Taskmaster Grinders Play Central Role in Biofuel
A biogas station in Poběžovice, the Czech Republic could be a prototype for what the future holds for the production of energy from renewable sources. Built by the Spin Plzeň company, the facility is located on the grounds of an agricultural farm focused on pig breeding. The station processes a combination of biodegradable waste to produce the biogas. The main component is 100 m3/day of liquid pig manure which is combined with maize silage and slaughterhouse waste.
The components of the station were designed and manufactured by the company, Tomášek SERVIS, s.r.o. Various proposals for processing input raw materials were considered. The goal was to install size reduction equipment capable of handling 9.5 t/day of raw materials with a required particle size at output of 12 mm. Proper treatment was essential, as the form and output size of solid particles was strictly regulated.
After meeting with a technologist and several company representatives, a recommended solution was the addition of two Franklin Miller -TASKMASTER twin shaft grinders: a horizontal twin-shaft model with a feeding hopper and a second vertical grinder further down the line. Following several test runs, the two grinders were installed and the station began production in 2009.
In operation, the input raw material passes through the TASKMASTER, Model TM2342, where the primary grinding of solids is carried out. The raw material continues gravitationally to a reservoir where the ground solids are mixed with liquid pig manure. The combined material is sent to the TASKMASTER, Model TM8512-04 for secondary maceration and piped into the pasteurizing vessel. The material is then put into a digester which begins the biogas production process.
At present, the grinders process raw materials several times a week prior to pasteurisation. Since their installation, the operation of the units have been excellent. A problem arose only once when animal hides with bristles were erroneously added to the input material. Franklin Miller solved the problem by providing optional combs for automatic cleaning of these areas and advising personnel of the necessity of following guidelines in the operating manuals.
According to both the station owner and operators, the units do an excellent job of size reduction, are extremely reliable and easy to maintain. The pasteurization process, an important step, has successfully passed several inspections by state agricultural, environmental and health agencies, an indication that the units are optimally processing the raw material. And to top things off, the station recently decided to expand their operations and subsequently ordered two more Taskmaster grinders.
Taskmaster® grinders set the standard for effective solids reduction, reliability, easy maintenance and exceptional durability. These grinders are provided from small units that can be installed directly in pipe systems up to large shredders that feature 40, 75 and 100 HP motors for handling everything from solid waste and hides to tires and solid rocket fuel. These units are provided with Franklin Miller's unique sealing technology which makes them uniquely suited for wet processing under pressure conditions as well as for dry gravity applications. TASKMASTER grinders are available with many innovative features including patented "cutter cartridge technology." With these cartridges, multitudes of individual cutter and spacer disks are replaced with a few one-piece multi-cutter cartridges that greatly enhance unit strength and performance
Taskmaster Grinder Solves Paint Problems for Car Makers
A major automobile manufacturer had a problem with the paint finishing effluent line. A Taskmaster® TM8512 grinder was chosen as the most effective way to handle dried paint chunks that were passed through a four inch pipeline and deposited into a collection tank.
Large pieces of paint debris often clogged the line and needed to be reduced to a smaller size. The Taskmaster was attached to the line in the area at the bottom of the collection tank. Special “combs” were added to optimize the cutting and shearing of the paint pieces and to help remove anything that would stick on the cutters, spacers or shafts.
On each pass or rotation, material that adhered was scraped off and pushed to the cutters again. The paint chunks were ground to desired output size of ¼ inch, flowing easily through the pipeline.
The application at another automotive facility was to break up clumps that formed in paint agglomerates in a paint tank. The paint balls clogged the recirculating pump resulting in down time and frequent maintenance. To remedy the problem, the solution was to install a Super Shredder® SS—8000 between the paint tank and the pump.
Franklin Miller’s high performance grinders and shredders have been instrumental in solving size reductions problems at manufacturing plants worldwide. They easily process agglomerates, paint solids, food, chemicals, oil solids, pulp and paper, pharmaceuticals and more. They prevent pump and pipeline clogging, reduce downtime and maintenance and help increase plant efficiency
Case Study: Super Shredder® To The Rescue
The City of Corning, New York Wastewater Treatment Plant handles wastewater generated by its 10,500 residents. The utility provides full secondary treatment with nitrification, typically processing 1.2 mgd with a peak flow of 6.8 mgd. After grit screening and primary settling, the flow enters a trickling filter, is passed to biological contractors for nitrification and the effluent is released to the Chemung River.
