APP seminar Advanced Material Handling Solutions

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2 APP seminar Advanced Material Handling Solutions Subhabrata Sarkar Country Manager Sales Page 2 - APP Seminar:2015: Advanced Material Handling Solutions

3 Family tree Page 3 - APP Seminar:2015: Advanced Material Handling Solutions

4 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 4 - APP Seminar:2015: Advanced Material Handling Solutions

5 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 5 - APP Seminar:2015: Advanced Material Handling Solutions

6 Considerations to define a pneumatic conveying systems Before one can define and select a pneumatic conveying system the following questions need to answered What are the goals of the material transfer system? What are the priorities of the individual targets inside the overall goal? How do we strike a balance between As good as possible, AND as good as needed? Page 6 - APP Seminar:2015: Advanced Material Handling Solutions

7 Considerations to define a pneumatic conveying systems To function correctly, a pneumatic conveying system... Must have the proper amount of material feeding into the system. Must have the proper amount of conveying gas in the system. Must be able to overcome the restrictions between the start and end of the system. Page 7 - APP Seminar:2015: Advanced Material Handling Solutions

8 Considerations to define a pneumatic conveying systems In addition, to work optimally Consider the gas temperature / product temperature Use suitable materials of construction Make sure the convey line geometry & components (particularly bends) are suitable. Page 8 - APP Seminar:2015: Advanced Material Handling Solutions

9 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Pellets Powder Fibers Recycled material Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 9 - APP Seminar:2015: Advanced Material Handling Solutions

10 Material aspects Test Your Materials for Optimum Results Pellets Powders Recycled material Glass Fiber Page 10 - APP Seminar:2015: Advanced Material Handling Solutions

11 Material aspects Bench Test for Material Evaluation A Bench Test usually only requires less than 5 Liters of bulk material and gives us the material characteristics and data required for SIZING and equipment SELECTION! Bulk Density Flow Angles Sieve Analysis Can Velocity Terminal Velocity Bulk Velocity Fluidity Abrasion Particle Shape Characteristics Visual Observation In most cases a Bench Test avoids a full scale test! Page 11 - APP Seminar:2015: Advanced Material Handling Solutions

12 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 12 - APP Seminar:2015: Advanced Material Handling Solutions

13 Types of MH systems Material Handling With Different Types of Pneumatic Conveying Continuous Vacuum System (Dilute Phase) Continuous Pressure System (Dilute Phase) Vacuum Sequencing (Dilute Phase) Batch Pressure System (Dense Phase) Continuous Pressure System (Dense Phase) Page 13 - APP Seminar:2015: Advanced Material Handling Solutions

14 Types of MH systems Several choices for pneumatic conveying phases Slow motion Dense phase Strand phase Dilute phase degradation gas velocity [m/s] Page 14 - APP Seminar:2015: Advanced Material Handling Solutions

15 Types of MH systems Continuous Dilute Phase Vacuum and Pressure Conveying Proper air flow sizing for Positive Displacement blower Altitude considerations Conveying velocities Temperature considerations Calculating back pressure correctly Pressure systems are typically metered with a rotary valve. Proper sizing of Air Separator for continuous duty. Understanding the total volumetric rate of gas Proper gas-to-cloth ratios Can velocity considerations Page 15 - APP Seminar:2015: Advanced Material Handling Solutions

16 Types of MH systems Coperion K-TRON refilling systems Vacuum sequencing: cost-effective refill of LIWF Sequence valves closed Receiver 1 Receiver 2 Pump active Secondary filter Bypass valve in vent position Discharge valve closed Page 16 - APP Seminar:2015: Advanced Material Handling Solutions

17 Types of MH systems Vacuum Sequencing Systems Powder Design considerations Works in a batching mode with short draw/dump cycles. Minimal equipment stack-up. Can be used for both powders and pellets. Typically designed for rates that fit in a 80mm - 100mm convey line size. Very high gas-to-cloth ratios for short periods of less than 1 to 2 minute draw cycles. Easily equipped with gravity or powered operated discharge gates. Motive gas source is flexible for venturi, regenerative blowers, or positive displacement blowers Often used to refill feeders or small bins. Must consider that it is not continuous - needs time to dump and possibly pulse-clean the filters. Can be operated in dilute or dense phase mode Pellet Page 17 - APP Seminar:2015: Advanced Material Handling Solutions

