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Range of business

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Philosophy KOMPTECH is a leading international supplier of technology for machinery and compact systems for the mechanical and mechanical-biological treatment of solid wastes and biomass. Innovation, dynamism, quality and closest possible proximity to customers are pivotal and govern day-to-day business activities in accordance with the following principle: ”Customer benefit is the focal point of our collective actions.“

Innovation In light of the ever-increasing speed of change in the area of waste and material flow management, a key demand made of suppliers of technological equipment such as KOMPTECH is to quickly adapt to ever-changing requirements. It is for this reason that innovation has become a pivotal strength of the company. Our customers benefit from those solutions we provide, solutions which need to address all these requirements.

Quality The KOMPTECH brand is synonymous with quality, reliability and stability in product value. Where quality is concerned, we refuse to settle for compromise and use only the highest-quality outsourced components alongside our own components manufactured in-house. KOMPTECH products offer the highest possible quality and safety standards together with an excellent price-performance ratio.

Organisation Besides its headquarters in Frohnleiten (Austria), responsible for international machinery sales, KOMPTECH also has sales organisations in Germany and Great Britain as well as distribution partners in more than 30 countries. The KOMPTECH offices in Vienna (Austria) and Oelde (Germany) assume world-wide project management responsibility for stationary and system technology. Four competence centres are the focal point of research, development and production activities for the separate product groups – Frohnleiten, Austria (composting and shredding technology), Oelde, Germany (drum screen and separation technology), Lauterbach, Germany (star screen technology) and Stockholm, Sweden (ballistic separation and pelletising technology). 2

COMPETENCE


Household waste,

Bulky waste,

Production waste,

Packaging waste,

residual waste

commercial waste

tyres etc.

paper, DSD material

Splitting

MBT

RDF

Green waste

Composting

Treatment of biomass/wood

Volume reduction

Treatment for anaerobic digestion

Waste treatment

Untreated waste

Treated

Biowaste,

wood, root stocks

waste wood

sewage sludge

Spoiled food

• •

• •

• BUSINESS SECTORS

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The KOMPTECH product portfolio comprises more than 20 different types of machines, covering the key process stages in modern waste treatment – shredding, separation and biological treatment. We provide our customers in the business segments highlighted with reliable mobile machinery, powerful stationary machinery and complete system solutions. Always a focus: Innovative technology and solutions that maximize customer benefit.

Mobile machines KOMPTECH mobile machines combine high performance under adverse conditions with high mobility on different surfaces, compact size and low weight for easy transportation. Intelligent modular design with different power levels, modern engines with emission and noise control and a comprehensive sales and servicing network are decisive factors in the successful deployment the world over.

Stationary machines For large plants and in plant construction generally, it is practical to use electrically-driven systems. With this in mind, KOMPTECH offers a comprehensive range of stationary shredding, screening and separation technology. Designed for continual operation with precise tailoring to the location and job at hand, stationary technology from KOMPTECH frequently operates as a key component and meets a broad spectrum of needs within the field of recycling.

System technology By combining the right products from our own portfolio, complete solutions can be fashioned that can then be complemented as and when required with tried-and-tested components from other established manufacturers. These system technology solutions overcome complex problems, such as those required in the treatment for anaerobic digestion or for the production of refuse derived fuels. 4

