General Questions
CRS-BERAHN®, aqua-CRS-BERAHN®, and aqua-N-Filter-System
This question implies two different issues: one is the biggest/smallest capacity of a module and one is the size and therefore the capacity of a plant. Generally, the capacity of one module depends hardly on the kind of the input and the mode in which the input is available. When recycling tires, for instance, the capacity is 2.4 mt per day (24h) per module whereas the capacity of one module is 5.38 when recycling waste oil. The capacity of a module is not modifiable. It is always adjusted to the input. The size and therefore the capacity of a plant depends, correspondingly, to the kind of input and number of modules. The smallest plant size is the size at which it operated economic. Theoretically, there are no limits in the number of modules. Because of efficiency reasons, we recommend operating a maximum of 30 modules per production hall.
The optimal size of a plant is calculated on basis of the input material and the amount per year you tell us.
Example calculation for scrap car tires
You want to recycle 8,000 mt of scrap car tires per year. One module treats 2.4 mt per day in average. When assuming 332 operation days per year (worst case) you need to recycle 24.1 mt of scrap car tires per day. Ten modules are sufficient to reach your goal:
10 modules x 2.4 mt per day x 332 days = 7,968 mt of scrap car tires
Yes.
Questions concerning treatable waste
Basically, all kinds of hydrocarbon-containing waste can by treated via pyrolysis. However, not every input can be treated economically. Our technology does not only do pyrolysis. When recycling waste oil, for instance, the process is desorption. Next to waste, also products can be improved in their quality as far as hydrocarbon volatiles are the challenge.
Examples of waste that can be treated with the CRS-BERAHN® via pyrolysis: (list is not concluding)
- Rubber waste of any kind, e.g. scrap tires, conveyer belts, rubberized chains, rubberized components, rubber cable, and so on
- Biowaste of any kind, e.g. canola pellets, rice husks, palm oil residues, green waste, sawmill waste, and so on
- Other, e.g. rejects (e.g. from producing diapers), with oil contaminated textiles (e.g. from cleaning oil tanks), and so on
Several kinds of plastics, such as PET or PA6, as well as material in powder form cannot be treated with our technology. In addition, halogenated inputs are not appropriate.
No. Tires need to be treated in a whole. This is also true for giant tires.
Shredding requires high energy and maintenance efforts for the machines. For the reason of energy efficiency, this pretreatment is disadvantageous. Another disadvantage is the heat during the cutting, which causes that the steel burns into the rubber. This negatively affects the quality of the carbon after a pyrolysis. However, in most cases the quality of the carbon is crucial for the profitability of the plant.
Very light-weighting waste, such as industrial film scraps or many kinds of biowaste, should be pelleted to reach an economic throughput.
Yes.
Questions about the technology
Yes. Since at least the (residual) gas is utilized directly within a power-producing unit (e.g. CHP), typical combustion emission occur. Compliance with statutory emission limits will be considered in the design of the generating units and, if necessary ancillary facilities.
Usually we offer the technology of complete recycling plants. This comprises of the modules as well as the complete periphery that consist of the filling, emptying, separation, oil collection tanks, power producing unit(s) and all necessary safety installations.
Certified specialized companies in Germany and Europe manufacture all machines, equipment, and functional parts. The design is always based on our requirements. Although it is standard technologies, for example, in the periphery, they are configured to the individual needs of the entire recycling plant. Of course, we also pay attention when choosing the technology to the current state of the art, so that always the highest standards are guaranteed in terms of safety and the environment.
The first commercial plant is within the environmental approval procedure. The set-up takes place in Germany.
We have one module in industrial size. However, it is not operated around the clock since this is not economic. We use the module to test new inputs under industrial conditions. The environmental authority approved the module and the periphery.
Basically, yes. However, in individual cases, the costs and benefits must be compared.
Questions concerning the profitability
If you have more input on a regular basis and if you want to increase the capacity of your plant permanently, then you can install additional modules at any time.
The modules operate independently from each other. Just turn one (or more) module/s off to safe energy and other costs. As soon as your input availability increases, you turn it on again.
As far it is similar waste, yes, you can do. For instance, if you usually recycle scrap tires you can also treat other kinds of rubber waste. If necessary, adjustments within the separation are required to avoid disturbances.
No, since the modules operate independently from each other.
Yes. The quality characteristics as described on this website are part of the contract.
Yes. With proper handling of machinery and equipment, a smooth operation is guaranteed. Once a year, the plant will be shut down for maintenance and repair work for two to three weeks. Thus, the actual number of working days will be at least 344 day which is above the assumed (worst case) utilization in the example.
The modules operate 24 hours / 7 days a week. A regular 3-shift-system does not cover operation during the weekends. There are different 4-shift-models we will discuss with you.
The construction of the recycling plant requires adequate real estate and a suitable industrial hall. The estate has to have all the necessary infrastructural connections such as telecommunications (telephone, internet), water and sewage, electricity (also for feeding in the excess current). Those standard installations have to be installed in the production hall as well as in the office and social space. At the hall, a medium-voltage power supply must be provided.
During the construction of the plant, you must take care of reasonable temporary site power and social and office space.
As far as your project will be realized outside the EU, costs such as (over sea) transportation, import licenses, customs duties, and interpreters on site are not considered in our prices. Fees for permissions, such as building permits or approvals according to environmental laws, are generally not included in the price, since those fees have to be paid by the applicant and operator, who is you in the end.
Next to the machinery and equipment, several services are included in our price. Our range of service you find here.
For this case we offer research & development services. You find further information here.
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