One-stop-shop services for the Recycling Plant sector

Australia’s recycling plants are working harder than ever. A number of factors are contributing to the “24/7, 365-day” operating service recycling plants are having to provide, including the restrictions of recyclables imported to China imposed in 2018.

Up until the ban, Australia had sent 619,000 tonnes of recycling waste to China annually. This caused a strain on local recycling plants. Enabling seamless 24/7, 365-day operations was first and foremost on its mind when BSC Australia targeted its house-brand supply of industrial consumables to recycling plants.

Marlin offer a range of products which include chemical cleaning, materials handling goods, and lifting and hoisting equipment. The industrial consumables stream, secondary to BSC’s core business of bearings and power transmission solutions, was established with the intention of providing a one-stop-shop service to the industries they look after, according to National Accounts Manager Wayne D’Souza.

“The extensive range of industrial consumable products that BSC has to offer outside of bearings and power transmission is an attractive proposition for our customers. Ultimately, they’re looking at reducing their tail-end spend, and including these product ranges in their overall scope of purchases from us,” says D’Souza.

“Generally, our customers haven’t thought about us for this and they’re quite impressed when we start demonstrating the range we’ve got.”

“The industrial consumables range is really a valued-added solution for our customers. Many of our customers and contracts are looking to rationalise their supplier base to save valuable time and money and our BSC valued-added solutions go hand-in-hand with increased efficiencies in procurement and supply chain strategies,” says Industrial and Engineering Consumables Category Manager, Dominic Arena.

BSC uses international and local suppliers for the Marlin range of products, with full control of the sourcing and supply chain, allowing for full traceability from the manufacturing stage through to the end user.

“Through this distribution method we can also offer customised solutions for real-world problems that our customers may face with product development and technical engineering at the forefront of what we do,” says Arena.

BSC also has the technical capabilities to be able to customise its products to suit the different industries it supplies.

“We can offer customised solutions as well, because we have that technical engineering product development capability, which differentiates us from the standard distributor who just walks in and sells right off the catalogue. We’ve got eyes and ears in the field that pick up on feedback and customer needs, and we’re able to develop products and product ranges that suit their requirements,” says Arena.

Through this field experience, BSC saw the challenges to recycling plants that Marlin can alleviate.

“In these recycling plants, there are a lot of extremely heavy, awkwardly-shaped products moving around at a high velocity,” says Arena.

“You’ve got lots of equipment and lots of operators. Having the correct load restraint equipment that’s properly labelled for the weight and the dimensions is essential to ensuring best practice for how things get moved around.”

By improving visibility and enabling a better flow of movement throughout the plant, the materials handling products ensure safe practise as well as preventing the loss of time that results from on-site injuries. One of the most important factors to keeping recycling plants and their machinery operational is keeping them clean.

“If contamination or foreign matter were to get into bearings or critical pieces of equipment, it could cause catastrophic failings,” says D’Souza.

“It could just be something as simple as dust, or it could be heavy, chunky grease that forms over time; that’s just as dangerous as having dust. You’ve got to remove that because that can not only contaminate the recyclables, but it can get into some of the equipment that we provide, such as bearings, and lead to stoppages. It can also cause an OH&S issue when its dropping on factory floors, making it unsafe at the workplace for traffic to go through.”

The chemical cleaning products Marlin supplies can be used while the machinery is running. To break down contaminants, such as built-up dust, oils, and thick chunky grease, users can spray and wipe down machinery components and equipment without needing to slow down operations. Best practice, however, says D’Souza, means sometimes having to shut the equipment down now and then. However, Marlin enables this down time to occur less often.

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Schaeffler’s bearing solution for vibrating screens helps recyclers maximise productivity

In the complex recycling sector, operators need a robust and reliable vibrating screen to ensure they can separate their feedstock down to an appropriate size at a high frequency.

With long service life an important consideration, Original Equipment Manufacturers (OEMs) have aimed to continually improve their design to ensure operators get the most from their vibrating screens.

