BHS Sonthofen

Rotor impact mill and system control from a single source

Building materials supplier Dachser is currently expanding and optimizing its gravel plant in Türkheim by integrating a second rotor impact mill of type RPM 1113 from BHS-Sonthofen. In addition, BHS supplied the complete control system to ensure seamless coordination of the two machines. This makes the plant easier to operate and also increases productivity and efficiency.

For more than 60 years, Dachser has been reliably supplying numerous construction projects with building materials such as ready-mixed concrete, sand, and gravel. At its Türkheim site, the company’s own gravel plant produces high-quality sand with a grain size of 0-4 millimeters for concrete production from excess gravel. “Since we blend the crushed sand with natural sand, the resulting grain shape must be as close as possible to that of natural sand,” explains Michael Zacher, Head of Technology at Dachser. Previously, this task was accomplished using rod mills. However, these proved to be energy-intensive at low throughput rates.

Replacing the rod mills leads to improved system performance

Since 2019, a rotor impact mill of type RPM 1513 from BHS-Sonthofen has been crushing the material to the required fine particle size. This high-performance vertical shaft impact mill, which is employed by Dachser in a customized configuration, is particularly suitable for crushing all low to medium-abrasive minerals.

To keep up with growing market demand, the company decided to further expand its plant in early 2023. Based on the positive experience with BHS-Sonthofen, they decided to replace the remaining, outdated rod mill with a new BHS rotor impact mill. In the case of the RPM 1113, Dachser opted for a bottom-mounted drive for easier maintenance access and a modified, elevated machine housing with optimized flow performance. In close cooperation with Dachser, BHS carried out the project and commissioned the machine in the spring of 2023.

Special design ensures less wear and higher throughput

This particular machine’s housing is a special version of the standard model with two enlarged openings in the discharge area, which allow for faster discharge of both crushed material and air. A downward-facing flanged motor was installed to provide more space for operation on the platform. The functionality of the RPM 1113 enables significantly higher throughput while consuming less energy compared to the rod mill.

Benedikt Weber, who is responsible for building materials machinery sales in the region, highlights that alternating right and left operation of the machine maximizes the utilization of the components used in this series. “In terms of efficiency, the cost-benefit ratio of the rotor impact mill far surpasses that of a rod mill. It offers a very high degree of crushing and delivers excellent cubic sand with a high proportion of fines and round corners.” Consequently, the mill is predominantly used to produce sand for the concrete, asphalt, and dry mortar industries.

Optimized system performance thanks to efficient control systems

BHS-Sonthofen also provided the complete control system for the two rotor impact mills and the corresponding environment, customized specifically for Dachser’s needs. This includes powerful frequency converters for energy-efficient operation of the machines and a state-of-the-art user interface featuring touch screens. “Despite different feed materials, both machines deliver identical, high-quality crushed sand, something that is particularly sought after,” says Michael Zacher, summarizing the advantages of the two plants. “Having both the plant and control system from a single source, i.e. from BHS-Sonthofen, streamlined installation and daily operations significantly.”

Further information:
BHS-Sonthofen GmbH
www.bhs-sonthofen.de

BHS-Sonthofen, a leading supplier of machines and process solutions in the field of metal-containing composites, will be focusing on metal recovery from metal-containing waste materials such as electric and electronic scrap (WEEE), incinerator bottom ash (IBA) and automotive shredder residue (ASR) at this year’s IFAT (Booth B4-351/450). A second focus topic is the efficient and safe recycling of lithium-ion batteries.

BHS-Sonthofen’s mission is “Transforming materials into value”, meaning to extract the full economic value from various materials. The company will be splitting its booth into different topic worlds and showcasing how it is fulfilling this mission in both the recycling of metal-containing residual and waste materials on the one hand and in battery recycling using its in-depth process expertise on the other hand. Our innovative, efficient recycling solutions are the result of our broad technology portfolio, tests in our in-house test center, system engineering and international project management, combined with decades of experience.

