CDS R-O2 Presentation - Ceramics & Refractories
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- 1. CDS GROUPRO2 Drying Presentation forRefractories, advanced ceramics & allied products.
2. CDS GROUP the history Privately owned and formed in 1983. Based in StokeonTrent, England. 80 people employed throughout the CDS Group, covering:SalesDesignEngineeringFabrication, and InstallationCommissioning Annual Group Turnover of $20,000,000.00 US Dollars. Accredited to ISO 9001/2000. 3. CDS GROUP the team 4. CDS GROUP capabilities Design, consultation and feasibility study. From small scale engineering design to full turnkey packages.Flexibility of contract structure. Complete Supply from the UK. Local manufacture and equipment supply.Complete installation and commissioning service.After sales service from the UK.Research & Development facilities. 5. What is RO2 Drying? RO2 Drying is a method of drying which uses dry superheated steam at atmospheric pressure to perform the drying process.RO2 Drying is safe to operate, easy to control (only temperature is controlled & not humidity) & offers ultra fast drying times with high thermal efficiencies. RO2 Drying Advantages include:Reduction in process drying timesReduction of energy requirementsHigh thermal efficiencySmaller Footprint requiredMinimal exhaust emissions to atmosphere. Traditional stack is not needed.Energy recovery potentialVirtual elimination of the potential explosion and or product combustion risk 6. How Does Steam Replace air? The steam is generated from the moisture contained only within the product. When water boils & becomes steam its volume increases by a factor of 1,670. As the water evaporates, each Kg of water occupies a volume of 1.67 m3 RO2 Dryers operate on full recirculation so no new air is required to enter the system. As both the recirculation mix and the product get hotter, 1.67m3 of increasingly humid air is vented as each Kg of water is evaporated. This process continues until the Dryer is virtually free of air which is replaced with dry superheated steam. 7. How Does Steam Replace air? 8. How Does Steam Replace air? 9. What is the RO2 Drying Cycle? The RO2 drying cycle consists of only 2 phases: The Warm Heat Up Phase between ambient and 100C. The Drying Phase Above 100C. During the Warm Up Phase the small amount of water evaporated from the product effectively raises the humidity level. This suppresses undue evaporation and allows the product to be rapidly heated to 100C without rapid shrinkage. 10. What is the RO2 Drying Cycle? Additional heating further heats the product and evaporates the remaining water, while the additional steam generated from the moist product continues to be vented from the chamber. Heating continues until the product is dry at which stage ambient air is introduced into the dryer to cool both chamber and products. In summary, the combination of the rapid heating during the warm up phase and rapid moisture removal during the drying phase allows RO2 drying to achieve such substantial reductions in drying times against conventional techniques. 11. What is the RO2 Drying Cycle? 12. What is the RO2 Drying Cycle? 13. Temperature profile in a Continuous RO2 Dryer 14. What Are The Advantages ofRO2 Drying? As the Specific Heat of steam is twice that of air, less Fan power is required to supply a given amount of heat to the moist product. RO2 Drying is more energy efficient because, not only is fresh air excluded from the process (which in conventional Dryers needs heating), most of the Dryers heat input can be usefully recycled, and is typically around 80% of the total heat input. In summary RO2 Drying is aSAFE Drying Methodis more energy efficient andoffers vastly reduced drying times. 15. Schematic Flow DiagramRO2 Drying Process 16. Isometric Drawing of a Typical RO2 Drying Chamber 17. RO2 Drying Chambers 18. RO2 Drying Chambers 19. RO2 Drying Chambers 20. RO2 Drying Chambers 21. RO2 Continuous Systems 22. RO2 Continuous Systems 23. RO2 Dryer in prebuild stage 24. RO2 Processing Systems 25. RO2 Processing Systems 26. Examples of Products DriedRefractory Blocks Refractory Bricks Refractory Bricks Fire Backs 27. Examples of Products DriedTableware Silicon Carbide Tubes De-Nox Catalyst Automotive Catalyst 28. Examples of Products DriedFibre pressed ShapesSteel RefractoryDart heads 29. Examples of Products Dried SanitarywareFibre BoardsInsulators Fibre Boards 30. Examples of Products DriedSlide Gate Products Refractory Shapes Formed Fibre ShapesCrucibles 31. Examples of Products Dried Fused Silica Crucibles Fused Silica Rollers Refractory Block for thefloat Glass Industry 32. RO2 Research & DevelopmentFacilities 33. RO2 Trial Plants We have extensive testing facilities located in Stoke onTrent, UK. These facilities consist of a wide range of RO2 processing equipment which allows us to carry out trials on almost any type of product, producing trialsized quantities of up to 1,000 kg/hr. 34. RO2 Trials Batch Dryer 35. RO2 Trials Chamber Dryer RO2 Trials Batch Dryer 36. RO2 Process Control Systems 37. RO2 Process Control Systems 38. RO2 Process Control Systems 39. RO2 Control Cabinets 40. RO2 Technology Independent Verification 41. End User Proximate Energy SavingsIndependent Bodies found Potential End User ProximateEnergy Savings of 45% when using RO2 Technology: (556Development of an Energy Efficient System to Reduce the Costof Drying Food and Food Waste WREEED, CORDIS RTDProjects / European Communities FP5 Project Record) 42. Independent Verification `Energy Efficiency Best Practice Programme (UK) Future Practice Final Report 58 by ETSU, Harwell, Didcot, OX11 0RA, acting on behalf of the DETR 1997. Found: RO2 Drying offers energy consumption savings over industry survey averages of between 60% and 85%. `RO2 Drying for Ceramic Products Ceram Research Report KAIRIV Final Project Report, J. Fifer (Project Manager) and T. Evans (Report) 1996: Found: Savings relating from shorter cycle times and or reduced product damage; Savings achievable by full reuse of the RO2 Dryers exhausted steam energy and or use of its flue gas energy CERAM 43. More Independent Verification `556 Development of an Energy Efficient System to Reduce the Cost of Drying Food and Food Waste (WREED) CORDIS RTDPROJECTS / European Communities FP5 Project Record. Found: the potential to save up to 75% of the current energy loss. Utilising a non pressure steaming approach, with a unique sealing method for continuous production with features for maximised energy efficiency. `RO2 Drying Trials for Calcium Silicate Boards, Cape Calsil Systems Ltd 1999. Found: using superheated steam as the heat transfer medium, enhanced heat transfer performance, relative to air and because RO2 drying has the added virtue of virtual `no air being present, there is an enhanced product quality.CapeCalsil Systems Ltd 44. RO2 References Worldwide Dutch Govt Kermansavi Calortec SeShin Palmex R.S.I. Morgan MatrocKanthal Cookson Mathey Vesuvius Ideal Standard Parkinson Spencer Refractories IFGL & MIR GlobalDyson Refractories Incesa StandardHarbison Walker Villeroy & BochMorganite Crucible Kohler Sanimex Morgan Thermal Steelite plc Hepworth Refractories Dudson plc Carborundum Vista Alegra Ceradyne Pfalzgraph Norton Ceramics Harbison WalkerDiamond Refractories Swell CorporationAcme Marls American Standard Aguascalientes Cape Insulation Jacob DelafonCERAM Celtek ECU Promat Doncasters National Metalurgical Laborities Skamol Marine System Technology 45. CDS GROUPWhere there is NO COMPROMISE when it comes to. QUALITY & RELIABILITY