Operating principle of HDPE agglomerator. Agglomerator for plastic waste recycling

Obtaining agglomerate is the first production stage of processing recycled plastic. Of course, to reduce large waste to a fraction acceptable for crushing in an agglomerator, preliminary crushing in industrial shredders or crushers is necessary. However, many enterprises are focusing on processing more accessible materials that do not require preliminary preparation.

Application of agglomerator

The agglomerator is the equipment of the first processing line plastic waste- stretch films, polypropylene, polystyrene, as well as low and low polyethylene high pressure and other types of polymers. The machine allows you to obtain an output product - an agglomerate - that is ready for further use or sale.
In addition to grinding raw materials, technological process allows additional drying of the material during the agglomeration process, however, the use of raw material reduces the productivity of the equipment. For this reason, it is recommended to use more efficient solutions for pre-washing.

Production of plastic agglomerate

The crushing of plastic in the agglomerator occurs due to the rapid rotation of movable knives. The shape and sharpening angle of knives can have a significant impact on the efficiency of working with various types waste. Because due to the friction of the crushed mass against the agglomerator body and the surface of the moving and stationary knives, the material is heated. A homogeneous heated mass cools sharply and, under the action of chopping knives, rolls into separate uneven balls various shapes, ranging in size from 0.5 to 5 mm depending on the feedstock. The resulting agglomerate can be used directly in injection molding machines or sent for granulation.

AGL series agglomerators

We produce agglomerators of various modifications for use as first-line machines for processing plastic waste and producing agglomerate. Based on your request, we will select the necessary equipment modification or manufacture any agglomerator to order according to technical specifications.

Technical characteristics of the agglomerator AGL-02

Plastic agglomerator price

The current price for the basic agglomerator AGL-02 for plastic processing is in the price list.

The second stage in the processing of film waste polymers is agglomeration. Why the second one - because, as a rule, the first stage is preliminary grinding. Film waste of any size must not be thrown into the agglomerator. For most agglomerators, with the exception of powerful models (productivity from 250 kg/hour and above), preliminary preparation of the film is required: either crushing in a crusher, or manually cutting into pieces up to 500-1000 mm, which will later be further crushed by the agglomerator itself and converted by increasing the temperature in the agglomerate.

FAQ

What can an agglomerator do?
- Process waste film, burlap or fiber into agglomerate.

What is an agglomerate?
- Pieces of film pre-crushed by agglomerator knives, sintered into balls irregular shape due to thermal effects. Depending on the purity and size, it can be used immediately in the further production of films or products or sent for granulation.

What kind of film waste can the agglomerator process?
- Film waste is different: High-Density Polyethylene (LDPE), Low-Density Polyethylene (HDPE), Polypropylene, Stretch (special grade of LDPE with glue), Polyamide (PA).
There are also waste polypropylene woven bags and fibers (PET). They can also be processed in an agglomerator.
ATTENTION! Not all agglomerators are designed to process all of the above types of film waste! In practice, it often happens that the type of waste supplied may change, and the agglomerator is not designed to process it. Therefore, our designers have developed a new series of extremely versatile agglomerators of the AGM series, presented below. Moreover, the design is constantly being improved, as we always encourage our customers to help us identify shortcomings and modernize the models we produce.

Where is the resulting agglomerate used?
- Depending on its purity: In the further production of film or goes to the production of products obtained by injection molding.

What is a washing agglomerator?
- Agglomerator operating in two modes: either washing or agglomeration.
A washing agglomerator is not the most effective solution; it is better to install a separate sink. When using the washing mode of the agglomerator, productivity drops by 2-3 times. Therefore, in principle, we do not produce washing agglomerators. There is no point in complicating the design.

