation.<br />

Perfect in the result.<br />

>>> Page 12<br />

2<br />

Smash Boom Bang<br />

Gentle and effective<br />

>>> Page 12<br />

UNI-CUT®SP<br />

tyre wire cleaner<br />

clean steel wire from<br />

tyre recycling<br />

>>> Page 17<br />

2 3


<strong>Recycling</strong> plants for used tyres<br />

From old tyres to acti<strong>MeWa</strong><br />

>>> Page 6<br />

Cable recycling plants<br />

high-quality fractions in primary<br />

raw material quality<br />

>>> Page 8<br />

Processing of domestic<br />

and industrial waste<br />

solid recovered fuels with<br />

high energy content<br />

>>> Page 10<br />

Plant engineering<br />

Refrigeration<br />

recycling plants<br />

highest recycled resource rates –<br />

complete cFc separation<br />

>>> Page 14<br />

over 300 large-scale plants worldwide<br />

speak for themselves: with size<br />

reduction machinery from in-house<br />

development as well as the specific<br />

separation, sorting and conveying<br />

technology, <strong>MeWa</strong> delivers turnkey<br />

recycling solutions at one stop. Modular<br />

construction means that the<br />

systems can be put together quickly<br />

and efficiently to meet individual requirements.<br />

Processing plants<br />

for electrical<br />

and electronic scrap<br />

single-stage and fully automatic<br />

>>> Page 14<br />

Increased gas output<br />

by up to 30 %<br />

life‘s a gas with the QZ<br />

>>> Page 18<br />

Metal-cleaning plants<br />

effective separation<br />

>>> Page 16<br />

4 5


Tyre recycling<br />

From old tyres to fine rubber powder<br />

Three-stage process delivers high-quality secondary raw material<br />

With the active fine milling process for used tyres, <strong>MeWa</strong><br />

produces a substitute raw material of a single material type.<br />

<strong>The</strong> fine granulate (Acti<strong>MeWa</strong>) can be mixed with other<br />

materials without difficulty to manufacture rubber products.<br />

In road construction, there is a great demand for Acti<strong>MeWa</strong><br />

