Can High Output and Low Energy Consumption be …...energy consumption REItorque drive technology...
Transcript of Can High Output and Low Energy Consumption be …...energy consumption REItorque drive technology...
Can High Output and Low Energy Consumptionbe married ?
2009 Flexible Packaging SymposiumMumbai / New Delhi
Reifenhäuser says:
Yes they can
© Reifenhäuser Extrusion GmbH & Co.KG, proprietary information, all rights reserved
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Improving your ROIHigh Output low Energy Consumption
Saving on Resin Cost
Higher Productivity by minimizing of down times
High Flexibility- Only one Production Line for different Products
Saving on Energy Cost
Savings on total Production Cost
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Key Elements of production costs
resin
down time
interest
energy
labour costs
Dosing
Die
Mixing ZonesIntake Zone
VacuumDomesDosing screw
VacuumPump
P1 P2 P3 P4 P5
Protection screen
Pump 1
Backflush screen
Pump 2
Technical overview Twin Screw Technology
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Improving your ROIHigh Output low Energy Consumption
Saving on Resin Cost
Dosing
Mixing ZonesIntake Zone
VakuumDomes P1 P2 P3 P4 P5
Pump 1Pump 2
Web width adjustment
During Production
without Die deckling possible
Why ?Up to 40% Refeedingpossible
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Improving your ROIHigh Output low Energy Consumption
Higher Productivity by minimizing of down timesDosing
Mixing ZonesIntake Zone
VacuumDomesDosing screw
Vakuum Pump
P1 P2 P3 P4 P5
Pump 1Pump 2
Why?Absorbing of monomers
direct during Extrusion Process!
Production Stops for Cast Roll cleaning can be minimized !!!!!
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Improving your ROIHigh Output low Energy Consumption
High Flexibility- Only one Production Line for different Products
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2
3
1
2
3
PP
PE, PET
EVA, TPU
Filler Ca Co3
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Improving your ROIHigh Output low Energy Consumption
• Saving on Energy Cost
Copper cooling rolls for cast film process
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Improving your ROIHigh Output low Energy Consumption
• Saving on Energy Cost
T [°C]
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10
Stahlλ
α
Kupferλα
Outer sheel madefrom steel or copper
ΔT steel or copper
Cooling water
Plastic film
Copper cooling rolls for cast film process
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Improving your ROIHigh Output low Energy Consumption
• Saving on Energy Cost
Advantages of copper shelledcooling rolls
Cooling water of higher temperature can beused with identical heat transfer timesThe total energy consumption of the chillingunit can be reduced
The Line speed can be increased
Haze and transparency of the film can bebetter influenced
The line capacity can be increased
Optimizing of cast film lines concerningenergy consumption
EAP: Extrusion heat-up program
An intelligent heat-up program copes with individualheating-up times of the extrusion section
Optimizing of cast film lines concerningenergy consumption
REItorque drive technology (EP 1 182 027)Comparsion of extruder construction
520
mm
860
mm
Conventional drive technology REItorque direct drive motorRT 501-1-60-33D-ht
1 = Motor 2 = coupling3 = gearbox
1 = drive motor
RT 501-1-60-33D
• no need for a mechanical gearbox• due to the lack of gearbox, the extruder screw can be removed from the back through the drive
unit• vibration-free operation (no mech. gearbox)• low noise level• backlash-free running• no need for an external fan• free of mechanically wearing parts
• the extruder is almost maintenance-free due to the lack of gearbox and power transmissionbelts
• space-conserving design (approx. 30 % smaller footprint) • small space requirement especially for coextrusion lines• water cooling (heat recovery is possible)• efficiency increased by approx. 8% (mean value)
Optimizing of cast film lines concerningenergy consumption
REItorque drive technologyAdvantages:
Return on investment “direct drive extruder“ from customer‘s viewpoint: Ø 80 – 11000 Nm
Optimizing of cast film lines concerningenergy consumption
= 8,33 Cent / kWh (Energy price)= 1,23 Cent / kWh (Energy tax)= 8000 h / a (production hours per year)
kW11,75=)92,01( 98,0 · 9550
125·11000−VP =
a/ €8.986=94.000 · 0,0956 W· K ages =VK =
8000 · 11,75 t· P aV =aW = kWh94.000=
= 11000 Nm (Motor torque)= 125 min-1 (Motorspeed)= 0,98 (cos φ Motor)= 0,92 (cos φ gearbox)
kWhCent / 9,561,238,33K K StK =+=+gesK = kWh/ €0,0956=
StKKK
att2nt2M
ϕηGη
VP = )1( · 9550 · t2t2
GnM ηηϕ
−
a / € 8.986 KV =
Please remember!Savings on total Production Cost
CF -V18
Key Elements of production costs
resin
down time
interest
energy
labour costs
Can High Output and Low Energy Consumptionbe married ?
Reifenhäuser says: YES they can
Improving your ROIHigh Output low Energy Consumption