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Wrapped bales – solutions for SRF/RDF handling, transportation and storage: Heikki Jyrkinen, Crosswrap (Finland)

Filmed at Cemtech Europe 2015, 20-23 September, Intercontinental Hotel, Vienna, Austria.

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Thank you very much and good afternoon to every one, [UNKNOWN] that's in Finnish, good afternoon. So I'm here to tell you about the miracle of cross wrapping. This is what, Keith already said, I think we are capable of talking about it because we have as he mentioned the numbers are today over 350 deliveries in 47 countries all over the world.

So we know a little bit about the wrapping and also the bale opening. The main reason why waste fuel is baled and wrapped is quite obvious. Of course baled materials is, it becomes compact and dense so is itself is already after bailing an economical solution for transportation and after you wrapped a bale, you also get the benefits of EC and economical clean handling and transportation.

In addition the wrapping gives the possibility to store the waste fuel, so basically if you have the needs to transport or store waste fuel, then you should seriously consider baling and wrapping. If course it depends on your distances or other logistical issues, but transportation and storage, if those are the needs then, definitely baling and wrapping should be considered. And the reasons for the benefits in transportation some examples, yesterday someone asked Mr Tallen[sp?] he was telling about the example in Indonesia.

They have a site they are running the site close to the kiln, so obvious they don't need the transportation, but someone asked why we have hundreds of kilometers from the waste sources to the kiln. Well baling and wrapping is the solution, you bale and wrap and then the transportation is much more economical and you can use a normal truck for transporting the fuel and then you can bring something back from the kiln like cement or something else. Also since the material is baled you reach the maximum loads for the tracks very easily and that's something you depends on the country and the case but sometimes if you try to transport loose material you don't reach the maximum loads and then you are losing money again. Besides the benefits for transportation by baling and wrapping you will have the possibility for intermediate storages. It can be that you store at the producer or the production facility or then at the kiln.

Those depend on the spaces available and things like that, and of course since the bale is wrapped, the material is protected, so you will also do a lot less slithering when handling the material. You can store the bales outside but a little more on the storage benefits later. I will show you some transportation examples. These are from real customers, some of you here already are using crosswrap, some of you will have soon a crosswrap and I hope that some of you will consider this for future possibilities.

So truck transportation is quite normal, you can, it's obviously seen, obvious to see in the picture that it's easy to load, you can use a normal truck, you can reach the maximum load so all the benefits you need for transportation. Also in some countries they use flat-bed trucks.

This is actually from US going from processing plant, this one goes to landfill but it could be as well going a to cement factory. Close trailers, trains, this picture is actually from Germany, these bales are going to waste to end this plant. By train you don't need that much films over the bales because it's less handling on the other hand if you use track and ship you need a bit more but those can be taken cared of.

Shipping is also done. UK is a very good example of transportation of waste fuels as most of you know millions of bales are going out from UK to cement and waste energy plants in Europe Sweden, Denmark, Germany, Holland, Portugal, Spain so, and most of the material is going out in bales.

So shipping is also possible. And obviously the handling of the material, you can use a normal forklift with the clamps of course to move the bales, then move several at the same time, so it's very straightforward and simple way. So transportation is the one reason for selecting baling and wrapping the other one is storing the most common reasons for storage's are storing the material before the plant starts that is often the case with waste anticipate also in waste energy they tore the material in bales from low season to high season, but in cement kilns I think the main benefit for storing at the kiln side would be the maintenance stores.

When talking to the producers and the cement kilns, many times it's a big issue when the kiln goes down and they cannot use the waste fuel. The waste is coming in to the waste fuel production all the time so they need to take it in, they need to process it but if there is no way to store it there's problem somewhere.

With baling and wrapping you can store the material, you can store it outside and when the bale is wrapped the material also stays in good shape. Otherwise you would store it outside as loose material gets wet and it's not good material anymore. Some kilns consider the security of making it secure that the material waste fuel is always available, depends from country to country but if you have logistical problems or certain time of the year the roads may be in bad condition, you can have the waste fuel storage at the kiln site in bales and then use it when you need it.

