Chemical Applications

Chemical, HPJ Motion Controls

Confidential / Property of Danfoss Drives A/S 1
February 2007 – Rev 1.0
 Chemical Business Definition - Typical Applications

Refinery
Petrochemical
Mixers Pumps
Paint, Varnishes & Lacquers Basic Chemicals
Detergent & Cosmetics Specialty Chemicals
Agricultural Chemicals …in most chemical processes

Centrifuges
Extruder Basic Chemicals

Plastic & Plastic Products

Specialty Chemicals Beam Pump
Rubber & Rubber Products
Text
Pharmaceutical & Life Sciences
Oil & Gas

Chemical, HPJ Motion Controls

Confidential / Property of Danfoss Drives A/S 2
February 2007 – Rev 1.0
Short Application Description
Extruders and Blow Moulders
Plastic extrusion and moulding
 Plastics extrusion (or Extrusion Moulding) is a high volume
manufacturing process in which raw plastic material is melted and
formed into a continuous profile.
Extrusion produces items such as pipe/tubing, weather stripping,
window frames, plastic sheeting, adhesive tape and wire
insulation.

 Moulding – The forming of a resin/fibre material into a solid

mass of prescribed shape and size. Moulding or casting is the
process of manufacturing by shaping pliable raw material using a
rigid frame or model called a mould.
Moulding produces items such as buckets, plastic parts,
dashboards for cars, medical products and technical moulds.

 Stretching – The process where extruded plastic is formed

through a stretching process (calander) in order to end up as
plastic foil. The foil is used for packaging, technical purposes,
capacitors etc.
Source: Plastics Wiki, Kolsite, Arburg, Uponor

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Essentials of an extruder
 Tubular barrel, usually electrically heated to
facilitate melting of the resin
 Revolving screw, ram or plunger within the
barrel
 Hopper at one end from which the material to be
extruded is fed to the screw, ram or plunger
 Die at the opposite end for shaping the extruded
mass

Operation of the screw in a steady and predictable manner is vital making quality extrusions. Friction
represents about 85% of the energy used in heating resins, meaning that the power transmission equipment
must be capable of supplying the energy to overcome this friction, particularly if starting from rest or recovery
from a maintenance outage.
Speed control is extremely important to assure that adequate resin is being fed to the process. However the
ability to maintain even pressures to get consistent flow is equally important. Good response to torque changes
as well as steady speed control of high friction loads is the challenge.

Source: Plastic Wiki, Reifenhauser

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Essentials of a blow moulder
 A blow moulder consist of
 Injection unit – Basically an
extruder (see previous page)
 The clamping unit where the
mould is happening. Today the
mechanism is controlled electrically
or hydraulically

 The reciprocating screw is controlled by a high torque motor – Historically a hydraulic

motor, but development in PM motors have changed concepts to be electrical driven.
Motors often liquid cooled (cooling present anyway)
 Benefits of electrical drive
 More quiet
 Lower energy consumption
 Faster
 Higher accuracy
Source: Plastics Wiki, Arburg

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Other applications in plastic and rubber
 Converting process
 Calandar – Stretching mechanism which converts
plastics through differences in the surface speed
on each roller. Used in foil production
 Precise control of speed for each roller is
essential in order to perform a precise stretching
process.
 Winder – Winding foil after processing

 Material Handling of finished parts

 Pick and place equipment –Servo drives often
used
 Conveyors

 Handling of extruded parts

 Cut on the fly applications

 Generic applications
 Fans for cooling
 Pumps for cooling water

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Characteristics of drives
Function Typical Power Key requirement Drive type
Main spindle drive 45-600 kW Short acceleration time FC302 (Flux)
Repetitive cycle
Sin-Cos encoder or resolver
High torque motor
Liquid cooling (higher power)
Clamping system Up to 110 kW Short acceleration time FC302 (FLUX)
Repetitive cycle
Sin-Cos encoder or resolver
High torque motor
Liquid cooling (higher power)
Calandar Up to 22 kW Synchronising FC302 (FLUX)
Parallel drives – DC link
Precise control
Kinetic backup
Cut on the fly Few kW Synchronising position FC302
Precise control
Speed change
Cooling fans Few kW Scalar control FC51

