waste recycling solutions...frans moorman is project manager at attero in wijster. he was actively...

waste recycling solutions

eng

banzo Serv ice Solut ionS

Bu i t envaa r t 1 409

7905 SJ Hoogeveen

the ne the r l ands

+3 1 (0 ) 88 58 85 000

www.banzo.n l

4 banzo Was te Recycl ing solut ions

the way to recycle

5

banzo was te recyc l ing so lu t ions 08

in t roduct ion : f rom was te to resource 1 1

separa t ion p lan ts 13

Househo ld was te 1 6

P la s t i c s 23

Sou rce seg rega ted ma te r i a l s 30

o rgan i c we t f r ac t i on 35

con s t r uc t i on , demo l i t i on and bu lky househo ld was te 38

7 d i sc ip l ines, f rom des ign to main tenance 45

about banzo 53

contac t 56

table of content

7

waste recycling solutionsBanzo designs, manufactures, installs and maintains recycling plants. It is our goal to improve the quality and economic feasibility of recycling through modern and complete facilities that help cities and regions to process waste and create resources, in the Netherlands and throughout the world.

cu s t omi z at ion With Banzo, you can rely on 70 years

of experience. In recent years, we have

experienced strong and steady growth by

flexibly responding to questions from our

customers. Installations are designed to

customer specifications. By making use

of standard components, we can quickly

translate a design to a working plant. We

take our responsibility very seriously,

and in working with clients we continue

to distinguish ourselves in the market by

providing solutions that work.

Pr o jec t s We are pleased to present you with our

brochure. You can read about our separation

plants, about projects that we have

successfully built and gain an understanding

of how we work. From engineering to delivery

and service and maintenance, it’s all here,

you’re your consideration.

Let this inspire you to connect with us to

make your project become reality.

Marcel Kroon, CEO


tHe way to recycle

9

from waste to resourceWorldwide attention is paid to reducing waste, because of the enormous impact on public health and the environment. Waste landfilling is seen as the worst solution to handling waste, and waste prevention is seen as the best. The European Union wants to dump maximum 10% of waste by 2030. On average, however, only 40% of it is recycled waste. In the United States, they’ve deposited more than the half of the waste in landfills, nearly 134 million tons in total.

At the same time, there is an awareness of the social

and commercial implications which causes a variety

of industries, multinational corporations and public

organizations to formulate sustainability goals. To

achieve these progressive goals, capacity is needed.

P o s t-separ at ion P l ant s We believe in post-separation, because capacity will

prove to be one of the decisive factors in achieving

the ambitious goals. The growth of large cities, the

lack of storage at waste disposal sites, and reduce

transportation mileage all point naturally to post-

separation as the best solution. Especially when we

can realize up to 96% pure mono streams.

Recycling is about enhancement, about creating

additional value from expired resources. Both

municipal solid waste and source separated

materials need post-separation to be reprocessed

into raw material. Banzo specializes in

installations for subsequent separation.

1 1

seParation Plants

13

seParation PlantsDesigning and developing the ultimate solutions, thinking through customer processes, comprehending the organized and structured plans that have been developed, delivering on time and to the correct specifications at the lowest possible build and maintenance cost of this type of installation is our expertise. It’s in our DNA.

Banzo is specialized in seperation plants for various products:

• Household waste • Plastics• Source separated materials • Organic wet fraction • Construction, demolition and bulky

household waste

15

household wasteThe purpose of the installation is separating hard plastics, foils, metal, paper and organic wet fraction from household waste, and to do so as efficiently as possible. In each step in the separation process is aimed to create multiple recyclable products to be reused as a raw material for further processing.

Basically, the subsequent separation system

consists of a reducer, magnets, windshifters,

ballistic separators and Near InfraRed (NIR)

scanners. The smallest fraction (0-70mm) is the

Organic Wet Fraction (OWF). It is possible to

ferment the integral OWF fraction or to separate

through our OWF reprocessing plant through

monostreams such as glass, plastics, metals and

stone. What remains is an organic fraction with a

much higher gas yield.

The fragments that are larger than 70mm are

passed through a separator, where the material is

first separated in a 2D and 3D flow. The 2D stream

consists of flat parts, such as foils, paper and

textiles. The 3D stream are rigid materials such as

hard plastic and cartons.

From the 2D stream are paper and foils are

evaluated and separated by means of wind

shifting. The paper and foil fragments are

determined by means of NIR-scanners.