as an additive to bitumen.<br />

Granulation line.<br />

Acti<strong>MeWa</strong><br />

Recycle before incineration – this<br />

guiding principle also applies to<br />

used tyres from passenger cars<br />

and trucks. in hungary and Kazakhstan,<br />

<strong>MeWa</strong> recently built two highly modern<br />

processing plants for old tyres, producing<br />

acti<strong>MeWa</strong> for direct deployment in road<br />

construction.<br />

in the three-stage processing principle<br />

(pre-granulation, granulation, fine milling),<br />

rotary shears first of all fragment<br />

the complete used tyres into shreds the<br />

size of the palm of your hand.<br />

the precisely machined cutters of the uc<br />

are seated on a polygon-shaped rotor. this<br />

enables the machine to achieve optimised<br />

power transmission. even with metallic<br />

parts, the uc shows its irresistible bite.<br />

subsequently, a granulation line processes<br />

the pieces of tyre step by step into a rubber<br />

granulate of a single material type.<br />

in a complex process, various separation<br />

processes separate the steel and textile<br />

fibres from the pieces of rubber. the<br />

size of the granules is between 0 and 4<br />

millimetres with a final purity of 99.95<br />

percentage by weight.<br />

Active fine milling<br />

<strong>MeWa</strong> integrated the newly developed<br />

fine milling process as a third process stage<br />

for the first time in both plants in hungary<br />

and Kazakhstan. Powdery acti<strong>MeWa</strong><br />

of the highest purity is the result at the<br />

end of the process. it can be added directly<br />

to the new rubber to manufacture<br />

rubber products.<br />

Deployment in road construction<br />

acti<strong>MeWa</strong> is also used in road construction<br />

as an additive to bitumen. the rubber<br />

granulate not only balances out temperature<br />

differences to a considerably better<br />

degree, thus preventing the formation of<br />

cracks, but the mixture also dampens the<br />

noise level of the road surface and provides<br />

significantly greater adhesion for vehicles<br />

in the rain.■<br />

Universal rotary shear UC 150.<br />

Rotor shears and granulator<br />

Active fine milling.<br />

A double plus<br />

With their reliability, the versatile<br />

granulators and rotary shears have advanced<br />

to become the truly successful<br />

team of machines in the <strong>MeWa</strong> machine<br />

pool. together, the two machines fragment<br />

above all tyres, cables, oil filters<br />

and mixed wastes into homogeneous<br />

fractions in all desired grain sizes.<br />

Perfectly geared to one another<br />

the duo is deployed at several<br />

h<strong>und</strong>red locations in pre-granulation and<br />

finish-crushing. here, operation times<br />

of more than 70,000 hours of operation<br />

are no rarity. as far as throughput<br />

is concerned, the team of machines is<br />

perfectly co-ordinated.<br />

the rugged machines have been<br />

conceived for metal processing, which<br />

means they display exceptional stamina<br />

even in highly demanding applications.<br />

UG cutting mechanism.<br />

6 7


CableCutter<br />

Cable processing CableCutter and USM<br />

<strong>The</strong> modern copper mine<br />

Turnkey cable processing plants from <strong>MeWa</strong><br />

have been delivering the highest output<br />

qualities for years. A processing plant in Budapest<br />

has now integrated the newly developed<br />

UNI-CUT ® CC CableCutter into its plant.<br />

Initial conclusion:<br />

grade 1 in economic efficiency.<br />

Electrical scrap, telecommunications,<br />

old cars, mining, high-voltage cables<br />

- today, approximately 150,000 metric<br />

tonnes of cable waste is produced per<br />

year in Germany alone. <strong>und</strong>ergro<strong>und</strong>, millions<br />