As a renowned Australia-wide distributor of bearings, power transmission and industrial products, CBC Australia offers a suite of products from a range of premium suppliers.

As part of its offering, CBC specialises in delivering quality, high precision and cost-effective spherical roller bearings. CBC are well recognised for offering a strong service provision in the management, supply and distribution of bearings throughout Australia.

Tony Tormey, CBC Australia Product Manager – Industrial Bearings, says the FAG T41D Spherical Roller Bearing series from Schaeffler is the latest iteration in the shaker screen bearing solution for vibrating screens.

Schaeffler stock a range of screen bearings, including the T41A, T41B and T41D series to suit the application.

“The T41D screen bearing is proving to be essential in the vibrating screen industry,” Tormey explains.

Tormey says that in order to allow thermal expansion of the shaft, loose fits are commonly used, which usually leads to fretting corrosion. This can restrict thermal expansion of the shaft, increasing bearing loads ultimately reducing bearing life.

The T41D – design however, has a premium hard chromium coating (Durotect CK) on the bore, avoiding fretting corrosion as well as elevated bearing load. This results in a longer service life.

Additional benefit of the coating is the prevention of shaft damage as fretting corrosion is avoided. This reduces repair costs.

“If you put a machine component under the microscope, you will see the peaks with a standard bearing. With the hard chromium coating on the bore, basically it alleviates a lot of those peaks and provides a more of a consistent surface,” Tony says.

With superior qualities of the T41D bearing series with Durotect CK coating on the bore, operators can work more efficiently with a low total cost of ownership, all while delivering a higher level of performance and machine reliability.

The vibrating screen is one of the toughest applications for a bearing due to the high oscillating loads impacting the bearing components, including the grease.

Tormey says the FAG shaker screen bearings from Schaeffler feature Bainite heat treatment giving improved productivity through temperature stability up to 200°C.

Additionally there is a surface hardened cage with high wear resistance and outer ring guidance to accommodate centrifugal forces. The internal design also allows for a relatively larger volume of grease, which is critical in such an application.

Tighter ID and OD dimensional tolerances also provide better control of fit in both housing and shaft.

CBC recommends Schaeffler’s FAG Spherical Roller bearings in X-life quality as they operate 70 per cent longer than regular bearings in the same installation position. Bearings from 22317-EL-XL-T41D right through to 222330-E1-XL-T41D are supplied standard with Durotect CK coated bores.

Tormey says Schaeffler also provide a range of bearing housings with four different sealing options available, depending on application and spherical rollers as a complete package. These include a double lip seal, V-ring seal, labyrinth and taconite seal option depending on the medium.

Additionally, Schaeffler offers tools for the mechanical, hydraulic and thermal mounting and dismounting of bearings.

Moreover, CBC branches across the country offer national sales and local support. This extends to engineering services that include condition monitoring and process improvement.

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Packaging belt life to capitalise on industry growth

As the 2025 National Packaging Targets deadline approaches, resource recovery facility operators are presented with an opportunity to capitalise on expected throughput growth.

Between 2017-18, Australia generated 4.4 million tonnes of packaging waste, with only 68 per cent collected. Of that 68 per cent, 56 per cent was recovered via recycling.

In contrast, the national packaging targets aim to ensure 70 per cent of all plastic packaging is recycled by 2025. In addition to delivering significant environmental outcomes, the targets are set to grow economic opportunity in the sector through increased material availability.

To capture this potential, Mark O’Brien, BSC Product Manager, says recycling plant operators need to invest in streamlined equipment processes to ensure consistent throughput levels and quality recyclate. He adds that this includes the installation of durable and high efficiency belt drives.

While belt drives might not represent the most high-tech or glamourous component of an average recycling plant, Mark says superior strength and high grip belts are critical to maintain operations and minimise downtime.

“Sorters, conveyors and crushers are all central to the recycling process and are typically belt driven by an electric motor,” he says.

