rotacut - gerpinis.gr1).pdf · 6 7 rotacut | designs and range type designation rcq-20 rc 3000 rc...
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E n g i n e e r e d t o w o r k
Railway AgricultureBiogasWaste waterIndustry
ENGINEERED TO WORK
RotaCut®High performance macerator and solids separator
EFFICIENT PROTECTION, M ACER ATION, TREATMENT
32
RotaCut | Technology
Technology that lets nothing slip by
Efficient maceration of coarse and fibrous
matter in liquid media with effective
protection from foreign objects and heavy
matter – only the RotaCut can offer this.
Invented by Vogelsang over 25 years ago
and continually developed ever since, the
RotaCut is the ideal cost-effective solution
for challenging applications. RotaCut
macerators are used throughout the world,
and thanks to our leadership in know-how
and experience, they are now the best
choice when it comes to reliable and
efficient maceration technology.
FunctionsAll RotaCut models perform two functions
simultaneously, solids reduction and solids
separation. Coarse and fibrous matter
(fibers, hair, bones, wood, etc.) is macerated
by rotating, self-sharpening blades, which
avoids clogging and blockage. The liquid
is also homogenized in the process. Hard
foreign objects and debris (stones, metal
parts, etc.) are separated from the liquid
stream. This prevents damage to down-
stream pumps and equipment. As a result,
RotaCut ensures the smooth flow of liquid
throughout your system.
RotaCut® – guarantee your success with pump systems for media containing fibers, coarse matter and solid objects.
Intelligent solids protection & sludge conditioning.
Maceration technologyThe RotaCut has many applications as a
macerator. Fibrous and coarse matter are
filtered through the cutter head of the
RotaCut with the flow of the pump medium.
The sophisticated cutting-screen geometry
and an innovative blade-guiding system
enable reliable maceration and an extremely
smooth cutting result. Solids such as hair,
rags and other suspended objects are
reduced to a suitable size that can pass
through the system without blockage or
clogging.
Conditioning
The RotaCut is also a very effective
tool for conditioning viscous liquids. It can
be used in several locations throughout a
wastewater treatment plant, in the food
industry, in slaughterhouses, biogas plants
and wherever suspensions with stable con-
sistencies are required. The RotaCut even
effectively macerates hair and industrial
fibers, turning the media into a homoge-
neous suspension.
RotaCut advantages at a glance
• Reliable maceration of fibrous and
coarse materials
• Protection from foreign objects for
all downstream components
• Fluids and suspensions are
homogeneous and less viscous,
requiring less power consumption
by mixing and pumping equipment.
Protection from foreign objectsAn important function of the RotaCut
is protection from foreign objects by
means of an effective heavy material
separator. Stones or metal parts that
cannot be macerated are safely separated
out based on their size or weight and chan-
neled into a collecting container. They can
be easily disposed of later via a cleaning
port. As a result pumps, pipework and
components are effectively protected.
54
RotaCut | Range of Applications
Innovations for maximum cost- ef fec tivenessMaceration technolog y for many applications
Range of applications and mediaWhether compact and mobile or installed in a pipe system, the
diversity of the RotaCut line provides a solution to any problem
in the area of pump and maceration technology as well as
protection from foreign objects. The RotaCut comes in seven
basic versions with different materials, drive units, screen sizes,
rotors and blade shapes.
Around the world, RotaCut macerators have stood the test under
the toughest conditions. Possible fields of application include the
waste water engineering and sewage treatment plants, biogas
plants, paper and cellulose, waste management, agriculture, and
food industries as well as slaughterhouses and rendering facilities.
The RotaCut cost-effectively and efficiently processes a
wide range of media, such as primary and treated sludge,
biosuspensions, food waste and abattoir waste, potato pulp,
oil sludge, and liquid manure. Thanks to its versatility, new
applications are continually emerging.
Examples of common RotaCut applications:
• Prevention of clogging in digestion towers
• Installation in front of a Belt Press, Centrifuge or Gravity
Thickener to ensure that sludge is well conditioned and free of
damaging solids and fragments
• Protection of pumping equipment from foreign objects during
vacuum extraction of small waste water works and sewage stations
• Maceration of abattoir waste and by-products, including
treatment prior to sanitation in accordance with EU Directive
using the Cut&Pump meat plant
• Protection of tanker trucks and distribution technology from
foreign objects and fibers when liquid manure, slurry or brewing
residues are used as organic manure in agriculture
• Digestion and homogenization of biosuspensions in biogas
plants for increased efficiency and gas yield
• Protection of mobile pump systems from foreign objects and
coarse matter
RotaCut is also ideal for any system that
is experiencing build-up or other nagging
problems such as septage/grease receiving,
sludge transfer, primary and secondary
sludge, RAS, WAS, Scum, DAFT, SBR and MBR.