more kilometres have been laid, and<br />

these have to be replaced at some time or<br />

other. With the copper, aluminium, lead<br />

and steel metals they contain, the lines are<br />

extremely rich in recyclable resources.<br />

in hungary‘s capital Budapest, a company<br />

has specialised in recycling cables.<br />

not far from the banks of the Danube,<br />

the facility has installed a processing line<br />

with pre-granulation, granulation and fine<br />

granulation.<br />

Partner for precision work<br />

if aluminium, copper cables, plastics<br />

or tyres are to be granulated, the unicut<br />

® usM cutting mill handles the precision<br />

work. the rugged <strong>MeWa</strong> cutting<br />

mill is in demand everywhere small grain<br />

sizes are required.<br />

in cable processing, the cutting mills<br />

cut the enclosed metal from its cladding.<br />

co-ordinated cutting and separation<br />

units then extract metal fractions<br />

of a single material type, for example<br />

copper. Plastics and rubber from the insulation<br />

material are left behind.<br />

in the modern tyre processing plants,<br />

the machine is often set up in a row of<br />

four located upstream of the cutting<br />

and separating units. in a number of<br />

runs, the rubber granulate is cleaned<br />

and finally fragmentised by the 5.5 metric<br />

tonne machine to a size of less than<br />

4 millimetres in diameter.<br />

CableCutter CC 1200.<br />

Specialist for cable fragmentisation<br />

the company has now invested in an<br />

additional special machine that can further<br />

increase the efficiency of processing.<br />

the cutting geometry of the new cc 1200<br />

cablecutter from <strong>MeWa</strong> has been specially<br />

geared to taking cables apart.<br />

With a throughput of up to three metric<br />

tonnes per hour, this technical innovation<br />

is highly effective. the easy-to-change<br />

granulating screen achieves grain sizes of<br />

10 to 50 millimetres in diameter. special<br />

sizes are available as required. the input<br />

shaft is 2.30 metres wide, i.e. configured<br />

for loading by means of power shovels.<br />

Copper sorted by material type<br />

the initial processing with the new unit<br />

is so precise that even one subsequent granulation<br />

stage is sufficient to be able to<br />

feed the material directly to the final cutting<br />

mills. the result: copper in primary<br />

raw material quality. ■<br />

Cutting mill USM 1000.<br />

8 9


Solid recovered fuels AlphaCutter<br />

Turnkey <strong>MeWa</strong> plant in Ghent with<br />

vibrating screen, wind screening,<br />

metal separator and granulation line.<br />

Pre-granulation takes place outside<br />

of the shop.<br />

Flywheel mass drive<br />

For more than 20 years now,<br />

<strong>MeWa</strong> granulators have been driven<br />

by flywheels weighing 3 to 5 metric<br />

tonnes. the flywheel serves simultaneously<br />

as a belt pulley for a simple<br />

V-belt drive that works with the<br />

lowest possible losses due to friction.<br />

the energy of the disk flywheel covers<br />

the peak torques required in the<br />

short term. this means that the electrical<br />

drive motor runs smoothly, significantly<br />

below the rated voltage<br />

range. expensive peak loads do not<br />

occur in the first place.<br />

Maintenance-free coupling system<br />

a sophisticated coupling and<br />

control system monitors the speed,<br />

torque and current consumption of the<br />

machine. this prevents high start-up<br />

peaks of the electrical drive motor<br />

and in the event of sudden blocking<br />

the flywheel is uncoupled so that the<br />

machine is not damaged.<br />

Manufacture of Solid Recovered Fuels<br />

<strong>MeWa</strong> has developed the high-performance<br />

AlphaCutter for large throughput volumes and<br />

materials that are difficult to process such as<br />

mattresses, truck tarpaulins, large compressed bales<br />

or rolls of foil. <strong>The</strong> unit is handling the pre-granulation<br />

in plants for the manufacture of solid recovered fuels.<br />

the new alphacutter series from<br />

<strong>MeWa</strong> is equipped with four disk<br />

flywheels. two of these on each side<br />

gear down the speed of the drive<br />

motors from 1500 revolutions to<br />

approx. 70 revolutions. <strong>MeWa</strong> CEO Ulrich Hink in front of two of the four<br />

disk flywheels of the AlphaCutter XXL 3700.<br />

<strong>The</strong> first encounter leaves a lasting impression:<br />

the alphacutter is hungry.<br />

the new bulky waste shredder<br />

devours enormous quantities of household,<br />

commercial and industrial waste.<br />

the homogeneous fragmentation means<br />

that the throughput can also be increased<br />

in the downstream granulation<br />

line by more than 30%. Particularly in the<br />

Der Schwungmassenantrieb<br />

im AlphaCutter XXL 3700.<br />

case of materials that are difficult to process<br />

such as mattresses, truck tarpaulins<br />

or large compressed bales, the progress<br />

made compared to other machine solutions<br />

is enormous.<br />

AlphaCutter XXL for<br />

high throughput<br />

the alphacutter XXl 3700 is particularly<br />

suitable for facilities that have to<br />

handle very large volumes of waste. up<br />

to 60 metric tonnes of mixed wastes per<br />

hour can be processed with the high-performance<br />

unit.<br />

Depending on requirements, version l<br />

with a rotor length of 2200 millimetres and<br />

version Xl with a rotor length of 3200 millimetres<br />

supplement the range of available<br />

products.<br />

Turnkey plants<br />

<strong>MeWa</strong> builds and delivers turnkey<br />

plants for the processing of household<br />

and industrial waste, providing services<br />

from the first draft design to commissioning<br />

at one stop. Depending on the requirements<br />

of the customer, <strong>MeWa</strong> creates<br />

pure sorting plants with manual sorting or<br />

mechanical separation all the way to complex<br />

plant concepts with sophisticated cutting/separating<br />

techniques for the manufacture<br />

of solid recovered fuels.<br />

near Ghent, for example, the<br />

British shanks Group operates<br />

a complete <strong>MeWa</strong> plant for the<br />

processing of mixed construction waste.<br />

Three granulators<br />

Following pre-granulation, vibrating<br />

screens, wind screening, metal separators,<br />

near-infrared technique as<br />

well as three large granulators ensure<br />

output sorted by material type and a<br />

throughput of 35 metric tonnes per hour<br />

the main purchaser of the high-calori-<br />

fic substitute fuels is the cement industry<br />

in Belgium. ■<br />

10 11


Querstromzerspaner<br />

<strong>The</strong> patented UNI-CUT ® QZ Querstromzerspaner has<br />

replaced the traditional fragmentation technology with<br />

chain tools – and thus thoroughly revolutionised the<br />

process with a level of success that literally makes a bang.<br />

<strong>The</strong> new Smash Boom Bang is the junior partner in electrical<br />