Should the agglomerator barrel be made of stainless steel?
- During daily (weekly) work on the agglomerator inner surface barrels are polished to a shine. Even on a barrel made of ferrous metal, scale does not form. If the agglomerator has long downtime, you can use a stainless steel barrel. However, in our opinion, this is also not the most effective solution. In 1-2 runs of the material, all the scale is removed by itself, there is no point in paying a lot of money for stainless steel. But you can’t forbid living beautifully - we offer as an option inner part stainless steel barrels.

PURPOSE OF AGGLOMERATORS ( general information)

AGGLOMERATOR designed for grinding, washing, agglomeration, pre-drying of secondary film waste of polymeric materials, for example, used agricultural film, bags (including wicker), as well as technological waste films.

AGGLOMERATION is a process of sintering crushed pieces of film into small irregularly shaped balls. Depending on the skill of the agglomerator operator and the AGGLOMERATOR the size of the resulting agglomerate varies from 0.5mm to 5.0mm in diameter. As a rule, large agglomerates are obtained on agglomerators with high productivity (over 200 kg/hour). The finer the resulting agglomerate, the more applicable it is as a secondary raw material without an additional granulation step.

AGGLOMERATOR is a device of periodic action and can be used both for carrying out a full processing cycle, including all of the above stages, and for individual stages: for example, only agglomeration or only drying of the material. In combination, for example, with pre-shredding in a crusher, productivity AGGLOMERATOR rises. The resulting agglomerate is either sold as raw material ready for use in extrusion lines or injection molding machines, or it is granulated to remove dust and small foreign particles, which increases the cost of raw materials.
To make the selection task as specific as possible AGGLOMERATOR, You need to answer the following questions:

We manufacture and supply equipment for plastic waste processing (recycling). Thank you for choosing us. We hope your choice will be an easy and effective decision.

The annual increase in waste processing volumes in the Russian Federation attracts start-up entrepreneurs into the field of solid waste processing household waste), but, as in any business, there is a risk of not making a profit or going into the red. The fact is that the process of recycling polymer waste requires significant financial investments.

The most expensive stage is the purchase of the necessary equipment - few people can afford to purchase a full-fledged waste processing line from scratch.

One of the ways to implement the site would be to start small, covering one area of ​​processing, gradually increasing capacity and expanding the types of raw materials processed.

Films account for a significant portion of waste subject to recycling. Recycling polymer film waste is quite a profitable business - the difference between raw materials and agglomerate ranges from 8 before 20 R. per kg.

One of the main types of equipment for processing film waste is an agglomerator - a device that processes film into a commercial product for further use, the following film waste:

* HDPE polyethylene low pressure,

* LDPE low pressure polyethylene,

* PP polypropylene,

* Stretch film.

AGGLOMERATOR WITH YOUR HANDS

On this moment manufacturers offer great amount various options however, their cost turns out to be unaffordable at the stage of starting a business. Of course, purchasing an already fully equipped product is a simpler solution, but we suggest paying attention to a solution that allows you to save up to 60 percent of the cost of new equipment - making it yourself.

The agglomerator consists of a frame, a bearing unit with installed tools, an electric motor, a belt tensioning device, a working body with a loading window, elements for unloading the finished material, and a control panel.

Manufacturing of bearing assembly is the most complex and labor-intensive process, which takes much more time than the manufacture of other components.

Our company offers to purchase the heart of the agglomerator - bearing units, which we install on the APR series agglomerators we produce, which have proven themselves not only in the center of Russia (more than 20 APR agglomerators “work” in Moscow and the Moscow region) but also in the vastness of Russia from Kaliningrad to Khabarovsk .

