Dosing, screening, drying, sifting and conveying with JOEST machines!
Recycling is a growing market – especially in glass recycling new plants are currently arising or existing ones are updated and upgraded. JOEST is an expert for vibratory equipment conveying and processing bulk materials. As such, JOEST offers plant manufacturers customized solutions for glass recycling. With dosing, screening, drying, sifting and conveying, the company covers five fundamental processing steps in a plant.
Thanks to the continuous development of standardized components and subsystems, the JOEST competence center recycling in Duelmen can assist each client with the individual configuration of their plant layout, especially regarding the procedural design of the individual processing components.
The challenge of wear and tear
JOEST covers a wide spectrum of applied technologies throughout the glass recycling process and simultaneously goes in depth with various versions as well as the corresponding periphery. The individual components are specifically designed for the demands of each industry and size, performance and features are determined by the client. The operational availability of the plant is very important. In particular the high wear resistance, thus the low abrasion of plant components plays a big role in Glass Recycling since glass brakes and is one of the most abrasive materials. Using highly wear resistant chromium carbide plates or special ceramic, the machines set standards and ensure high runtimes and yet low maintenance costs.
Dosing – with an innovative drive
From bottle caps and labels to cardboard and plastic: Glass waste can contain up to 50 % organic and waste materials. Depending on this composition and the final desired quality of the recycled material, a variety of sorting processes are necessary. The first step is to convey and dose the glass waste out of the hopper. JOEST magnetic feeders are ideal for such an application, since the feed rate is continuously variable and after being shut down, the machine stops immediately. In addition, the JOEST Hopper Discharge Feeders use an innovative, self adjusting JM-Magnetic Drive. With relatively high amplitude in combination with a comparably average vibration frequency, this drive system results in an efficient discharge. For their particular application, different parameters such as hopper pressure and geometry, grain size, ease of flow, moisture and tendency to bake-on must be considered. The optional covers and discharge hoods are also specifically designed for Glass Recycling. The drive´s self learning mode, enabled by the digital control unit, is as easy to maintain as it is economically efficient. This JM-Drive is an exclusive and unique JOEST product in the world market.
Pre-Screening – via Rod Finger Screen and Air Separation
Special JOEST Finger Screens pre-classify the glass waste into cross cuts between 10 and 40 mm grain size. The high acceleration rates and oscillation of the fingers loosen the material on the screen deck. They also ensure a near clog free screening process.
Fine fractions are screened out, coarse grain continues on to a crusher. In another processing step, the JOEST Air Vibe separates the first material flow and sorts out the coarse light weight fraction like foils or paper for example.
Screening – with the OSCILLA Flip-Flow-Screen
The JOEST Flip-Flow-Screen is designed for inhomogeneous or moist and thus difficult to screen materials. Particularly glass waste has varying levels of contamination with organic material, depending on the country and region it originates from. Here, the OSCILLA Flip-Flow-Screen provides ideal preconditions with a feed grain size of 0 to 80 mm. With its trampoline-effect, this special process prevents the product from sticking on and near-mesh grain from getting clog the sieve. The elastic screen mats which are fixed under tension with the traverse mutually beams and thus the dynamic frame and screen body, are decisive to the process.
The low maintenance is just as beneficial. Changing over the mats is quick and easy to do. In the newest OSCILLA generation, JOEST implements viroblocks between the dynamic frame and the screen body, following the demand for a simple, cost efficient, yet robust solution. The traverse beams also feature special profils to ensure flexibility and efficiency. They are simply cut to the desired length and bolted to the machine body.
Drying – via Fluidized Bed Dryer
The raw material in Glass Recycling contains about 7 % moisture. This moisture sticks to the product and complicates processing it. A drying stage eases further processing. For this purpose, JOEST uses a Fluidized Bed Dryer. With airstreams of more than 150 °C, it reduces the moisture level to a target value of 1 %. Thanks to the special design and layout of the air distribution chamber(s), the air passes evenly through the material and thus results in an equally even drying result. The conveyance within the dryer occurs via micro throwing motions, which are characteristic for vibration conveying technology. Amplitude, frequency and throwing angle are adjusted individually to the application and machine type. Additionally, air outlet hoods are available and follow the motion of the machine. JOEST delivers anything from the machine alone all the way to the entire drying plant including air handling equipment, air filtration, ductwork, steel construction and electrical control unit.
