Professional Documents
Culture Documents
GUIDE 20
September 1991
Mr W R Pollock
Director
' British Rubber Manufacturers' Association
June 1991
GUIDE SUMMARY
PREFACE
GUIDE SUMMARY
1. INTRODUCTION 1
2. PROCESS DESCRIPTION 2
4. THE SURVEY 8
6. ACTION PLAN 18
7. FURTHER INFORMATION 21
1. INTRODUCTION
- 1 -
2. PROCESS DESCRIPTION
- 2 -
- Typical multi-stage mixing process (Natural Rubber)
-
1 NR pre-heat
I
I
I
weigh
I 1
internal mixer for mas1.cal on
I
I dumo milildumo extruder I
I cool
I
II
1
I dum0 mill: sheetina 1
I
I cooler I
store
rL--
nlerna rn /I:secona stage
I
dump mill
I
Store
I
Typical single-stage mixing process
A
I cooler
Store
.
*
Mills can be used for a variety of purposes:
as a dump mill receiving material from the
internal mixer and re-shaping it ready for further
processing;
as an open mixer, though specific energy consumption
is much higher than for an internal mixer;
for the addition of curatives to mixed compounds;
for warming compound to reduce viscosity and
increase workability prior to calendering or
extrusion.
- 4 -
3. ENERGY USAGE AND COST
LPG
1% Fuel Oli
22%
Other Electricit
LPG 17%
1%
ANNUAL COST f 8 0 M
Basis: 4 t h Qtr. 1990 Drices from D.En.
~ Compressed air
*
- 7 -
4. THE SURVEY
.
variables upon which electricity consumption depends includes:
..
method of mixing (internal mixer or mill);
number of mixing stages;
machine size and type;
..
product mix in terms of compound material and
viscosity (including the percentage of NR and CR);
..
batch size and batch time;
control of power input;
..
proportion of master batching;
proportion of blendingjmixing on the two-roll mill;
..
control of ingredient addition;
amount of re-work;
percentage utilisation;
..
frequency of product change and machine
cleaningjwarming;
use of mills for compound heating;
internal mixer and mill cooling efficiency.
- 8 -
No of companies
14
12
10
0
0 - 0.251 0.501 0.751 1.001 1.251 1.501 3.001
0.25 - 0.5 - 0.75 - 1.00 - 1.25 - 1.50 - 1.75 - 3.25
- 9 -
kWh/Kg OF OUTPUT
2
1 3.25
~ . _ _ _ _ ~~.~
- ~ .. -. . . . ~.. ~ ~~ ~
1.5
. .~ . ~ ~ .. . . . . . .. .~.
1
.
0.5
~
0
2 8 10 30 2 8 14 13 2 3 2 7 2 1 1 2 2 4 3 2 9 10 12 18 8 11 0 18 6 2 5 2 2 4 7 8 2 0 16 17
COMPANY CODE
1.5
0.5
40
35
30
25
20
15
10
5 HARDNESS
(IRHD)
-
60
80
06
0
NR SBR NBR EPDM HALOBUTYL CR MlSC
COMPOUND TYPE
- 11 -
Minimum Maximum
Custom compounders 0.32 0.33
Moulding and other products 0.23 1.14
Belts and hoses 0.24 1.45
Tyres 0.37 0.80
Seals 0.20 1.62
Rollers 0.78 3.25
.
- 12 -
MWh/y
42000
. .
.
.
. ........
36000
I
i I
+___
I
l2O0O __. ._
I
Enlarged Below :
MWh/y
3000
2000
!
0
IOOC
C
2000 4000 6000 8000 10000
TONNES / Y
TYRES
aexdudingprbhaatluuel-mptim - 9OWlvbmswlput
b abc pod- other GRG. *mar prehealed
BELTS & HOSES
13 0.30 11 70 2 5 0 5 0
16 a 3000 0.53 12 60 10 10 50 30 10
19 b 4000 0.35 9 150 10 7 9 0 3
20 380 1.45 5 72 1W
23s 6030 0.30 12 135 10 9 3 8 4 5 6
26 137W 0.24 15 203 ea 67 33
L)tignifisantr~mkraquiredon mills belore fuamer pnrsssinp
b voallquan~~loufpufmixed-tMrmallmiib.~metpeheat
-
c a x ~ i n g ~ ~ r p r b h e a t f l l e l m n s u m p t i o1 n
30kVfMon~oupui
SEALS
4 62M 0.33 7 240 12 1 95 4
6 8 m 1.22 9 70 m v.rmall 21 11 4542 1
8 b 350 0.61 3 40 10 5 9 0 5
15 C 330 1.62 6 32 m m 31 32 30 26 12
18 d 180 0.66 15~2 ZL 50 50 60 10 30
24 e 450 1.04 50115 VAR €4 mal1 70 m 10
mi 2000 0.20 10 65 5 20 7 39 42 12
a 50%femilledthrwghdumpmill
b rnbjngonmilboniy,fawmatsrialrn-ter btllched by ohera
c 20%rem~mroughdumpmilion~,cmlinQ~slemproblsMincrsarsSEC
d 50%remkedonmiilsloradditiveadditione
B sdlerhslchesmixedonmiil, 50%rs-mixonmills
lele&isityrnnsumptionruspecf. low
ROLLERS
17 380 3.25 2 50 1W 25 10 53 37
25 250 0.78 4 50 10 90 10 m m
MOULDINGS&OTHER PRODUCTS
7 a 750 1.14 15 52 ea 1W 2 85 13
9b 9w 0.65 8 60 50 2 5 4 4 4 6 5
10 c 2m 0.23 6 70 50 35 5 5 5 5
12 d 2000 0.44 8 70 15 aoall 55 5 3 5 5 5 5
14 e 2030 0.28 9 1W 32 1 9 8 0 11
27 I 1860 0.32 7 115 10 10 103 10 50 30 10
30g 5x0 0.24 10 im 15 30 15 55
52 9 6 4 2 1 6
30 42 42 15
- 14 -
Other important elements of energy consumption for which some
results were obtained from responders were material pre-heat,
compressed air usage and cooling water loading.