BUSINESS ACTIVITIES


SHREDDING

Single shaft shredder Single shaft shredder Dual shaft shredder

mobile / stationary stationary mobile / stationary

TERMINATOR RASOR CRAMBO

TREATMENT

Screw mixer

stationary

MASHMASTER

SCREENING

Drum screen

mobile

JOKER PRIMUS JUMBO MAXX MUSTANG MAGNUM

Drum screen

stationary

1440 / 1845 / 2055 2255 / 2278 / 2290 2590 / 25120

Star screen

mobile

EASYSTAR MULTISTAR MULTISTAR MULTISTAR MULTISTAR

Star screen

stationary

MULTISTAR 2-SE MULTISTAR 3-SE

Disc separator

stationary

FLOWERDISC

SIFTING

Windsifter

mobile / stationary

HURRIKAN

SEPARATION

Solid / liquid separator Ballistic separator Swim/sink separator

stationary stationary stationary

MASHSEPARATOR BRINI MK AQUASPLIT WS15

PELLETISING

Pellet press

stationary

PELLETIERER 130

TURNING TECHNOLOGY

Windrow turner

mobile mobile mobile

TOPTURN 300 / 3500 G TOPTURN X SIDETURN

SPREADING TECHNOLOGY

Universal manure spreader

mobile

MEGAFEX

M3 / M2 L3 / L2 L3 FLOWERDISC XL / XXL

PRODUCT OVERVIEW

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KOMPTECH has been manufacturing professional machine technology for the composting of organic waste since 1992. KOMPTECH has the necessary expertise, the right machinery and the right plant technology to address all applications – be they the composting of green waste, biowaste, municipal solid waste or sewage sludge.

In collaboration with experts in the fields of natural science, agriculture and mechanical engineering, KOMPTECH develops composting products and solutions that, when tailored to their on-site environment, guarantee a maximum efficiency both ecologically and economically.

The aim of composting is to decompose organic substances as efficiently and odour-free as possible and to convert them into stable, plant-compatible humus substances with the intention of producing a high quality product within a rotting period that is as effective and as short as possible, and without generating high emission levels.

One-stop supplier Business activities range from the requirements of an agricultural composting site with tractor-pulled turner and mobile drum screen, right up to large-scale plants with pretreatment, closed rotting technology and output treatment.


COMPOSTING Preparation - shredding, cleaning, mixing Mobile or stationary machinery prepares the input material. The CRAMBO wood shredder is the ideal solution for preparing green waste for composting. Contaminated input materials such as biowaste can be effectively freed of contraries using disc separator or star screens. The MASHMASTER mixing unit ensures the mixing of different materials (homogenisation).

Green waste Bio-waste Household waste

Contraries

Closed intensive rotting

Open systems – windrow composting In open systems, the rotting process takes the form of triangular or rectangular windrow composting on a secure surface. The rotting process is controlled by mobile turning technology. With higher content of easily degradable material (biowaste, grass etc.), the system can benefit from the implementation of triangular windrows (oxygen intake through flue) using the TOPTURN X. Because of the efficient use of surface area, trapezoidal windrow composting with the SIDETURN is recommended for material with low oxygen consumption (green waste/ MSW output).

Sewage sludge

Treatment: shredding, screening, mixing

Windrow composting: triangular windrows

Contraries

Windsifting

Mobile screen technology

Trapezoidal windrows

Stationary screen technology

Closed systems – rotting tunnels The decomposition process in closed systems takes place in rotting tunnels complete with ventilation and emission control/treatment. With on-line recorded data of parameters relevant to the degree of decomposition, along with ventilation and irrigation, the METAEROB process from KOMPTECH guarantees a perfect rotting process. Statutory requirements regulate treatment of extracted air. The subsequent maturing process is generally a windrow composting process – either as a triangular or a trapezoidal windrow on a secure surface.

Post treatment – screening, windsifting A useful and marketable product results from compost through storing to the required maturity and configuring through the use of screening, air separation or mixing with other substrates. The broad spectrum of mobile and stationary drum and star screen products includes the right machine for any requirement.

COMPOSTING

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The use of replenishable raw materials is the order of the day. The wood in its different guises plays a key role here – from woody biomass to waste wood. Besides material recycling, such as with composting, energy recovery as a renewable energy source is becoming increasingly significant. KOMPTECH has developed a comprehensive range of mobile and stationary machinery for the treatment of this raw material.

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Processing untreated biomass The following maxim applies, especially for the treatment of non-toxic, woody biomass for use as fuel: Minimal energy expenditure – maximum fuel yield.

Processing of waste wood Treated waste wood is an important recycling product. For example, when shredded and freed of any metal, it may be used in the manufacture of chip board. Use as fuel in suitable adapted power plants is also an option.