Primary and secondary sludge and solids skimmed from the settling tanks are fed into an anaerobic digester heated to 95 to 97F by a spiral heat exchanger. After a retention time of several weeks, the digested solids are mixed with polymer, dewatered, and sent to a landfill.
Since 1994, the facility has relied upon the powerful grinding capabilities of several strategically placed Super Shredder Disintegrators to ensure that operations run smoothly. “The Franklin Miller Super Shredder has come to the rescue of the spiral design heat exchanger not just once but at two different municipal wastewater plants during my career, restoring their true efficiency and value in handling raw municipal sludge,” said Alan M. Bontorno, Chief Operator.
“Prior to the installation of in-line Super Shredders, raw sludge pumped through the boiler hot water fed heat exchanger, on its way to anaerobic digestion tanks, would hardly go two days in operation before debris slowed and plugged the flow,” Bontorno explained. “ The smooth spiraling vanes of the heat exchanger should have allowed unconstricted flow despite entrained debris. Yet entanglement occurred between the varying materials and sizes. The Super Shredder got the debris uniform and flowing.”
“Modular construction of the cutting area allows me the option of seal/bearing pre-assembled cartridge replacement for the drive or driven ends when needed, or ordering of individual parts for skilled mechanics to use in a re-build. Either way, in- between the cartridges are housed a rugged and effective cutter and cage assembly that has not failed to make operations better.” “The service has been very good and the staff is helpful and knowledgeable. Thanks for making a great machine,” Bontorno concluded.
The SUPER SHREDDER® in-line disintegrator easily reduces the toughest solids in sludge or raw sewage lines. The unit combines unsurpassed grinding capabilities with streamlined, easy to maintain features. Innovative design provides a high level of open area to fluid flow making the Super Shredder ideal for applications requiring a heavy duty size reduction processor that can handle high flows with minimal headloss.
The SUPER SHREDDER features a patented “spherical shredding” mechanism that cuts and shears tough sewage solids into fine bits. The hard faced stainless steel cutters offer unsurpassed wear resistance. Because of the spherical rotor design, the SUPER SHREDDER has far less moving parts and therefore requires far less maintenance than units with banks of cutter disks. With two easily replaceable one piece cutters, maintenance is convenient and down time is minimal. Included with the SUPER SHREDDER™ is a S-250 Auto-Reversing control system that senses jam conditions and automatically reverses.
Delumper® LP Protects Downstream Equipment from Tramp
For the past eight years, a paper products manufacturer has used the Delumper® 1075LP in an unusual application on an expensive process line. The material being processed is a mix of carbon and sulfuric acid. During production, tramp materials such as ferrous and nonferrous bolts become trapped in the products and can play havoc on the downstream equipment if they are not removed.
According to the plant manager "We tried all kinds of metal separators and none of them did what we wanted. They couldn't handle non-ferrous objects or they didn't work on metal bolts trapped in the product. We use the Delumper LP like a sacrificial component to catch both kinds of material and it has been the best solution for our needs.
During the processing operation, oversized lumps and clumps are de-agglomerated by the Delumper's long fingers to a size that easily fits through the unit's heavy bar grating. Encapsulated bolts are broken free from the product and are caught on the grating. The unit is installed in a free falling position
"We want to purchase another 1075LP with a finer grating to capture even smaller bolts," concluded the plant manager. "It definitely protects our equipment."
The Delumper 1075 LP is provided with a one-piece seamless uni-body housing. The extended LP cutter teeth rotate completely through a heavy bar cage, self-clearing the slots with each rotation. Each tooth is built for precise balance, interchange ability and smooth operation. Optional feature includes an extended outboard bearing, convenient side door for easy access, and hopper for feeding. Output sizes are adjustable by changing the speed or the comb. The size of the material handled could be as large as the throat opening. The ultra compact Delumper Crusher is designed to be used in open or closed systems such as ducts, chutes or pipes. The unit requires only 13" headroom space in-line.
The Delumper can be supplied as a stand-alone unit or as part of a complete engineered system.