Pre-heating, mainly of natural rubber, is carried out to
ensure that there are no crystalline formations in the core of
the block. The two valid responses were from companies using
warm rooms. Fuel consumptions were 0.13 kWh/kg output and
0.09 kWh/kg for 3,000 tonnes and 9,000 tonneslyear of output
respectively. Since rubber needs 0.012 kWh/kg to raise its
temperature from 10°C to 35OC, the best of these two
compounders is 15% efficient in overall terms. Both these
respondents used warm rooms, which are indirectly heated and
have high standing losses; hence the low overall efficiencies.
For compressed air use, the average consumption represented 8 %
of the total electricity consumption. This in turn is
equivalent to 0.05 kWh/kg across all sectors.
Cooling, whilst only a small proportion of total electricity
consumption, at 1.5% or about 0.01 kWh/kg has a much more
significant effect on overall batch cycle time. Cooling water
inlet temperatures vary from once through systems at 10°C to
tempered systems at 35OC. This range results in significant
differences in heat exchange, the higher inlet temperature
providing 20% less heat transfer capacity than the lower for a
similar cooling water temperature rise.
- 15 -
5. OPPORTUNITIES FOR ENERGY SAVING
- 16 -
It may be that chilling could reduce overall electricity usage
by maintaining cycle times around the year. A lower limit on
water temperature will need to be set to prevent condensation
and consequent problems of slip between the compound and the
mixer walls.
Utilisation of exhaust air from the rams or of alternative and
more efficient methods of providing ram power on larger mixers
may be worthwhile.
Milling
Control of mills depends mainly on effectively matching power
supply with demand, minimising power consumption when
operating at no-load conditions and optimising cooling water
system operation as described above.
The main saving is likely to be achieved by switching mill
motor power either down or off. With smaller mills it should
be possible to switch motors off provided they are switched on
in sufficient time to allow the rolls to reach stable working
temperatures. Larger motors may require installation of a
motor controller which will sense low load conditions and
reduce the voltage supply to the motor accordingly.
- 17 -
6. ACTION PLAN
Material
pre-heat
. Use well sealed and insulated
rooms or chambers for holding
. polymer.
Separate polymer blocks to allow
S
.
circulation of warm fluid to the
largest possible surface. S
Employ fully recirculating warm air
.
systems where these are in use or
proposed. S
.
Control pre-heat temperature (in
warm rooms or chambers). S
Store polymer outside the heated
.
container in closely packed blocks
to limit heat loss. S
Check heater efficiency on a weekly
.
basis using a portable efficiency
monitor. S
..
Consider the use of microwave pre-
heating. L
Heat extender oils. L
Employ waste heat if available from
other site operations for pre-heat
duties. L
- 18 -
Area Energy Saving Measures Payback
Period
.
-
.
by using accurate weighing methods
(+/-0.2%). s
Install kilowatt-hour meters on a l l
mixers both to allow recording of
consumption throughout each batch and
hence tighter control over processing
and to provide data for more detailed
.
kWh/batch checks, ie monitoring and
targeting. M
Install systems to measure and record
temperature in the mixer and use this
in conjunction with kWh recordings to
.
optimise processing. M
Motor load Consider the application of variable
control speed control on mixer and mill
drives using speed in conjunction
with integrated power control to
.
optimise energy consumption during
on load and off load operation. M
As a less expensive option to
variable speed drives, consider
soft start devices on mills. M
(See Good Practice Guide 2 - Guidance
Notes for Reducing Energy Consumption
.
Costs for Electric Motors and Drives).
Cooling system Temperature optimisation employing
.
chillers (using condenser heat for
the polymer pre-heat duty). M-L
Application of pressure controlled
variable speed pumping in conjunction
.
with temperature control of mixer
batches. L
.
Control of tower fans from tower
base water temperatures. M
Monitoring of water quality in terms
of salts and iron content to minimise
.
fouling on cooling surfaces. S
Ram operation Where low pressure air is used for
conveying, consider collecting ram
.
exhaust air at low pressure for
this duty. M-L
On large machines, consider the use
of alternative methods of providing
ram power such as linear motors. L
- 19 -
Area Energy Saving Measures Payback
Period
c
Extender oil use Ensure that all systems are well
insulated and temperature controlled
where heat loss is significant. S
On circulating systems, use pressure
controlled variable speed drives. S
- 20 -
7. FURTHER INFORMATION
Good Practice
Guide No 2 - Guidance Notes for Reducing
Energy Consumption Costs of
Electric Motor and Drive
Systems.
Tel: 0 1 2 3 5 4 3 6 7 4 7
Fax: 0 1 2 3 5 4 3 3 0 6 6
- 21 -
. Information on Energy Efficiency in Buildings can be
obtained from:
Enquiries Bureau
BRECSU
Building Research Establishment
Garston
Watford
WD2 7JR
Tel: 01923 664258
Fax: 01923 664097
- 22 -