TREATMENT OF BIOMASS AND WASTE WOOD Shredding

Biomass Treated waste wood/ untreated

Green waste (leaves, grass)

The slow-running CRAMBO wood shredder generates maximum required particle fraction from different output materials – with less overlengths and less fine fraction. An intelligent system with different screen particles, with changeable teeth and counter-cutting tailored to the job in hand all offer reliability in producing the required particle spectrum at any time and with a range of different input materials.

Shredding

Intensive rotting on triangular windrows

Shredding

Shredding

Fe Fe-scrap

Fe option

Fe-scrap

Rotting process- green waste With grass waste having a high leaf or grass content, adding a further rotting process is a sensible option: After pre-shredding, triangular windrows are turned using TOPTURN. After a rotting process of around two weeks, green parts are largely decomposed and the material moisture reduced. Screening with star screen technology produces a fuel fraction for immediate use. Fine parts are processed further into compost.

Treated waste wood/ untreated

Screening Fine shredding

Fuel fraction Screening Compost

NE

Fuel fraction

NE-scrap Fuel fraction

Screening

Screening Fine particle

Fine particle

Screening MULTISTAR star screen technology is perfect for further tailoring of the shredded material if needed. In one screening operation, one fine, one medium (usually a fuel fraction immediately usable) and one coarse fraction are produced. Integratable and optional air separator and ferrous metal removal saves additional operations - all this saves wheel loader and personnel costs ensuring outstanding cost-effectiveness.

Options Fe/non-iron separation: Stationary, (non-)ferrous separators or overhead conveyor magnets mounted to the shredders discharge any foreign material. Swim/sink separation: The fuel fraction can be cleaned of impurities (stones, glass, etc.) using the AQUASPLIT separation system.

TREATMENT OF BIOMASS AND WASTE WOOD

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Waste treatment technologies from KOMPTECH comply with the broad range of technical innovations used globally within waste treatment. At the low end of the product portfolio are mobile shredders for reducing volumes prior to dumping. The next highest product category includes mobile or static splitting systems for separation and recycling of reusable fractions from the waste stream.

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Volume reduction Volume reduction is often the first stage in well-regulated waste treatment. Saving on landfill volumes, reduction of transportation costs and the necessity for shredding prior to subsequent recycling stages all make the use of the shredder a sensible option.

Waste splitting For separation of fractions for material recycling or energy recovery out from the waste stream, a shredding process for homogenisation is generally necessary as the first stage in the treatment process. In the subsequent screening stage, separation follows according to particle size – also according to density when used in conjunction with ballistic sifting.


VOLUME REDUCTION – WASTE SPLITTING Shredding The single shaft TERMINATOR is used for pre-shredding necessary for separation of household and commercial waste. The degree of shredding is tailored precisely to the requirements of the system by selecting the shredding unit and cutting gap. The majority of foreign bodies can be separated from contaminated bio-waste with treatment. The dual-shaft CRAMBO shredder is a perfect solution for coarse shredding.

Household waste, residual waste

Single shaft shredder

Drum screens, star screens or disc screens are used for screening, depending on quality of the material. KOMPTECH drum screens are available in different sizes and are equipped especially for waste screening. Boasting smooth, low-wear operation, MULTISTAR disc separator for the screening of commercial and residual waste are the ideal solution. Star screens operate particularly efficiently with biowaste. Both disc and star screens are efficient for biowaste.

Bio-waste

Single shaft shredder Single shaft shredder/ dual shaft shredder

Screening Drum screen

Screening

Bulky waste, commercial waste Production waste

Fe/NE

Screening Disc screen

Screening Disc screen/star screen

Fe/NE Ballistic separator Stabilisation/ landfilling

For the production of RDF

Incineration or landfilling

Contraries

For composting

Fe/non-iron separation Stationary, (non-)ferrous separators or overhead conveyor magnets mounted to the shredders (above the discharge belt) discharge any foreign material. KOMPTECH cooperates with reputable suppliers in this respect, integrating these components into system and plant-level solutions.

