The waste recycling industry has seen significant change over the last few years, with ever increasing land fill taxes, recycling companies are investing in more sophisticated sorting, screening and separation equipment and plant, reducing the tonnage going to landfill, reducing their tax bill, increasing and funneling more products back into the manufacturing industry.
It was a natural progression having supplied conveying and storage equipment to a number clients in other industries, it became evident that Orthos Projects could turn their materials handling expertise to the waste recycling industry and produce superior waste recycling systems using Orthos designed conveyors and selected propriety equipment, the aim being to build bespoke plant maximizing the clients recycling capability, combined with an after sales service, spare parts availability and build quality that is second to none.
Materials Recycling Facility (MRF)
Orthos Projects understand the fundamentals of an efficient Materials Recycling Facility (MRF) which must be designed to produce clean, consistent, marketable products from heterogeneous materials that contain some level of contamination. Designing, constructing and equipping a new MRF, or redesigning an existing facility, requires an efficient integration of automated technologies and manual labour. When designing our MRF’s, the following are generally considered as some of the key objectives in order to maximize efficiency and cost-effectiveness:
- Maximise material throughput.
- Maximise material recovery and minimise processing residue.
- Maximise automation and minimise manual labour.
- Create a safe environment for operators.
- Produce consistent streams of quality recovered materials.
- Optimise the system performance and reduce downtime.
The Orthos designed MRF’s and Skip Waste Sorting Plants are designed to withstand the arduous conditions in which they are subject to, in an ever increasing demand for quality, reliability and longevity. Our plants incorporate quality and robust equipment to include the primary screening and separation utilizing Finger Screens, Taper-Slot Screens or Trommels with the apertures set to the customer’s requirements. These are followed by density and air classification separation units, Dense Out and De-Stoner. Oversize material conveyors pass under large electro over band magnets from followed by processing through a powerful air knife system and into a custom built picking station. The fines (undersize material passing through the screen) are then diverted and conveyed to a further screening operation with a finer cut utilizing the Star Screen or Flip Flop Screen, prior to this passing under permanent over band magnets to remove the ferrous metals.
Orthos have developed similar systems utilizing Trommell Screens with Vibratory Feeders; it’s a feature of the Orthos Material Recycling Facilities that with very little modification it will accommodate all recognised forms of separation equipment. The system can easily accommodate an Eddy Current Separator (ECS) should there be enough non-ferrous metal in the waste stream to warrant the extra investment.
Part of the turnkey project management offered by Orthos is the latest in dust and odour control utilizing water mist systems, and the reduction of noise pollution. Noise reduction is taken into account at all stages of the plant design and the latest silencer systems are employed with the air separation equipment. All the equipment specified in our plant proposals is selected from reputable manufacturers and suppliers with a history of producing process equipment of exceptional reliability and quality.
Solid Recovered Fuel (SRF) and Refuse Derived Fuel (RDF) Processing Plant.
The industry has also seen demand increase for Solid Recovered Fuel (SRF) and Refuse Derived Fuel (RDF). Solid Recovered Fuel is a high quality alternative to fossil fuel produced from commercial waste including paper, card, wood, textiles and plastic. It can be produced to a range of specifications to meet customer requirements. With a moisture content of less than 15 per cent, solid recovered fuel has a high calorific value and is used in facilities such as cement kilns and other industries operating kilns and calciners an as alternative fuel to the fossil fuels currently used, this in turn reducing their carbon footprint and fuel costs.
Refuse derived fuel is made from domestic waste which includes biodegradable material as well as plastics, and has a lower calorific value than solid recovered fuel. Refuse derived fuel is used in combined heat and power facilities, many of them in Europe where they produce electricity and hot water for communal heating systems in the local area.
Compared to land filling, the lower carbon emissions resulting from this approach to processing waste far outweigh the emissions associated with transporting the reclaimed fuel.
Producing SRF and RDF to meet your clients specification, requires upfront and expert knowledge from plant design specialist’s and suppliers of the processing equipment. Orthos projects recognise the importance of process plant and machine selection in order to deliver a first class facility producing and delivering a fuel that meets the exacting and stringent specification of the end user.
This can only be achieved through trust, an understanding of the requirements and a close working partnership in the design of the plant. We will only specify and build the best equipment that’s fit for the purpose that it will be employed, this quite often means that the processing machinery installed comes from the best manufacturers in the industry who themselves have a thorough understanding and knowledge of the processes involved.
Technology with the various levels of automation in modern plant design comes at a cost, without cutting corners we’ll implement and design in, the latest and most up to date systems to produce a cost effective and efficient plant, providing you with total quality control and integrity, for minimum maintenance and maximum return on your investment. To spend a little more at the beginning pays dividends times over at the end.
It’s important that you know your incoming product (essentially waste), the bulk density, handling characteristics, size etc. Is it to be grab fed, or belt fed into the shredding operation, the plant builder should be advised of the worst case in terms of waste characteristics so the plant and equipment can be designed and specified to accept all products that is likely to be presented for processing.
It is essential to remove the unshredable and non-combustible materials from your incoming Commercial and Industrial (C&I) Waste, through an MRF or an alternative pre-sorting system but don’t process clean (C&I) waste, recycle it.
Our plants are custom designed to either fit within an existing facility, in the confines of the area designated or a new site with the consideration of the constraints applied by the local planning authority, whether being installed into an existing building or an open area where the building will be designed around the plant.
The high quality of the processing equipment specified, the design, manufacture, supply, installation and commissioning will fit within a realistic budget, quality in, equal’s quality out. Everything is of a robust build avoiding single point failure, with good access at all levels, making maintenance easy.
It’s important to know your clients exact requirements and deliver a consistent fuel, through monitoring the incoming product, with effective shredding, screening, density separation and removing ferrous and non-ferrous metals, the plant will produce a consistent quality fuel.
For a high quality, reliable, low maintenance SRF plant put your trust into a company that wins repeat business from existing clients, (the surviving few still after 35-years) and has been recommended from satisfied customers time and time again.