scrap recycling.<br />

Smash Boom Bang<br />

Where the hurricane rages inside<br />

<strong>The</strong> Querstromzerspaner and Smash Boom Bang revolutionise<br />

recycling technology<br />

Electrical and electronic scrap, refrigeration<br />

devices, aluminium composites, plastic-metal<br />

composites of all types, but also biological<br />

waste - the Querstromzerspaner is deployed<br />

everywhere different material mixtures have to be<br />

broken down. the patented QZ was developed to<br />

separate a wide variety of composite materials.<br />

in the meantime, the technology that works<br />

according to a completely new concept has developed<br />

into the most successful machine in the<br />

<strong>MeWa</strong> range of products. in contrast to cutting<br />

tools, the Querstromzerspaner separates the material<br />

with its acceleration instruments. here, the<br />

chains generate a kind of cyclone in the processing<br />

chamber.<br />

the QZ exploits the physical forces of the impact<br />

energy, thus guaranteeing particularly fast<br />

and gentle material separation. even after a few<br />

seconds, secondary metals of high purity that are<br />

fit for the market exit from the drum of the machine.<br />

Low wear costs<br />

compared to cutting processes or swing-hammer<br />

pulverisers, the resulting<br />

wear costs are significantly lower. in the<br />

meantime, the patented Querstromzerspaner<br />

is deployed worldwide in<br />

a wide variety of plant variants.<br />

refrigeration devices<br />

and electrical scrap in particular<br />

can be gently and<br />

economically fragmented<br />

with <strong>MeWa</strong> technology.<br />

With different drum<br />

sizes from 900 to 2500<br />

millimetres, the suitable machine for every requirement<br />

is on hand.<br />

Smash Boom Bang – the solution for small<br />

electrical appliances<br />

in the field of pre-granulation of electrical and<br />

electronic scrap, <strong>MeWa</strong> has conceived a supplementary<br />

solution: the smash Boom Bang. this<br />

technical innovation is particularly suitable for<br />

small electrical appliances. after processing, the<br />

housing, processor boards, motors, cables, transformers<br />

lie exposed; parts containing pollutants,<br />

for example capacitors and batteries, remain<br />

intact. the individual components can be<br />

easily taken from the conveyor belt by hand in<br />

the next operation.<br />

the dismantling machine saves the time-consuming<br />

and costly manual pre-dismantling of the<br />

electrical appliances while still enabling the plants<br />

to carry out combined processing of the wastes in<br />

one mechanical and manual system. ■<br />

Smash Boom Bang.<br />

12 13


Fridge recycling<br />

Single-stage, fully automatic and environmentally friendly<br />

WEEE processing plants for electrical scrap and refrigerators convince with their economic efficiency and the highest environmental standards<br />

In line with the WEEE Directive of the European Union, many<br />

nations have established an effective recycling system for<br />

electrical and refrigeration devices. Very often, the Querstromzerspaner<br />

(QZ) from <strong>MeWa</strong> plays the main role in this process.<br />

<strong>The</strong> machine takes the appliances apart in a single-stage process<br />