18 Types of MH systems Continuous dense phase conveying Design considerations It is a continuous operation allowing process equipment to run interrupted or require surge capacity at the source Can be designed to naturally or artificially for slugs in the convey line Typically under 3 bar capacity Can deliver smooth, slow flowing material pneumatically Used on abrasive materials or materials where degradation is an issue. Effective to reduce product degradation. Dense phase slow motion conveying by pressure CONTI-SCHUB with wear-protected rotary valve. Page 18 - APP Seminar:2015: Advanced Material Handling Solutions

19 Types of MH systems Dense phase slow motion conveying by vacuum Developed for compounding plants: VACU-TAKT Gentle vacuum dense phase conveying with 2 8 m/s Simple concept Low space requirements at supply point (often under classifier) Distances up to 70 m, capacity up to 10 t/h Optional with wear protection (e.g. for glass fibers) Product supply Continuous predosed Air intake Vacuum pump with frequency converter Air intake Bypass Vacuum conveying vessel with filter Product discharge Page 19 - APP Seminar:2015: Advanced Material Handling Solutions

20 Types of MH systems Closed looped designs with N2 to prevent moisture exposure or mitigate explosion risks Filter Receiver Design Explosion Relief Panel Grounded Filter Cartridges Stainless Steel rotary valve to prevent metal to metal sparking Block-Off and Bleed Valves Exhaust fan to reduce system back pressure O2 Sensor Design Tunable Diode Laser Spectroscopy sensor Sampling Pump, for pulling from a non-atmosphere pressure line 4-20 ma signal, 0-100% O2 sensing range Backup sensor for redundancy N2 balancing valve to adjust nitrogen feed Page 20 - APP Seminar:2015: Advanced Material Handling Solutions

21 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 21 - APP Seminar:2015: Advanced Material Handling Solutions

22 Equipment: Receiver Coperion K-TRON refilling systems I Compact modular design Capabilities: Receivers are designed to handle powder, pellet, regrind, or granular materials. The modular designed receivers allow flexibility in the selection of material construction, filtration, and receiver inlet sections to meet the application requirements. Standard Features: Aluminum or Stainless Steel Pellet Modular design with a selection of filtration media Single or Dual inlets Powder Page 22 - APP Seminar:2015: Advanced Material Handling Solutions

23 Equipment: Receiver Coperion K-TRON refilling systems I Venturi loaders Venturi Loader Configurations: Cost-effective, compact alternative for loading applications Venturi power unit utilizes compressed air to create vacuum Eliminates need for separate vacuum blower package Page 23 - APP Seminar:2015: Advanced Material Handling Solutions

24 Equipment: Feeder Feeders and how they interact with pneumatic conveying equipment Design considerations Best to refill loss in weight feeders quickly. During the feeder fill cycle it is in volumetric mode. Material flow properties are critical. Feeders need to be vented during their refill cycle. Pulse-cleaning from receiver above or dust vent can affect accuracy. Best is receiver volume and feeder hopper volume are close in size to minimize over filling. Receiver can discharge during it s draw cycle if it is equipped with a rotary valve. Otherwise it will have to stop conveying to discharge. Loss in Weight Screw Feeder Weigh belt Page 24 - APP Seminar:2015: Advanced Material Handling Solutions

25 Equipment: Feeder There are two basic feeding principles Volumetric (volume flow) Gravimetric (mass flow) G t G2 G1 G Refill hopper Refill hopper t1 t2 t G = G2 - G1 t = t2 - t1 Refill device Feeder controller Refill device Feeder controller Load cells Weight signal Meteringzone Speed Meteringzone Speed Drivecommand Drivecommand Page 25 - APP Seminar:2015: Advanced Material Handling Solutions

26 Equipment: Feeder The Smart Force Transducer (SFT) offers... F Vibrating wire measurement technology Resolution 1: Built-in microprocessor One-time calibration at factory Noise-free signal transmission Fast sampling time (112 samples/sec.) High short-term accuracy in any conditions Not affected by vibrations Weight (g) Weight (g) GND Conventional Weighing Technology Frequency (Hz) K-Tron SFT II Output With Digital Filtering Frequency (Hz) Page 26 - APP Seminar:2015: Advanced Material Handling Solutions

27 Coperion rotary and diverter valves for pneumatic conveying Rotary Valves Powder < 1 mm Pellets 1-10 mm ZXQ ZAQ ZXD ZRD ZKD ZVH ZVB ZVD ZGM Pressure [bar] 3,5 3,5 1,5 1,5 1,5 3,5 1,5 1,5 Diverter Valves Pellets and Powder Pellets WZK WHK WHT WGV DWR WYK WEK WET Principle Pressure [bar] 4/ >> The right component for each pressure, application and conveying product Page 27 - APP Seminar:2015: Advanced Material Handling Solutions