“BSC provides a wide range of belt drives to facilitate recycling applications, from our economy range right up to high performance V and Timing Belts.”

To provide a complete power transmission package, Mark says BSC works closely with American manufacturer of Carlisle drive belts by Timken.

Carlisle belts have been manufactured in the USA since 1905. The billionth Carlisle belt was sold in 2015. Recently acquired by The Timken Company, Carlisle belts are backed by a long history, yet continue to innovate and introduce new belt lines and products to market.

New lines include the Panther XT synchronous belt which acts as a powerful alternative to chain and polyurethane belts. Timken also launched its Drive Engineer mobile web app to assist in the design and maintenance of Carlisle belt drives in 2017.

“We have been working with Carlisle since the early 90s and have developed a very strong working relationship, which will continue to grow under The Timken Company for the marketplace,” Mark says.

BSC is the sole distributor of Carlisle belts in Australia and offers a range of Carlisle belts including Raw Edge Cog Belts. Super II, Blue Label, Power-Wedge, Wedge-Band belts, Super Vee-Band belts, Double Angle v-belts, Poly-Rib belts and Panther timing belts.

With over 15,000 different industrial belt combinations available, Mark says BSC are able to handle most power transmission applications; notably packaging recycling facility conveyor belts. He adds that different application requirements insist on varied and specific belt drives.

“In applications that require some level of slippage, a V belt is the best solution and you have variety of options within the Carlisle range” Mark explains.

“For applications with no slip requirements and synchronised drives however, I’d recommend a timing belt such as the Panther synchronous belt.”

According to Mark, correct installation and tensioning is necessary to ensure the proper operation of the entire belt drive and will guarantee long service life.

“When a drive is set up correctly and still failing, it likely points to something else incorrect in the system, belts act as a safety fuse in the system” he says.

“In that case, our engineering service can work on the machine to identify incorrect maintenance practices and drives or detect issues with other components that are affecting the belt life.”

Mark adds that by upgrading their belt drives, facility operators can reduce energy consumption, pulley sizes and hub loads through a lower quantity of belts required.

Additionally, he explains that belt drive construction and design can influence overall lifespan, power transmission and efficiency.

“The longevity of belt drives equates to less downtime, greater motor efficiency and reduced maintenance costs. Carlisle belt efficiency can be as high as 98 per cent,” he says.

“BSC recognises the positive impact its specialised products and services can, and do, have on helping customers become more sustainable across economic and environmental objectives.”

With the functionality of Carlisle belts specifically designed for the harsh environments of resource recovery, Mark says BSC is perfectly situated to assist capacity upgrades in the growing packaging recycling sector.

“BSC has extensive experience working with numerous companies in the packaging industry across Australia,” Mark says.

“That experience enables us to understand the special needs of those businesses and product processes, including energy conservation, high sustained speeds, continuous production, heavy leads and wet and dusty environments.”

For more articles like this go to: www.lets-roll.com.au

                                             

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Registrations launched for Waste Expo Australia

The future of waste management and resource recovery is high on the agenda at all levels of government as Australia’s largest and most comprehensive conference and exhibition, Waste Expo Australia launches registrations.

Hosting more than 120 brands and over 100 speakers across three conference stages, Waste Expo Australia will return to the Melbourne Convention and Exhibition Centre on October 23 and 24.

Waste Expo Australia will offer free-to-attend conference content across the Waste and Wastewater Summits, attracting the largest gathering of waste management and resource professionals in Australia.

The Waste Summit Conference brought to you by Oceania Clean Energy Solutions will cover six targeted streams from resource recovery, waste-to-energy, collections, landfill and transfer stations, construction and demolition waste as well as commercial and industrial waste.

Key speakers will include Victoria’s Minister for Energy, Environment and Climate Change Lily D’Ambrosio, Victorian EPA CEO Cathy Wilkinson and Acting Executive Director for Waste Strategy and Policy at the NSW EPA Kar Mel Tang.

