Where the energy flows when moulding
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 1
Shape moulding production, energy-wise
Survey:
l Energy usage in pre-expanding
l Energy usage in shape moulding
l Comparison of shape moulding production methods
l Energy Agenda
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 2
Shape moulding production, energy-wise
What is Energy?
Energy in its
quantity is always
limited, but in its
existence it is
unlimited
Energy is stored
labour
O
Energy can never be
produced or destroyed,
it can only be converted
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 3
Shape moulding production, energy-wise
Energy usage
with batch pre-expanders
when moulding
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 4
Shape moulding production, energy-wise
Batch pre-expander
Energy supply
Pre-Expansion Vessel
Raw Material
Sieve
Dampf
Fludi Bed
..
.... ..
Weighing Device
Cellular Wheel Sluice
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 5
Shape moulding production, energy-wise
Batch pre-expander
Steam usage consists of:
Steam requirement of EPS beads
Steam requirement of expansion vessel
Radiation loss through continuous venting
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 6
Shape moulding production, energy-wise
Batch pre-expander
Pre-expander steam users
Dampfverbraucher
7%
32%
61%
Dauerentlftung
Material
Verluste
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 7
Shape moulding production, energy-wise
Batch pre-expander
Influence of continuous venting
without continuous venting:
low densities are not achievable
Steaming times are multiplied
Inhomogeneous density distribution
Goal: increased steam concentration in the steam-air
mixture
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 8
Shape moulding production, energy-wise
Batch pre-expander
Dam pfverbrauch [kg/Zyklus]
Steam usage and density
0,80
0,70
0,77
0,60
15g/l
0,50
0,40
0,62
20g/l
0,44
25g/l
0,30
0,20
0,10
0,00
minimum density = maximal expansion
Kurtz GmbH
09.09.2002 [Link]
= maximum steam usage!
[Link]
Page 9
Shape moulding production, energy-wise
Batch pre-expander
Usage and weighed-in quantity
0,8
spez. Dampfverbrauch [kg/kg]
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
1
Masse EPS [kg]
Always use your full capacity!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 10
Shape moulding production, energy-wise
Batch pre-expander
Usage and weighed-in quantity
0,8
specific steam usage:
steam mass
EPS mass
spez. Dampfverbrauch [kg/kg]
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
1
Masse EPS [kg]
the specific steam usage sinks with increased capacity usage
of the pre-expander volume
Always use your full capacity!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 11
Shape moulding production, energy-wise
Batch pre-expander
Pre-expanders for every throughput requirement!
VSD6300
VSD1000
VSD100
Always use your full capacity!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 12
Shape moulding production, energy-wise
Energy Usage
with batch pre-expanders
when moulding
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 13
Shape moulding production, energy-wise
Shape moulding machine
Energy costs with moulding production
Kostenverteilung
11%
4%
Dampf
7%
Luft
Vakuum
58%
20%
Wasser
Strom
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 14
Shape moulding production, energy-wise
Energy usage
Filling air
Steam
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 15
Shape moulding production, energy-wise
Shape moulding machine
Air usage with pressure filling
Luft
Luft
Users:
Fill injectors
Pressure fill tank
SAir = VInjector + VVessel
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 16
Shape moulding production, energy-wise
Shape moulding machine
Air usage with pressure filling
Air usage during filling depends on:
Tank pressure
Filling time
Fill injector design
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 17
Shape moulding production, energy-wise
Shape moulding machine
Comparison of air quantities with increased tank pressure
0,25
Luftmenge [Nm]
0,2
0,15
0,1
0,05
Luftmenge
Fller [Nm]
0,5
0,8
1
1,5
Behlterdruck [bar]
Luftmenge
Behlter
[Nm]
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 18
Shape moulding production, energy-wise
Shape moulding machine
Comparison of total air usage with increased tank pressure
0,3
0,29
Luftmenge [Nm]
0,28
0,27
0,26
0,25
0,24
0,23
0,22
0,21
0,2
0,5
0,8
1,5
Behlterdruck [bar]
Air usage increases with tank pressures over 1 bar!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 19
Shape moulding production, energy-wise
Shape moulding machine
Air usage with pressure filling
Air usage during filling depends on:
Tank pressure
Filling time
Fill injector design
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 20
Shape moulding production, energy-wise
Shape moulding machine
Influence of increased tank pressure on filling time
0,3
0,29
6,5
0,28
Fllzeit [s]
0,27
5,5
0,26
0,25
4,5
0,24
0,23
0,22
3,5
0,21
3
0,50
0,60
0,70
0,80
0,90
1,00
1,10
1,20
1,30
1,40
Fllzeit [s]
Luftmenge
gesamt
[Nm]
0,2
1,50
Behlterdruck [bar]
The higher the tank pressure, the faster the filling!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 21
Shape moulding production, energy-wise
Shape moulding machine
Air usage with pressure filling
Air usage during filling depends on:
Tank pressure
Filling time
Fill injector design
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 22
Shape moulding production, energy-wise
Shape moulding machine
Choice of fill injectors
Comparison of air throughput
1000
900
800
700
Air
Luftdurchsatz
consump.