In case of independent assembly manufacturing You will need:

1. lathe
2. milling machine
3. surface grinding machine
4. cylindrical grinding machine
5. band saw
6. drilling machine
7. welding machine
8. Heating furnace

• materials and components:

1. circles st.3-20 2 , 45, 40x with a diameter of 70-300 mm
2. sheet metal vv.3-20 2 thickness 10-30 mm
3. bearings 3
4. oil seals 3
5. hardware

For manufacturing the frame and working body- "barrels":

• equipment:

1. angle grinder/mounting saw
2. drill/drilling machine
3. arc welding/semi-automatic welding

• materials and components:

1. sheet metal st. 3-20 2 2-14 mm

2. angle/profile pipe for making a frame

3. thick-walled pipe for the body, with a diameter of at least 530 3

4. motor with pulley, power of at least 22 kW 3

5. stud + nut for tensioner

6. belts 3

Of course, to make your own agglomerator, it is necessary to consult professional technologists and designers who will draw up an individual drawing that meets the requirements of GOST and ESKD. Only you will be able to control the agglomerator manufacturing process at all stages, and you will also receive a guaranteed high-quality product made according to correct and competent drawings.

Please note that it is better not to use drawings and sketches found on the Internet without consulting with specialists, of course, if you are not one yourself, because they are first of all:

• outdated
• are unrolled graduation projects
• contain errors and/or omissions

Our company guarantees the high quality of manufactured parts. Many years of operating experience at many of the largest enterprises in the Russian Federation and foreign countries testify to the effectiveness and profitability of using our units. The design developed by our specialists is unique and patented.

We urge you to take a responsible approach to the issue of equipment, weighing all the pros and cons, and also carefully select artists for the drawings if you decide to make an agglomerator with your own hands. The reliable and efficient operation of the future product depends only on the professionalism of all links in the production chain.

2 weldability without restrictions

3 included in the spare parts and accessories for APR 342 series agglomerators

FILM RECYCLING IS PROFITABLE, PROMISING AND ENVIRONMENTALLY FRIENDLY!

The demand for processing polymer waste and at the same time producing new film materials is increasing from year to year. In addition to large factories, for Lately Quite a lot of small ones have opened manufacturing enterprises who need timely recycling of used film. Huge volumes of film waste are also provided by shopping centers and stores of various profiles. The segment of potential consumers of the product obtained after processing (agglomerate) are companies that are in one way or another engaged in the production of films, as well as various products from non-food polymers. If you build your business on processing film waste, you will be able to work with both their suppliers and consumers of the agglomerate.

What is needed?

Not needed for processing large areas and a whole staff of specialists. You can organize this work on your own, even if you have limited area. For these purposes, you will need to purchase a rotary agglomerator - special equipment for processing HDPE (low-density polyethylene, LDPE (high-density polyethylene) and stretch film. Using an agglomerator, you can also process polypropylene bags and big bags, but it all depends on the modification of the equipment.

How does an agglomerator work?

This equipment is used for grinding, washing, drying and agglomerating waste. Depending on the configuration, agglomerators are single- or double-rotor. Structurally, the agglomerator consists of a frame, an electric motor, a housing and a unit with knives attached to the shaft. The operating principle is simple: film waste is loaded into the working chamber, after which it is crushed and sintered. Adding “shock” water allows this mass to cool and polymerize. The output is irregularly shaped granules (pellets) measuring 3-10 mm.

Depending on the performance of the equipment, it may be necessary to pre-shred the film with crushers before filling it into the chamber. This will allow the use of low-capacity agglomerators for processing. Powerful agglomerators (more than 200-250 kg/hour), as a rule, produce large granules. However, what smaller size agglomerate, the more suitable it is for use as a secondary raw material.

Where is the agglomerate used?

The resulting product can be used both as a secondary raw material for the production of films and for granulation, which also expands opportunities for business development. Film materials are in great demand today in almost all areas, so there will be no shortage of customers for agglomerate.

How much can you earn?

The cost of a budget-class industrial agglomerator ranges from 195,000-370,000 rubles. According to average calculations, the difference in price between film and agglomerate is from 10,000 rubles/t. Let's take as a basis that the profit per kilogram of raw materials is 5 rubles (this figure can be twice as much).