Technology leader for metal recovery from metal-containing composites

“We see the pure recovery of valuable metals as one of the key issues in the industry,” says Daniel Zeiler, Head of the Recycling Technology division. “In recent years, BHS-Sonthofen has continuously invested in development to further improve metal recovery from a wide variety of input materials. Depending on the material, we offer an optimized process tailored to our customers’ individual requirements, along with the core machines needed from our own production.” Visitors interested in the metal recovery topic can get an idea of the input material, the respective processing step and the recycling result.

French company Envie, located in the southern city of Toulouse, is the most recent customer to benefit from the implementation of a metal recovery solution. Envie specializes in the recycling of waste of electrical and electronic equipment (WEEE). In 2023, the customer expanded its capacities and markedly enhanced the quality and quantity of its output with the introduction of a new plant, featuring the BHS Pre-shredder and Rotorshredder (type RS).

Complete solutions for efficient battery recycling from a single source

Battery recycling now plays a key role in the development of sustainable energy storage solutions. A few years ago, BHS-Sonthofen developed a new, safe process for the efficient recycling of lithium-ion batteries, which has since proven to be a success on a production scale with several customers. The mechanical drying process occurs within a protective atmosphere and comprises three main stages: shredding, vacuum drying, and sorting. The drying process is supplemented by condensation for electrolyte recovery and gas purification. These three stages have now reached a high level of maturity that they are offered as pre-configured standard modules. The process allows valuable raw materials concentrated in black mass such as lithium, nickel, cobalt, and manganese to be returned to the material cycle at a rate of more than 97%. In addition, a high proportion of recyclable materials such as aluminum, copper and iron can also be recovered. Visitors can find out more about the process and the solution at its dedicated topic area.

“We are the only provider that covers all the key process steps in mechanical battery recycling on a technological level, uniquely offering the relevant process modules from a single source. Customers benefit from our extensive experience and the combined process expertise in processing and traditional process technology,” Zeiler explains. “For instance, we utilize drying technologies from our Process Technology division typically used in the chemical or pharmaceutical industry.” BASF in Schwarzheide is the most recent customer to benefit from this at its large-scale plant for the recovery of black mass, which is currently under construction. “Together with BASF, we are successfully implementing our third major project in the last two years,” says Zeiler. “This experience ensures process and investment security for the customer.”

Comprehensive portfolio of machine technologies and systems

BHS-Sonthofen offers a comprehensive range of machine technology and full-scale plants, including separation and screening technology, for the efficient processing and pre-/post-shredding of valuable waste materials. The latest product development for pre-shredding is the RAPAX, a powerful, universally applicable pre-shredder that combines design and functionality. A versatile and sturdy machine, the RAPAX is particularly suitable for processing various metal fractions and e-scrap, as well as commercial and industrial waste. When it comes to pre-shredding batteries, the Rotary shear type VR is often used as a powerful twin-shaft shredder. The Universal Shredder (NGU) single-shaft shredder is used for pre- and post-shredding a wide variety of materials that can be cut, such as non-ferrous light metals, batteries, data carriers, cables, and refuse-derived fuels. The further development of VR and NGU into fully inertizable and gas-tight machines – developed specifically for the reliable shredding of batteries – is also worth a special mention here.

When it comes to the specialized selective shredding of e-scrap or light metal scrap, BHS offers the low-maintenance and durable Rotorshredder (RS), which selectively shreds, isolates and cleans the input material using impact, shock and shearing forces. Metal components are optimally dissolved and particle sizes are reduced in a targeted manner. The high-performance Rotor impact mill (RPMX) crusher also reliably isolates different materials from pre-crushed, metal-containing material composites and removes cable sheathing and other adhesive substances from metals. Shaping the metals into balls facilitates their separation by type.

BHS rounds off its trade fair exhibit with separation, sorting, and classification technology. Investment in Swiss company RW Recycling World has made it possible to integrate technologies and machines from this sector into BHS processes, offering the user significant added value in processes for recovering unmixed metal fractions.