[l/min]
600
500
400
300
200
100
0
Nymphius
Kurtz
Sarga
Kurtz
Schaltdrossel
Injector
types
Fllertypen
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 23
Shape moulding production, energy-wise
Shape moulding machine
Choice of fill injectors
Comparison of the loading:
Material quantity
Loading =
Air quantity
Transport capacity of the fillers is considered
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 24
Shape moulding production, energy-wise
Shape moulding machine
Choice of fil injectors
Comparison of loading
12,00
10,00
8,00
Beladung
[%]
6,00
4,00
2,00
0,00
Kurtz
Kurtz Schaltdrossel
Nymphius
Sarga
Fllertypen
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 25
Shape moulding production, energy-wise
Shape moulding machine
Fill injector influences
Comparison of filling costs
Filling costs = Air costs + Machine costs
Time factor is considered
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 26
Shape moulding production, energy-wise
Shape moulding machine
Choice of fill injectors
Comparison of filling costs
12
10
8
Fllkosten
[cent/Zykl]
6
4
2
0
Kurtz Schaltdrossel
Kurtz
Nymphius
Sarga
Fllertypen
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 27
Shape moulding production, energy-wise
Shape moulding machine
Fill injector influences
Air usage when filling
Injektor Fllkosten Mehrkosten
p.a. []
E
D
A
48.700
51.700
198.300
0
3.000
149.600
Related to a plant with 15 m foaming area, 60 sec. cycle and 2-shift operation
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 28
Shape moulding production, energy-wise
Energy usage
Demoulding air use
Steam
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 29
Shape moulding production, energy-wise
Shape moulding machine
Steam chamber volume influences
Air requirement depends on mould design
Spacer frames are not always removed when mould
is changed
Male side is partly not reduced
Use of deeper steam chambers for demoulding reasons
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 30
Shape moulding production, energy-wise
Shape moulding machine
Steam chamber volume influences
Demoulding
only with transfer and ejection air
supported by mechanical ejectors
with AZA demoulding support
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 31
Shape moulding production, energy-wise
Shape moulding machine
Demoulding with transfer and ejection air
Transfer air
Ejection ar
I
I
II
II
when comparing,
a relatively high air pressure is necessary
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 32
Shape moulding production, energy-wise
Shape moulding machine
Demoulding with mechanical ejector support
Ejection air
Transfer air
Movable
side
Movable side
Fixed
side
Mechanical
ejectors
Mechanical ejectors
Reduced air pressure
due to mechanical demoulding
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 33
Shape moulding production, energy-wise
Shape moulding machine
Demoulding with AZA support
Transfer air
Auf/
open
Ejection air
Zu/C
losed
Auf/O
pen
Mov.
side
Increased usage, due to 2 x transfer air
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 34
Shape moulding production, energy-wise
Shape moulding machine
Comparison
Transfer air
[bar]
0,3
0,3
0,3
Ejection air
[bar]
0,7
0,3
0,3
approx.
costs [/a]
30.400
11.400
7.600
approx.