Ballistic separation Depending on material quality, oversized grain is separated into several fractions in subsequent screening stages and with ballistic sifting: A highcalorific fraction for the production of refuse derived fuel, a medium-calorific fraction for the incineration in fluidized bed plants and a remaining fraction for landfilling.

VOLUME REDUCTION – WASTE SPLITTING

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The requirement to reduce the amount of waste reaching landfill sites with no pre-treatment, or to eliminate dumping altogether, makes intensive treatment a necessity. Mechanical and biological treatment stages are a necessity irrespective of current legislation.

Biological treatment includes organic decomposition by closed composting in an intensive rotting process and a post-rotting stage for stabilisation. KOMPTECH mobile turning machines provide the ideal conditions for the post-rotting process on triangular or trapezoidal windrows.

KOMPTECH is focusing on the stages necessary for mechanical treatment. The product spectrum includes key components such as shredders and screening machines as well as their interlinkage into complete processing lines.

Using mobile and stationary screening technology (star screen or drum screen), and using wind sifting, remaining fractions high in calorific value are separated and landfill criteria are met.


MECHANICAL BIOLOGICAL WASTE TREATMENT Mechanical treatment - shredding Shredding with the single-shaft TERMINATOR shredder produces perfect grain size for subsequent separation stages. By selecting the degree of shredding and adjusting the cutting gap, focus can be placed on input material and on the conceptual design of the plant.

Household waste, residual waste

Treatment: Shredding, screening

Mechanical treatment - screening KOMPTECH drum screens are used to separate undersized particles (organic or inert fraction) from oversized particles (usually high in calorific value -> generation of RDF). The wide range of models provides a suitable screen system for any plant size. One option is the screening of oversized particles (>80 -100 mm) using the sturdy, high-performance FLOWERDISC disc separator. Fe/non-metal separators are used for intermediate separation of metallic contraries.

Closed intensive rotting

Post-rotting: Triangular windrows

Contraries (incineration)

Windsifting

Mobile screening technology

Fe

Treatment Refuse derived fuels

Sewage sludge

Trapezoidal windrows

Stationary screening technology

Landfilling

Biological treatment – rotting process The undersized particle of the screening ends up in a closed intensive rotting system. The use of a MASHMASTER mixing unit is a sensible option when adding sewage sludge/for homogenisation. The rotting process takes place in rotting tunnels – with optional automatic entry and discharge systems. With on-line recorded data of parameters relevant to the degree of decomposition, along with ventilation and irrigation, the KOMPTECH METAEROB process guarantees a perfect rotting process. Statutory requirements regulate treatment of extracted air.

Treatment of MSW output Stabilisation of the organic fraction usually takes place in the form of an open maturation process on trapezoidal windrows. The SIDETURN trapezoidal windrow turner is used for regular turning for aeration. Following the rotting process, the material is screened using MULTISTAR star screens or drum screens. Oversized particles with high calorific values are incinerated, undersized particles are landfilled.

MECHANICAL BIOLOGICAL WASTE TREATMENT

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Legal regulations state that commercial waste, production waste and bulky municipal waste – in short waste that was landfilled untreated in the past - now require complex, sophisticated treatment processes. But this treatment also provides the opportunity to separate potentially recyclable materials and to generate selected secondary fuels from those fractions high in calorific value. Fuels from waste - making a contribution to the preservation of energy resources.

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KOMPTECH has developed a processing line whose modular design generates a maximum level of recyclable fractions from the broad spectrum of input material. Fractions with high calorific value are separated using selective waste splitting (shredding, screening and ballistic separation). Quality-assured fuels result regardless of material composition. A KOMPTECH postshredder generates fuel sized suitably for the incineration process. From high calorific fractions, the KOMPTECH post-shredder generates the fuel size suitable for the incineration process. Medium calorific waste containing contraries can also be shredded with the two-shaft CRAMBO shredder.


PRODUCTION OF REFUSE DERIVED FUELS Pre-shredding

Household waste, bulky refuse Commercial waste, production waste

The single-shaft TERMINATOR F shredder is used for the shredding necessary for subsequence stages. Reliable shredding is guaranteed even with materials having high strength properties and of different types. The degree of shredding can be tailored perfectly to the material and subsequent stages by adjusting the cutting gap.