Easy to serviceThe RotaCut is designed to be low
maintenance and easy to service. All
wear parts are easily accessible and can
be replaced in a few easy steps.
Innovative screen geometryOur engineers developed software for
calculating cutting screens with optimum
geometry for all screen sizes and rotational
rates, in many different media. In this way,
we can select a cutting screen for every
task and tailor it precisely to the medium
to be processed. All cutting screens can
be used on both sides. The well-adapted
geometry reduces wear to maximize blade
and screen life.
Blade and rotor constructionThe steel blades of wear-resistant,
Martensitic stainless steel can be quickly
and easily exchanged and are held
against the RotaCut cutting screen by a
self-adjusting cutter head. Thanks to the
sophisticated blade holder in the rotor
there is constant contact between the
blades and cutting screen. Optimized
blade arrangement, combined with the
constant contact between blades and
cutting screen, guarantees vibration-free
motion as well as maximum efficiency
and cost-effectiveness.
Well-thought-out details and a consistent
overall concept make the RotaCut an ideal
solution for a wide range of applications. More
and more users are choosing the RotaCut because
it reliably protects pumps and other components
from foreign objects, fibrous and solid matter and
efficiently processes suspensions.
Always the Right Choice: RotaCut®
76
RotaCut | Designs and Range
Type designation RCQ-20 RC 3000 RC 5000 RC 10000 RCX-48 RCX-58Motor type
Maximum flow rate m3/h gpm
90 396
180 792
300 1320
600 2640
600 2640
750 3300
Geared motorOptional speedOptional motor power
min-1 /rpmkWhp
87 - 320 1.1 - 2.2 1.5 - 3.0
76 - 326 1.5 - 4.0 2.0 - 5.0
73 - 330 1.5 - 7.5 2.0 - 10.0
66 - 319 2.2 - 7.5 3.0 - 10.0
114 - 311 5.5 - 11.0 7.5 - 15.0
94 - 276 7.5 - 15.0 10.0 - 20.0
Hydraulic motor Required oil pressure
Required oil quantity
barpsil/mingpm
50 - 70 725 - 1015
4011
60 - 80 870 - 1160
4512
70 - 100 1015 - 1450
6016
180 - 230 2611 - 3336
7520
Design type overview Inline Inline Cyclone
MXL
Inline Cyclone
MXLM/MX
Compact Compact XL
Inline Cyclone
MXL
Compact Compact XL
Inline Inline
MXL
Cutting screen with available free passage
mm 10/15/20 8/10/1215/20/28
4/8/1015/24/30
4/8/1012/16/2025/34/38
4/8/1012/16/2025/34/38
8/12/1625/34
The right design for ever y task RotaCut Compac t pro
RotaCut Inline This model is easy to integrate into existing systems because
the intake and discharge points are positioned directly opposite
one another. Heavy objects such as stones and metal parts are
separated out and fibrous matter is reliably macerated. This
version is typically used in communal waste water systems and
industrial plants.
RotaCut CycloneThis model is especially suited for applications where heavy objects
such as stones and metal parts must be separated out and a small
amount of fibrous matter must be macerated at the same time.
Typical media include waste water or organic fertilizer.
RotaCut Compact proThe ideal macerator for reliable and cost-effective treatment of
media with large amounts of fibrous matter. Thanks to its robust
design, it can also be used on the discharge side (up to 3 bar is
possible). With the XL design, large amounts of heavy matter in
the medium can be reliably separated out. This type is mainly
used in industry and in biogas plants.
MXL This type is the ideal solution for special requirements in the field
of vehicle construction. It cuts fibers just as reliably as it separates
heavy objects and can be easily installed on a vehicle. Its large
opening provides easy access for service and maintenance, and
heavy objects can be easily removed.
For extreme situations: RotaCut® proFor use in the harshest environments we have developed a
particularly robust version: the RotaCut pro. Thanks to the
modified design and the strengthening of major components,
it is the perfect solution for highly demanding jobs. It achieves
particularly even and homogeneous results. The increased power
enables even greater cutting output in the same space.
Easy to service: RotaCut® RCQThe RotaCut RCQ is characterized by a high degree of serviceability
and user-friendliness. Maintenance and replacement of cutting
knives can be done extremely quickly. Thanks to ACC, the condition
of the blades can be checked during operation without opening
the RotaCut.
We build your RotaCut® to order! We configure every RotaCut to meet the exact needs of your application.
