Blog

May 7, 2017

Used Scrap Metal Ferrous Shredding System for Sale

Tom Stanek

An effective energy efficient metal shredding line up

5000 HP Ferrous Scrap Metal Shredding System for sale.  The heavy duty shredder box is 88 x 101 inch with 4 inch thick walls.  This is a complete package with infeed conveyor, ferrous line, motors, pumps, water injection, and coolers.  Many extras such as power systems and a computer managed over sized double feed roll allow this machine to shred serious volume in a compact package.  150 tons per hour ferrous out production.

The primary drive is a 5000 HP (3730 KW) A/C Wound Rotor Motor.  The hard charging Schorch motor keeps churning day after day.  Dual axial pole magnets, cyclone air cleaning system, and split picking station allow for extremely clean and dense ferrous scrap.

Slip Power Recovery Drive is included.  Motor rotor current is managed in a switchable duel system using either liquid rheostat or solid state SPR drive.  The SPR efficiently runs the motor with greater power, cooler temperatures, more tons per hour, while allowing less flicker and inference with local electrical grid, thus greater options for relocating the installation.  Comes with heavy duty GE transformer (25kV/4160), power factor capacitors, and many extras that take the added cost out of relocating the machine.

The system includes infeed conveyor, shredder dampening springs, under mill oscillator, conveyors, magnets, water injection system, de-dusting air cleaning zee box, dual picking station, stacking conveyor, and non-ferrous radial stacking conveyor.  Many spare casting wear parts and spare parts are available.  The motor room is protected by an air filtration system.  Roof mounted coolers, control cabin, infra red camera, and shredder management computer round out the system.  Non-ferrous separation system as NOT part of this package.

An effective and energy efficient equipment line up.  A very complete system, well cared for with low tons on the machine.   This unit represent an excellent opportunity for a new installation or if you are looking to replace an aging shredding plant.

Spare motor and rotor available as extras.

Contact us at k2.castings.com for more details.  Serious inquires only.

 

February 17, 2017

What’s Needed to Replace Your Shredder Rotor?

Tom Stanek

Shredder Rotor Replacement

Your wear parts have been doing a great job for many tons of production.  After several years, it’s time to replace your shredder rotor.  What are your options and what exactly do you need to plan the job?  How do you start finding a replacement?  Here’s some information and explanation to get you started.

Find your rotor arrangement drawing.  The drawing shows the entire rotor and describes its major dimensions, weight, shaft size and general assembly.  With this drawing, a rotor builder understands the style and quantities needed to build a rotor.

Example Rotor Assembly Drawing (courtesy of PG&H Engineering)

They can estimate materials and general time needed, enabling them to provide you a quote.  You need to describe what it is you are buying. A picture is worth a thousand words.  Here is a rotor template drawing from PG&H if you need to make your own.

Describe your hammer and hammer pin size.  A drawing with some basic dimensions is ideal. If you don’t have one, go to our quote page and download the hammer template you need (such as bell hammer) and use it to describe your hammer.  The rotor builder needs to confirm your hammer swing radius, thickness, and pin hole size.  Provide them hammer pin diameter and length.  We have a template for hammer pins as well.

Get with your operating crew and determine the specific needs at the shredder.  Yes, you need a new rotor, but what else?  Here are the common replacement items for a rotor change out.

Bearing housings

These hold the bearings and attach the rotor shaft to the shredder.  They get worn and damaged as well.  If in good shape they can be renewed.
You should have a spare set on hand and can plan to use them.  If they have yet to be renewed, get them cleaned up and sent out to a shop that can build them up and machine them to restore a secure fit.

Oil seals

Seals keep the lubricant inside the bearings housings.  They are long lasting, but always replace with new during a bearing change.

Rotor bearings

FAG Beargings by Schaeffler Group

Photo courtesy of Schaeffler / FAG Roller Bearings

Generally spherical tapered roller bearings are used.  You should have a spare set on hand.  If you need a fresh set, order early as lead times can vary by many weeks.  Be sure your spare set is well stored and free of minor rust and dirt.  Larger machines have oil cooled bearings, smaller mills may use greased bearings (not needing an oil re-circ system).

Coupling device

A means to connect the drive shaft to the rotor.  You may be able to remove the old one and reuse it, use a spare, or plan on having a new one made by your rotor shop.

Drive Shaft

You will have the rotor out, so it’s the right time to service your drive shaft.  Plan for it.