28 Coperion rotary and diverter valves for pneumatic conveying ZRD - Discharge and metering valve Large inlet / outlet Outboard bearings Without restriction of the cross section for the highest capacity Separated from product by purged seal arrangement and product drop out opening Page 28 - APP Seminar:2015: Advanced Material Handling Solutions

29 Coperion rotary and diverter valves for pneum. conveying Blow through rotary valves - ZXD Large inlet Without restriction of the cross section for the highest capacity Outboard bearings Separated from product by purged seal arrangement and drop out opening Blow-through channel Optimal pocket sweeping at low pressure drop Page 29 - APP Seminar:2015: Advanced Material Handling Solutions

30 Coperion rotary and diverter valves for pneum. conveying Accessories and options for rotary valves Chamfered blades - Reduction of the surface by relief grinding - Decrease of the friction with powders Scraper blades - Scraper blades for scraping of build-ups in the housing bore - Used for adhesive and sticky products Shallow pockets (F-Design) - For better discharge performance or volume reduction - Used for adhesive and slightly cohesive products Seal purge - Gas purged labyrith rings to protect the shaft seal at open end rotors The optimum accessory according to the application Page 30 - APP Seminar:2015: Advanced Material Handling Solutions

31 Special features for gentle conveying of the product ZVB/ ZVD Anti chopping inlet geometry Reduces destruction of the conveying product Reduction of dust generation Page 31 - APP Seminar:2015: Advanced Material Handling Solutions

32 Equipment: Separator Cleaning of pellets by elutriation Horizontal Fluidbed Separator HFS Product Integrated dosing valve Wash Air Fluidised bed Throughputs from 750 kg/h Easy to retrofit due to low installation height of 635 mm Page 32 - APP Seminar:2015: Advanced Material Handling Solutions

33 Equipment: Cooler / Heat-Exchanger Cooling of strand pellets I Bulk materials heat exchanger BULK-X-CHANGE product buffer product distribution plate heat exchanger mass flow cone Page 33 - APP Seminar:2015: Advanced Material Handling Solutions

34 Equipment: Cooler / Heat-Exchanger Bulk materials heat exchanger BULK-X-CHANGE Cooling of strand pellets prior to bagging Integration of a BULK-X-CHANGE into 2 suction conveying systems Advantages compared to other solutions: free positioning closed system no vapors no noise emission no product degradation The Bulk-X-Change can also be applied to reduce surface humidity. Page 34 - APP Seminar:2015: Advanced Material Handling Solutions

35 Equipment: Controls Page 35 - APP Seminar:2015: Advanced Material Handling Solutions

36 Equipment: Controls Page 36 - APP Seminar:2015: Advanced Material Handling Solutions

37 Equipment: Ancillary Equipment Considerations Convey line accessories Elbows and connections Design considerations Elbows add pressure drop to dilute phase systems, but have less effect in dense phase systems Gamma bend elbow design can reduce angle hair formation Pipe line joint can be designed to reduce ledges. Impact edges depending on assembly tolerances Chamfering reduces impact edge Male/female flanges lead to no impact edges Page 37 - APP Seminar:2015: Advanced Material Handling Solutions

38 Agenda Considerations to define a pneumatic conveying systems Material aspects Bench test Types of MH systems Dilute phase Vacuum Sequencing Dense phase Close loop design Components and equipment Receiver Feeder Valve Separator Cooler / Heat-Exchanger Controls Ancillary Equipment Considerations Complete plant design Compounding plant Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 38 - APP Seminar:2015: Advanced Material Handling Solutions

39 Compounding complete plants from one single source Content Compounding plants Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 39 - APP Seminar:2015: Advanced Material Handling Solutions

40 Compounding Plants Key equipment compounder pelletizer feeders and refill systems classifier materials handling automation steel structures bagging & palletizing Page 40 - APP Seminar:2015: Advanced Material Handling Solutions

41 Compounding plants One envelope for the key elements of the process scope INSTALLATION & COMMISSIONING RAW MATERIAL HANDLING REFILL COMPOUNDER FEEDER PELLETIZER CLASSIFIER FINISHED PRODUCT HANDLING BAGGING & PALLETIZING EQUIPMENT DESIGN PROCESS KNOW-HOW ENGINEERING COMPETENCE PROJECT & SITE MANAGEMENT Page 41 - APP Seminar:2015: Advanced Material Handling Solutions