“As our Group is headquartered in Allgäu, IFAT essentially brings the international industry meeting place to our own doorstep. We look forward to providing visitors from all over the world an insight into the value chain with processes and technologies from BHS-Sonthofen,” concludes Zeiler.

BHS-Sonthofen at IFAT in Munich: Booth B4-351/450, from 13 to 17 May 2024

Further information:
BHS-Sonthofen GmbH
www.bhs-sonthofen.de

BHS-Sonthofen is supplying BASF with a plant for the mechanical reprocessing of lithium-ion batteries into black mass. This marks the third large-scale plant for BHS, with the first one having operated successfully for over a year. As a result, customers can benefit from the combined experience and know-how of this machinery and plant manufacturer from the South German Allgäu region, providing them with increased investment security.

”In the period of just over two years, we have successfully implemented two large-scale plants in Europe in addition to two pilot plants in the field of battery recycling. With the third large-scale project, we are now reaching a high degree of maturity of a still very young, novel recycling process,” comments Daniel Zeiler, Vice President in the Recycling Technology Business Unit at BHS-Sonthofen. “We are particularly proud that we have been able to secure another renowned and innovative customer like BASF.”

At the end of June 2023, BASF, together with partners and customers celebrated the opening of Europe’s first co-located center for battery material production and battery recycling. A significant component is the plant supplied by BHS for the mechanical processing of lithium-ion batteries. This plant is seen as an important step towards closing the loop for the European battery value chain and raw material supply, ultimately reducing the CO₂ footprint.

Scheduled to commence operations in 2024, the plant will have a processing capacity of 15,000 metric tons of spent lithium-ion batteries and scrap from battery production per year. The BASF facility is currently under construction in Schwarzheide, Brandenburg, where it already produces cathode active materials for lithium-ion batteries. The black mass produced at the plant contains valuable metals such as nickel, cobalt and lithium, which undergo chemical extraction in a subsequent processing step at BASF. These metals are then utilized in the production of new battery materials.

Recycling plant meets the high safety standards of the chemical industry

BHS-Sonthofen and BASF both equally benefit from this extensive cooperation. ”The plant in Schwarzheide is being constructed to the highest environmental, health and safety standards. To meet our customer’s stringent requirements, we have developed tailored solutions for our machines and components in close coordination with BASF,” Daniel Zeiler explains, reflecting on the results of the first year of cooperation.

Knut Zöllner, Senior Vice President at BASF, confirms, “In BHS-Sonthofen, we have chosen a partner who seamlessly combines the worlds of classic recycling technology and chemical process technology particularly well, complementing BASF’s own experience.”

Exceptional material disintegration

In 2020, BHS-Sonthofen introduced its innovative and safe process for recycling lithium-ion batteries. The mechanical process consists of the main stages of crushing, drying and screening. Crushing takes place in two stages, enabling exceptional material disintegration and yielding the valuable black mass as the main product. This process achieves high recovery rates, depending on customer requirements, while maintaining the highest quality standards. Moreover, the continuous gas-tight process from shredder to dryer, ensures a safe evaporation of electrolytes, meeting BASF’s stringent criteria for plant safety and environmental compatibility.

BHS vacuum dryer extracts electrolytes

The heart of the plant is the vacuum dryer of type HTC, which gently heats the crushed batteries. Here, too, BHS utilizes its in-house technologies and expertise: through its Process Technology business unit, the company is a leading global supplier of process technology components and systems for the chemical, pharmaceutical, and food industries.

During the heating process, the electrolyte remaining after crushing evaporates, while the material is gently homogenized and further broken down autogenously. The electrolyte components can be recovered via the multi-stage condensation unit. As a key element of this innovative recycling process, BHS has already supplied the vacuum dryer to market companions and customers with large-scale battery recycling plants.

Over the past two years, BHS-Sonthofen has further optimized the technologies and process parameters used in the process, focusing on material selection, work safety, and ease of maintenance. “For example, operation of the shredders is now easier and safer. Additionally, enhanced accessibility allows for better cleaning and maintenance of the machines,” says Zeiler. Furthermore, BHS incorporated valuable operating experience gained from pilot and large-scale plants into the Schwarzheide project, ensuring efficient scaling.