For the many different applications of a RotaCut, there are just as many versions to match: two series, five sizes
in several different designs, a range of configurations and materials as well as different drive unit options.
You define your specific requirements and tasks and we configure a tailored RotaCut macerator for you. High
performance and outstanding ease of maintenance are two things all models have in common.
The powerhouse: RotaCut® RCXWith the models in the RCX series, we have continued to develop
our RotaCut pro concept. They epitomize cost-effective maceration
for rugged applications in tight spaces. The new RCX types feature
extremely robust motors as well as solid and sturdy construction,
allowing for use on the discharge side at up to 6 bar. Reduced wear
and a longer service life mean lower operating costs. All RCX types
feature cartridge seals that require less time to change, enhance
safety and increase serviceability overall.
RotaCut M XLRotaCut RCXRotaCut Inline RotaCut Cyclone
98
ACC advantages at a glance
• No manual blade adjustment required; fully automatic,
uninterrupted operation
• Contact pressure can be readily adjusted to the medium
without interrupting operation
• Low operating costs thanks to minimum wear and low
current consumption
• Optimal results due to consistently high cutting
performance and constant grinding levels
Cut ting screen and blades always func tion in per fec t harmony
RotaCut | Automatic Preloading Unit
ACC – Automatic Cut Control Even pressure at all times
The RotaCut is a macerator that uses direct contact between the
blades and the cutting screen. It reliably macerates long-fiber
materials (such as hair, entangled material, GPS, grass) in media.
ACC ensures high cutting performance at all times:
It automatically adjusts the blades and continuously maintains
the necessary pressure between the blades and the cutting
screen. Manual maintenance is no longer necessary. Furthermore,
the pressure can be externally adapted to suit the medium during
operation.
The automatic control unit maximizes blade and screen life
The ACC adjusts the contact pressure between the blades and
cutting screen to a level as high as is necessary and as low as
possible. This considerably prolongs the service life of the blades.
As a result, ACC is a reliable basis for increased efficiency. It is the
key to largely automated operation in continuous use because
the contact pressure is kept constant until the end of the life
cycle. Once the blades have reached their service life expectancy
limit, a signal is emitted. Within a control facility, this can be
used to inform the operator.
ACC plusWith ACC plus, you can reduce your maintenance and monitoring
costs even further and ensure failure-free operation. This is
because with ACC plus, the RotaCut is monitored online and does
not have to be opened in order to check the blades. An external
display informs the operator of the condition of the blades at all
times. As an additional feature, this can be displayed graphically
by the control system, a useful option if you want to monitor and
check the RotaCut centrally or by remote control. A message
informs you when the blades require changing so that you can
plan replacement part orders and maintenance well in advance.
Optimal pressure between the cutting screen and blades
ACC – stable pressure
Manual preloading system: fluctuating pressure; excessive pres-
sure causes unnecessary wear
+
Optimal pressure-
is the basis for
efficient maceration. ACC®, automatic cutting pressure control,
ensures that this pressure remains even at all times
so you never have to worry about it.
1110
RotaCut | Control Technology
We leave nothing to chance in the service area Whether you require start-up, training or full service with a maintenance contract and a wear parts service package – we provide comprehensive support with our individualized all-round service, helping you to keep your systems running smoothly from the start.
Support and supply from A to ZBecause we are aware that close customer
proximity is essential for our joint success,
we design our services to best meet your
needs. Our international presence in
countries in which we have subsidiaries or
trade partners, Vogelsang service centers
and contractual partners generates an
active dialogue with our customers and
provide reliable support. That means
you get the precise support you need in
Comprehensive ser vices for smooth operation and a long ser vice l ifeTwo details, one prof itable result
LifeGuard – to guarantee a maximum
service life for our products. The service
life of a Vogelsang machine is determined
by specific LifeGuard factors. We take
these factors into consideration and
offer you features that are relevant for
maximum productivity and service life.
Years of experience shared by biogas
plant operators have shown that
LifeGuard services in combination with
our Performance Control Units (PCUs)
lead to optimal results throughout a
long service life without complications.
every phase of our partnership. Our highly
qualified staff makes it possible – expert
consultants and technicians who know
your Vogelsang machines inside and out.
We think aheadThinking ahead in your best interest
begins with our extensive and detailed
product documentation. Spare parts are
available within a short period of time
due to our high degree of vertical
integration in production. In addition,
you will always find an authorized service
partner in your area who can help with
repairs and wear part replacement. The
Vogelsang ServicePack completes the
offer. Whether you need start-up, on-site
training, training at the Vogelsang facility,
or full service support with a maintenance
contract or a wear part service package –
we offer a support program tailored
specifically to your needs.