Other national and state-based bodies will be represented, along with case study presentations from local governments including Campaspe Shire Council, City of Holdfast Bay, Yarra City Council and Albury City Council.

Leading off day one of the Waste Summit, a panel will discuss the pressing issues surrounding Australia’s waste-to-energy (WtE) sector.

One of the panel members, Director of Enhar Consulting Demian Natakhan, will discuss the status of landfill solar generation and propose that the final resting place for municipal waste may be the beginning of new energy generation.

“Solar farming on former landfill sites offers a way to put otherwise unproductive land to a valuable use,” Mr Natakhan suggested.

“Where landfill gas is already collected in sufficient quantities to firepower generation, solar can be added onto existing grid infrastructure. In sites with lower landfill gas volumes, new solar generation with grid upgrades can unlock significant solar generation, avoiding the competition between solar farming and productive agricultural or industrial land.”

Confronting the challenges and opportunities in wastewater treatment will also be tackled at the Wastewater Summit brought to you by EnviroConcepts.

Waste Expo Australia Event Director Cory McCarrick said the event continues to grow with more speakers and suppliers on board this year than ever before.

“We have seen an increase in the total number of exhibitors this year to 120 and around 50 of these are exhibiting for the first time at Waste Expo Australia,” Mr McCarrick said.

Key exhibitors this year include Bost Group, Cleanaway, Caterpillar, HSR Southern Cross, Tricon Equipment, Applied Machinery and Hitachi.

“Add to this list our impressive line-up of speakers, there is no other waste event in Australia that gives you access to such thought-provoking content that address the major issues facing the industry coupled with the opportunities to be immersed among the key players and products for free,” Mr McCarrick said.

Waste Expo Australia is co-location with All-Energy Australia, Energy Efficiency Expo and ISSA Cleaning and Hygiene Expo — forming a significant showcase for the waste, recycling, wastewater, renewable energy, energy efficiency and cleaning industries.

Across the two days attendees will have access to industry speakers and suppliers across waste management, wastewater treatment, energy generation, energy efficiency and cleaning and hygiene.

Registration gives you access to all four events on Wednesday 23 and Thursday 24 October 2019.

To register visit www.wasteexpoaustralia.com.au

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Global waste management market to reach $484 billion by 2025

The global waste management market will add over $180 billion to its value in the next six years according to Allied Market Research (AMR) report.

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SUEZ propose six-year expansion to Sydney landfill

SUEZ has proposed to expand its Elizabeth Drive Landfill at Kemps Creek in Sydney.

The expansion would increase the current height of the landfill by up to 15 metres which could increase by around 5 million cubic metres. No changes to the existing cell design, cap design or waste disposal methods are involved in the project plan.

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Proposed changes to the capacity of the landfill are estimated to extend the life of the landfill by approximately six years to 2030.

The proposal comes in response to an anticipated increase in waste generation from Sydney’s growing population and several large infrastructure projects in the areas.

Elizabeth Drive Landfill is one of the only sites in the Sydney Basin that is able to receive general construction and demolition waste, according to SUEZ.

SUEZ is currently preparing an Environmental Impact Statement (EIS) for the approval that will assess the likely impacts of the construction and operation of the project.

It will focus on topics including waste management, air quality, hazards and risks, noise and vibration, soil and water, traffic and transport, biodiversity, fire and incident management, visual amenity and heritage.

The EIS is expected to be put on public display for comment in late 2018 or early 2019 by the Department of Planning and Environment.

Approval from the Sydney Western City Planning Panel is required following this step before SUEZ can proceed with construction.

Project approval is expected to be decided by mid 2019 with construction aimed to begin in late 2019.

National Plan for PFAS released to protect environment and health

The heads of all state and territory EPAs and the Federal Government have released a National Environment Management Plan for PFAS (per-and poly-fluoroalkyl substances) to help protect the environment and human health.