“Battery recycling is a crucial prerequisite for fostering the circular economy and meeting EU quota requirements,” Zeiler concludes. “We are currently witnessing substantial investments in battery recycling on a global scale, and recycling technology is continuously improving. The process from BHS-Sonthofen has now more than proven itself in practice.”

Further information:
BHS-Sonthofen GmbH
www.bhs-sonthofen.de

 

The Recycling Technology division at BHS-Sonthofen GmbH, Sonthofen/Germany, is reporting a personnel change. Daniel Zeiler has taken over as the head of the division. Alfred Weber, who had successfully managed sales for the company’s Recycling Technology division since 2007, retired at the end of last year (Figure 1).

BHS offers complete plant solutions, including control and sorting technology, all from a single source. BHS has developed proprietary innovative processes such as the recycling of lithium-ion batteries, keeping in tune with the times. As BHS moves into the future, it will be Zeiler’s task to further establish the company’s foothold in this market segment. Zeiler has worked closely in the area of machinery and plant engineering for the recycling industry for over 20 years. He spent more than ten years in a management position with an international equipment supplier for the scrap processing industry and most recently he spent five years as head of sales at a plant manufacturer in the plastics recycling industry. Zeiler joined BHS-Sonthofen in September 2022. (BHS/Si.)

The Recycling Technology division at BHS-Sonthofen is reporting a personnel change. Daniel Zeiler has taken over as the head of the division. Alfred Weber, who had successfully managed sales for the company’s Recycling Technology division since 2007, retired at the end of last year.

Alfred Weber has witnessed a number of milestones at BHS-Sonthofen. The Recycling division was still in its infancy when Mr. Weber started working in sales at BHS 20 years ago. At that time, he was in the construction machinery and special mixing technology sales area. Starting in 2007, Mr. Weber was put in charge of sales for the Recycling division. “The initial challenge was to build the sales network for recycling machinery and associated solutions from the ground up. Back then, it was about machines and plants with impact crushing, which were already used for the processing of residual materials containing metal. It was only years later that the tearing and cutting technology was added,” reports the skilled chemical worker and process engineer. BHS now offers complete plant solutions, including control and sorting technology, all from a single source. BHS has developed proprietary innovative processes such as the recycling of lithium-ion batteries, keeping in tune with the times. “Mr. Weber has been instrumental in making BHS an established brand in the recycling industry today. We sincerely thank him for his work and commitment over the past 20 years,” says Dennis Kemmann, Managing Director of BHS-Sonthofen, summing up Mr. Weber’s career with the company.

BHS continues to grow with recycling expert Daniel Zeiler

As BHS moves into the future, it will be Daniel Zeiler’s task to further establish the company’s foothold in this market segment. Hailing from the Rhineland, Mr. Zeiler, who is 48 years old, has worked closely in the area of machinery and plant engineering for the recycling industry for over 20 years. He spent more than ten years in a management position with an international equipment supplier for the scrap processing industry and most recently he spent five years as head of sales at a plant manufacturer in the plastics recycling industry. Mr. Zeiler joined BHS-Sonthofen in September 2022. “We have exciting tasks at BHS, as we will continue to build up the new market segments, such as battery recycling, and at the same time grow with the established products, such as the processes for fine processing of metalliferous wastes. I see great potential in this intersection of proven products and new ideas – and at BHS, the necessary know-how and innovative spirit to develop new solutions for the industry,” says Daniel Zeiler, pleased about having switched to BHS now.

Future-oriented strategy and new point of contact – with a sense of assured continuity

There have been several new developments at BHS-Sonthofen in recent years. One of these developments included a focus on individual business areas, which are now even more closely aligned to the specific needs of the respective customers. Another change involved a consistent expansion of the product and service portfolio. Mr. Zeiler now heads the Recycling Technology division. His position as Vice President combines the responsibilities for sales, project engineering, process development, and the test center. “We are delighted to welcome Mr. Zeiler into the fold – a colleague who will maintain continuity in the Recycling Technology division with great pleasure and commitment, while at the same time working with us to further expand the market position of BHS,” remarks Dennis Kemmann on the choice of the new Vice President.