in a particularly efficient and gentle manner.<br />

E<br />

lectrical appliances and refrigeration<br />

devices constitute the flow<br />

of waste with the highest growth<br />

in europe. alongside numerous recyclable<br />

resources, however, the devices and<br />

appliances also contain harmful substances.<br />

across europe, more than 200 million<br />

cFc refrigeration devices are still<br />

operated. these generations of devices<br />

are now coming in for recycling. the environmentally<br />

harmful chlorofluorocarbons<br />

are in the refrigerant and in the<br />

appliance insulation.<br />

in austria, a country that requires<br />

particularly high environmental stan-<br />

dards in this area, <strong>MeWa</strong> commissioned<br />

a highly modern refrigeration device recycling<br />

plant recently. the new operators<br />

and attending guests from the field<br />

of politics agreed at the opening: „With<br />

<strong>MeWa</strong> technology, we are setting new<br />

standards in the disposal of refrigeration<br />

devices in europe.“<br />

<strong>The</strong> plant achives 900,000 metric<br />

tonnes of CO 2 reduction<br />

up to 300,000 refrigeration devices<br />

per year will be processed here in future,<br />

recovering aro<strong>und</strong> 90 metric tonnes<br />

of cFcs. the functioning principle of<br />

the plant corresponds to an annual reduction<br />

in the environmental burden of<br />

900,000 metric tonnes of co 2 . For this<br />

Environmental Award for the <strong>MeWa</strong><br />

fridge recycling plant: Daphne in gold.<br />

Fully automatic WEEE-plant in Daventry.<br />

Refrigeration device pro-<br />

cessing plants from <strong>MeWa</strong><br />

convince with high rates<br />

of recycled resource recovery<br />

and complete CFC separation. achievement, the plant in Kematen received<br />

the austrian environmental award<br />

„Daphne“ in gold in March 2009.<br />

With the Querstromzerspaner technology,<br />

cFc and pentane appliances<br />

can be processed simultaneously without<br />

their having to be sorted beforehand.<br />

not only the recovery rate of the<br />

cFc is exceptionally high, but also the<br />

economical operation of the plant and<br />

the high recycled resource rate with ferric,<br />

aluminium / copper and plastic fractions<br />

sorted by material type at the end<br />

of the process have led to the plant type<br />

being deployed in almost all european<br />

countries.<br />

<strong>MeWa</strong> plants for processing<br />

household appliances, home electro-<br />

nics or computers are even more widespread.<br />

With the first plants in canada<br />

and california, the step across the<br />

atlantic has been made.<br />

the patented Querstromzerspaner<br />

also handles the dismantling work for<br />

electrical scrap processing. the parts<br />

containing pollutants, for example capacitors<br />

or batteries, remain intact in the<br />

chain fragmentation process and can<br />

then be sorted without difficulty using<br />

separating techniques or by hand. at<br />

the end of the process, more than 90%<br />

of the input volume is available, cleanly<br />

separated and sorted according to different<br />

material fractions.<br />

Fully automatic operation<br />

in Daventry, england, a highly mo-<br />

Ferric fraction, separated into<br />

a single material type.<br />

Fridge recycling<br />

dern <strong>MeWa</strong> plant configured for fully<br />

automatic sorting was recently commissioned.<br />

after processing in the Querstromzerspaner,<br />

metal detectors, ferric<br />

and non-ferric separators, plastic sorting<br />

devices, circuit board separators, proximity<br />

infrared devices as well as air separators<br />

separate the material into different<br />

material flows. only four to six<br />

employees per shift are responsible for<br />

ongoing operation.<br />

the combination of refrigeration device<br />

and electrical scrap processing can<br />

also be implemented using QZ technology.<br />

in st. helens, england, <strong>MeWa</strong> put<br />

europe‘s biggest processing plant into<br />

operation for mixed treatement with devices<br />

classified according to the european<br />

Weee Directive. ■<br />

14 15


Metal composites<br />

Resistance is pointless<br />

QZ separates metal composites ready for<br />

the steel mill<br />

When breaking down metal-plastic mixtures, the Querstromzerspaner<br />

delivers particularly good results. One of the tasks is to<br />

clean metals that have already run through magnetic separators<br />

in sorting systems for domestic and industrial waste.<br />

Companies that specialise in processing<br />

special scrap have moved into<br />

industrial centres with very good<br />

transport links.<br />

at first glance, the volume of waste collected<br />

there in the yard and in the shop<br />

High quality fractions in<br />

primary raw material qualities.<br />

looks like normal domestic and industrial<br />

waste.<br />

Processing for use in steel works<br />

however, the composition differs<br />

f<strong>und</strong>amentally. the waste consists of<br />

