TPT March 2009

T echnology U pdate

Complete systems for energy efficient pipe production

Cincinnati Extrusion GmbH, Austria, presented its new KryoSys system for manufacturing polyolefin pipes at the company’s in-house pipe symposium in Vienna. Cincinnati claims that the system can reduce energy consumption by up to 30 per cent. The gain in efficiency with KryoSys is achieved by the combination of a high- speed extruder with a newly developed pipe die, an efficient pipe cooling section and a heat recovery system. Kryosys lines lend themselves to the production of smooth mono-layer and multi-layer PE or PP pipes with diameters ranging from 110 to 2,000mm. They are also suitable for the production of corrugated pipes. The length of the cooling section can be halved compared to conventional extrusion lines, even for large pipe diameters. For example, a total length of 40m is sufficient to produce a 400mm PO pipe with a wall thickness of 36.4mm, using a Monos+ 90-37G extruder. On the assumption of an identical output level of 1,300kg/h, the total length of a comparable, ‘normal’ pipe extrusion line would be 85m. To ensure optimal melt distribution, the KryoS pipe die, specially developed for the system, has been designed on the basis of a spiral mandrel die. The advantage of this particular pipe die is its innovative melt cooling system which makes it possible to start cooling the melt in the die, allowing a substantial reduction in the length of the cooling section. The lower melt temperature also brings about an increase in viscosity at the point of exit from the die, which counteracts sagging, especially in thick- walled pipes. KryoS features a large internal aperture that allows air cooling of the extruded melt. The system is rounded off by a highly efficient pipe cooling section. In this aggregate, the pipe is cooled simultaneously from the outside and the inside by a combination of water and air cooling, which permits a further shortening of the cooling section. With its direct drive, the Rapidex high- speed extruder operates with a high level of energy-efficiency. There is a reduction in the number of vacuum and spray cooling baths required for the downstream aggregates and the optimised cooling system consisting

 The newly developed KryoS pipe die is a core component of the KryoSys line, featuring a melt cooling system in the pipe die

of water and air cooling. This means that energy consumption can be cut by up to 71kW (about 27kW is saved by the reduction in circulation pumps, and about 44kW is saved by less water circulation). Another source of energy savings is the use of heat released by the pipe cooling system in the die. This energy can be used for material pre-heating. The torque of the

extruder can be reduced, resulting in energy savings of up to 95kW. By combining all of these measures, Cincinnati claims that a total reduction in energy consumption of roughly 186kW can be achieved. Cincinnati Extrusion GmbH – Austria Fax : +43 1 61006 266 Email : steger.c@cet-austria.com Website : www.cet-austria.com

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