“I am looking forward to continuing the BHS success story as part of a strong team with flat hierarchies. The proximity to the mountains is a clear advantage after having relocated,” says Zeiler, who enjoys pursuing various mountain sports in his spare time, explaining his decision for the new position with a little smile. Alfred Weber confirms the positive working atmosphere and looks back with gratitude on his time at BHS: “It was a nice time: the great colleagues, customers and partners, the short decision-making processes, and an employer who always supported my further personal development. I’ve been able to drive many things forward at BHS over the last 20 years, but now it’s time for me to just drive my Harley instead.”

Further information:
BHS-Sonthofen GmbH
www.bhs-sonthofen.com

Harborlite Aegean in Turkey, a subsidiary of Imerys, now processes different types of perlite for the juice industry with an impact crusher of type PB 0806 from BHS-Sonthofen. This is the first time for the machine to be used for this purpose. Tests with original material in Sonthofen and previous experiences with the maintenance-friendly machines from BHS gave the customer the confidence to make this unusual choice.

Performance minerals are key to many different industries, from plastics and paint production to batteries and filtration purposes. Imerys, a world leader for mineral-based specialties for industrial use, is an expert in producing a wide variety of performance materials. In Turkey, Imerys’ subsidiary Harborlite Aegean processes two types of perlite, an amorphous volcanic glass, mined in a nearby quarry. The product is used as a filtration medium by the Italian and Spanish juice industries.

Reliability and reduced wear costs

In 2021, one of the crushers in Harborlite Aegean’s plant in Dikili needed replacement. The old Turkish impact mill had reached the end of its service life as it could no longer produce the required grain size of 35 millimeters. Imerys decided to contact BHS-Sonthofen, which the company knew from a related project. BHS-Sonthofen had recently delivered a rotor centrifugal crusher of type RSMX to another Imerys plant in Teutschenthal, Germany. There the machine processes aluminum oxide – a highly abrasive mineral. For the sturdy RSMX the material was no real challenge. It proved to be a reliable choice with low wear costs. The technology and the service from BHS-Sonthofen convinced Imerys that the German company could be a good fit for replacing the Turkish perlite crusher as well.

Tests with original material in Sonthofen

After a first assessment of the requirements, BHS and Harborlite Aegean decided that an impact crusher of type PB 0806 with an output of 50 tons per hour was the ideal choice for the task at hand, even though the BHS machine had never been used in this application before. The chance to thoroughly test the machine’s capability in the BHS Test Center in Sonthofen gave the team confidence. For this purpose, a truck brought both varieties of the original materials to Germany. One of them was a pre-crushed perlite that was to be reduced from 0 – 90 mm to a target size of 0 – 35 mm, the other one was a pre-crushed fraction with 0 – 300 mm of another type of perlite also with a target size of 0 – 35 mm.

“Running tests with original material is a standard procedure at BHS-Sonthofen,” explains project manager Hans Traut from BHS-Sonthofen. “With our tests we make sure the machine is the best choice for the client. They also ensure optimal machine configurations for minimal wear and help us to adjust the machine so that the processed minerals match the company’s crushing requirements.”

The tests confirmed the experts’ recommendation. The impact crusher is a particularly economical solution for the fine crushing of perlite with a maintenance-friendly design. The adjustable gap width is a key advantage for Harborlite Aegean as it allows their employees to adapt the machine and avoid wear to produce inaccuracies regarding the desired grain size. This guarantees consistent quality of the product with low-maintenance costs. Also, a throughput rate of 50 tons per hour and the size of the machine were a good fit for the existing plant and Harborlite Aegean’s demands. The Turkish company successfully installed the machine in late December 2021. “The impact crusher from BHS proved to be a perfect fit for our plant and has been running smoothly since production started in January,” resumes Hikmet Bozkurt, Plant & Mine Manager at Harborlite Aegean in Izmir /Turkey.