Sifting and sorting – via Zig-Zag
Inside the Zig-Zag Sifter, a multi stage separation of organic material from the individual pre-classified fractions takes place – the goal is an entire elimination of pollution from the raw material. In order to achieve this, the raw material is fed into the zig-zag shaped sifter-channel through an air-tight feeding mechanism. After the Multi Cross Flow Sifting Process, the light weight fraction separates itself from the heavy fraction. The Zig-Zag Sifter is also adapted to the glass material in abration intensive areas. Thus the JOEST Zig-Zag Sifter uses a Vibrating Trough Type Feeder, as opposed to a Rotary Feeder. This results in an even distribution across the width of the machine and feeding of the machine, whilst keeping the wear resistance high. Here too, JOEST offers the complete system with air handling equipment, used air filtration, pipelines, steel construction and electrical control unit.
And time and time again – Conveying
Depending on the glass recycling plant, there are different demands: Covering distance, feeding and distributing. For this, JOEST offers the matching drive technologies, like for example Unbalanced- or Resonance Vibrating Trough Type Feeders. All Trough Type Feeders feature an abrasion resistant lining and can be configured as dust tight if the client wishes so. In general, conveying stretches of up to 80 meters with a single machine are possible. Appropriate solutions for shorter distances with difficult installation situations can also be carried out.
Light Machine Shop (Vapi) has CNC Lathes, VMCs, HMCs, Grinding Machine and Key Slotting Machine.
EJV has a Heavy Duty Lathe (400 mm swing diameter x 2500 mm long) along with 2 machines have been bought from Germany (a) TOS Horizontal Boring Machine with Spindle diameter 130 mm and (b) Scharmann make Horizontal Boring Machine 90 mm Spindle diameter.
Sand attrition units type ZUFS are very powerful and compact machines for chemically bonded mould and core sand. These proved and tested machines are often used in well-known foundries. Generally the sand attrition units are integrated in sand reclamation plants between shake-out and sand cooler. Powerful, linear vibrations are disintegrating the lumps in the attrition sink and repulverize them to sand. Following the attrition sink the oversize grains are screened out with an easy to maintain mounted, well accessible and visible fine screen.
The ZUFB machines are pre-reclaiming sand attrition units (Vibro V-jaw crusher) for big lumps of chemical bonded moulding and core sand. They are typically used for the primary reduction of core sand blocks. The sand block is mainly destroyed by squeezing it between two vibrating jaws. The width of the outlet gap is adjustable. The result: Small sand lumps, ready for further attrition. Note: A friction-based reclaiming unit model ZUFS needs to be installed after a ZUFB sand attrition unit. If high quantities of metal are embedded in the processed sand lumps, it is necessary to remove them before they enter the device.
Furan sand reclamation plants for cold resin bonded sand. The available perfomance is from 1 t/h up to 20 t/h in single line applications. The available screen deck size range is up to 4500 x 4500 mm / 50 ton deck load in single deck applications.
Vibrating tables are used to compact various bulk materials, i.e. cold resin bonded moulding sand in nobake mouldlines. Jöst supplies vibrating tables combined with suitable roller track sections; this combo can be placed directly underneath the whirl mixer swivel range.
The counter-current setback classifier is used for screening of chemically bonded sand. This means that the organic binder components that are abraded from the sand grain surface before the classifier (such as by a tube shredder) are removed as much as possible. Accordingly, the loss on ignition is greatly reduced. Lowering classifiers are usually part of cold sand resin regeneration plants.
The fluid bed cooler cools down the moulding sand which is conveyed from a crusher through an upstream magnetic drum into the cooler. The machine is not vibrating but stationary. The sand is fluidised by means of a special fluidisation plate by a powerful vertical air flow. It then has flow characteristics like water. When fluidised, the heat is released via contact heat exchange to a tube matrix with high surface passed by water.
The spiral breaker is designed for unmoulding cold resin bonded sand moulds on its shakeout deck surface by powerful, directed vibrations. Furthermore, the sand lumps are disintegrated in the lower deck which is located the crusher body. The reclaimed sand is conveyed upwards to gain hight in a helical shaped trough which surrounds the machine body.
Sand attrition units are very powerful and compact machines for chemically bonded mould and core sand. These proved and tested machines are often used in well-known foundries. Generally the sand attrition units are integrated in sand reclamation plants between shake-out and sand cooler.