Some pictures of storages from different countries, different sizes of bales, different sizes of storages, basically the limitation is the lifting capacity. 4-7/8 layers is quite normal in this one I think there were 10 layers on top of each other. Even storing inside in bales, you see that there is no littering going on, no fluff moving around.

So baling and wrapping is already wide proven technology. It's automatic process, baler and the wrapper work in conjunction automatically and it's already widely used. So nothing special about that, however if you are not familiar with the things, there are some things you should consider when choosing the, if you are producing waste fuel yourself, you should consider the capacity.

Prices go up, if you need more capacity tonnes per hour the bale prices go up. The bale size might be important for you, there are different balers for different bale sizes, and of course the type of waste is SRF/RDF it might require a bit different baler to be used. Today I would say almost 100% of cement customers they require plastic or twine tying for the bales. There are some kilns that get metal tied bales.

The number of those is decreasing it still can be handled with bale openers but most of the, both waste energy plants and cement kilns they require the plastic ties. The film itself is the commercial product. The wrapping film it's a stretch film PE film, UV protected, there are several suppliers around the world, it's a commercial product available from many sources. So we start, that's also very standard product, then when you go from baling to wrapping there are some things you should consider, by wrapping you can also save in the number of ties, you make the strength of the bale for the transportation by the method you wrap it, that makes the strength.

And it's also important to optimize the amount of film that you put on the bale depending on the distance you transport, the amount of handling you do and the fact that how long you will store the material, because you can put more film or less film depending on the need. Also of course if the kiln is receiving materials in bales, the bale need to be opened, but there are solutions for that, that also. But first some examples how baling and wrapping solutions looks like, there are different balers, different materials, different bale size and different layouts in these pictures. But each and every one makes a good product for the transportation and storage.

Today it's also possible to make a bale that has also wrapping film no ties. For some of you this may not be familiar, but some could find this very interesting. Because then the bale would not have any ties in it just wrapping film, and that gives more possibilities for the opening of the bale.

As I said bales can be opened and how they are opened varies from place to place. The basic things you need to consider when opening, is first of all do you need to remove the films, the film and the ties, or can they be left with the material. You need some workforce to do it, in many countries it's also a safety issue and it requires the whole investment for bale opening to have a safe operation. Capacity definition some need to open five bales per hour, some do 40 bales per hour and there is a proper solution for each and every case. And of course money is what makes the decision so operating cost, maintenance and service cost is very, very important.

Possibilities, usually companies who start using or getting bales in they start with manual opening and once they get the volumes they start doing it in more automatic way. Some open it by excavators but it's very difficult to remove the film and the ties, so I would say that in cement industry the excavator is not the right way to do it. In some kilns you already have a shredder which you could use to open the bale.

However the shredder needs to be quite big which makes it costly and also when you put the whole bale in sometimes it decreases the capacity of the shredder. But those are the possibilities and of course there are also bale openers like we have with our dedicated for opening the bale.

Our opener it can remove the plastic and the film so that only the material inside the bale goes to the process, it's all automatic. Of course it's safe, no human intervention it is very high capacity, we can do 40-50 bales while removing the plastic and ties even more if everything can go to process. And what is the most important with us is that the operating cost is very low.

We have figures from our customers that the opening cost without the investment cost is some Euro cents. 10-30 Euro cents per tonne, so that's not a lot. I show you some pictures of the bale opener, I would have had film, but I think it's too, we don't have enough time, so if you want to see the machines in action you can come to our booth or contact us and I can show you the videos how the equipment work.

But these are the bale openers in different countries, different application and this is one in a cement kiln, the picture is taken during the start up so they have a docking station where they unload the trucks and the bale opener here on the side to open the bales to the same input source. So baling and wrapping is your solution for the transportation and storage and there are technologies to open the bales, so it's not a major issue considering how the bales could be opened.

So thank you very much.

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