Further information:
BHS-Sonthofen GmbH
www.bhs-sonthofen.com

Sonthofen, Germany, 28. July 2022. BHS-Sonthofen will be presenting its wide range of mixing and crushing technologies at this year’s bauma in Munich. The team is looking forward to meeting its customers, distributors and partners in person again from 24-30 October 2022 at booth 449 in hall B2. At the world’s leading trade show, the technology expert will be exhibiting the twin-shaft batch mixer, which is considered the benchmark in mixing technology, as well as a single-shaft continuous mixer, a rotor impact mill and a rotor centrifugal crusher on a total floor space of 391 m².

“The machines are clearly the main attraction at bauma. That’s why we keep the lid open when we present our machines – so that visitors can take a look at the inner workings of our mixers and crushers,” says Bahar Yerlikaya, Marketing Manager for the Building Materials Machinery division at BHS-Sonthofen and emphasizes: “We are pleased to be present again on site in Munich for our customers and partners after an interruption of almost two years. After all, digital technology cannot replace personal contact.”

The right mixer for every project

At the BHS booth, the twin-shaft batch mixer of type DKXS 4,50 takes center stage (Figure 1). In major projects throughout the world, the twin-shaft batch mixer from BHS-Sonthofen is being used to produce all types of concrete. Due to the increasing demand for fast and efficient construction, the demand for high-performance mixers continues to rise as well. The DKXS 4,50 is particularly suitable for industrial mixing processes in the medium to high output range and delivers four and a half cubic meters of hardened concrete per batch. The three-dimensional mixing principle of the mixer leads to a more intensive material exchange and thus to shorter mixing times with less energy requirement. At bauma, visitors can learn about the standard mixer’s globally proven, comprehensive modular system and the wide range of mixer sizes and accessories that are available.

In addition to the twin-shaft batch mixer, BHS will also be presenting a single-shaft continuous mixer of type MFKG 0520 at bauma (Figure 2). With its continuous mixing system, the mixer is the right solution for mixing fine materials – whether dry, moist, pasty or suspension-like mixtures. The special feature of the BHS single-shaft continuous mixer is the self-cleaning rubber trough, which prevents caking of hardenable mixing material on the inner wall of the trough.

Efficient crushers for stone and sand production

In the field of crushing technology, BHS-Sonthofen is the expert for the final processing stage – the refinement of high-quality end products. Visitors of the exhibition can have a look at a rotor impact mill of type RPM 1513 in its latest design (Figure 3) at the BHS booth. The high-performance crusher with vertical shaft is ideally suited for the production of quality sand. BHS will also present a rotor centrifugal crusher of type RSMX 1222, which is used for crushing and refining mineral materials (Figure 4).

BHS-Sonthofen at bauma: Booth B2-449 in Munich, Germany, 24-30 October 2022

Further information:
BHS Sonthofen GmbH
www.bhs-sonthofen.com

The Italian manufacturer of planetary mixers Eurostar Concrete Technology S.p.A. and BHS-Sonthofen have joined forces as of March 18, 2022. With the sale to a highly recognized partner, Eurostar’s Managing Director Mario Zaccaron is strengthening the company’s position and ensuring its further development. At the same time, BHS-Sonthofen is expanding its own portfolio of twin-shaft batch concrete mixers to include high-quality planetary mixers for building materials applications for batch sizes up to 6,000 liters. The added solutions will offer customers of both companies additional equipment and service flexibility.