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Generic key specifications
 Voltage - 380-500V and 690V
 Cooling - Forced convection and Liquid cooling
 Ambience (up to 45° C)
 Enclosure rating - IP20 and IP54/55
 Trends
 Permanent Magnet motors – High Torque
 Servo performance on handling equipment
 Liquid cooling on higher power
 One supplier of motor and drive (PM motor)
 Market going from hydraulic system to electrical systems

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Further resources, information – Some examples
 Extruder OEMs:
 Berstorff/Krauss-Maffei (Germany)
 Battenfeld Extrusionstechnik (Germany and US)
 Brückner Maschinenbau (Germany)
 Kolsite – Kabra (India)
 Cincinatti Extrusion
 Reifenhauser (Germany)
 Arburg (Germany and Switzerland)
 Engel (Austria and Canada)

 Other resources:
 http://plastics.inwiki.org (Wiki version on plastics - A lot of generic info)
 Brochures – Krauss-Maffei and Arburg

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Short Application Description
Centrifuge and Decanter
 Separation of liquids and solids

 A centrifuge separates substances with different

densities like solid-liquid or liquid-liquid by means
of the centrifugal power

 Two main principles exist for continuous

processes:
 Disk stack centrifuges (low amount of solids)
 Decanter centrifuges (high amount of solids)

 For batch processing batch centrifuges are

used

Reference: Alfa Laval

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Centrifuge
 Features
Filter
Liquid outlet
 Simple structure and filtration principle
 Turning of drum speeds up sedimentation of
solid
 Solid scraped out of drum when liquid is
removed
 Intermittent (batch) or continuous process

 Areas of use
 Chemical
 Food & Beverage
Sediment (solid)  Pharmaceutical
 Textile printing & dyeing
 Sugar production

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Typical centrifuge cycle (continuous process)
 A typical process
 1. Start up
 2. Filling phase
 3. Washing phase
 4. Separating at high speed
 5. Emptying the centrifuge (scraping)
 6. New filling
 …..

 Key features of drive

 Regenerative front-end
 Reduced energy consumption and mechanical
wear
 Low losses compared to brake resistor
 Robustness to high load changes (overload
torque ability in Flux mode)

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Disc stack centrifuge
 Features
 Continuous operation mode
 Discs stacked inside the drum
 Reduced sedimentation distance
 Accelerate subsiding speed
 Enlarged area of sedimentation
 Highly concentrated solids
 High separation efficiency

 Areas of use
Liquid discharge  Chemical and pharmaceutical
Inlet  Dairy Technology
 Oils and Fats Processing
Solid discharge
 Oilfield

Disk stack area

 Key drive feature
 Robustness to load changes
 Trend towards direct drive use from gears
Reference: Alfa Laval

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 Decanter
 Continuous separation of solid from suspensions
with very high (up to 60%) solids content
 Clarification of liquids Screw drive Inlet
 Concentration of solids Screw

Drum drive

 Typical use:
 Waste water sewage plants
 Chemical processing
Solid discharge
 Food/Beverage processing Liquid discharge
Drum
 Mineral separation

Reference: Flottweg

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Decanter function
 Process functionality
 Centrifuge (drum) turned by large drive
 Screw turned at different speed (compared
to drum speed) to remove solid parts
 Liquid part flows out from liquid outlet

 Why drives?
Main drive
 Allowing fast adjustment of process
parameters and adaptation to varying load
 Optimise control of process
DC link
 Robustness to load variations

 Typical control set up

 Drive control principles
Screw drive  Main drive: Speed open loop
 Screw drive: Torque control
 DC link utilises braking energy from screw
drive

Reference: GEA Westfalia

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Process example: Clarifying process

 Separation process using decanter

and centrifuge
 Decanters for high solid content in
the solution
 Solid substance (salt particles)
 Liquid with fine solids
 Centrifuges removing small
particles from decanter overflow
 Solid substance (small salt particles)
 Liquid (oil additives to other process
steps)

