Plant Layout

The economical design of your
infrastructure
Kurtz GmbH
03.09.00.smvs-mb/jd-us
In-house fair 2002
page 1
Plant layout
1 Pre-expanding
2 Silos
3 Steam generation plant
4 Compressed air plant
5 Cooling water supply
6 Shape moulding machines
7 Recycling plant
8 Extruder
5
4
Kurtz GmbH
In-house fair 2002
page 2
Plant layout
Media
Steam
Water
Air
Vacuum
Electricity
Kurtz GmbH
In-house fair 2002
page 3
Plant layout
Steam supply
Steam
Kurtz GmbH
In-house fair 2002
page 4
Plant layout
Steam supply
Chimney
Pressure reducing
valve 0.2-1.2 bar
Feed water tank

Locking valve
Steam boiler
To shape
moulding
machines
Water
conditionin
g plant
To preexpander
Pressure reducing valve

Main steam line
Kurtz GmbH
In-house fair 2002
page 5
Plant layout
Steam supply, steam boiler
Taking out of steam

in batches
Steam consumption
during purging and autoclave steaming higher than
capacity of generator (steam boiler)
Kurtz GmbH
In-house fair 2002
page 6
Plant layout
Steam supply, principle steam accumulator
Energy output by opening of steam valves:

low evaporation temperature
water evaporates abruptly by pressure decrease
Baffle sheets
Steam pipe
Steam
Water level control
Water
Steam from boiler
Kurtz GmbH
In-house fair 2002
page 7
Plant layout
Steam supply, pipes
Steam pipe
Steam velocity 25 m/s
Kurtz GmbH
In-house fair 2002
page 8
Water quality
Conditioning of the boiler feed water

Aim:
to eliminate negative effect of water components
Negative components:
lime (water hardness)

iron
silicates
oxygen
carbon dioxide
Kurtz GmbH
In-house fair 2002
page 9
Water quality
Conditioning of boiler feed water
Optimum temperature of feed water between

95 and 110 C
Feed water tank designed as degassing station

(pressure 0.2 0.6 bar)
Removal of the gases responsible for corrosion

(CO2 + O2)
Kurtz GmbH
In-house fair 2002
page 10
Water quality
Kurtz GmbH
In-house fair 2002
page 11
Water quality
Corrosion - Carry Over, example
Corrosion at
steam chamber,
2 years old !
Kurtz GmbH
In-house fair 2002
page 12
Water quality
Steam outlet:
original material
thickness 15 mm,
in this case only
3 mm !
Kurtz GmbH
In-house fair 2002
page 13
Water quality
Kurtz GmbH
In-house fair 2002
page 14
Water quality
Steam chamber useless because of corrosion

Cause: Carry Over of steam accumulator
Kurtz GmbH
In-house fair 2002
page 15
Water quality
Corrosion - Carry Over
Carry Over caused by...

1. High decrease of pressure in accumulator or boiler
2. Unfavourable removing outlet at accumulator or boiler
3. Pipe diameter too small
Kurtz GmbH
In-house fair 2002
page 16
Water quality
Indication and increase of Carry Over effects in case of ...

unusually strong corrosion
excessive conductivity values of the condensate
boiler or steam accumulator not regularly cleared from mud
frequent stand-still times of machines
Kurtz GmbH
In-house fair 2002
page 17
Water quality
How a Carry Over is indicated and noted

recommended conductivity value for boiler:
< 5 mS/cm
recommended conductivity value accumulator:
<< 1 mS/cm
(theoretical conductivity inside the accumulator
= 0 mS/cm)
at a sample temperature of 25 C
recommended pH value boiler water:
between 8 and 9
condensate has pH value of 7

region 1 - 7:
acid
(drags at finger test)
region 7 - 14:
alkaline/soapy
(smears at finger test)
Kurtz GmbH
In-house fair 2002
page 18
Water quality
4. Regular measuring and control of the water values of the plant
measuring of
total hardness
of water
pH - value
measuring
conductivity
measuring
measuring
content of
ferrous metals
Kurtz GmbH
In-house fair 2002
page 19
Plant layout
Water supply
Water
Kurtz GmbH
In-house fair 2002
page 20
Plant layout
Water supply
Water is required for:

Condenser cooling
Mould cooling
Vacuum pumps
Steam generation
Kurtz GmbH
In-house fair 2002
page 21
Plant layout
Water supply
Cooling tower
Cooling water
circulation pumps
Water circuit
Condenser and vacuum
pumps
Water pressure
tank
Fresh water
supply
max.
min.
Hot water cycle for

mould cooling
Level switch
Hot water 50C

Pumps for
hot water
Overflow
Pumps for cold
water
Cold water 25C
Kurtz GmbH
In-house fair 2002
page 22
Plant layout
Water supply
Optimum:
2 Water circuits
Hot water circuit
Cold water circuit
50C
25C
to cool moulds
to cool condenser
seal water for vacuum
pumps
Kurtz GmbH
In-house fair 2002
page 23
Plant layout
Water supply
Advantages of 2 water circuits

