Aluminum Shredder Feed And Out-feed Super Steel Belt Conveyor With Low Power Consumption Jam-free Operation Design

SUPER STEEL BELT SOLUTION FOR ALUMINUM PROCESSING

BOYUAN ^TM su per s teel b elt conveyor for aluminum recycling plants is the most advanced solutions with a high level of engineering excellence.

As the transition to a low-carbon economy intensifies, secondary aluminum production will play an increasing role in meeting future demand.

Effective handling of aluminum scrap is, therefore, crucial to keep the production line running smoothly.

Super Steel Belt Conveyor F or A luminum R ecycling P lants

BOYUAN ^TM provides best-in-class conveyors that handle cold scrap (“new scrap” from production processes and “old scrap” from post-consumer use) upstream and downstream of the sorting & comminution process, as well as hot aluminum shreds from the decoating process, thus contributing to improve the downstream smelting process and ensure high throughput, low energy consumption, heat losses and maintenance costs.

To BOYUAN ^TM , conveying is not a matter of merely moving something from one place to another. Its bulk material handling systems are meant to streamline production flows, increase availability, and enhance overall plant efficiency. Extactly what secondary aluminum smelters/recycling plants need .

In response to the increasing global demand for processed recycled metals, BOYUAN ^TM has put its extensive know-how in complex material handling systems at the service of the unique needs of aluminum secondary smelters/recycling plants.

S econdary A luminum S melter

BOYUAN ^TM bulk material handling solutions integrate seamlessly with the scrap management and recycling processes in secondary aluminum production, or aluminum recycling.

In particular, they suit cold scrap conveying and hot aluminum shreds transport. The smooth running of those processes is largely reliant on the reliability of the conveyors that interlink the different stages of production. That is why BOYUAN ^TM su per s teel b elt conveyors are one step ahead: they offer a range of benefits over conventional technologies that set us apart from all the others:

- High reliability. - Increased uptime
- Class-leading performance. - Greater process streamlining and control
- Outstanding energy savings - Low O&M costs
- Low noise emissions. - Safe operations
- Environmental sustainability - Long service life

Super Steel Belt Technical Solution Aluminum Processing

ALUMINUM FEED & OUT-FEED SUPER STEEL BELT CONVEYOR

BOYUAN ^TM su per s teel b elt conveyor is suitable for efficient and safe transport of aluminum scrap/shreds.

Secondary aluminum production is a shining example of the circular economy. Virtually fully recyclable, aluminum is used in the form of scrap to produce casting alloys for foundries. The closed-loop cycle prevents manufacturing waste from going to landfills, saves energy, and reduces the environmental footprint.

It is vitally important that the recovered aluminum scrap is properly treated, before being further processed, to maximize the efficiency and profitability of the remelting process. As such, after collection, scrap is sheared into smaller pieces. Shredding aluminum reduces and reshapes the metal scrap into desired sizes, making it easier to sort and remove impurities.

BOYUAN ^TM tailored its s uper steel belt conveyor technology to feed aluminum scrap to and from the shredder, delivering top performance with minimum maintenance.

Fig. 1 Shredder Feed & Out-feed Super Steel Belt Conveyor

Hi gh Reliability

BOYUAN ^TM super steel belt is made up of partially overlapping steel pans securely bolted on a patented steel double-wire mesh system.The belt damage-tolerant design is based on a multi-link concept that ensures redundancy, little to no maintenance, and trouble-free continuous operation. Even if the mesh is severely damaged, the conveyor will keep on running till the scheduled maintenance, without sudden failures.

The trouble-free operation of BOYUAN ^TM super steel belt ensures the productivity and profitability and results in greater efficiency and uptime during 24/7, year-round operation.

Fig. 2 Stable Operation fo Shredder Feed & Out-feed Super Steel Belt Conveyor

Jam-free operation design

Due to sharp edges, thin projections, and irregular shapes, aluminum scrap tends to become caught in the belt.

With BOYUAN ^TM su per s teel b elt conveyor, this issue is solved thanks to the tight pan structure featuring a perfect fit in the overlap area for an effective seal. This feature prevents material from snagging or getting stuck, thus avoiding conveyor jam-ups or damage.

Fig. 3 J am-free Design of Shredder Feed & Out-feed Super Steel Belt Conveyor

Safe operation

Eliminating manual scrap handling keeps operators safe and more productive.

By completely automating the scrap/shreds handling process, BOYUAN ^TM su per s teel b elt conveyor minimizes safety risks related to forklift traffic and operators’ exposure to falling scrap. The conveyor design, featuring high skirtboards that follow the belt sidewall profile along its entire length, prevents material overflow during transportation.

Fig. 4 High Skirt - board Design of Shredder Feed & Out-feed Super Steel Belt Conveyor

Low power consumption

Designed to avoid sliding friction among the moving parts, BOYUAN ^TM Super Steel Belt Conveyor is very energy-efficient. Its power demand is about one-tenth of that of vibratory conveyors.

Fig. 5 L ow Power Consumption Drive Unit of Shredder Feed & Out-feed

Super Steel Belt Conveyor

L ittle to no maintenance

BOYUAN ^TM super steel belt casting conveyor requires little to no maintenance as it is devoid of critical wear points (no wear bars, pins, hinges, chains, or sprockets). The only points requiring lubrication are the bearings of the head and tail pulley, which can be greased with the belt in operation. The other components are designed for continuous operation and can be checked during preventive maintenance over a multi-year schedule.

Fig. 6 H ead Drive Drum of Shredder Feed & Out-feed Super Steel Belt Conveyor

PAKAGING & SHIPPING

COMPANY INFORMATION

FREQUENTLY ASKED QUESTIONS (FAQ) ABOUT BOYUAN ASH COOLER SYSTEM

Q: Can the Super Steel Belt be repaired or replaced with the boiler in operation? What is the time period for replacement?

A: The BOYUAN ^TM Super Steel Belt with its updated unique mesh and pan arrangement is very sturdy and extremely dependable. The mesh is grossly over - designed in order to ensure that even if one or more wires break, the belt can keep on operating till the next planned stoppage of the plant. In more than hundreds of power plants which the BOYUAN a sh c ooler systems installed, till date there has not been a single instance of a sudden need for replacement of the belt or even a piece of the belt. From the 19 years long experience with BOYUAN a sh c ooler systems in operation now, it follows that the average expected life of the BOYUAN Super Steel Belt is at least 10 years, and BOYUAN gives a warranty on the belt of 5 years.

So, any repair or replacement of the belt can be executed during planned outages. Replacement of the entire belt can be done in 6-8 hours, replacement of a single piece would need maximum about 4 hours.