more than 60 % metal. the plants have<br />

specialised in processing the so-called<br />

metal separation fraction<br />

from sorting or metal processing<br />

plants so that it can<br />

be used in steel works. the<br />

delivered metal fractions,<br />

for example tinplate cans,<br />

still adhere to a great extent<br />

to external materials.<br />

the <strong>MeWa</strong> Quer-<br />

stromzerspaner has proven<br />

to be the ideal technology<br />

to separate these<br />

stubborn composites. the<br />

positive results have<br />

led a number of companies<br />

to invest in this<br />

direction in the past few<br />

months. existing plants<br />

Input motor blocks: the QZ separates<br />

brass-aluminium composites.<br />

have also extended their processing to include<br />

other lines with the patented Querstromzerspaner.<br />

Low wear costs<br />

together with the separating techniques<br />

that are geared to it, the chain<br />

principle of the <strong>MeWa</strong> QZ ensures high<br />

throughputs, output fractions sorted by<br />

material type and low wear costs. Particularly<br />

in the last point, the advantages<br />

compared to cutting shredder systems are<br />

huge.<br />

Metal composites of all types<br />

as a general principle, the QZ process<br />

is suitable for the separation of a wide variety<br />

of metal composites. applications involving<br />

components made of aluminium<br />

are just as frequent as the processing of<br />

swarf and metal chips. after all, the result<br />

is plastic, non-ferric and ferric fractions –<br />

ready for collection by the steel works and<br />

resmelting shops that are connected by<br />

the relevant transport systems. ■<br />

Tyre wire cleaner separates<br />

steel and rubber<br />

Tyres contain a substantial amount of steel wire. For this<br />

content, <strong>MeWa</strong> has developed the UNI-CUT ® SP tyre wire<br />

cleaner. This special machine removes textile and rubber<br />

residues from the steel wires, fully recovering the metal<br />

in the highest quality.<br />

16 17<br />

I<br />

n order to protect the machines in the<br />

downstream tyre recycling process<br />

steps against excessive<br />

the wire is removed<br />

from the process<br />

directly after the<br />

first granulation step<br />

by magnetic separators.<br />

this fraction, however, is in a very unclean<br />

state at this point. along with the<br />

wires, aro<strong>und</strong> 10 to 35 percentage by<br />

weight of rubber and textiles is also withdrawn.<br />

this proportion is too high for use<br />

in a steel smelter. <strong>MeWa</strong> has now specifically<br />

devoted its attention to this fraction.<br />

equipped without sensitive blades,<br />

the tools mounted on the rotor shaft rub<br />

Tough refinement<br />

<strong>The</strong> double swing-hammer mill<br />

uses a kinetic impact effect to<br />

pulverise the material to be<br />

gro<strong>und</strong>. two rotors, to which steel<br />

hammers are attached, rotate in a metal<br />

housing. the impact of the hammers<br />

pulverises the conveyed materials.<br />

the hammers sling the units<br />

against the grinding wall, where the<br />

impact breaks them up further. the<br />

gro<strong>und</strong> material remains in the pulverisation<br />

zone until it is small enough<br />

to pass through a defined screen. this<br />

screen determines the output size of<br />

the material. a characteristic of the<br />

hammer mill is also the spherical output.<br />

■<br />

the rubber and steel mixture on the stator<br />

shaft of the machine against one another,<br />

thus exposing the<br />

individual fractions.<br />

specially configured<br />

vibration<br />

channels and magnets<br />

separate the<br />

exposed wire, textile<br />

and rubber fractions. the entire separation<br />

plant is encapsulated. this enables<br />

exposed textiles to be blown out via air<br />

separation devices and captured in a filter.<br />

the turnkey <strong>MeWa</strong> line is also equipped<br />

with its own control system. at the<br />

end, the wire emerges with a purity of greater<br />

than 98% – ready to use in a steel<br />

smelter. ■<br />

<strong>The</strong> UNI-CUT ® UHM Hammer mill has proven effective<br />

in the preparation of material mixtures of plastic, aluminium<br />

and copper. <strong>The</strong> advantage: fractions sorted by<br />

material type can be extracted in defined grain sizes.<br />

This is frequently a requirement for the manufacture of<br />

new products from recycling material.<br />

Output: Copper<br />

and aluminium.<br />

Tyre wire cleaner and<br />

Hammer mill


Bio QZ Bio QZ<br />

Extract the maximum<br />

Biogas plants: Querstromzerspaner from <strong>MeWa</strong><br />

prepare substrates ideally for the bacteria<br />

Increasing the gas yield, stabilising the operating state,<br />

reducing the holding time in the fermenter – in short:<br />

many plant operators will soon be optimising<br />

existing biogas plants. With the Querstromzerspaner<br />

(QZ), <strong>MeWa</strong> offers a solution that starts right at<br />

the front of the process chain. „Properly preparing<br />