From the 3D stream, hard plastics are separated

by means of NIR-scanners. Where necessary, this

stream is run under the magnets and is further

stripped of iron or non-ferrous metal and beverage

cans. Plastic is separated up to the level of PET, PP

and PE by a NIRscanner.

The separation plant can be customized, designed

and implemented with a processing capacity of 10

tons / hour to 70 tons / hour.

seParation Plants


household waste

17

removing metals

s i ev ing in 5 fract ions through shaking screen

ball i st ic seParat ing

s eParator featured household waste

household waste


nir-seParat ing

outPut f i lms

outPut owt to d ige ster

windshif t ing

Product seParators

for fo i ls

outPut hard Plast ics

Product seParator fans

re s idue outPut

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seParation Plant household waste aeb amsterdamAEB Amsterdam, BAM and Banzo were selected for the construction of a post-separation plant for household waste. The plant will come on-line in the autumn of 2017. With the installation AEB makes an important contribution to achieving the sustainability objectives of Amsterdam and other participating municipalities: separation of 65 to 75 percent of household waste by 2020.

With this post-separation line, household waste,

plastics, beverage cans, metals, and the organic

fraction wet paper / cardboard are recovered

from the residual waste. These raw materials are

sustainably processed by AEB or other end users.

Many municipalities have declared they will

divide their household waste to the AEB plant.

The capacity of the plant - 300,000 tons per year -

will thus be fully exploited.

household waste – reference


seParation Plant household waste aeb amsterdam

Mark Hagoort is Plant Manager of AEB

Amsterdam. “We opt for post-separation, because

waste being separated at the source in a city like

Amsterdam does not lead to the desired result.

The combination of source and subsequent

separation produces the best results. There is a

lot of high-rise buildings, space is limited on the

street. Therefore, much waste still ends up in a

garbage bag. So for us, a garbage becomes a source

of raw materials.”

“What was very important in the procurement

of this project required collaboration between

the builder and the other parties to figure out the

installation. We wanted to work with superior

companies, in this case BAM and Banzo. They can

see the hurdles, and Banzo saw the challenges and

challenge understood them. They have also been

the most creative in devising solutions, something

others have failed at.”

Moreover, the contract was political. Amsterdam

City is a shareholder of AEB and had to approve

the investment of AEB. “We had to make sure

that the post-separation plant would contribute

to the sustainability goals of the Amsterdam

municipality.”

The construction of this mega plant fits into the

transformation of AEB, which originally burned

waste. Now they are focused on waste, energy

and now reuse. “We are transforming a waste and

energy company to an energy and commodities

business. The implementation of a post-separation

plant fits perfectly into this strategy.”

“ Banzo waS tHe moSt creative in finding SolutionS”

household waste – reference

21

PlasticsPost-separation focuses primarily on separating valuable streams. After sorting and separating, we can upgrade raw materials. This happens largely in the plastic sorting plant (PSP).

The reprocessed 3D material from a post-separation plant for

household waste can serve as input for PSP. The 3D stream

consists of ferrous, nonferrous, cartons and rigid plastics.

(Non-) Ferro’s are separated by using a magnet, and eddy

current. By a number of Near InfraRed (NIR) scanners placed

in succession, the cartons and plastics, PET, PE, PP and

mixed plastics are separated. Quality reviewers then ensure

that the plastic monostreams are at the desired specifications.

The plastic monostreams are pressed into bales and serve as

raw materials for the plastics processing industry.

The plastic sorting plant can be customized, designed and

implemented with a processing capacity of 1 ton / hour to

15 tons / hour.

sePeration Plants

23

focus on Plast ics sort ing Plant

baler sorted mater ial

n ir seParat ion fo i ls

n ir seParat ion hard Plast ics

ball i st ic seParat ing fo i l

Products stocked PP / Pet / fo i l / Pe / mix

Plastics


ball i st ic seParat ing fo i l

handPick ing graded mater ials

comPre ssedbale s

ball i st ic seParat ing hard Plast ics

suPPly hard Plast ics

suPPly fo i ls

25

Post-seParation Plant atteroIn 2015 Banzo completed a new plant for Attero Wijster for the sorting of plastics, cartons, ferrous and non-ferrous metals from source segregated material. Banzo designed the installation, manufactured and assembled it. The sorting takes place via a film grabber, ballistic separator, 10 optical (NIR) separators, overhead magnets, eddy current and hand sorting.

