At a glance
RAGG was looking for a new shredder and downstream sorting line to replace the old plant. Space was limited, connection points had already been determined, and the company wanted to restart as soon as possible. RAGG was also looking for a reliable partner that develops and produces its own solutions.
Lybover specialists in air treatment, sorting techniques, bulk handling and conveyors put their heads together to design a high-performance total solution based on 3D scans of the site.Thanks, among other things, to an innovative patented ultrafilter for the shredder, RAGG would be well within the applicable emission standards.
Close consultation between all parties involved meant that they quickly found answers to any challenges that arose – and the installation was completed smoothly.
Austrian scrap processor RAGG wanted to replace its old shredding line with a new shredder and downstream sorting line that produces purer metal fractions, including air treatment that meets current and future emission standards. The family-owned company was convinced of the total solution offered by Lybover. Thanks to close cooperation between the Lybover teams and other partners, the installation was built and delivered smoothly.
Wanted: future-proof metal sorting line
The picturesque Hall in Tirol, near Innsbruck in Austria, is home to the scrap processing company RAGG. This family-run business has been in operation since 1947. The current generation wants to eventually hand over the business to the next and is therefore already investing in a thorough renovation of the facilities. One of these is the shredding line for end-of-life vehicles and scrap metal.
RAGG decided to completely demolish the existing shredding line. In its place will be a brand new, state-of-the-art plant that achieves higher efficiency and lower emissions. Germany’s Lindemann was to supply a feed belt and shredder. Lybover took care of the downstream sorting line and air treatment of the entire plant. The non-ferrous line would be retained, as it is only a few years old.
Under control
‘RAGG chose Lybover because we do everything in-house ,’ begins Frederick Thoma, Business Unit Manager Lybover AIR. ‘We analyse the problem and think out the processes. Then we produce the necessary machines and conveyors ourselves or supply them through our partners. We assemble them and carry out repairs in our own workshop. RAGG attached great importance to this. This comprehensive approach also enabled us to provide a transparent and complete quotation from the outset, which RAGG also appreciated.’
The added value of downstream treatment
‘This extensive project is a sampling of the technologies we offer in terms of sorting and air treatment,’ Frederick Thoma continued. ‘Whereas previously shredder technology was decisive in the scrap sector, the focus is now shifting to the downstream treatment of fractions. By more precise sorting, a recycler obtains purer and thus more valuable metal fractions that serve as raw materials for Green Steel, for example .’
Patented ultrafilter
How does Lybover help scrap-processing companies meet today’s emission standards? Everything starts with high-performance air treatment of the shredder. Here, a Venturi wet scrubber is necessary as the first filter step to answer the many challenges posed by the many dust components in the air. But today, the wet filter is no longer enough to comply with European directives, which are moving towards zero emissions. The emission after this wet filter not only still contains too many dust and gas components, but also too many PCBs, dioxins, etc… This is why Lybover, in collaboration with Keller Lufttechnik , developed an ultrafilter that removes dust, PCBs and dioxins from the air. This ultrafilter is also resistant to the sticky components and moist air of the wet filter. With this patented filter technology, RAGG more than meets Tirol’s current emission standards. ‘It is a state-of-the-art system that has proven itself for a decade and is future-proof, just as the family envisaged,’ Frederick Thoma says.
Sorting techniques and air treatment
After the shredder, the scrap ends up on conveyor belts that Lybover installed. Lybover also built the sifter installation that removes light parts from the metal and supplied and assembled the vibrating tables from Spaleck and the magnetic drums from Steinert that further separate the fractions into ferrous and non-ferrous metals. The ferrous fraction is dumped via a swing conveyor into a bunker at the site or into train wagons. The non-ferrous metals go via a conveyor belt to a container or to the non-ferrous hall for further upgrading. Lybover also supplied the air technology for the sifter, with a dry filter, and piping. The existing dedusting of the non-ferrous plant was replaced and co-integrated into this new air system. ‘Thanks to the new air technology, RAGG achieves a much higher efficiency with much less residual waste and dust,’ explains Frederick Thoma.
Moveable container lids
Light fractions from the sifter – including textiles, foams and plastics – and dust extracted from the sorting lines end up in containers via a covered conveyor belt. As this material flies up easily, the containers must be able to remain closed during filling. To this end, Lybover developed movable lids that fit on the containers. A screw system spreads the light fractions evenly over the container. Sensors in the lid register when the container is almost full and signal the operator. As soon as the container is full, the conveyor belt automatically switches to the second container.
Time and space
Lybover mapped the site with a 3D scan. This allowed the new plant to be accurately fitted into the limited space available – a complex puzzle with machinery and conveyors. Moreover, the starting point – the shredder – and the end points for the ferrous and non-ferrous metals were already fixed. Using a total station, all assembly points were precisely plotted. Time, as so often, was the other challenging factor in this project. RAGG would not be able to process metal scrap from the shutdown of the old shredding line until the start-up of the new one. The fastest possible execution was therefore crucial to reduce downtime.
The power of collaboration
That the works went so smoothly was partly due to frequent meetings between all parties involved: RAGG, Lindemann, the civil works contractor, the electrical installation company, the builder of the steel structures and Lybover. ‘After signing the contract, we spoke every fortnight through Teams, combined with regular meetings on site. It seems like a lot, but this intensive communication ensured smooth cooperation, where we quickly found answers to challenges,’ says Thierry Sabbe, Teamleader Projects, Lybover AIR.