Reduced water consumption
Faster temperature decrease at mould
Reduced cooling tower capacity
Dryer mouldings
Kurtz GmbH
In-house fair 2002
page 24
Plant layout
Water supply
Principle of heat transfer during vacuum cooling

Phase 1:
Aluminium plate (hot) under steam atmosphere

(condition of steam chamber before cooling)
Steam
Kurtz GmbH
In-house fair 2002
page 25
Plant layout
Water supply
Principle of heat transfer during vacuum cooling
Phase 2:
Water is injected, (step condensation)
Water injection
Water film
Kurtz GmbH
In-house fair 2002
page 26
Plant layout
Water supply
Principle of heat transfer at vacuum cooling
Phase 3:
Water evaporates under vacuum (stabilization)
Vacuum (< - 0.6 bar)

Water film
Kurtz GmbH
In-house fair 2002
page 27
Plant layout
Vacuum system
How a condenser works

Steam
Vacuum
Water
Outlet
Kurtz GmbH
In-house fair 2002
page 28
Plant layout
Water supply
Condensate
with
EPS beads
EPS beads accumulate at surface
Kurtz GmbH
In-house fair 2002
page 29
Plant layout
Vacuum supply
Vacuum
Kurtz GmbH
In-house fair 2002
page 30
Plant layout
Vacuum supply
Reasons for the use of vacuum during stabilization :

faster cooling through evaporation
moisture reduction in the mouldings
reduction of stabilization time
shorter cycle times
Kurtz GmbH
In-house fair 2002
page 31
Plant layout
Vacuum supply
Single vacuum
Central vacuum
one or several
pumps at one
machine
central vacuum
station with 4 or 6
vacuum pumps
pumps are running

continuously
some pumps are

running continuously
remaining pumps are
only used when
needed
Kurtz GmbH
In-house fair 2002
page 32
Plant layout
Vacuum supply
Advantages of the central vacuum system:

Vacuum is available much faster
Fewer pumps are required than for single
vacuum
reduced energy consumption
energy saving ~ 30 - 50 %
reduced need for spare parts
Increased production safety
Kurtz GmbH
In-house fair 2002
page 33
Plant layout
Compressed air supply
a
b
9
a
b
4
ir
a
r
ir
a
r
Kurtz GmbH
In-house fair 2002
page 34
Plant layout
Air is required for :

Control air
Fill injector
High pressure
Compressed air in
general
Pressure fill tank
Low pressure
Demoulding
Drainage
Kurtz GmbH
In-house fair 2002
page 35
Plant layout
Kick back valve
Air tank HP
(control and filling air 9.0 bar)
Air tank LP
(Transfer and
ejection air 4.0 bar)
Compressor
HP 9.0 bar
Condensate
outlet
Fresh air
Compressor
LP 4.0 bar
Stand by
compressor
Kurtz GmbH
In-house fair 2002
page 36
Plant layout
Optimum:
2 air circuits
Low pressure
High pressure
3...4 bar
7...9 bar
Demoulding
Control air
Drainage
Filling air
Pressure fill device

Air quality:
clean, dry, oil-free

use filter, oil separator and cooler
Kurtz GmbH
In-house fair 2002
page 37
Plant layout
Specifications for compressed air

Temperature
: < 30 C
Techn. dust-free
: No solid particles > 10 m

particle size
Techn. oil-free
: Content of residual oil < 0,01mg/m
Humidity
: When a cooler is used only

water drops < 3 m are in the
compressed air, low humidity
Kurtz GmbH
In-house fair 2002
page 38
Plant layout
Compressed air water content depending on the temperature
Kurtz GmbH
In-house fair 2002
page 39
Plant layout
Water content in compressed air
Quelle:
Kurtz GmbH
In-house fair 2002
page 40
Raw material and product transport

Ways of conveying
Mechanical transport systems

Pneumatic transport systems
Kurtz GmbH
In-house fair 2002
page 41
Material conveying
Basics
Material transport
Raw material
transport
Transport or pre-expanded
material
To pre-expander
Mechanical
transport
From pre-expander
to silo
Pneumatic
transport
Pneumatic
transport
3
From silo to
moulding machines
Pneumatic
transport
Kurtz GmbH
In-house fair 2002
page 42

Raw material conveying
Careful transport
Avoidance of abrasion of the thin material coating
Avoidance of lumps
Kurtz GmbH
In-house fair 2002
page 43

Raw material conveying to the pre-expander
Material feeding
through suction pipe
air
Material feeding
through hopper
air
fan
dust
separator
fan
dust
separator
material
material
suction
pipe
hopper
octabin
Kurtz GmbH
In-house fair 2002
page 44
Material transport
Ways of conveying
Low loading (1....10%)