Plastics – reference

Frans Moorman is project manager at Attero in

Wijster. He was actively involved in the realization

of a post-separation plant for household waste.

It was a large-scale project involving Banzo, the

design, installation and maintenance they worked

on.

e s t imat e s ‘’We put a quote in the market and choose a

supplier who came out on top on the parts, price,

quality, safety and speed. Banzo was a logical

choice, because they scored the best in these

areas. This is a project with a total investment

of 8 million euros. To give you an idea, this

system separates 280,000 tons of waste per year.

That is waste from 500,000 households in the

Netherlands.”

Pr oce ss ‘’Banzo worked out the design detail. Thanks

to well-developed 3D drawings, our technical

department saw exactly where the parts were. We

saw that everything was correct and in a logical

place. For example, there is plenty of walking

space on the platforms and connect a relief

well into the next device. It was a constructive

cooperation between Banzo and the project

team. Banzo are the work specialists who deliver

consistent quality.”

compl e t ion ‘’When the components were produced, the plant

could be built. This too went well. Banzo thought

through and had everything well organized.

The parts arrived on time. This ensured that the

delivery took place earlier than planned.”


“ tHe delivery took Place earlier tHan Planned”

27

Plastic sorting Plant - attero wijster


source segregated materialsIn addition to post-separation, we also have source separation. Independent source material consists mainly of plastic, metal and beverage cartons.

sePeration Plants

The source separated packaging comprises

roughly 40% of foils. The source separated

packaging material also consists of ferrous,

nonferrous, cartons and rigid plastics.

First, the bags are opened and the fine

material is separated in a sieve. Windshifters

and a ballistic separator ensure that the

sheets are separated from the source

separated packaging. (Non-) Ferro’s are

separated by using a magnet and eddy

current.

By placing a number of Near InfraRed

(NIR) scanners in series one after another,

the beverage cartons and plastics in PET,

PE, PP and MIX are separated from plastic

fragments. Quality control reviewers

ensure that the plastic monostreams are

at the desired specifications. The plastic

monostreams are pressed into bales and

serve as raw materials for the plastics

processing industry.

From the 2D stream paper and foils are

sorted and separated by means of shifting

wind and sorting the paper and foil fraction

by means of NIR-scanners to be further

worked up.

The separation plant for source separated

materials can be customized, designed and

implemented with a processing capacity of

1 ton / hour to 15 tons / hour.


seParation Plant for source segregated materials - attero wijster


organic wet fractionEverything that is less than 70 millimeters from the separation plant for residual waste is considered organic wet fraction (OWF). Often this stream is directly deposited in a digester for bio-gas. However, OWF are even more valuable materials or inert streams, which are extracted from this plant. For example, 3% of OWF is still plastic.

OWF is composed of 50% moisture. The moisture

is smaller than 6-8 mm to a large extent in

the fraction. With a sieve, this fraction can be

separated. The gas yield of the fraction smaller

than 6-8 mm is small. By drying this fraction, the

mass is reduced by 50%. Further work-up of this

fraction is possible.

The 6-70mm fraction are many 2D deformable

materials. Via wind shifting, foils and paper

are separated from the 3-D materials, such as

plastics, wood, stone, glass, metals and nonferrous

materials. After the removal of iron from the 3D

materials using magnets, the plastic is removed

using near infrared (NIR) scanners.

What remains is in an X-tract, a radiation machine

that on the basis of X-ray technique and infrared

recognize materials on a molecular level. On the

basis of permeability, stone and glass are removed.

The organic fraction that remains is for the

digester and ensures a high gas yield.

Stone fraction can be sold as a raw material. The

glass is delivered with a purity of more than 95%

and is suitable as a raw material for the glass

processing industry.

A separation plant for OWF can be customized,

designed and implemented with a processing

capacity of 5 tons / hour to 40 tons / hour.

sePeration Plants

35

owf-installation omrinOmrin is a collector and processor of waste that handles the collection for 173,000 households in 16 municipalities in and surrounding Friesland, Groningen, and almost 7,000 companies. They are also processing approximately 800,000 households, and many businesses. They are doing their utmost to recover as much raw material as possible from waste to produce renewable energy.