Separation by screening Separation of the fraction high in calorific value >100 mm is managed perfectly by the FLOWERDISC disc separator. Amongst the benefits this new development can boast are low-maintenance operation and high throughput whilst attaining a satisfactory level of selectivity and protection from contraries. After an Fe/Ne-separation stage, the MULTISTAR screen unit separates undersized particles having a suitable composition into a low calorific fraction, a medium calorific fraction and an inert fraction.

Pre-shredding

Screening

Fe/non-metal scrap Fuel fraction Low/ medium calorific

Fe

Fe/NE

Fe/NE

Fe/non-metal scrap

Screening

Ballistic separation

Inert fraction Swim/sink separation Inert, heavy fraction

Fuel fraction/ medium calorific

Post-shredding Fuel fraction/ high calorific

Shredding

Fuel fraction/ medium calorific

Ballistic separation Following FE/NE-separation, ballistic separators are used to cleanse the oversized particles of contraries which can reduce the calorific value or negatively impact the combustion process. The BRINI separation processes forms three fractions – a high calorific, two-dimensional lightweight fraction, a screen fraction and a heavy three-dimensional fraction. This can be separated further using the AQUASPLIT swim/sink separator.

Post-shredding With its exchangeable screen baskets, the RASOR post-shredder from KOMPTECH is suitable for the generation of both fuels for fluidized bed plants (particle size ≤100 mm) and injectable fractions for rotary furnace plants in the cement industry (≤ 30 mm). A medium calorific fuel fraction in the range 100-150 mm can also be generated by the (contrary-resistant) two-shaft CRAMBO shredder.

PRODUCTION OF REFUSE DERIVED FUELS

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Anaerobic digestion is the most sensible economic and ecologic treatment method for certain organic waste. The generation of renewable energy and, depending on input material, usable liquid fertilisers, are key arguments in favour of the anaerobic digestion process.

When using the pulper process, treatment stages extract a substrate for digestion from waste having high organic content. This is then added to the wet anaerobic digestion process. The process may be used for input material having a high contrary or packaging content as well as for household and residual waste.

The emphasis for KOMPTECH lies with complex treatment stages. The input dictates whether the pulper or pressing processes are used.

The pressing process is the perfect solution for wet bio-waste, left-overs, etc. The key components of the MASHSEPARATOR separate into a liquid fraction for wet anaerobic digestion and a dry fraction for composting. KOMPTECH also provides tried-and-tested components for the dry anaerobic digestion process.


TREATMENT FOR ANAEROBIC DIGESTION Pre-treatment Pre-treatment is dependent on input material. The first stage is shredding by the CRAMBO (dual-shaft shredder) or the TERMINATOR (single-shaft shredder). In the pressing process, the use of MULTISTAR star screen technology is recommended as a cleaning stage for the input material. For household waste, a complete waste splitting process is to be implemented upstream for separation of organic substances.

4°C

Treatment of gas

Input

Shredding

Pulper – wet screen – press

Sand Hygienisation separation

Pulper process The first stage in the pulper process is the separation and liquidising of the input material in the pulper. Sinking inert substances are separated in an automated process. In the second stage, a MULTISTAR star screen separates the substrate for digestion from the oversized particles. A press unit, positioned downstream, separates additional digestion substrate from oversized particles and is either used or disposed of depending on quality and contrary content.

Anaerobic digestion

Contraries

Solid residual from digestion: Composting

Centrifuge

Liquid residual from digestion: Agriculture option

Pressing process The input material is first pre-conditioned perfectly in the mixing vessel of the MASHSEPARATOR. Four screw mixers provide intensive mixing and fraying. A separation takes place in the subsequent pressing stage in the separator - into a liquid phase for anaerobic digestion and into solids for composting.