The pre-reclaiming sand attrition units for big lumps of organic bonded moulding and core sand are typically used for the primary reduction of core sand blocks. The sand block is mainly destroyed by squeezing it between two vibrating jaws. The width of the outlet gap is adjustable.
Shakeout screens are machines which are equipped with a heavy duty deck. The vibration features high acceleration and is directed vertically. This enables the machine to shake out nobake sand moulds.
Used sand coolers serve for the cooling of hot foundry sand. The sand cooler consists of a vibrating conveyor made with an air-permeable bottom, a stationary exhaust hood, a moisturizing unit, a fan and a control unit. The sand is cooled under optimum heat transfer conditions in the fluidised bed by evaporation of water. The final moisture level is adjusted by the precisely controlled addition of water according to the temperature and throughput.
Gate feeders, which are especially suitable for the cast iron transport, are basically consisting of the vibrating trough, the trough carrying frame and the modular executed and standardised vibration absorber stations. The flexibility of the design allows a large distance between the absorber stations.
Sand conveyors are used below shakeout machines to convey the used sand over long distances in direction to the place where the sand is treated.
Sorting conveyors are robustly manufactured special vibrating conveyors. They are normally used in foundries with green sand mould line installations. The sorting conveyors are installed either directly after a separating conveyor or ideally directly after a casting cooler.
Sorting conveyors are robustly manufactured special vibrating conveyors. They are normally used in foundries with green sand mould line installations. The sorting conveyors are installed either directly after a separating conveyor or ideally directly after a casting cooler.
Due to vibration parameters, selected accordingly, the castings on a helical casting cooler are conveyed downwards. The cooling is effected by means of a convection heat exchange in counter flow.
Casting coolers are heavy duty slow speed resonance conveyors which are equipped with an airtight hood. Typically, this machine is arranged after the shakeout. The cooling effect is based on convective heat exchange between the hot castings and a powerful cooling air flow.
Vibration shakeout drums are used, when the castings which have to be unpacked, are small and have few fins on the outside. When unpacking the castings, they will slightly collide with each other due to vibrations. Shakeout drums are mainly installed after vertically divided flaskless mouldlines.
The shakeout machines are equipped with an electronically adjustable angle of attack. Typically they are installed directly after a green sand mouldline. These proved machines are in a high quantity in practical operation in noted foundries. In general the machines are in use when sensitive cast parts needs to be unpacked.
The spiral conveyor is a special type of vibratory conveyor that lifts product vertically. The product moves up the spiral as the conveyor vibrates.
Vibrating dryer uses indirect heat transfer to cool product while it is conveyed on the dryer surface. Hot water, steam, or hot oil can be used as drying medium. The product and cooling medium are kept separated to ensure product quality and purity.
Vibrating fluid bed dryer uses temperature controlled zones to dry the product quickly and evenly. The product is fluidized in warm or hot air and cooled by convection to achieve high drying rates and excellent uniformity.
Vibrating fluid bed coolers transfer heat from the product to the cooling medium directly by convection. Either ambient air or cooled air can be used as a cooling medium and mutiple cooling zones are possible.
Vibrating contact coolers use indirect heat transfer to remove heat from the product. Indirect heat transfer means the product and the heat transfer medium are kept separate. Water or brine can be used as the heat transfer medium. The cooler can be designed with an open feed trough or with an enclosure. The enclosure can be either vibratory or stationary.
The stationary fluidized bed cooler is used to cool chemically bound sand via convective heat exchange with cooling water flowing through tubes.
The helical casting cooler simultaneously supports the product and cools it to the desired temperature. The cooling of the product is achieved by exploiting the natural chimney effect via tangentially arranged air jets on the standpipe.
The circulating air is used for limited cone separator flowing products, wherein the feed material is blown with a defined air flow into the classifier zone. As a result, the particles reduce forces among which high product flow capacities are possible. Classifier diameter about 750, 1000 and 1500mm are available.
The hybrid classifier uses a patented separator channel that makes it possible to drive speeds even with a very small sifter. This classifier type is mainly used for sorting in the flour and fines range. Working widths from 240 to 900 mm.
With the cone separator, after the multi-cross-flow perspective method, in combination with a counter-current inspection, the light material gets separated from heavy. We distinguish: The standard cone separator for free-flowing products is connected via clip on Aspiration with a cyclone and filter system. Classifier diameter of approximately 500, 750 and 1000 mm are possible. The design of the cone separator Dust for effective dusting of plastic granules and pellets is connected via clip on Aspiration with a filtration system. Classifier diameter of approximately 300, 500, 750 and 1,000 mm are possible.