saving[/a]
0
19.000
22.800
Related to a plant with 15 m foaming area, 60 sec. cycle time and 2-shift operation
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 35
Shape moulding production, energy-wise
Energy usage
Air
Steam
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 36
Shape moulding production, energy-wise
Shape moulding machine
Energy balance sheet
Qzu = Qfoam + Qpurging + losses + Qmould
Schaum
0,4%
Splen und
Verluste
46,6%
Werkzeug
58,0%
Werkzeug
Schaum
Energieanteile
Splen und Verluste
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 37
Shape moulding production, energy-wise
Energy usage
Air
Steam saving with the proper mould
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 38
Shape moulding production, energy-wise
Shape moulding machine
Influence of the mould weight
Mould is heated up and cooled down
Steam quantity
mmould O cpAl O DT
msteam =
Dh
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 39
Shape moulding production, energy-wise
Shape moulding machine
Example calculation
Mould for a machine with 1 m foaming area
mmould = 160 kg
cpAl
= 0.92 kJ/(kgK)
DT
= (120C 80C) = 40 K
Dh
= 2203 kJ/kg with 1.2 bar
Reduction of wall thickness by 2 mm ~ 35 kg Alu
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 40
Shape moulding production, energy-wise
Shape moulding machine
Example calculation
Steam saving / cycle corresponds to
35 kg O 0,92 kJ/kg/K O 40 K / 2203 kJ/kg = 0.58 kg
Saving / year in 2-shift operation
0.58 kg O 60 cycles/h O 3520 h/a = 120 t steam
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 41
Shape moulding production, energy-wise
Shape moulding machine
Example calculation
Average operation with 15 m foaming area
Reduced usage approx. 1,840 t steam
Steam costs approx. 25 / t
Saving potential approx. 46,000 p.a.
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 42
Shape moulding production, energy-wise
Energy usage
Air
Steam saving with the proper adjustment
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 43
Shape moulding production, energy-wise
Shape moulding machine
Energy balance sheet
Qzu
= Qfaom + Qpurging + losses + Qmould
Schaum
0,4%
Splen und
Verluste
46,6%
Werkzeug
58,0%
Werkzeug
Schaum
Energieanteile
Splen und Verluste
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 44
Shape moulding production, energy-wise
Shape moulding machine
Influence of adjustments during purging
Steam valve
Steam chamber
M II
Steam chamber
MI
Filler
Purging ~
3 x exchange of steam
chamber volume
MI
M II
Kondensate valve
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 45
Shape moulding production, energy-wise
Shape moulding machine
Zeitvariation Splen bei 0,8bar
3,5
3
Dampfverbr. [kg]
2,5
Splen
Quer
Auto
1,5
Summe
1
0,5
0
0
Zeit [s]
Extended purging time = high usage!
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 46
Shape moulding production, energy-wise
Shape moulding machine
Example
Shape moulding machine with 0.5 m foaming area
1 sec. purging ~ steam usage 0.5 kg (measured)
Reduction of purging times by 0.5 sec.
Saving potential approx. 40.000,-- p.a.
Purging:
As short as possible as long as
necessary
Related to a plant with 15 m foaming area, 60 sec. cycle time and 2-shift operation
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 47
Shape moulding production, energy-wise
Shape moulding machine
Druckvariation bei 2s
3
Dampfverbr. [kg]
2,5
2
Splen
Quer
1,5
Auto
Summe
0,5
0
0,2
0,4
0,6
0,8
1,2
Druck [bar]
Increased pressure during purging and cross steam =
reduced usage
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 48
Shape moulding production, energy-wise
Energy usage
Air
Steam saving with the proper steam
chamber
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 49
Shape moulding production, energy-wise
Shape moulding machine
Steam chamber volume influences
Mould design
Spacer frames are not always removed when mould
is changed
Male side is partly not reduced
Use of deeper steam chambers for demoulding reasons
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 50
Shape moulding production, energy-wise
Shape moulding machine
Example calculation:
Spacer frame (h= 100mm) is not removed
Moulding machine with 1 m foaming area
Steam volume approx. 1.4 m x 0.1 m = 0.14 m
Steam quantity = steam volume / spec. steam volume
Steam quantity ca. 0.14 m x / (0.8915m/kg) = 0.12 kg
Additional usage ca. 3 x 0.12 kg / cycle = 0.36kg / cycle
Related to a plant with 15 m foaming area, 60 sec. cycles and 2-shift operation
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 51
Shape moulding production, energy-wise
Shape moulding machine
Example calculation:
100 mm spacer frame is not removed
Saving potential approx. 30.000 p.a.