Treatment for dry anaerobic digestion For the dry anaerobic digestion process, the CRAMBO (or TERMINATOR) has proven to be perfectly suited for the shredding stages, as has MULTISTAR star screen technology for the separation of the fraction for digestion. The feedback of process water after the digestion stage is simplified by specially equipped MULTISTAR wet screens. Efficient drainage/pressing of the digestion residue can be achieved using the MASHSEPARATOR.

TREATMENT FOR ANAEROBIC DIGESTION

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BRINI separation technology opens up a new business segment for KOMPTECH: The separation of potential recyclables (plastics, paper and cardboard) for further recycling. Recycling of packaging plastics contributes significantly to resource preservation. Separation of this separately collected waste allows material recycling for the manufacture of new products from recycled plastics as well as energy recovery.

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Following the separation process (the complexity of which depends on the input material) comes ballistic separation – the most important stage. Inside the KOMPTECH BRINI separator, the material fed in is separated (purely mechanically) according to its physical properties – resulting in favourable investment and operating costs. The high level of separation accuracy simplifies subsequent recycling of the separated fractions. For example, given a particular in-take mix of potential recyclables, PET plastics can be passed on for subsequent sorting or high calorific plastic film can be used for the production of secondary fuels.


TREATMENT OF POTENTIAL RECYCLABLES Separation of packaging waste Following coarse pre-sorting, packaging waste is separated using KOMPTECH bag opener. A TERMINATOR (single-shaft shredder) or CRAMBO (dual-shaft shredder) is used if difficult materials, high throughputs and a fixed degree of shredding are required. A material distributor provides uniform material feed to the subsequent separation stage.

Material distributor BRINI PET plastic bottles

Ballistic separation The ballistic principle of operation of the BRINI separator splits the material mixture into soft fractions having a large surface area - mainly plastic foil and plastic bags, as well as into more substantial threedimensional shaped and hard fractions, such as plastic bottles and hard plastics. A fine fraction, mainly screw caps, small plastic items and contaminants is also separated. If there is a large paper and cardboard content in the waste, a 4-fraction separator can be used alongside the 3-fraction separation. In this way, paper can be separated off as a usable fraction by selecting the appropriate screen holes. Plastic film freed of contaminants is an ideal output material for the generation of a highly caloric secondary fuel.

Removal of coarse contraries

Bag opener

Packaging waste

Fe/NE

Fine fraction/ contaminants Automatic sorting or

Flat press

Plastic film Generation of secondary fuels (high calorific)

sorting by hand

PE, PP PET, clear/blue PET, clear PET, colour Other Residual fraction

Inspection

Fraction for material recycling

Baling press

Three model sizes are available (light, standard and heavy duty), ensuring that the separator is tailored perfectly to the application.

Sorting and pressing After undergoing Fe/NE-separation and a flat pressing process, the fraction containing plastic bottles and hard plastics enters an automatic (or manual) sorter, where the material is sorted according to material properties such as colour (white, blue, green, etc.) or chemical composition. The intention is to produce as pure a fraction as possible for subsequent recycling. Baling is sensible for reasons of transportation and storage.

TREATMENT OF POTENTIAL RECYCLABLES

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KOMPTECH Vertriebsgesellschaft Deutschland mbH D-59302 Oelde, Herrenstraße 7 [t] +49 2522 93 45 - 0 [f] +49 2522 831 841 info@komptech.de

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KOMPTECH GmbH A-8130 Frohnleiten, Kühau 37 [t] +43 3126 505 - 0 [f] +43 3126 505 - 505 info@komptech.com

KOMPTECH UK Ltd. Forge End, Lodge Farm, Kineton, Warwickshire, CV35 0JH [t] +44 1926 64 29 72 [f] +44 1926 64 29 71 info.uk@komptech.com

KOMPTECH Scandinavia AB Box 1294 SE-17125 Solna Sweden [t] +46 8 519 33 - 000 [f] +46 8 519 33 - 149 info@komptech.se

We reserve the right to make technical changes due to ongoing development.

KOMPTECH Anlagenbau GmbH A-1020 Wien Wehlistraße 150/ Top II [t] +43 1 219 91 31 - 0 [f] +43 1 219 91 31 - 10 anlagenbau@komptech.com

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