Bearing Base Plates and Shim Kit

The saddle is the mounting area on the shredder base where the bearing housing sits to anchor the rotor to the shredder itself.  These surfaces are subject to wear themselves.  The bearing housings should wear first, but in reality, both wear.  The saddles will have to be cleaned and ground flat.  The bottoms of the bearing housings will be milled flat in the shop.  A steel base plate is used when you need to make of the difference in height from the wear of these two surfaces.  A shim kit is useful for rotor alignment.  It is a set of pre-cut metal shims to help you adjust rotor height when aligning the rotor drive train.

Thermocouples and Instrument Wiring

Oil cooled bearing generally have a temperature monitoring probe on the bearing oil. Often the probes and wiring will be damaged after years of shredder service.  If they need to be replaced, plan for it now.

Bearing oil piping, hoses, fittings

Similarly, your bearing oil delivery system takes abuse over the years.  You may need to replace piping or use fresh hose.   You might want to get the bearing oil pump & reservoir cleaned and serviced during the rotor change as well.

Bearing bolts

The studs or bolts that hold down the bearings to the saddle base should generally be replaced.  Bolts are made to have a certain amount of stretch.  Once they have stretched and done their job, they don’t stretch and hold quite the same the next go around.  Its a finer point and often, the bolts or studs are often reused.  It’s best if you change them.  Often the threads and nuts get damaged, so a fresh fastening system is good.  After spending so much to  replace the  rotor, you’re are going to cut corners elsewhere in the installation?  Just saying.

You have your shopping list.  Go find yourself a rotor and replacement supplies.   Call you your Original Equipment Manufacturer or one of the replacement builders out there, such as PG&H Engineering.   Contact us if you need some advice.

February 12, 2017

Rebuilt Hagglunds MB 283 Drive Motor Available

Tom Stanek

Many of our customers continue to run the venerable, long lasting MB series hydraulic drive motors with their shredding installations.  Infeed conveyors and double feed roll drives are commonly powered by the MB 283.

As you know, Hagglunds is now part of Bosch Rexroth and the MB series is no longer in production.  The CA series of radial piston motors is the current supply in many new shredder installations.  If you want a new motor, it will be a CA or CB series.  Replacing an older MB with a new CA requires adapters and a little conversion.

Fortunately, the well made Hagglunds units are tough.  Units can be rebuilt with new parts.  You just have to find them!   One of our shops has one.

The unit is rebuilt with new parts including a new roll pin, cyinder roll bearing, wear ring, gasket set, radial lip seal dust seal, and piston ring.  Its been tested and is backed by a 6 month shop warranty.

Why wait for new or go through a conversion?  Get this in your spares inventory.  Grab it while you can.  Contact us for details.

June 24, 2016

Double Feed Roll Drive Shaft

Tom Stanek

DFR SHAFT READY Our fine friends at PG&H Engineering have a Doubled Feed Roll (DFR) drive shaft ready in their shop for immediate delivery.  This shaft fits Metso Generation III DFR rollers using CA280 splined Hagglunds drive motors.

Click here to request more information.

INFEED SPLINED 2

May 24, 2016

Summer Fire Prevention for Recyclers

Ben Guerrero

Summer is here and the risk of a fire in your scrap feed stock and fluff piles go up substantially.  Summer brings an uptick in yard flow and several holiday weekends.  Many of us have received that call in the middle of the night that you have a fire emergency at the yard.  We all need to remain vigilant and not let our guard down. Here are some simple rules to minimize the chances of that call.

Scrap-Fire-iStock_medPreventive measures to take:

  1. Keep your scrap piles at least twenty feet away from both fixed and mobile processing equipment. Infeed conveyors, loaders, cranes, need clear space from scrap storage piles. Space means access and time in the event of a fire.
  2. Don’t accumulate large feed stock piles. Production schedules that keep intake to a minimum are best.  If you are down for extended maintenance, add fire breaks and gaps to segregate large piles.  Once you shred it, the problem is gone.
  3. Regular housekeeping is needed at the shredder. Excessive material buildup becomes a problem when contaminants hit the piles.  Consider this scenario.  Scrap builds up between your shredder and the motor room over several weeks.  An auto slips by inspectors with a full fuel tank and it ruptures as it slides down the feed chute.  Flammable liquid runs out of the mill and into that pile of build-up right where your important machinery is located.  Your bearings, hydraulic lines, drive shafts, control wiring, or your mill motor won’t be the same if that pile ignites.  Clear what does not belong on a weekly rotation.
  4. Make sure your fire control systems are in place, hoses and nozzles are in good condition, all fire extinguishers checked monthly, and missing items replaced promptly.
  5. Review with your inspectors hazardous materials which can start a fire such as batteries, gas tanks, propane bottles, and other ignition sources. While 99% of infeed scrap is remediated and prepared for shredder, some things get through the inspection process.  Sometimes dressing up the piles of infeed materials received earlier that day can trigger a problem load lurking in the day’s intake.
  6. Make sure all shreds have been run off the conveyor belts and wet down the conveyors belts and area around the shredder. Be sure to look closely at all of the fluff piles for signs of hot spots.  Make it a priority to have the fluff piles at minimum levels especially before an extended holiday shutdown.
  7. Lastly, have a supervisor walk around the processing area prior to shutdown. An early morning inspection can help set expectations for the end of day shut down walk when your team is wrapping up for a holiday weekend.