Reference: GEA Westfalia

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Characteristics of drives
Function Typical Power Key requirement Drive type
Stack Centrifuge 4-200 kW Short acceleration time FC302 (Flux)
Repetitive cycle
Direct drive PM motors (substitutes
gear/belt)
Liquid cooling (higher power)
Shock load capability
Decanter Up to 200 kW Short acceleration time FC302 (FLUX)
DC connection/Regeneration
Shock load capability
Three column Few kW – 800 High torque FC302 (FLUX)
centrifuge / Batch kW Stable to shock loads
centrifuge Brake functionality
Regen. operation (high power)
Brake resistor
AC brake
PM motors
Flying start / kinetic backup
Shock load capability

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Generic key specifications
 Voltage - 380-500V and 690V
 Cooling - Forced convection and Liquid cooling (high power)
 Ambience (up to 45° C)
 Enclosure rating - IP20 and IP54/55
 Active front-end (regenerative braking for high power)
 Trends
 Permanent Magnet motors
 Active front ends (harmonics and regeneration)
 Liquid cooling on higher power
 One supplier of motor and drive (PM motor)
 Motor and gear substituted by PM (multi pole motors)

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Further resources, information
 Centrifuge and Decanter OEMs:
 GEA Westfalia (Germany)
 Alfa Laval (Sweden)
 Flottweg (Germany)
 Ellerwerk (Germany)
 Broadbent (Great Britain)
 Pieralisi (Italy)

 Other resources:

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Short Application Description
Pumps
Pumps
 A pump is a device used to move liquids or
slurries. Liquid is moved by increasing
pressure. The pump overcomes the difference
in pressure by adding energy, using
mechanical forces to push the material, either
by physically lifting, or by the force of
compression.

 Two types of pumps

 Centrifugal pumps are based on bladed
impellors which rotates within the fluid. The
velocity of the fluid is increased by a centripetal
force and the casing of the pump then acts to
the conversion of the increased velocity to a
pressure increase.
 Positive displacement pumps cause a liquid
to move by trapping a fixed amount of fluid and
then forcing (displacing) that trapped volume
into the discharge pipe.

Picture: Grundfos and ????

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Centrifugal pump characteristics
 Energy consumption by affinity law
 Significant energy savings at lower pump
speed
 Reduced wear and tear on pump, well,
filter and valves
 Increased pump and filter lifetime
 Reduced maintenance
 Easy and accurate flow adjustment
 Full efficiency with no impeller reduction

 Key features
 VT mode
 High starting torque
 du/dt and sine-wave filters
 PID control of pressure

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Displacement pump characteristics
 Reduced wear and tear on pump,
filter and valves
 Increased pump and filter lifetime
 Reduced maintenance
 Easy and accurate flow adjustment
 Full efficiency with no impeller
reduction

 Key features
 CT mode and FLUX
 Robustness to load shock
 High starting and overload torque
 du/dt and sine-wave filters

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Characteristics of drives for pumps
Function Typical Power Key requirement Drive type
Centrifugal pump 4-1200 kW Variable torque FC302/FC301
High starting torque
PID controller
Displacement pump Up to 100 kW Constant torque FC302 (FLUX)
Reciprocating High starting torque
Pulsating load
Displacement pump Up to 100 kW Constant torque FC302 (FLUX)
Rotating High starting torque
Pulsating load

 Other pumps used are:

 Dosing pumps (small power sizes)
 Vacuum pumps

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Generic key specifications
 Voltage – 400, 500V and 690V
 Cooling - Forced convection and Liquid cooling (high power)
 Ambience (up to 45° C)
 Enclosure rating - IP20 and IP54/55
 Built in protective features in drive
 Filters used together with drive to protect winding and comply to installation
demands

 Trends
 Permanent Magnet motors
 Liquid cooling on higher power

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Further resources, information
 Extruder OEMs:
 Grundfos (Denmark)
 ITT (United States)
 Wilo (Germany)
 KSB (Germany)
 Flowserve (United States)
 Lewa (Germany)
 …

 Other resources:
 Pump handbook, Grundfos

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