In an hour, a two-rotor agglomerator easily processes 200 kg of raw materials - a total of 1000 rubles. (200 kg x 5 rubles = 1000 rubles/hour). For an 8-hour shift it turns out to be 8,000 rubles. (1000 x 8).

If you work in two shifts, then this is already 16,000 rubles/day (1000 x 16).

For a month (22 working days) the profit will be 352,000 rubles. (16000 x 22).

Thus, in one month you can completely recoup the purchase of equipment and start making a profit the next month.

Spin off

• To organize work and place equipment, large areas are not required, therefore, this is a significant saving on rental costs. You can organize film processing in a warehouse or other suitable premises.
• One or two specialists can work with the agglomerator (depending on the scale of processing and the model of equipment). No special qualifications or special knowledge are required either. Therefore, the costs for wages employees will also be insignificant.
• When purchasing a high-performance, but at the same time energy-efficient agglomerator, energy costs are also reduced.
• Other operating costs, such as maintenance and replacement of parts, also depend on the quality and reliability of the equipment. Based on this, it is advisable to buy agglomerators from leading manufacturers. Even if the payback period in this case increases, this will be compensated by the absence of regular repair costs.

Bottom line.

Organizing the processing of film materials to produce agglomerate is a stable business that does not depend on seasonality or fluctuations in demand. The demand for processing film and purchasing agglomerate for its production will only grow. Purchasing an agglomerator is a win-win investment with a quick payback and the possibility of further expansion of activities. Subsequently, it will be possible to purchase equipment of a different modification for processing more wide range materials.

The invention relates to devices for processing waste of thin-sheet and film thermoplastic polymer materials into agglomerate - bulk material and can be used in enterprises that process plastic waste. The agglomerator contains a base on which there is a folding vertical container with loading and unloading openings, in the lower part of which there is at least one grinder connected to the rotation drive in the form of a traverse mounted on the drive shaft with knives rigidly fixed at its ends. The knives are made with straight cutting edges shifted in the plane of their rotation relative to a line passing through the center of rotation by a given amount so that the directions cutting edges knives form a sliding angle with this line, and are fixed on a traverse with the ability to regulate the magnitude of this displacement and the possibility of rigidly fixing them in various positions with the choice of sliding angle corresponding to the optimal processing conditions of the corresponding polymer material. The vertical container can be made oval in cross section. The agglomerator will allow optimizing the process of grinding waste of thin sheet and film polymer materials with different physical and mechanical properties when processing them into agglomerate. 1 salary f-ly, 4 ill.