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 52
Shape moulding production, energy-wise
Energy usage
Energy saving with the proper production
method
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 53
Shape moulding production, energy-wise
Comparison of production process
Selection of the production process
Vacuum technology
LTH- Classic
LTH- Eco
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 54
Shape moulding production, energy-wise
Shape moulding machine
Description of process methods
1. Conventional technology
Machine and mould design :
Steam/Air
Universal steam chamber
Shaping contour made of Al
Ejector
Water
Water
Nozzles in mould walls
Rel. in-expensive mould design
Fill injector
Cooling of mould mass
Vacuum /
Kondensate
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 55
Shape moulding production, energy-wise
Shape moulding machine
Description of process methods
Machine and mould design :
2. LTH
No steam chambers
Steam distribution in the mould
Steam/Air
Vacuum
Ejector
No mould cooling
Steam/Air
Coating of all sides of areas
contacting steam
Vacuum
Fill
injector
Faster mould change
Rel. high mould costs
High productivity
Lowest energy usage
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 56
Shape moulding production, energy-wise
Shape moulding machine
Description of process methods
3. ECO-LTH
Mould design:
Same as with LTH
Lower mould costs than with LTH
Ejector
Almost same productivity as with
Steam/Air
Vacuum
Steam/Air
Vacuum
Fill
injector
LTH
Higher energy usage than with LTH
Considerably reduced energy usage
compared to conventional method
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 57
Shape moulding production, energy-wise
Comparison of production process
Energy consumption of production processes
[ kg / m / Zykl.]
1. Steam
4
3,5
3,5
3
2,5
1,7
1,1
1,5
1
0,5
0
Vacuum technology
Vakuumtechnik
Eco-LTH
Classic-LTH
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 58
Shape moulding production, energy-wise
Comparison of production process
Energy consumption of production processes
[ m / m / Zykl.]
2. Air
2,5
2
2
1,5
0,9
0,8
0,5
Vacuum technology
Vakuumtechnik
Eco-LTH
Classic-LTH
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 59
Shape moulding production, energy-wise
Comparison of production process
Determination of producion costs
Company-specific data
Machine-specific data
Mould-specific data
Process-specific data
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 60
Shape moulding production, energy-wise
Comparison of production process
Kosten [ ]
K813 Vakuumtechnik
K813 LTH-Classic
K813 LTH-Eco
120.000
100.000
80.000
60.000
40.000
20.000
0
0
150.000
300.000
450.000
600.000
Anzahl [ Stck. ]
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 61
Shape moulding production, energy-wise
Comparison of production process
Survey:
LTH-Classic and LTH-Eco:
Advantages in countries with high energy costs
LTH-Classic
unbeatable with high piece numbers
LTH-Eco
cost-cutting even with low piece numbers
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 62
Energy for Productivity
Where the energy flows when moulding
Energy Agenda
Re: Planning stage
No.
Action required
Done
Pre-expander: maximum use of expansion volume
by selection of suitable pre-expander
2
3
4
Maximum use of foaming area
Reduce mould mass (e.g. mould milling instead of casting
Use ECO- LTH for medium size orders
5
6
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 63
Energy for Productivity
Where the energy flows when moulding
Energy Agenda
Re: Steam usage - production
No.
Action required
Done
Cross steam and autoclave steam pressure as high as
possible and as short as necessary!
Reduce steam chamber volume !
(Remove unnecessary spacers, use steam chamber reductions!)
3
4
Use economic steaming!
Adjust tank pressure during filling to 0,8 bar
5
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 64
Energy for Productivity
Where the energy flows when moulding
Energy Agenda
Re: Steam usage - maintenance
No.
1
2
Action required
Done
Exchange defective sealings immediately!
Exchange leaking valves immediately!
3
4
5
6
7
Kurtz GmbH
09.09.2002 [Link]
[Link]
Page 65
