Research and developement
Innovative R&D investment at the ALCUFER Kft.
In the ALCUFER company life beside the successful business results there was always a very important issue to achieve a mid- and a long term sustainability of operation. Therefore the shredding plant in Fehérvárcsurgó was after its official opening ceremony in October 2009 a place for continuous developments. The shredder equipment was developed 50 years ago for assuring the proper recycling of metal construction materials originated of end of life vehicles (ELV’s), wastes from bigger household machines (WEEE-wastes) and residential loose-sheet-wastes. Until the last ten-years-period the 20-25% non-metallic shredding-residues were landfilled in mono-landfill-stations and this activity was an accepted and practically applied solution for the treatment of Shredder Light Fractions (SLF).
In this period (in the years 1999, 2000 and 2002) new EU-Directives were put in force, these tried from one side to relieve the landfill-stations of high-calorific-value, for material or energetic recycling applicable organic materials (plastics and elastomers), from other side they wanted to achieve a higher recycling ratio in case of complex technical products.
These regulations, the Landfill-Directive, the End of Life Vehicles Directive (ELV) and the Directive on Waste Electrical and Electronic Equipment (WEEE) are already a long time ago harmonised regulations in Hungary too.
The ELV-Directive prescribes, that “no later than 1 January 2015, for all end-of life vehicles, the reuse and recovery shall be increased to a minimum of 95% by an average weight per vehicle and year. Within the same time limit, the re-use and recycling shall be increased to a minimum 85% by an average weight per vehicle and year.”
Be based on, that the vehicles today will be recycled – mostly manufactured in the time period between 1985-90 -, contain 70-75% of metallic-materials, the 95%-target in 2015 can already be appreciated.
To be able to comply with the expectations laid down in the regulations, to assure the sustainable work of company, in addition to promote the achievements of Hungary’s national economy targets, ALCUFER Kft. has continued a serious innovation and R&D activities in the last tree years. ALCUFER did it, because she strongly believes in, that the fastest way to get out of the crisis is the innovation and R&D activity combined with cooperation with universities and other innovative entities, supported by possible European or national subserviencies.
In the RECYTECH project between 2009-2011 the ALCUFER Kft. headed a 6-member-consortium, which developed two system-plans, they enable to recycle a former landfilled shredding-residues.
Based on its results the project with the name “Realisation of complex waste-treatment systems for processing organic residues originated out of ELV’s and WEEE-wastes” and identifier GOP-1.1.1-08/1-2008-0061 has established two free paramerisable prototypes, one of them is an experimental separation unit, one is an experimental thermocatalitic converter unit prototype. With these two units, according to the today’s expectation it will be possible to reach the 95% recovery-ratio.
The equipment and the relating infrastructure developments are realised for the planned deadline, the ceremonial presentation of prototypes, also the closing program of GOP-1.1.1-08/1-2008-0061 project will be hold on the 22th of November 2012 in Fehérvárcsurgó.
The separation equipment settled in one of the new 1.000 sqm workshop mills in the first step the shredding residues to a proper dimension for a further sifting. Different separation units combined with each other, in proper sequence assures the extraction of as material recyclable fractions. Used separation methodologies are the magnetic-, eddy-current- and air-blow-methods. The separated metal-fractions are magnetic steel and iron, rustless-steel, copper, red copper, aluminium. Beside of these fractions there are originated stone- and concrete-fractions which are usable for ballast material in road-building. In addition the end-product will be high-purity mixed organic fraction containing plastics and elastomers. These materials will be further used in the second experimental equipment settled in the second workshop.
The second 1.000 sqm workshop contains the thermocatalytic conversion technology prototype, which enables the energetic recycling (recovery) of mixed organic materials. This production-line feeds the milled organic material into the thermocatalytic reactor during a two-steps extruder. In the reactor-line there are three pipes above each other settled, in which during screw-driving-gears, with exclusion of oxygen the mixed organic materials are moved forward, whilst they are getting heat from the outer surfaces. These pipes are covered from outside with a closed space in which hot gases are transmitting the heat into the pipes. The during heat-transmitting dissolving mixed organic materials step out of the last pipe in form of solid coke. Out of the continuous moving organic materials there are come out gases and steams. These product-gases pass through a preliminary burning-chamber, where they are burning on a very high temperature of 1200ºC. These burning gases assure then the heat-supply for the whole procedure. The product-steams will be separated in a condensation-system from the product-gases, the steams are detached in a form of oil products as liquid fractions. This oil-fraction will be cleaned with a distillation-system as long as the quality enables the usage of this oil in slowly rotating, high-performance Diesel-internal-combustion engines and connected generator. As a next project step it can be settled the new electricity producing unit beside the thermocatalytic converter to enable a generation of green-energy. The quantity of green-based electricity can be according to the today’s abilities of Fehérvárcsurgó-premise about 2 MW.
The system is completed with extra heat-changers which are recycled the waste-heat originated out of the procedure, these assure the energy-supply of individual technology-elements. This activity saves remarkable amount of electricity.
Thermocatalytic conversion starts with external PB-gas-supply, which automatically switches-up into internal product-gas source, when the procedure already reaches its working temperature. So the whole procedure will be then self-supporting, it needs no more external source, only in the starting phase.
Our company has seriously taken into account the environmental issues. The accumulation and treatment of rainwater associated with wastes are realised in closed system. The rainwater goes over oil- and sludge-separator, than will be aggregated in an 8.000 sqm surface rainwater-reservoir. This water can only be used for the dust-exemption of premise, but no drop of rainwater get out of the industrial-area.
The thermocatalytic conversion technology disposes with all the prescribed technical defences by the regulations for treatment of dangerous wastes, and was built in a workshop which has liquid-locking isolation, impairment-exoneration units and controlling leakage system.
The emission point-source belonging to the technology will be provided with continuous emission-measuring system, until its realisation regular emission-measurements will be done according to the local environmental authority prescriptions.
These innovative and environmental protecting activities enable the sustainable development and assure for ALCUFER the right to use its slogan “ALCUFER the responsible waste-keeper”.
Mr. Dr. Pál Lukács Tel.: +36 96 512 700 E-mail: firstname.lastname@example.org