Planetary mixers are widely used to produce precast concrete parts, such as concrete blocks and pipes, as well as special concrete designed for environmental purposes and in the glass industry. By purchasing the Italian manufacturer, BHS-Sonthofen acquires a key technology in the building materials industry, which expands the existing mixer portfolio with another widely used mixing method. In this way, BHS-Sonthofen aims at consolidating its position as a technical expert for quality mixers in the long term. “The combination of twin-shaft batch mixers and planetary mixers as well as other types of mixers enables us to respond more specifically to our customers’ demands,” emphasizes Dennis Kemmann, Managing Director at BHS-Sonthofen. These requirements not only include a flexible choice of equipment for a wide range of tasks, but also a reliable and vast service network. Thanks to the integration of both companies, Eurostar customers will benefit from several additional BHS service hubs and a thorough spare parts management across the globe. “For plant manufacturers and sales partners, the expansion means an even more attractive product portfolio at a high technological level and with robust drive technology.”

Technological parallels

Like the twin-shaft batch mixers from BHS-Sonthofen, the machines from Eurostar Concrete Technology have specially designed robust drives. In addition, the business models of both companies complement each other: Eurostar and BHS both act as manufacturers of mixers for end customers, plant manufacturers and resellers. “Among many others, this is a further reason why BHS-Sonthofen is the best partner for us,” explains Mario Zaccaron, Managing Director of Eurostar Concrete Technology S.p.A. “Both Eurostar and BHS-Sonthofen will equally benefit from the acquisition. Thanks to BHS-Sonthofen’s experience and its extensive network, we can produce even more efficiently and open new markets.”

Mr. Zaccaron remains Managing Director of Eurostar Concrete Technology, ensuring the continuity of business activities from Eurostar’s site near Udine in Italy, with the aim to further improve and strengthen the company’s position.

Further information:
BHS Sonthofen GmbH
www.bhs-sonthofen.de

BHS-Sonthofen has launched its proven rotor impact mill, which features a new hammer design and maintenance concept (Figure 1). The high-performance crusher with a vertical shaft is used to recycle metalliferous composites and industrial waste for fine processing. Customers benefit from significantly improved output quality, easier maintenance and a higher degree of machine availability.

Recovering valuable metal concentrates from various composites and industrial waste is a challenge. Users have been achieving good results with the BHS rotor impact mill of type RPMX for many years, especially when utilizing it for fine processing. The machine is a high-performance crusher with a one-of-a-kind impeller rotor that, combined with a toothed anvil ring, processes the feed material with remarkable intensity. The rotor impact mill can process a wide variety of metalliferous residues, including materials such as stainless steel and cable strands, which were previously considered problematic.

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Reinvisioned hammer design

BHS has further optimized the stable, horseshoe-shaped hammers while increasing their strength at the same time – setting them apart from the machine’s previous design (Figure 2).

“The results and findings of a wide variety of tests conducted over the past few years have been incorporated into the new design,” says Manuel Huber, who is in charge of designing the machine at BHS-Sonthofen. “We studied how geometric changes to the hammers affect the output. Our tests show that making the front of the hammers wider makes the processes for disaggregating and shaping the respective material run much better, which significantly increases the output quality,” Huber explains further.

Customers therefore benefit from even better output quality and less wear at the same time. When processing critical material, this increased output quality translates to better throughput performance, as the number of times the material must be passed through the machine can be reduced.

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New concept ensures effective maintenance

In conjunction with the more stable, robust hammer design, the new maintenance concept ensures customers a higher degree of machine availability and easier, more effective maintenance (Figure 3).

“A special tool for dislodging the hammers, known as a mandrel, was integrated into the design to facilitate the replacement of cast-iron percussion hammers that are stuck in place. We also integrated a load hook to aid the replacement process. In contrast to the previous method, the new load hook can be hooked into the hammer to easily lift it out or set it in place using a crane. Now, personnel no longer have to expend extra energy lifting the hammer – which reduces the physical strain on employees,” said Huber.

With its new design and maintenance concept, the durable BHS rotor impact mill offers customers investment security and ideal conditions for the secondary crushing and fine processing of metalliferous fractions. The BHS-Sonthofen rotor impact mill sets a new precedent in the recycling industry. As a technology leader for the recycling of metalliferous composites, the company has the ability to use tests to map various processes in its Test Center on a production scale and individually adapt them to respective customer requirements.