PFAS are a group of manufactured chemicals which have historically been used in firefighting foams and other industrial and consumer products for decades, according to EPA Victoria. PFAS can also be found in soil, surface water and groundwater in urban areas, and some PFAS are being phased out around the world as they may pose a risk to human health and the environment.

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The National Environment Management Plan for PFAS describes how to properly deal with and clean up contaminated sites, how to best treat soil and waste, and methods for safely destroying the chemicals.

PFAS can make products heat resistant, non-stick, water repellent, and weather and stain resistant.

Prior to the plan, there was no consistent guidance or direction for communities that had been affected by PFAS.

Environment Protection Authority Victoria’s Executive Director Assessments, Tim Eaton, said PFAS chemicals have been used in a range of products in the past, including pesticides, stain repellents and fire-fighting foams.

“PFAS compounds have had a wide range of uses because they resist heat, chemical and biological degradation, and are very stable,” Mr Eaton said.

“There is now growing concern worldwide about the effects of PFAS on our health and on animals and plants, because of that chemical stability and the fact that they easily enter the environment, moving into soil, creeks, rivers and lakes. We know there are sites with PFAS contamination, so we are working collectively to manage them.”

The plan can be read here.

New recycling technology processes tyres into resources

Tyre processing company Pearl Global has begun commissioning its first production plant to recycle tyres into valuable secondary products.

The technology uses an applied heating process called thermal desorption, which converts waste tyres into liquid hydrocarbon, high tensile steel and carbon char, and can be sold separately or processed further.

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Pearl has constructed its first production plant, with two thermal desorption units (TDUs) in Stapylton, Queensland and initial commissioning under way. The second TDU is owned by Pearl’s intellectual property licensor and contracting partner Keshi, and will be purchased by Pearl as soon as practical.

Each TDU can process approximately 5000 tons (4536 tonnes) of shredded rubber at full production, equivalent to 50,000 car tyres. On average, this equates to a weekly output 1.5 million litres of raw fuel.

“This is the first plant of its type in Australia and we expect to be ramping up to full production over the coming months,” Pearl Executive Chairman Gary Foster said.

The materials are being developed into potential commercial products, including a degreaser product.

With assistance from The Centre for Energy at the University of Western Australia, Pearl’s degreaser products have been tested and compared to existing commercial degreasers and have surpassed the standards required for commercial degreasers, with one of them showing the best performance of all the degreaser products, according to the company.

Over 51 million used tyres get discarded in Australia a year, but only five per cent are recycled. Pearl’s technology focuses on extracting the resources from tyres instead of using them for constructing children’s playgrounds or exporting. Pearl (formerly Citation Resources Limited) in February rejoined the ASX following a reconstruction and a $5 million capital raising.

Pearl recently received planning approval from the Gold Coast City Council and has approval from Queensland’s Department of Environment and Heritage. It already holds an environmental licence from the Western Australian Government Department of Environment Regulation.

“This is a turning point for used tyre processing in Australia. We are the first company in Australia to receive licenses for the thermal treatment of rubber, to reclaim and recover valuable products for resale,” Mr Foster said.

“Our technology is a significant advancement on other methods of processing waste tyres because it has low emissions, no hazardous by-products, requires no chemical intervention and is the only process that meets the standard emissions criteria set by the Australian regulators for this type of technology,” he said.

Mr Foster said the technology will help Australia handle a serious global environmental problem.

“We believe there is great potential in Australia to immediately deploy our technology at sites close to where tyres have been stockpiled,” Mr Foster said.

“With governments seeking or mandating solutions for waste, Pearl is well placed to offer a solution that is both environmentally sound and commercially viable.”

Pearl has applied to be an accredited member of Tyre Stewardship Australia.

When size matters: waste management in East Gippsland

One of East Gippsland Shire Council's waste innovations - an 8 cubic metre split waste and recycling trailer bin
Since adopting a new waste strategy in late 2014, East Gippsland Shire Council has ticked off many of its objectives and won awards along the way, with ‘doing more with less’ its mantra.

Read moreWhen size matters: waste management in East Gippsland

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