Have a safe production summer!!

Take steps to be sure this is not you

January 21, 2016

Hammermill 96×104 Excess Parts Available

Tom Stanek

Excess Parts 96104  A customer has a large inventory of excess, unused wear parts for a Hammermill 96 inch by 104 inch shredder.  If you are running or rebuilding one of these workhorse machines, this is a great way to save some money.  Please contact us if you have interest in learning more.96104 Parts 2

Hammermill machines are one of the storied brands in the shredding world, both productive and reliable.  With a bolt together shredding box, they are easier to rebuild.  As time moves on,  support is not always easy to obtain from the current brand owner.

These manganese steel parts include hammers, grates, cutter bars, and pin protectors. Tie rods and end disk caps are also part of the assortment.

Hammermill 96×104 Excess Part Inventory

PART NUMBER / REFERENCE

DESCRIPTION QUANTITY
ET9903-                           21-9980 ROOF COVER BREAKER BAR 1
ET9900-                           21-9970 ROOF COVER 1  
CH-73096-A201RH         22-7000 LOWER SIDE LINER RH (22) 1
CH-73096-A201LH         22-0705 LOWER SIDE LINER LH (22) 1
CH-73096-B201RH         22-0690 LOWER SIDE LINER RH (23) 1
CH-73096-B201LH         22-0695 LOWER SIDE LINER LH (23) 1
 CH-73096-C201RH        22-0680 LOWER REAR LINER RH (24) 2
CH-73096-C201LH         22-0685 LOWER REAR LINER LH (24) 1
CH-73096-D201RH        21-2050 UPPER REAR LINER RH (25) 1
CH-73096-D201LH         21-2055 UPPER REAR LINER LH (25) 1
CH-73096-E201RH         21-9950 UPPER CENTER LINER RH (26) 1
CH-73096-E201LH         21-9960 UPPER CENTER LINER LH (26) 1
CH-73096-FlOlRH           21-9930 UPPER FRONT LINER RH (27) 1
CH-73096-FlOlLH           21-9940 UPPER FRONT LINER LH (27) 1
 DH-73096-208UA          21-9900 INNER TOP BREAKER BAR (13) 1
J-44194-                          21-8910 SOLID GRADE BAR (37) 5  
CH-7896-Al-                   21-9910 GRATE BAR (36) 10
DH-73074-A129              20-9230 LOWER BREAKER BAR (30) 2  
BH-73096-213-Al            21-9920 INTAKE BREAKER BAR (14) 2
DH-73074-A330-            21-9220 CUTTER BAR (35) 4
B-7283-1 CAP HD (54) 112+76
BH-7996-30 HAMMER 500 LBS (53) 137+76
DH-73074-C344 HAMMER PINS 16
KN-179 COMP.FLIGHT (3 CROWSERS) 25
(SB-18252) petit (16) END DISC CAP WO/POCKET 27
(SB-18253) grand (22-5605) (8) END DISC CAP W/POCKET 19
B-D449 (48) PIN END DISC CAP 40
B-B525 (48) WASHER END DISC CAP 38
101-639A PADS96″ 23
CH-73074-J-19 TIE BOLTS 126″ 11
CH-73074-J-308 TIE BOLTS 140″ 9
#22-3020 (DESSIN PDE 57715) COMBO 0
#22-0260 (DESSIN PDE 58991) FULL SOLID 0

 

96104 Parts 1

December 22, 2015

The Risks of Not Staying on Top of Shredder Maintenance

Tom Stanek

Ben Guerrero has penned a story for Recycling Product News ‘The Risks of Not Staying on Top of Shredder Maintenance.’  Survival in times of low markets dictate many cut backs in shredding facilities worldwide.  When you are low on people, finding man hours to tackle even the most basic maintenance is a challenge.  Ben outlines some of the do’s and don’ts in this article.

