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Compressed air for recycling plants operate under demanding conditions. A new plant with a capacity to process up to 250,000 tonnes per annum of mixed commercial and industrial waste required air compressors that could keep up with the demanding conditions it operates under. The new plant will supply refuse-derived fuel for energy from waste power stations as well as extracting a range of recyclable commodities.
As part of the installation, 11 optical sorters were required to identify and separate out different materials for recycling. Using cameras, sensors and lights waste materials are fed on a conveyor belt before being sorted using jets of compressed air to separate materials such as paper, wood and metals.
Our solution
Due to the large of amount of air required, four new energy efficiency Avelair VSD 132 kW air compressors were installed so they can be operated as 3 duty and 1 standby, to ensure full redundancy for the compressed air for recycling plant. The compressors have integrated inverters which ramp the motor speed in response to air demand, ensuring optimum energy efficiency. The compressed air system is controlled via a compressor management controller ensuring the system is run efficiently whilst sequencing the compressors, and starting/stopping the system out of hours. The system offers the client full remote visualisation, including real-time compressed air and pressure usage, status of the equipment, as well as identifying servicing requirements.
Oil-free air
Dry and oil-free air is critical, and a 5,000 litre galvanised air receiver was installed prior to the refrigerant air dryer with 2-stage filtration, to provide a high level of air purity to ISO 8573 class 2.4.1. The condensate from the system is piped into an oil water separator to ensure the condensate is split into clean condensate that can be disposed of down a foul sewer drain, and a smaller amount of oil which can be removed as environmental waste on servicing. 160mm Prevost smooth bore aluminium compressed air pipework was used for the main pipework. This offers a clean compressed air system with the flexibility of adding on additional equipment in the future. The smooth bore pipework has a 10-year warranty and offers increased efficiency through lower pressure drop. 6 point-of-use air receivers were installed within the system to ensure adequate compressed air at pressure is available at all times, as the system will use high levels of compressed air throughout the day.
Written Scheme of Examination
Our team completed a Written Scheme of Examination (WSE) for the system to ensure it complied with the Pressure System Safety Regulations 2000. If pressure equipment fails in use, it can seriously injure or kill people nearby and cause serious damage to property. This is why the WSE details all the safety components of a compressed air system and how often they should be checked and is essential for compressed air for recycling plants.
Avelair supply a wide range of air compressors suitable for the waste and recycling market in the UK. From powering heavy machinery to aiding in sorting processes, air compressors play a crucial role in keeping recycling plants running smoothly. If you’re considering installing or upgrading air compressors in your recycling facility, be sure to contact Avelair. Our experienced team will talk through the various options available to you and can provide a bespoke solution designed around your specific needs. Our UK-manufactured air compressors are backed by our engineering team providing service and support 24/7.
For more information on Avelair air compressors chosen for major UK recycling plant talk to Avelair Compressed Air Solutions