The invention relates to devices for processing waste of thin-sheet and film thermoplastic polymer materials into agglomerate - bulk material and can be used in enterprises processing plastic waste. The agglomerators in question are a vertical oval (cylindrical or ellipse in cross-section) container, in the lower part of which there is a high-speed rotating waste shredder (for a cylindrical container) or a pair of shredders (for an elliptical container). Shredders are a flat-rotary sliding cutting device, i.e. cutting carried out by knives with straight cutting edges, which are equipped with agglomerators, under the influence of mutually perpendicular forces n and P t applied to them, where P n is the force normally acting on the material, and P t is the tangential force necessary to excite the tangential movement of the blade knife according to material. Sliding cutting is possible in the presence of a sliding angle, which is achieved by shifting the knife in the plane of rotation by a certain amount relative to the radial line O B. With this arrangement of the knife linear speed V=r of any point of the blade when rotating the cutting apparatus can be decomposed into components: normal V n and tangential V t:V n =rcos=;V t =rsin=l. The component V n changes according to the law of a straight line, and V t remains constant value for all points of the blade, since =rsin=cos. The effect of sliding cutting is explained by the fact that when the blade slides along the material, it captures particles of the material with irregularities, tends to move them from their place and drag them along with them (sawing effect of the cutting edge). Between the displaced and neighboring particles of the material, normal tensile stresses and tangential shear stresses arise instead of crushing stresses, i.e. compression, as during normal cutting (cutting). It is the tensile and shear stresses that mainly ensure cutting, tearing of the material and maximum heat release during agglomeration. Heat is also released due to the friction of material particles among themselves, against the walls of the container and parts of the cutting apparatus. When processing elastic-viscous materials with different physical and mechanical properties, such as thermoplastics, the effect of the sliding movement of the blade can be significant only at certain sliding angles. The significance of this angle for the amount of cutting force is generally accepted. Thus, the choice of the angle for processing each specific material is one of the most important determining factors in optimizing the grinding process during agglomeration, i.e. conditions under which the greatest amount of heat is released at the lowest energy consumption. Film waste is periodically loaded into the agglomerator, where, thanks to high speed cutting apparatus are cut, torn and, heated to the plasticization temperature, compacted and agglomerated. To cool the agglomerate and fix the size of its particles, it is sprayed with a small amount of water, which quickly evaporates, and then the resulting bulk product unloaded. A device is known for processing plastic waste - thin sheet and film materials into agglomerate. The device contains a vertical cylindrical container with loading and unloading openings. In the lower part of the container there is a chopper installed on the drive shaft in the form of traverses with knives rigidly attached to them with straight cutting edges shifted in the plane of rotation relative to a line passing through its center. Guides made in the form of blades are mounted on the upper traverse (A.S. USSR No. 1595654, V 29 V 17/00, V 02 S 18/44, 1988 (publ.)). The material is fed into the container, which is crushed by the cutting apparatus and, due to the conversion of mechanical energy into thermal energy as a result of stretching, rupture and friction of the material particles against the walls of the container, the parts of the grinder and among themselves, is heated to softening and agglomerates into lumps. The size of the resulting agglomerate is fixed by introducing a small amount of water to rapidly cool the material. The disadvantage of the device is that the knives are rigidly mounted without the ability to regulate the amount of displacement of their cutting edges in the plane of rotation relative to its center. This design of the cutting apparatus involves sliding cutting with a constant sliding angle, which does not allow optimizing the agglomeration process when processing materials with different physical and mechanical properties, such as polyethylene, polypropylene, polyethylene terephthalate, PVC, etc. A known converter of waste film thermoplastic materials into granules (agglomerator), which is a cylinder in which two knives are located on a vertical rotating axis. Counter horizontal knives are attached to the walls of the cylinder, slightly higher than the rotating ones. Plates of rectangular cross-section are attached to the rotating knives for intensive melting (US patent No. 3949941, B 02 B 11/08, 1976 (publ.)). After crushing and melting the loaded waste film, water is sprayed into the cylinder and granules are formed from the waste. An exhaust fan sucks out steam and volatile substances from the waste, and the granules are unloaded. This waste converter has the same disadvantage - the knives are fixed rigidly without the ability to regulate the sliding angle, which eliminates the optimization of the agglomeration process of materials with different physical and mechanical properties. The closest in technical essence and the positive effect achieved is an agglomerator containing a vertical oval (ellipse) container with loading and unloading openings. At the bottom of the tank there are two grinders connected to the rotation drives in the form of traverses mounted on the shafts of electric motors with knives rigidly fixed at their ends with straight cutting edges shifted in the plane of rotation