substrates“ is the simple but effective formula for the<br />

patented machine.<br />

Whether fuel crops from the<br />

fields, expired foodstuffs, biological<br />

waste from bins,<br />

slaughterhouse waste or surplus seasonal<br />

crops – there is a great deal of energy<br />

in the biomass. converting this energy<br />

quickly and efficiently into usable biogas<br />

is the task of modern fermentation plants.<br />

this is how aro<strong>und</strong> 5,000 biogas plants in<br />

Germany produce environmentally friend-<br />

ly power and heat, and the trend is on the<br />

up and up.<br />

however, an important process step<br />

has often been neglected during planning.<br />

exploitation of the substrates in fermentation<br />

can only be optimised with the right<br />

separation. this means that the strains of<br />

bacteria in the fermenter can only begin<br />

their decomposition process quickly and<br />

Querstromzerspaner<br />

QZ 900.<br />

effectively when the cell structure of the<br />

input materials has been broken up.<br />

With the patented Querstromzerspaner<br />

(QZ), <strong>MeWa</strong> offers the suitable solution<br />

for this application. instead of cutting<br />

up the input materials, the Bio-QZ works<br />

with the principle of a pestle and mortar.<br />

this creates a significantly larger contact<br />

surface for the bacteria, enabling a significant<br />

rise in the energetic yield of the<br />

substrates. rotating chains on the floor<br />

of the machine chop up the fuel crops in<br />

seconds. „this gives the substrate a<br />

homogeneous composition, making it<br />

much more ‚palatable‘ for the bacteria,<br />

so to speak,“ says a biogas plant operator<br />

in describing the result.<br />

the principle provides sustained effects<br />

above all in the case of agricultural plants<br />

that feed fuel crops from the field into the<br />

fermenter. Where the Bio-QZ has been<br />

retrofitted, a significantly more stable<br />

operating state of the entire biogas plant<br />

has been achieved. the homogeneously<br />

prepared substrate can not only be<br />

pumped more easily, the energy-intensive<br />

stirring periods in the fermenter can also<br />

be more than halved. Floating layers disappear<br />

very quickly. a farmer in nördlingen,<br />

Bavaria, describes the situation in his plant:<br />

„the material in the fermenter now moves<br />

of its own accord. it‘s visibly alive.“<br />

30 % more gas yield<br />

Depending on the input material used<br />

originally, up to 30 % more gas yield is<br />

measured in plants with Bio-QZ operation.<br />

evaluations have also indicated a higher<br />

methane content in the biogas. and<br />

an even more far-reaching difference can<br />

be determined compared to before: in the<br />

plant in nördlingen, the yard now stock-<br />

piles not only corn silage but now also<br />

seasonal crops such as red beets, potatoes,<br />

oil radish, sugar beets or grass cuttings.<br />

„it is now much more flexible to feed<br />

the plant, enabling me to exploit seasonal<br />

business,“ says the farmer.<br />

Insensitive and versatile<br />

in the meantime, the machine has<br />

proven its suitability for the preparation<br />

of substrates on a wide variety of plant<br />

categories. alongside the renewable resources<br />

plants that operate with a high<br />

dry-substance content, the principle also<br />

delivers the same positive results in municipal<br />

fermentation plants with biological<br />

waste bins as well as for slaughterhouse<br />

waste and packaged foodstuffs, for<br />

example. the machine is also insensitive<br />

to metal parts or stones and completely<br />

unwraps packaging. in a downstream<br />

separator circuit, the packaging can be<br />

easily removed from the biomass. ■<br />

<strong>The</strong> QZ 1600 at work.<br />

18 19<br />

Corn silage.<br />

Fruit and vegetables. Slaughterhouse waste.<br />

Packaged food.<br />

Red beets.<br />

Sugar beets.


001 0810 2000/e<br />

Company<br />

Mewa recycling<br />

<strong>Maschinen</strong> <strong>und</strong> anlagenbau Gmbh<br />

Gültlinger straße 3<br />

75391 Gechingen/Germany<br />

tel. +49 (0)7056 925-0<br />

Fax +49 (0)7056 925-169<br />

info@mewa-recycling.com<br />

www.mewa-recycling.com<br />

<strong>MeWa</strong> recycling <strong>Maschinen</strong> <strong>und</strong> anlagenbau<br />

Gmbh has been playing a leading<br />

role in the recycling industry for more than<br />

25 years. the core business is on deve-<br />

loping and building recycling machines<br />

and engineering turn-key plant solutions.<br />

<strong>MeWa</strong> machinery is processing electric-<br />

and electronic scrap, fridges, tyres,<br />

domestic and industrial waste, oil filters<br />

and organic waste for biogas plants. Being<br />

an international market leader, <strong>MeWa</strong>’s<br />

innovative technology is patent-protected.<br />

at the headquarters in Gechingen/<br />

Germany and in other international sites<br />

more than 150 employees are working<br />

for <strong>MeWa</strong>.

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