Upload
han-han
View
219
Download
0
Embed Size (px)
Citation preview
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
1/29
Efficient Extrusion
Dr. Henning Stieglitz
October 2011
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
2/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
2
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
3/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
3
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
4/29
Development of energy costs
Due to shrinking resources energy costs will increase
> 120%
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
5/29
Production costs depend on output (film extrusion)
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
250 500 750 1000 1250 1500 2000 3000 5000 10000
Output [kg/h]
P r o d u c t i o
n
c o s t s
[ € / k g ]
Reihe2
Reihe3
Efficiency of an extrusion line
Production costs decrease with increasing output
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
6/29
Energy consumption of an extrusion line(film extrusion)
Complete line: 66% of total energy consumed by drives
Extruder: 90% of energy consumed by drive
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
7/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
7
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
8/29
Potential “High Speed” Extruder(film extrusion)
Energy savings = savings in production costs
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
9/29
Direct drive
Advantages:
High energy efficiency
Low noise emission
Compact flexible design
Less maintenance
Gearless drive(high torque motor)- integrated back pressure bearing
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
10/29
StartEnd
75-extruder 180-extruder
Volume in extruder [kg] 4 40
Material consum tion for colour chan e k 150 1300
Time for colour change @ low output [min] 30 50
Time for colour chan e @ hi h Out ut min 5 35
Colour change
Material consumption
= ~ 110 kg
@ 1,500 kg/h~ 5 min.
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
11/29
comparison:
Extruder Ø180 mm:
20-25 to
Extruder Ø75 mm:
3-4 to
Smaller extruders offer a lot possibilities
Weight reduction / handling
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
12/29
Less space required “leaner production”
Lower investment costs / lower costs for spare parts
Reduced residence time fast start up quick material change fast colour change
Easy handling (production, maintenace)
Less energy consumption
Better product quality
Advantages of „high performance“ extruders
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
13/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
13
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
14/29
1. Start:
High output
extrusion
2. Innovative downstreamtechnology
3. Highly efficient use of
water & air for cooling
4. End:
Increased output,
reclaiming energy
Closedenergy
cycle
Energy cycle
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
15/29
Total line concept is important for energy consumption
It is not enough to concentrate on the extruder only
Holistic investigation of the energy consumption(pipe extrusion)
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
16/29
Green Pipe: innovative concept for energy-efficient pipe production
Modular concept with 3 different options to save of up to 50% in downstreamlength and energy needed within the downstream, compared to regular pipeextrusion lines
• Efficient Air Cooling (EAC)
• KryoSys
• Green Pipe complete line concept
EAC system KryoS system
Green Pipe complete system
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
17/29
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
18/29
VB CB 1 CB 2 CB 3 PTAR
m_p = 450 kg/hV_ab = 1,12 m/min
Borstar 3494LSH
Outer layer
Inner layer
Centre
Measuring points
Crystallisation range
T_ Start = 205°C
T_ End-I = 48°CT_ End-O = 44°C
HDPE pipe 160 x 14.6 without internal pipe cooling- temperature distribution in the pipe wall
Exemplary savings calculation & comparisonto standard line (EAC)
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
19/29
Measuring points
Outer layer
Inner layer
Centre
T_ Start = 198°C
T_ End-O = 24°CT_ End-I = 19°C
m_p = 450 kg/hV_ab = 1,12 m/minBorstar 3494LSH
Crystallisation range
VB CB 1 CB 2 CB 3 PTAR
HDPE pipe 160 x 14.6 with internal pipe cooling- temperature distribution in the pipe wall
Exemplary savings calculation & comparisonto standard line (EAC)
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
20/29
Inner pipe cooling system:economical benefits
Comparable investment costs to conventional extrusion lines
Increased efficiency
• higher line speed or
• reduced length of extrusion line
• reduced material consumption due to more precise wall thickness
• improved utilization of energy
• possibility to use standard PE materials (not always LS materials)• use of standard PP materials (esp. fibre compounds)
Less environmental pollution/air pollution on shop floor
• extraction of pipe internal air
Benefit of waste heat without additional heat-exchanger
• wax separation by electric filter
• granules pre-warming
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
21/29
the “conventional” cooling process
chiller 15°C20.000 l/h
20°C
20.000 l/h
5.000 l/h5.000 l/h5.000 l/h5.000 l/h
20°C 15°C 20°C 15°C 20°C 15°C 20°C 15°C
melt
200°C 160°C 120°C 80°C 40°C
Investigation of the cooling process(pipe extrusion)
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
22/29
water control: water inlet at the last spray bath „n“ counter flow principle water outlet bath „n“ = water inlet bath „n-1“ easy handling – just one controller
“Green Pipe” line concept
the “Green Pipe” cooling process
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
23/29
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
24/29
cooling capacity[kW]
chiller cooled[kW]
„free“cooling[kW]
flowvolume[m³/h]
temperatur-difference
[C°]
water returntemperature
[C°]
conventional
Green Pipe
cooling water supply
cooling bath
10.7 1.3 3 20 26.8 43.3
37.3 31.6 20.6 0.8 16.7 30.8
Comparison of the conventional and the“Green Pipe” cooling process
In full production field tests
(with an industrial cooperation partner),we showed that:
• The volume flow was reduced by up to88%
• The temperature difference (in-out) wasincreased from 3°C to 20°C
• The percentage of free cooling wasincreased from 45% to 97% (at an
outside air temperature of 15°C)
During these tests an amount of heat of30.8 kW at a return temperature of thewater of 43.3°C would have been
available for waste heat usage
The pipes produced during these testshave been released for sale no reduction in pipe quality
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
25/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
25
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
26/29
Optimization of the energy consumption
Data acquisition
Visualisation
Build up data base
Optimisation of the energy consumption
Analyse
(components + processes)
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
27/29
Energy monitoring
Integration of intelligent measuring devicesinto the control system
Visualisation of the energy consumptionof the different components
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
28/29
Motivation
Potential extruder
Holistic line concepts
Monitoring
Summary
Agenda
28
8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption
29/29