LifeGuard – Leading viainnovationMaintenance generally results in
downtime as well as expenditures for
personnel and spare parts. We have
therefore developed a concept to limit
service and repair times to a minimum:
PCU – Performance Control UnitPCU is our intelligent control technology. It enables energy-
efficient and autonomous operation because it can monitor not
only the RotaCut itself, but all other upstream and downstream
functions. Based on this data, the individual components
communicate and the throughput rate of the RotaCut is increased.
The PCU registers the load of the RotaCut completely
automatically and regulates the operating parameters to
achieve the optimum result. Malfunctions are detected early,
the appropriate measures implemented and automatically
rectified in plenty of time using the PCU. The unit can also be
easily connected to a higher-level control system via Profibus
(Process Field Bus).
PCU advantages at a glance
• Reduced maintenance due to autonomous operation
• Efficient operation due to fully automatic and situation-
dependent control of operating parameters
• Lower operating costs due to a longer service life
• Reliable operation thanks to automatic fault elimination
• Increased throughput rate
Advantages of the auto reverse at a glance
• Increased efficiency through reduced power requirements
• Lower operating costs
• Reliable operation thanks to automatic blockage elimination
Greater Efficiencythrough Intelligence
Gain a key advantage by using our
intelligent control technology:
efficient, autonomous operation.
LifeGuard factors:
• Self-sharpening cutting unit
• Reversible cutting screen
• Optimized cutting screen geometry
• Self-adjusting blade, optimum
cutting pressure (ACC)
• Auto reverse function
• Optimized blade and rotor design
Auto reverseAuto reverse controls contact with
course and hard extraneous
materials in the RotaCut. The
system recognizes any blockage
in the RotaCut and reverses the
rotational direction of the blade
rotor: a renewed cutting attempt
then occurs from the other side of
the blocking matter. This process is
repeated until the blocking matter
is macerated. Yet another useful
function: regular, automatic
reversal of the direction of rotation
means that the pair of cutting edges
in use at the screen and blades is
always sharp, as it has been ground
on the reverse side beforehand. As
a result, you benefit from optimal
cutting performance with reduced
power consumption.
ENGINEERED TO WORK
Hugo Vogelsang Maschinenbau GmbH Holthöge 10–14 | 49632 Essen/Oldb., Germany Phone: +49 5434 83-0 | Fax: +49 5434 83-10 [email protected]
Our company
Innovation and progress have been
hallmarks of Vogelsang for over 80 years
and have made us a leading global plant
engineering company. Time and time
again we have achieved significant
milestones of progress. Today, we develop,
manufacture and distribute some of the
most innovative and reliable machines
and systems for agriculture, municipali-
ties and industry.
With our overseas subsidiaries and service
centers, we are world-renowned for
advanced engineering and customer-
friendly solutions.
Our product range
We offer solutions for the following
areas:
• Industrial sector
• Waste water treatment
• Biogas
• Railway waste water disposal
• Agriculture
We offer a broad range of products:
• Rotary lobe pumps
• Maceration technology
• Distributors
• Spreading technology
• Supply and disposal systems
• Complete solutions
We also offer customized solutions for
your specialized applications.
How to reach us
Vogelsang is present worldwide. Visit us
online for more information about our
company and wide range of services:
vogelsang.info
We are here to assist you and look forward
to speaking with you.
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USAVogelsang USA Inc. vogelsangusa.com
Great BritainVogelsang Ltd. vogelsang.co.uk
FranceVogelsang France S.A.R.L.vogelsang.fr
ItalyVogelsang Italy Srlvogelsang-srl.it
PolandVogelsang Poland Sp. z o.o.vogelsang.pl
Romania Vogelsang Romania SRLvogelsang.ro
ChinaVogelsang Mechanical Engineering (Shanghai) Co.vogelsang.com.cn
SpainVogelsang S.L.vogelsang-spain.es
AustraliaVogelsang Pty. Ltd.vogelsang.com.au
IndiaVogelsang India Private Limitedvogelsangindia.com
Czech RepublicVogelsang CZ s.r.o.vogelsang-czech.cz
DenmarkVogelsang A/Svogelsang-as.dk
BrazilVogelsang Brasil Ltda. vogelsang.com.br
MexicoVogelsang De México S. de R.L. de CV.vogelsang.mx
SwedenVogelsang Sverige AB vogelsang.se
MalaysiaVogelsang Malaysiavogelsang.info
Germany – Easter Branch Vogelsang Lutherstadt Eislebenvogelsang-gmbh.com
Product availability, appearance, technical specifications and details are subject to continuous development. All information presented here is therefore subject to change.