Solution for a 1000 ton Horizontal Centralized Spiral Hopper Steel Chips Briquette Press in Russia

I. Project Overview

1.1 Project Background

A large metal processing company in Russia, located in an industrial area of Moscow, generates approximately 15,000 tons of metal waste, including Steel Chips, annually. To improve the recycling efficiency of metal waste, reduce transportation costs, and achieve intelligent production management, the company decided to introduce a highly efficient and intelligent Steel Chips processing system.

1.2 Core Equipment

-Equipment Model: DSW Horizontal Centralized Spiral Hopper Steel Chip Briquette Press

-Rated Pressure: 1000 tons

-Processing Capacity: 10 tons/hour (steel chips)

-Control System: Fully Automatic Intelligent Control System

-Power Requirements: 380V/50Hz/Three-phase AC (Compatible with Russian local power standards)

II. Equipment Technical Solution

2.1 Overall Design Features

1. Horizontal Structure Design: Reduces equipment height, facilitates factory installation, and improves operational safety.

2. Centralized Spiral Hopper System: 15m³ volume, equipped with a double spiral feeding device to ensure uniform material supply.

3. Hydraulic System: Uses German Bosch Rexroth hydraulic components, equipped with a hydraulic oil cooling system to ensure continuous operation stability.

4. Mold System: Replaceable molds, capable of producing metal cakes with specifications of Φ150mm-Φ200mm.

5. Density Control: Finished cake density can reach 4.5-5.5g/cm³.

2.2 Intelligent Control System

1. PLC Control System: Siemens S7-1500 series PLC, equipped with a 10-inch color touchscreen

2. Automation Functions: - Automatic feeding, pressing, and discharging cycle; - Real-time monitoring of pressure, temperature, and oil level; - Automatic fault diagnosis and alarm

3. Data Management: - Automatic recording of production data (output, energy consumption, running time); - Support for remote monitoring (secure connection via VPN); - Multi-language interface (including Russian operating interface)

4. Safety Protection: - Double safety light curtain protection; - Emergency stop button (mushroom head type); - Hydraulic system overload protection; - Electrical system leakage protection

III. Production Process and Capacity Analysis

3.1 Process Flow: 

Steel Chips collection → Screw conveyor → Centralized hopper → Quantitative feeding → High-pressure pressing → Cake ejection → Finished product collection

- Cycle time: Approximately 15-20 seconds per cycle

- Single processing capacity: Approximately 120-150 kg of Steel Chips

- Cake weight: Approximately 20-25 kg per cake

3.2 Capacity Calculation: 

- Theoretical maximum capacity: 12 tons/hour; - Designed stable capacity: 10 tons/hour; - Daily capacity (based on 16 hours): 160 tons; - Monthly capacity (based on 25 days): 4,000 tons; - Fully meets the customer's processing needs of 15,000 tons/year

IV. Project Implementation and Results

4.1 Installation and Commissioning

1. Preliminary Preparation: Foundation construction, power connection (500KVA), compressed air pipeline (0.7MPa)

2. Installation Cycle: Equipment placement 3 days, pipeline connection 2 days, electrical wiring 3 days

3. Commissioning Cycle: No-load commissioning 2 days, load commissioning 3 days, operator training 2 days

4. Acceptance Criteria: Continuous 8-hour production test, capacity meets standard, equipment operates stably

4.2 Actual Operating Results

1. Efficiency Improvement: - Steel chip volume reduced to 1/6-1/8 of the original; - Transportation costs reduced by approximately 65%; - Reduced labor requirements: Only 1 person is needed for monitoring and operation

2. Economic Benefits: - Metal recovery rate increased by 3-5%; - Annual transportation cost savings of approximately 12 million rubles; - Investment payback period: approximately 18 months

3. Safety Performance: - No safety incidents in 6 months of operation; - Equipment failure rate <1%; - Simple maintenance, average monthly maintenance time <4 hours

V. Intelligent Features

5.1 Remote Monitoring System

- Real-time monitoring of equipment operation status at Moscow headquarters via encrypted network connection; - Automatic generation of daily, weekly, and monthly production reports; - Early warning system: Early warning of potential faults, reducing unplanned downtime

5.2 Adaptive Control

- Automatic adjustment of pressing parameters based on steel chip type and humidity; - Energy consumption optimization: Automatic selection of energy-saving mode while ensuring quality; - Die wear monitoring: Predicting die life and arranging replacement in advance

5.3 Data Integration

- Integration with the factory ERP system for integrated management of production data; - Quality traceability: Production time, parameters, and raw material batches for each cake block are traceable

VI. Environmental Adaptability Improvements

The equipment has been optimized for the special climate environment of Russia:

1. Low Temperature Adaptability: The hydraulic oil is a low-temperature type, capable of normal operation in environments as low as -25℃.

2. Anti-freeze Design: The piping system is equipped with an insulation layer and a heating device.

3. Corrosion Protection: Key components feature a special coating to withstand high humidity environments.

4. Backup System: Key electrical components are equipped with heaters to prevent condensation.

VII. Customer Feedback and Continuous Service

7.1 Customer Evaluation

This equipment fully meets our production needs, is highly intelligent, and easy to operate. The remote monitoring function, in particular, allows us to monitor production status from headquarters. The equipment operates stably, has low maintenance costs, and significantly improves our metal recycling efficiency.

7.2 After-Sales Service

1. Localized Service: Spare parts warehouse established in St. Petersburg, providing 24-hour response.

2. Regular Maintenance: Remote diagnostics quarterly, on-site inspection every six months.

3. Operation Training: Continuous online training support provided.

4. Technical Upgrades: Regular software updates and feature optimizations provided.

VIII. Conclusion

The successful application of this 1000-ton horizontal centralized spiral hopper Steel Chips briquetting machine solution at the Russian customer's site demonstrates its superior performance in efficiently processing metal scrap. The equipment not only achieved its designed capacity of 10 tons/hour, but also realized safe, efficient, and low-consumption continuous production through an intelligent control system. This case provides a reliable scrap treatment solution for metal processing enterprises in Russia and similar climate regions, and has broad application value.