Energy chain system for the composting plant

Profile

• What was needed: E4/4 roller energy chains of type 5050Rguide troughs made of 316 stainless steel
• Requirements: reliable energy supply system despite aggressive conditions (acids and high humidity) in the plant, installation under tight deadlines
• Industry: composting
• Success for the customer: quick installation of a state-of-the-art energy supply system, fast assembly without delaying operation

Problem

AVG's composting plant in Cologne processes bio-waste from Cologne households, green waste from gardens and forests, and organic waste from businesses into compost in various classifications. The central process step on the way from waste to compost takes place in a huge hall divided into two fields. Each field is about 26 metres wide and 150 metres long. An automatic heap handling device, similar to an indoor overhead travelling crane, travels above it, distributing the source material evenly in the hall with a conveyor unit.
These perform all essential functions in the composting hall fully automatically.  In order to supply the crane bridges and transfer units with energy and signals, chains and guide troughs from a competitor were previously used, which after ten years of continuous operation showed strong signs of wear and even led to the failure of the system. The reason: The heap handling equipment was supplied via a normal gliding chain - that such a chain shows wear with this length and its own weight is unavoidable and does not correspond to the latest state-of-the-art technology.
Furthermore, the careful selection of materials is an essential prerequisite for a long service life, because the atmosphere in the composting hall is very corrosive: organic acids are released during the composting process. Together with the very high humidity, this creates a type of climate that many materials cannot cope with: Even galvanised metal components corrode quickly here.

Solution

After the bad experiences with the competitor's gliding energy chain, the management was looking for a replacement. The most obvious solution was to ask the supplier to replace the chain. At the same time, however, they also made enquiries at igus. The specialists looked around on site and projected an alternative solution according to the current state of the art in a very short time. The fact that a gliding chain shows wear in the application given its length and dead weight is unavoidable and does not correspond to the latest state-of-the-art technology. igus therefore suggested distributing the weight on two chains that travel in opposite directions.An E4/4 roller energy chain of type 5050R with roller guide was therefore used to supply the crane bridges and transfer units with energy and signals, together with a guide trough of almost 150 metres in length. This system also proves itself in dirty and humid environments - and it was designed for long travels. A flexible interior separation ensures that the cables are guided in an orderly manner during movement. The cables within the chain are thereby responsible for the mobile media, energy and signal supply of the system. To take into account the aggressive environmental conditions, the guide trough is made of 316 stainless steel, which is resistant to corrosion in the long term.