The rotor impact mill of type RPMX is one of the exhibits BHS-Sonthofen will have on display at the IFAT in Munich, Germany from 30 May to 3 June 2022 (Stand B4-351/450).

Further information:
BHS Sonthofen GmbH
www.bhs-sonthofen.com

Vestforbraending relies on technology from BHS-Sonthofen for a new type of fly ash treatment process

BHS-Sonthofen has supplied two different technologies to assist an innovative recycling process in waste incineration: Since 2021, a rubber belt filter specially suited to the requirements of the new process and a belt filter have ensured fly ash at the Danish power plant operator Vestforbraending is treated efficiently. This brings two benefits: Recyclable materials can now be recovered from the ash and the ash previously declared as hazardous waste can be disposed of as normal waste. Extensive preliminary filtration tests on a laboratory scale were performed before the order was placed to obtain an optimum process result immediately upon commissioning.

The EU wants at least 50 percent of household waste to be recycled and the rest to be used as a source of energy in waste incineration plants. However, the operators of these plants face a number of challenges along the way. Waste incineration produces ash contaminated with salts and heavy metals, which is considered hazardous waste and must be disposed of in special landfills. This involves long transport routes and high costs. Vestforbraending developed a new type of fly ash treatment process under the name HALOSEP in cooperation with the Swedish recycling company Stena Recycling. The project, officially called LIFE HALOSEP, is supported by the EU through the LIFE financial instrument – a funding program for environmental protection measures.

Heavy metals and salts can now be recovered from the fly ash. This makes it possible to store the ash residue in normal landfills for non-hazardous waste, unlike the input material. The new process is therefore a win-win in two respects: It makes it possible to market recovered recyclables and reduces disposal costs.

The pilot plant in Copenhagen, equipped with technology from BHS-Sonthofen Process Technology, started operation in 2021. Samuel Moore, project manager at Vestforbraending, is convinced: “BHS-Sonthofen sets itself apart with its special expertise in the field of filtration. Having such a strong process engineering partner is essential for pilot plants in particular.”

Process efficiency thanks to the perfect technology

Treating fly ash produced during waste incineration is a multi-step process. First, it is mixed with the flue gas cleaning washing water, which leads to metals and salts being released from the ash. A BHS belt filter then filters the resulting suspension (Figure 1). After a further wash, the solid that remains is purified ash.

The process water used in the first step is treated further to recover both salts and metals. After the salt water has been separated, a BHS rubber belt filter (Figure 2) with continuous vacuum filtration filters the suspension; the metals are left behind as solids.

The process water can now be returned to the process. “Salts and heavy metals are highly corrosive. That is why a robust and corrosion-resistant design was crucial for this project,” says Simone Ahlert, Technical Sales Manager at BHS-Sonthofen Process Technology, summarizing the customer’s main requirements. “BHS-Sonthofen has extensive experience with problematic input materials. All of the machines can also be tested in advance with the respective material.”

Preliminary tests provide all the facts

Each process is unique. For that reason, all of the process parameters and design principles used to select the appropriate filter size must be determined on a case-by-case basis. BHS therefore carried out on-site tests on a laboratory scale directly at the customer’s site, using the exact material that will be used in the final process.

“A constant throughput is crucial in a continuous process – thanks to the laboratory tests, we were able to determine the best way to adapt the rubber belt filter used as well as the belt filter to the process in advance. This means it can be integrated into the overall plant much more efficiently, even with completely new processes such as HALOSEP – or related processes such as FLUWA,” says Ahlert, explaining the proven procedure.

15,000 tons of fly ash will be treated at the plant annually. Moore is confident that he will be able to further optimize the process with the help of strong partners such as BHS-Sonthofen. “Up until now, fly ash could only be deposited as hazardous waste in a mine or mountain, which involves long transportation routes. The aim of the HALOSEP process is to reduce the load on the ash so that it can be deposited locally. If we’re successful, we’ll look at the possibility of using the ash as a building material.”

Further information:
BHS Sonthofen GmbH
www.bhs-sonthofen.com