In 2015 a new plant for organic wet fraction

(OWF) was delivered. This installation separates

inert material. The purified OWF is used for the

production of bio-gas in a digester. The separation

takes place by means of a sieve, and then an

x-tract that separates with the aid of X-ray the

inert material in the OWF.

Bart-Jan van Dixhoorn manages projects and

operations at Omrin. He works closely with Banzo.

“We have our ideas on how such a system should

work, but we need the expertise of Banzo in order

to translate our ideas into drawings and technical

solutions. You can think of something, but it must

also be to build and run. The translation of ideas

to create something and install, is for us the added

value of Banzo.”

What factors play a role then? “Maximum

recycling efficiency, minimize human work, robust

installation safety. There’s engineering needed to

translate that into a steel structure, to fit in the

equipment, etc.”

“The goal we have with the OWF installation is to

retrieve all disruptors. In the input is 15% pebbles

and at the end of the process, all of that are out of

there. The plant processes 15 tons per hour, which

is 1.5 to 2 tons of stone per hour. It has its value as

a raw material and in addition, the fermentation of

the OWF then proceeds efficiently.”

organic wet fraction - reference


“With our approach, we are able to get 65 percent

of the waste we collect, to make it suitable

for reuse. This makes Omrin a leader in the

Netherlands.”

In 2016 Banzo is working with Omrin on a sorting

plant. “Our collaboration is actually continuous,

and Banzo is one of our permanent partners.

Together we work on our mission to finally have

100% of the waste be converted into raw material.”

“ no interfering SuBStanceS anymore in owf”

37

construction, demolition and bulky household wasteThe purpose of the installation is to separate hard plastics, foils, metal, paper, stone and wood from construction, demolition and bulky household waste. Wood, plastic and foils are the largest and most valuable streams.

Essentially the same thing happens as in the

plant for household waste, it is only coarser.

Reduction of fractions needs more attention,

as well as wear sensitivity. Ideally, there

is a separation plant with as few bends as

possible. At transfer points, wear plates are

placed with 400 to 500 Hardox applied.

The basis is the separator for construction,

demolition and bulky household waste from

a reducer, sieves, magnets, windshifters,

ballistic separators and Near InfraRed

(NIR) scanners.

The material is first separated in a 2D and

3D flow. The 2D stream consists of flat parts,

such as foils, paper and textiles. The 3D

stream are form-retaining materials such as

hard plastics.

From the 2D stream, paper and foils are

separated by means of wind shifting.

From the 3D stream, hard plastics are

separated by means of NIR-scanners.

Where necessary, these streams are culled

via magnets to remove iron or non-ferrous

metal and cans. Plastic is sorted by a NIR-

scanner up to the level of PET, PP and PE

separated. Wood and stone can be based on

specific weight, or separated with radiation

technique.

The separation plant for construction,

demolition and bulky household waste can

be customized, designed and implemented

with a processing capacity of 10 tons / hour

to 70 tons / hour.

sePeration Plants


sePeration Plants

39

seParation facility for construction, demolition and bulky household waste van gansewinkel amsterdam


engineering new SyStem witH exiSting comPonentS


The project for Van Gansewinkel was special

because of the removal of the two old lines. The

new line would consist partly of components

from the old sorting line in Amsterdam, and new

components.

“Banzo had the engineering done for us,” says

Peter Schout, head of maintenance at Van

Gansewinkel Amsterdam. “They made the

drawing on the basis of all required components.

That’s how determined they were to fit everything

together. In addition, we needed the expertise

of Banzo to determine if what we wanted was

actually feasible.” Banzo made certain that

parts and certain components were still in good

condition and had met the requirements.

The job was completed in less than 3.5 months,

which was an important condition. “We had to

be running January 1 in order to make a timely

replacement of the old line, in order to save money.

We had little time to deal with each other to have

extensive discussions, we wanted to put it simply

to a partner and get it done.”

“Through colleagues, we had already contacted

Banzo and were confident that they could do this

for us. That confidence was justified. The tonnage

of the old system, plus everything that went

through the old plant in Utrecht, it is now going

through this sorting plant. About 180,000 tons per

year.”

sorting line for bulky household and construction and demolition wasteAt the end of 2015, Banzo built a sorting line for bulky household and con-struction and demolition waste in Amsterdam for Van Gansewinkel. Van Gansewinkel dismantled the old sorting lines in Utrecht and Amsterdam and created a new line that processes 180,000 tons of waste per year.

construction, demolition and bulky household waste - reference

43

disciPlines

45

involved in all diSciPlineS


design

es timates

Project management

engineering

Production

delivery / ins tallation

service maintenance

disciPlinesOpting for Banzo means choosing a specialist for you to take the entire process off your hands.