relative to the line passing through its center (Russian patent No. 2120378, V 29 V 17/ 00, 1998 (publ.)). The agglomeration process in it is similar to that described in previous examples. But this agglomerator does not provide for the possibility of adjusting the sliding angle, and therefore, optimizing the grinding process during agglomeration of various materials. The objective of the invention is to optimize the process of grinding waste of thin-sheet and film thermoplastic polymer materials with different physical and mechanical properties during their processing in agglomerators, t .e. creating conditions under which the greatest amount of heat is released at the least amount of energy. The problem is solved by the fact that in an agglomerator for processing plastic waste, containing a vertical oval container with loading and unloading openings, in the lower part of which there is at least one chopper in the form of a traverse mounted on the drive shaft with knives rigidly fixed at its ends with straight cutting edges, offset in the plane of rotation relative to a line passing through its center; the knives are mounted with the ability to regulate the magnitude of this displacement. The ability to regulate the amount of displacement of the cutting edges of the knives allows you to select a specific sliding angle when processing each specific material, for example, polyethylene, polypropylene, polyethylene terephthalate, PVC, etc., i.e. material with its own physical and mechanical properties. The choice of a certain angle ensures optimization of the grinding process during waste agglomeration, i.e. lowest energy consumption at the greatest number generated heat. The essence of the invention is illustrated by drawings, where figure 1 shows general form an agglomerator with a cylindrical cross-section container with one grinder; Fig.2 is a general view of an agglomerator with an elliptical container and two grinders; Fig. 3 is a theoretical drawing of a plane-rotary cutting apparatus for sliding cutting and Fig. 4 is a top view of the chopper (one of the design solutions for fastening knives with the possibility of moving them in the plane of rotation). The agglomerator contains a base 1 on which a folding vertical oval container 2 is located (cylindrical or elliptical) with a closed loading lid 3 and a closed gate with 4 discharge openings. Inside the base there is an electric motor 5 (for a cylindrical container) or two electric motors located nearby (for an elliptical container). A traverse 6 is installed on the electric motor shaft with knives 7 rigidly fixed at its ends with straight cutting edges shifted in the plane of rotation relative to the line passing through the center of rotation by an amount , so that their directions form a sliding angle with this line. In the upper part of the container there is pipe 8, to which a fan is connected to quickly remove water vapor evaporated during agglomeration. The ellipse shape of the cross-section of the container is preferable to the cylindrical one, because it eliminates theft of material due to dull knives and better conditions mixing of individual particles, which is especially important when adding modifiers, dyes, etc. The knives are attached to the traverses in such a way that it is possible to fix them rigidly in various positions with the choice of the optimal sliding angle between the direction of the cutting edge and the line passing through the center of rotation of the chopper The agglomerator operates as follows. The waste of thin-sheet and (or) film thermoplastic material to be agglomerated is loaded from above into the container through hole 3. The waste falls onto a rotating chopper with knives 7, is crushed, the material is heated to the plasticization temperature, compacted and agglomerated into lumps. Then a small amount of water is introduced into the agglomerator, which quickly evaporates, fixing the size of the resulting particles (granules) of the material. Water vapor is quickly removed by a fan, and the resulting bulk product is discharged into the container through the unloading hole at the bottom of the container with gate 4 open. When processing a material with specific physical and mechanical properties, the knives are fixed on cross-beams at a sliding angle corresponding to the optimal processing conditions for this particular material, i.e. e. minimum energy consumption with maximum heat release during plasticization of thermoplastic. The production of agglomerators of this design is possible at machine-building enterprises that have universal metal-cutting, welding equipment and equipment for heat treatment of metals.

Claim

1. An agglomerator for processing plastic waste, containing a vertical container with loading and unloading openings, in the lower part of which there is at least one grinder connected to a rotation drive in the form of a traverse mounted on the drive shaft with knives rigidly fixed at its ends, characterized in that , that the knives are made with straight cutting edges, offset in the plane of their rotation relative to a line passing through the center of rotation by a given amount so that the directions of the cutting edges of the knives form a sliding angle with this line, and are mounted on a traverse with the ability to regulate the magnitude of this displacement and the possibility rigidly fixing them in various positions with the choice of sliding angle corresponding to the optimal conditions for processing the corresponding polymer material.2. The agglomerator according to claim 1, characterized in that the vertical container is oval in cross section.

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The invention relates to the field of processing waste reinforced rubber products, mainly car tires or their fragments, including tires reinforced with metal elements, and can be used to create installations for separating and grinding rubber from worn tires