42 All key elements for compounding from one single source Co-rotating twin-screw extruders Pelletizing systems Bulk materials handling Bagging and palletizing Automation systems Plant engineering Feeding technology Refill systems Vacuum sequencing systems Controls Pellet screening technology Proprietary equipment for the entire process chain Process know-how, competence in engineering and project management Huge installed basis nearly 100 complete compounding lines as reference Page 42 - APP Seminar:2015: Advanced Material Handling Solutions

43 Compounding complete plants from one single source Content Compounding plants Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 43 - APP Seminar:2015: Advanced Material Handling Solutions

44 Modular design 3D model of a ZSK 70 with Loss-in-Weight Feeders and Refill Systems Page 44 - APP Seminar:2015: Advanced Material Handling Solutions

45 Benefits of modular design Safety flexibility mobility Shorter project schedule compounding line is independent from the building module and building can be built in parallel Fast installation and commissioning pre-tested in workshop Easy to ship dimensions within standards for road and ship Easy to relocate quick disassembly and re-assembly Globally available Coperion produces modular plants in Europe (Stuttgart), China (Shanghai) and North America (Ramsey) React flexible to market changes Page 45 - APP Seminar:2015: Advanced Material Handling Solutions

46 Compounding complete plants from one single source Content Compounding plants Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 46 - APP Seminar:2015: Advanced Material Handling Solutions

47 Example for a compounding plant Pre-installation of modules at Coperion Stuttgart ZSK 133 and ZSK 70 Page 47 - APP Seminar:2015: Advanced Material Handling Solutions

48 Example for a compounding plant Installation of Modules on Site Page 48 - APP Seminar:2015: Advanced Material Handling Solutions

49 Example for a compounding plant 2 lines from pre-hopper to pelletizing Page 49 - APP Seminar:2015: Advanced Material Handling Solutions

50 Raw materials handling Premix transportation and feeding Page 50 - APP Seminar:2015: Advanced Material Handling Solutions

51 Finished product handling Bagging silos and blower room Page 51 - APP Seminar:2015: Advanced Material Handling Solutions

52 Removal of dust Central aspiration system Page 52 - APP Seminar:2015: Advanced Material Handling Solutions

53 House keeping Vacuum cleaning system Page 53 - APP Seminar:2015: Advanced Material Handling Solutions

54 Compounding complete plants from one single source Content Compounding plants Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 54 - APP Seminar:2015: Advanced Material Handling Solutions

55 From the process scope to a complete plant The LSTK scope: services and supplies beyond the process scope LSTK scope power supply civil works steel structures infrastructure process scope HVAC drain system exhaust air treatment buildings& facilities plant utilities Page 55 - APP Seminar:2015: Advanced Material Handling Solutions

56 From the process scope to a complete plant The larger envelope BUILDING CIVIL POWER SUPPLY UTILITIES INFRASTRUCTURE INSTALLATION & COMMISSIONING INSTALLATION & COMMISSIONING RAW MATERIAL HANDLING REFILL COMPOUNDER FEEDER PELLETIZER CLASSIFIER FINISHED PRODUCT HANDLING BAGGING & PALLETIZING EQUIPMENT DESIGN PROCESS KNOW-HOW ENGINEERING COMPETENCE PROJECT & SITE MANAGEMENT CONSTRUCTION & DISCIPLINE MANAGEMENT PERMIT ENGINEERING

57 Integration of process and LSTK scope Decreasing cost saving potential during project lifetime The smart, optimized and balanced concept offers the maximum savings The conceptual phase is the essential one! Page 57 - APP Seminar:2015: Advanced Material Handling Solutions

58 Compounding complete plants from one single source Content Compounding plants Modular design Example for a compounding plant Integration of process and building Complete compounding plants by Coperion Page 58 - APP Seminar:2015: Advanced Material Handling Solutions

59 LSTK jobs around the core business of Coperion The qualification of Coperion In-house development and design of core equipment and processes In-depth know-how of own and related process and equipment packages Focus on process optimization and total system integration Project management and engineering competence in all relevant disciplines Coperion is qualified to build a complete plant around its core business Page 59 - APP Seminar:2015: Advanced Material Handling Solutions

60 Complete compounding plants by Coperion Maximum benefit for the customer First-class equipment with technological edge Optimized process chain Perfect integration of process and LSTK scope Cost-efficient complete solution One partner for concept realization service Start of production on spec on time in budget Page 60 - APP Seminar:2015: Advanced Material Handling Solutions

61 Thank you very much for your attention.