efficient extrusion - sustainable solutions for lower energy consumption

8/16/2019 Efficient Extrusion - Sustainable Solutions for Lower Energy Consumption

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Efficient Extrusion

Dr. Henning Stieglitz

October 2011


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Motivation

Potential extruder

Holistic line concepts

Monitoring

Summary

Agenda

2


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Motivation

Potential extruder


Monitoring

Summary

Agenda

3


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Development of energy costs

Due to shrinking resources energy costs will increase

> 120%


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Production costs depend on output (film extrusion)

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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


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Energy consumption of an extrusion line(film extrusion)

Complete line: 66% of total energy consumed by drives

Extruder: 90% of energy consumed by drive


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Motivation

Potential extruder


Monitoring

Summary

Agenda

7


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Potential “High Speed” Extruder(film extrusion)

Energy savings = savings in production costs


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Direct drive

Advantages:

High energy efficiency

Low noise emission

Compact flexible design

Less maintenance

Gearless drive(high torque motor)- integrated back pressure bearing


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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.


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comparison:

Extruder Ø180 mm:

20-25 to

Extruder Ø75 mm:

3-4 to

Smaller extruders offer a lot possibilities

Weight reduction / handling


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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


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Motivation

Potential extruder


Monitoring

Summary

Agenda

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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


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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)


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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


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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)


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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)


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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


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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)


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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


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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


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Motivation

Potential extruder


Monitoring

Summary

Agenda

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Optimization of the energy consumption

Data acquisition

Visualisation

Build up data base

Optimisation of the energy consumption

Analyse

(components + processes)


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Energy monitoring

Integration of intelligent measuring devicesinto the control system

Visualisation of the energy consumptionof the different components


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Motivation

Potential extruder


Monitoring

Summary

Agenda

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efficient extrusion - sustainable solutions for lower energy consumption

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