The Zig-Zag classifier separates light material from heavy material. Feed material is introduced into the Zig Zag channel via a sealed feeder. The material drops through the channel, cascading from side to side of the channel while forced air flows upward. This cross flow lifts the light particles out the top of the channel while the heavy material falls out the bottom. Working widths from 80 mm to 2.0 m.
With the AirVibe technology, high separation efficiencies of coarse material is possible using a combination of cross flow air separation and ballistic sorting. The AirVibe is a one-stage design with either a stationary divider or a self-cleaning drum design for wet products. Working widths of 600, 1200, 1600, and 2400 mm. The AirVibe 2 offers multiple separation stages. Working width of 1,200 mm.
Grizzly screens are used as a primary separator for the preliminary separation of material in front of jaw crushers.
Wet sizing screens are used to increase the separation of fines and achieve accurate cuts. They are also used as washing screens. Wet sizing screens can be designed either as linear or circular motion.
The finger cascade screen TopSpin operates on the basis of a circular vibrating screen with above-average acceleration. The high accelerations work together with the conical opening finger strainer system to create a virtually clog-free strainer for difficult screening applications.
Rod screens are used for pre-separation with large gap widths or for classifying extremely difficult bulk materials which can not be separated on conventional screens.
Linear motion screens were developed primarily for dewatering and are now used in many industries. With a steep angle and high acceleration, extremely low residual moisture values can be achieved in the dewatered product.
Banana screens are large, high-strokes screens, developed with the latest technology using the “thin-bed theory” to increase the efficiency in the screening of fines.
Circular motion screens are used for preliminary or final sizing of medium to coarse-grained bulk materials. The screen moves in a circular motion. Decline angles of 10 to 30 degrees can be set to give optimal throughputs for a wide range of applications.
Linear vibrating screens are used for the highest separation efficiencies across a wide range of applications and industries. The largest screens in the world allow the highest production rates.
In the Flip-Flow screen, the elastic screen mats move like a Trampoline. The alternating cross members move relative to each other with a powerful spring mechanism, resulting in a clamping and releasing of the mats.
First Shed is equipped with 40 T (20/20) EOT Crane, 5T additional E.O.T. Crane and 6 nos. Jib Cranes mounted on the columns. There is also a 10T Mobile Crane, to shift the raw material from outside storage area to the Shop. Facilities available here are : Heavy Duty Shearing Machine, Heavy Duty Bending Machine, and a Shot Blasting and Painting Booth. Isolation Bays for testing Vibratory equipments.
Second Shed is equipped with 20/5 Ton EOT Crane. Facilities available here are:
Bed size of 6m * 2m ,Sheet Metal Cutting upto 16mm and 42mm with Gas Cutting.
Light Assembly Shop in Mumbai has induction heating element, light press, light machines and fixtures for assembly of motors and exciters.
Bed size of 4m * 3m ,Sheet Metal Cutting upto 120mm.
Vibration shakeout drums are generally located directly after the cast form a wet ball ejector system. From vibrations of suitable parameters with high acceleration, the separation of casting and molding sand. Unpacking the tube is at the end of the machine body is provided with a case, the use of customized grid surface, through which the used sand is discharged downwards. Unpacking pipes are suitable for castings, the outside have no fragile ribs or thin walls.
Furnace Charger for feeding to furnaces in foundry & steel melting shops.
Dosing feeders are used for small applications or as hopper discharge feeders. Highly accurate control of the feed rate is possible with the electro-magnetic drive and the infinitely variable thyristor controller.
Hopper discharge feeders with integral feed chutes for feeder from bunkers or hoppers are available in various designs. The FUFB deisgn uses unbalanced motors while the FRFB design has an exciter and a separate electric motor for high capacities and heavy products. Vibration amplitude of the feeder can be fixed or adjusted with a variable frequency drive.
Mould Dump conveyors are mass-compensated low-speed resonance channels with low acceleration values. The trough is made of Wear-Resistant steel. Complex lines with curves, climbs, and switches can be realized. Low noise levels are obtained by avoiding throwing motion.
Sorting/Casting conveyors are mass-compensated low-speed resonance channels with low acceleration values and low flow velocities. The trough is made of wear-resistant steel reinforced walls. On these machines, the casting is separated from the gate or feeder. Quiet, smooth transportation without micro throwing motion.