TPI April 2009

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34 Tube Products International April 2009
developmentsproducts &
Complete systems for energy
efficient pipe production
Cincinnati’s 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%.
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. Through a reduction in the number of vacuum and
spray cooling baths required for the downstream aggregates and the optimised
cooling system consisting of water and air cooling, energy consumption can be
cut by up to 71kW (about 27kW are saved by the reduction in the number of
circulation pumps, and about 44kW by less water being circulated).
Another source of energy savings is the use of heat set free 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
•
The newly developed KryoS pipe die is a core S S
component of the KryoSys line, featuring a melt
cooling system in the pipe die
Seamless
stainless and
carbon steel pipes
Guangzhou Hongda Steel Tube Co, Ltd,
established in 1988, specialises in the
production and sale of steel tubes.
In 2003, Hongda invested in a mill
– Guangzhou Junjia Steel Tube
Manufacturer Co, Ltd. The mill is located
inHuangpuDistrict of Guangzhou, China,
and occupies 34,000m2. The mill uses
advanced production equipment with
German technology, and precise testing
equipment using Japanese technology.
ODs range from 6 to 325mm, and wall
thickness ranges from 0.5 to 25mm.
Annual output is 15,000 metric tons
of seamless stainless steel pipe and
150,000 metric tons of seamless carbon
steel pipe.
Guangzhou Junjia produces 15,000 S S
metric tons of seamless stainless steel
pipe and 150,000 metric tons of seamless
carbon steel pipe per year
The company’s products are widely used
in fields such as petroleum, chemical
industry, aviation, power stations, energy,
environmental production, boilers and
heat exchangers. The company is a
specified supplier for Petro-China and
China Sinopec and exports products to
over 40 countries.
In order to improve quality and
management, the company has
introduced the ISO9001:2000
International Quality management
system, ISO14001:2004 Environmental
management system, OHSAS
18001:1999 management system, GB/
T2800-1001 Occupational health and
safety management, PED97/23/EC and
AD2000-WO/TRD100. The company
can produce pipes according to GB,
ASTM, DIN, EN and JIS standards.
Guangzhou Hongda Steel Tube
Co, Ltd – China