While it may be ‘preaching to the choir’ for operators, this simple advice should be acknowledged by senior management.  Shredders and non ferrous separating systems won’t keep running without minimum maintenance.  Idled plants won’t start up or hold much resale value if they are ‘put away cold and wet.’   Deferring too much maintenance could lead to larger issues.

Some scenarios to consider, all actual incidents:

  • Failure to clean the motor air cooling system filtration leads to dirt build up in the windings.  Warmer operating days lead to high motor temps, then overheating and a motor fire.
  • The cleaning crew continues to defer cleaning the spillage that slowly builds up between the shredder and motor building.  Your inspectors miss an auto with  fuel in the tank.  Fuel runs out as the auto slides down the infeed chute, it trickles down next to that scrap pile, and there is ignition.  A fire right next to your mill machinery now needs attention.
  • Extending runs times between grate changes saves part costs.  Eventually grate holes are 30% larger than new, the distance between hammer tips and anvils is large, and cream puffs of balled up sheet drop from your stacker instead of dense shred.  Your fluff loads have more metal than you remember.  You check the last 3 months of production records and realize your non ferrous recovery has dropped noticeably.  Ferrous production is up but shipping density is down, zorba volume is down, and so is revenue.  Was it feed stock, weather, or maintenance? Compare the savings in wear parts to the revenue decline.

Grates Its About the BenjaminsWhat’s the best balance? The answer is different for each plant.  Safety and environmental compliance are non-negotiable operating absolutes.  Operating maintenance is not too far behind.  Ideally it’s all the same mindset at your facility, and peak performance and efficiency continue to be the goal of all team members.  Yes, there must be rational tradeoffs between budget, readiness, and acceptable downtime.  Plan in advance to be ready for seasonal or market upticks in volume.  Be sure your facility stands ready to execute for a return to higher production when opportunity arrives.

Find Ben’s article Recycling Product News – Ben Guerrero.

November 17, 2015

Economic Impact of Recycling

Tom Stanek

Our recycling customers make a significant contribution to our economy as well as sustainability. The industry recycled 135 million metric tons of materials in 2014. The material was diverted from landfills to produce new products, reducing the need to mine or harvest new resources, with less energy expended during the process.  Recycled Materials

The Institute for Scrap Recycling Industries summarized the economic benefit of this activity in a 2015 study. The industry supports 470,000 plus jobs and generates $105 billion in economic activity. This includes downstream suppliers such as auto wrecking yards, independent scrappers, and firms that provide equipment and services to the industry.
Recycling contributes about 0.68% of the national economic activity and generates about $11 billion in federal, state, and local taxes annually. Recycling helps the US trade balance with exports to over 160 countries valued at nearly $21 billion in 2014.
ISRI summarized the report in this short video.

 

 

 

June 16, 2015

ISRI Safety Stand Down Day June 24th

Tom Stanek

Scrap Recyclers are encouraged to join the Institute of Scrap Recycling Industries (ISRI) industry wide Safety Stand Down Day on June 24, 2015.

All ISRI members are asked to recognize Safety Stand-Down Day by shutting down operations for at least one hour on every shift to engage in safety awareness training. Demonstrate to your workforce that safety is your number one core value and that you consider your workers to be the most important asset of your operation. Each Monday in June leading up to Safety Stand-Down Day,

safetystanddown-775x110

See the ISRI web site for useful resources to use as part of your training. These guides will focus on five topics: mobile equipment, lockout/tagout, confined spaces, machine guarding, and fall protection.

 

April 7, 2015

Used 98104 Auto Shredder for Sale

Tom Stanek

We have a customer with a used scrap metal auto shredder for sale.  The unit is a model 98104 Texas Shredder, 4000 HP, disk rotor, with infeed and ferrous downstream. Rated output is 100 tons per hour.

If you’re looking for a cost effective way into shredding, you found the right package. High output, solid key components, lots of extras. One of the most common shredder designs means parts are common as well.

  • System has new and overhauled parts.
  • Downstream consists of ferrous cleaning system only.
  • The Alstom 4000 HP wound rotor AC motor is in excellent condition.
  • Includes a very nice portable modular indoor substation for power distribution & receiving utility power, with a metering bay and disconnects.

u-jointsIncludes many extras needed to install and operate, typically not part of used auto shredding packages.  Contact us for details.  This system is located in the USA.

This unit processes automobiles, end of life vehicles (ELV), appliances, sheet metal, baled ferrous, and loose tin.