Our method is broken down to seven steps. By being

involved in the whole process, we can guarantee quality

in each step. Here is where we work closely with our

customers for the best results.

disciPlines

47

de s ign After an interview and a clear statement of

the requirements, we complete the first step

to translate the job into a preliminary process

flow diagram (PFD). Herein, the input, output,

volume flow and the materials to be processed are

determined. With the PFD, our concept design

is realized. In 3D CAD software, the required

components are positioned in a virtual model of

the environment. The result of this design is a

visual design of an installation.

e s t imat e sAfter the design, each of the components

needed to build the installation is described.

The specifications of the installation are listed

and the technical drawings are added to it. The

specifications also comprise the details of the

components.

Pr o jec t management Our project managers oversee the project from

start to finish. All process steps are monitored,

project progress is measured and communicated

with customers, suppliers and the internal

organization. Post-delivery also includes aftercare

under his responsibility. Therefore we guarantee a

successful completion of each project.

e ng ineer ingAt Banzo, design is expanded in manufacturing,

assembly and installation drawings. These are the

drawings that are necessary for the production,

assembly and installation of the system. We have

the capacity to perform multiple complex projects

simultaneously. A team of experienced specialists

is carrying out engineering in every detail.

Pr oduc t ion The components are produced and assembled

from the production drawings. We work

with advanced machines. The drawings are

automatically read and fabricated. As a result, the

probability of error is reduced to a minimum. We

have a large production capacity, enabling us to

quickly deliver large quantities. Our products meet

high quality standards.

disciPlines


disciPlines

49

del i ver y and a ss embl y Work safety is our top priority. Our people have

SCC and the necessary safety certificates. Banzo

Engineering is SCC, ISO 9001 and ISO 14001

certified.

In the interest of the process, we deliver all the

products just-in-time, on location. On the basis of

the predetermined schedule, the plant is built. Our

assembly team ensures the most efficient build-up

of the plant. After installation, we supervise the

commissioning and startup of a plant.

ser v ice & main t enance We help our customers not only during but after

the completion of an installation as well. A team of

experienced technicians are on stand-by 24 hours

a day, 7 days a week to step in and correct any

malfunction or problem.

We perform corrective and preventive

maintenance. When corrective maintenance is

required, we come into action.

For preventive maintenance, we will carry out

inspections at agreed intervals. We are your

partner to set up a preventative maintenance

schedule that will help you avoid unexpected high

costs for your installation after the fact.

If your system is not built by us, but you would

like to benefit from our knowledge and experience,

our service and maintenance team is always ready

for you to carry out inspections, maintenance and

repairs.

Planned turnarounds are something we can

completely take care of. In addition, our skilled

engineers are able to make adjustments and

improvements to facilities. With our advanced

methods and linkage with 3D software, it is

possible to carry out complex modifications to an

existing installation.

disciPlines

51

about banzo

53

about banzoBanzo Waste Recycling Solutions is part of Banzo Group.

Banzo designs, manufactures, installs and maintains recycling plants. It is our goal to improve the quality and economic feasibility of recycling through modern and complete facilities that help cities and regions to process waste and create resources, in the Netherlands and throughout the world.

With our knowledge of transport and storage systems,

Banzo is also strongly engaged in service and maintenance.

Banzo Service Solutions focuses on systems outside the

recycling industry, such as industrial conveyor systems,

bulk handling and bulk material handling and agricultural

systems. Ask for our brochure, Banzo Service Solutions, or

check www.banzo.nl for more information.


contactWe would welcome a talk with you, please feel free to contact us.

Banzo Waste Recycling Solutions+31(0) 88 58 85 000

[email protected]

www.banzo.nl

Buitenvaart 1409

7905 SJ Hoogeveen

The Netherlands


banzo Was te Recycl ing solut ions

Bu i t envaa r t 1 409

7905 SJ Hoogeveen

the ne the r l ands

+3 1 (0 ) 88 58 85 000

www.banzo.n l

waste recycling solutions...frans moorman is project manager at attero in wijster. he was actively...

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