High performance solid steel belt casting systems

Transcription

1 High performance solid steel belt casting systems Film casting

2 From Sandvik: the total solution to your film Feed end of seven steel belt casting systems If your products demand precise, close tolerance casting of sheet, film, and slabs Sandvik has the total-package solution: a system designed and built to meet your process parameters... to deliver high efficiency and productivity. We start with a major advantage: the Sandvik solid steel belt.the belt is made from solid strip, welded to an endless loop, available in various grades of stainless as well as carbon steel with a choice of surface finishes ranging from mill finish to super polished finish. To the process enhancing characteristics of the Sandvik casting system, we add versatility of heat transfer method and modular construction to deliver process lines backed by the assurance of Sandvik s total quality commitment and decades of application know-how. We re ready to put this unrivaled experience to work for you to add real value to your production and to your product. 2

3 casting demands Sitting and cutting system for cast foil The perfect casting process for every product The unique properties ot the steel belt and the versatility of construction and casting method ensure that a Sandvik casting line can be delivered to meet the widest range of product and process specifications for products, such as: Acetate films Acrylic sheets and slabs Cellulose triacetate Ceramic films Composites Films Foam rubber slab Micro-porous membranes Plastics Polyimide film Polymers Polypropylene sheet and slab Polyester slab Polyurethane sheet Polyvinyl alcohol film Polyvinyl chloride film Reconstituted tobacco foil Sheet Slurry & paste food Magnetic storage media Rubber sheet Rubber slab Check these process plus points Polymeric film can be solution cast to close tolerances, high clarity and low built-in stress. Powders can be sintered to sheet for use, e.g. as microporous membranes. Counter tops can be cast continuously. Temperature can be controlled with both heating and cooling for products with exotherm reactions. Reconstituted tobacco can be cast and gently dried to thin sheets. Sandvik casting lines provide continuous processing... maximum output and productivity. The Sandvik solid steel belt provides complete support during casting for high tolerances and quality casting. The Sandvik solid steel belt can be provided with super polish finish for optical type and very thin film. Sandvik casting lines are built to match your needs using the most appropriate form of heating method so your process parameters can be most precise. Modular construction adds even more versatility, enables temperatures and humidity profiles to be zoned during processing... you get precise product control with no wasted energy costs. Construction is simple and uses few moving parts... you get maximum uptime from minimal maintenance. Sandvik casting lines are low on energy consumption, high on reliability... whatever your product, you get the benefit on the bottom line. 3

4 Here s how we put your Process versatility Sandvik casting lines can be configured with different casting techniques and characteristics to ensure that performance requirements can be most precisely met. This system is widely used for casting of liquids, slurries and paste. The system can be engineered to suit various products and process requirements. A multiple zone concept is often used to facilitate varying process conditions from zone to zone. Process requirements and limitations, e.g. in temperature, humidity and airflow, during different parts of the process are accommodated by the multi-zone approach. Some products are thermosensitive and have to be handled in a low temperature, gentle process while with less sensitive products, a higher temperature, rapid process can be used. During certain parts of the process, humidity control may be required to avoid skinning of the product, leading to extended process times and off-spec quality. In addition to temperature and humidity, the drying rate may also be limited to the amount of air flow and turbolence the product can withstand. Different process heating arranggements to match your product requirements 1. Steam tanks under the belt and air nozzles above. 2. Zones with steam tanks under the belt and air nozzles above. 3. Steam tanks under the belt and longitudinal air flow. 4. Steam tanks under the belt and air nozzles above Air nozzles under and above the belt. 6. Air nozzles above and steam tank below. 7. Longitudinal ventilation and steam tank under the belt 4

5 product in perfect shape Here s how we get your product in perfect shape Sandvik casting lines are built to specific requirements.they are modular in construction and continuous in operation, with casting systems and zones provided to match process parameters as economically and efficiently as possible. A typical unit consists of: a feed terminal with a continuous casting head/system a Sandvik solid stainless steel belt an insulated tunnel enclosure modular process section with heating or drying modules discharge terminal with stripping/ offloading devices The product can be continuously cast in the form of slurry, liqid, extrudate or a continuous sheet onto the steel belt and Heating section showing steam tanks under the belt and air nozzles above evaporated and exhausted. Alternatively, infrared radiation can be used formed to a thin layer at close tolerances. A variety of casting devices are available to suit particular applications. The process section consists of a number of modular sections with heating, drying or cooling elements. Depending on the required process several methods can be combined. Hot air can be fed on top of the product through a series of nozzles or finger ducts, and then recirculated through a heat exchanger. Air temperature and velocity are controlled. Solvent can be The belt itself can be heated from the underside with hot air, hot water, steam or infrared radiation. Accurate temperature control, and uniformity of heating/cooling reduces tension in the product to an absolute minimum. Heating can be direct with gas or oil-fired burners or indirect through oil or steam heated heat exchangers or electrically heated elements. Discharge at the end of the casting line may be simple, with the product being released naturally as the belt passes around the drum. In some cases a stripping roller or a doctor blade will be utilized. The insulated tunnel enclosure design will depend on the application and is usually designed for easy access, to facilitate cleaning and maintenance. Consideration is given to factors such as the product, cleanliness and cleanability in connection with film products, hygiene and avoidance of noncompatible materials.

6 From Sandvik: a world of experience The steel belt is at the heart of our casting systems Casting box feeding system for thin foils The Sandvik steel belt: the heart of our high performance casting lines The Sandvik steel belt provides the perfect conveying medium through our casting lines. Its hard, smooth surface is tough and durable, yet gentle on your product. It is hygienic and easy to clean as it passes around the end drive-drum, and product is easily discharged without damage. Excellent heat conductivity and outstanding mechanical properties give it a long, trouble-free life, adding value to your drying process. High quality plus high productivity in one high performance package Sandvik process systems is a world leader in the application of leading-edge steel belt technology to all kinds of industrial processing.we are ready to work with you to design and engineer the system that puts added value performance into your product to contribute to your quality and product differentiation. 6

7 in steel belt casting Process visualising system Cooling section and discharge terminal Quality: our mission Quality is a way of life at Sandvik process systems. In the quest for continuous improvement and the highest levels of excellence, we constantly challenge ourselve to find better ways... better designs... better materials... better systems and services, to better meet the needs of our customers, anywhere in the world. ISO 9001 certification provides documentary evidence of this quality commitment.you will find it made real in the systems we deliver, and in the performance of our people: a total quality orientation aimed at giving you the competitive edge. Put us to the best... on your product Our application and design engineers are ready to discuss and analyze your particular problems.together with you we will work out the specifications for a system meeting your particular requirements. Our test centers around the world are available for developing small scale feasibility and larger scale process simulations.this together with our experienced personnel will assure you that your system is built on the best experience. Our analysis will make positive recommendations for the best casting, thermal processing, and finishing methods and how we can make a real contribution to your product and process enhancement. The package deal Sandvik brings you a single source of supply for your casting line.working with you, we will put together a system that starts with raw material handling, extends through the total casting line, and ends with finished product ready for packaging. Our aim is simple: to give you a total solution to your casting process demands... efficiently, effectively, and economically. Our service doesn t end when your line has been commissioned. Our global service organization gives you the reassurance of expert, total support... whenever and wherever it is needed. It is all a part of our total service philosophy: dedicated to delivering peak performance to our customers. Sandvik process systems is approved to EN ISO 9001:2000 and ISO environmental management the international recognition of highest standards and practices. 7

8 Base materials and final products treated on Sandvik steel belt casting systems PS-416 / ENG Printed in Germany