EPS share
Air share
Kurtz GmbH
In-house fair 2002
page 45
Material transport
Means of conveying
Packing density (%)
Density (g/l)
Conveying distances (m)
Venturi
Suction
Cellular wheel
0,75 - 1
3 10
8 20
8 20
10 40
10 150
- 10
- 150
- 300
Kurtz GmbH
In-house fair 2002
page 46
Filling methods
Conveying speed
Conveying speed (m/sec)

between 10 u. 16 m/sec
< 8 m/sec danger of clogging
> 18 m/sec density increase
Venturi highest conveying speed
Cellular wheel lowest conveying speed, most careful conveying
Kurtz GmbH
In-house fair 2002
page 47
Cellular wheel sluice

Basic design
Conveying
pipe
Material
Cellular wheel sluice
Fan
Cellular wheel
Kurtz GmbH
In-house fair 2002
page 48

Pneumatic conveying
Injector principle
Material
Fan
Air
Conveying pipe
Kurtz GmbH
In-house fair 2002
page 49

Pneumatic conveying
Suction and conveying via fan
Kurtz GmbH
In-house fair 2002
page 50
Material conveying
Outlet box
Kurtz GmbH
In-house fair 2002
page 51
Material conveying
Discharge of the silos
Even flow
Uneven flow
Kurtz GmbH
In-house fair 2002
page 52
Material conveying
Bridges are built
Wells are built
Kurtz GmbH
In-house fair 2002
page 53
Material conveying
Discharge with uneven flow
Kurtz GmbH
In-house fair 2002
page 54
Material conveying
Pipes
Aim:
From the feeding station to the material processing

place the density has to be kept as constant as
possible!
Kurtz GmbH
In-house fair 2002
page 55
Material conveying
Pipes / pipe bends
Bending radius R = < 2 x D
Bending radius R = > 2 x D
Bending radius = R
Pipe diameter = D
Bending radius = R
Pipe diameter = D
Material accumulation
no material accumulation
no even material flow
Even material flow
Kurtz GmbH
In-house fair 2002
page 56
Material conveying
Pipes
hard pipe fitting
soft pipe fitting
Material accumulation
no material accumulation
no even material flow
even material flow
danger of clogging
Kurtz GmbH
In-house fair 2002
page 57
Material conveying / blowing

Density and conveying distance depending on pipe diameter
Density EPS
[g/l]
P ... const.
i ... const.
30
20
D ... 50 mm
D ... 100 mm
10
D ... 200 mm
100
Conv. distance L [m]

200
Kurtz GmbH
In-house fair 2002
page 58
Material conveying / blowing

Density and conveying distance depending on number of bends
Density EPS
[g/l]
P ... const.
D ... const.
30
20
4 pipe
bends
6 pipe
bends
10
8 pipe
bends
100
Conveying distance L
200[m]
Kurtz GmbH
In-house fair 2002
page 59

Plant Layout

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The economical design of your

In-house fair 2002

In-house fair 2002

In-house fair 2002

In-house fair 2002

Feed water tank

Pressure reducing valve

In-house fair 2002

Taking out of steam

In-house fair 2002

Energy output by opening of steam valves:

Water level control

In-house fair 2002

Steam velocity 25 m/s

In-house fair 2002

Conditioning of the boiler feed water

to eliminate negative effect of water components

lime (water hardness)

In-house fair 2002

Optimum temperature of feed water between

Feed water tank designed as degassing station

Removal of the gases responsible for corrosion

In-house fair 2002

In-house fair 2002

In-house fair 2002

In-house fair 2002

In-house fair 2002

Steam chamber useless because of corrosion

In-house fair 2002

Carry Over caused by...

In-house fair 2002

Indication and increase of Carry Over effects in case of ...

In-house fair 2002

How a Carry Over is indicated and noted

recommended conductivity value accumulator:

(theoretical conductivity inside the accumulator

condensate has pH value of 7

(drags at finger test)

(smears at finger test)

In-house fair 2002

4. Regular measuring and control of the water values of the plant

In-house fair 2002

In-house fair 2002

Water is required for:

In-house fair 2002

Hot water cycle for

Hot water 50C

Cold water 25C

In-house fair 2002

Hot water circuit

Cold water circuit

In-house fair 2002

Advantages of 2 water circuits

In-house fair 2002

Principle of heat transfer during vacuum cooling

Aluminium plate (hot) under steam atmosphere

In-house fair 2002

Principle of heat transfer during vacuum cooling

Water is injected, (step condensation)

In-house fair 2002

Principle of heat transfer at vacuum cooling

Water evaporates under vacuum (stabilization)

Vacuum (< - 0.6 bar)