Energy Consumption Preexpanding

Energy Usage During
Kurtz GmbH
Sept.2002 Al-Ri-us
Energie_VS_Hausmesse2002
page 1
Energy Usage During Pre-expansion, Transporting and Storage
Kurtz GmbH
Sept.2002 Al-Ri-us
page 2
Survey:
l Explanation of pre-expansion process
l Minimum energy usage for steam
l Minimum energy usage for electricity
l Energy Agenda
Kurtz GmbH
Sept.2002 Al-Ri-us
page 3
Kurtz GmbH
Sept.2002 Al-Ri-us
page 4
Aim
Start
Up to 50 times
volume enlargement
Raw material
density approx. 650 g/l
Conditioned for final product

density > 15 kg/cbm (shape moulding)
density > 9 kg/cbm (block moulding)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 5
Conditions for the pre-expansion process:

l Raw material
l Optimum blowing agent content in the raw material
l Suitable energy and heat transfer medium
l Sufficient sojourn time in the heat transfer medium
l Suitable machinery
Kurtz GmbH
Sept.2002 Al-Ri-us
page 6
Pre-expander types:
l Continuous pre-expanders
l Batch pre-expanders
(pressure pre-expanders)
l Second pass expanders

(cont. and batch operating pre-expanders with
special equipment
l Special pre-expanders
(pressure and vacuum, contact heat)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 7
This presentation is limited to:
Examination of Energy Balance Sheet

for the
Batch Pre-expansion Process
Kurtz GmbH
Sept.2002 Al-Ri-us
page 8
Why limitation to batch pre-expansion

process?
l Higher densities with smaller tolerances
in comparably small quantities
l Low densities in large quantities

l Processing of material with reduced pentane
content
Kurtz GmbH
Sept.2002 Al-Ri-us
page 9
l Almost universally usable pre-expanders

l Market share of batch pre-expander increases
Kurtz GmbH
Sept.2002 Al-Ri-us
page 10
Batch pre-expander
Pre-expansion vessel
Feeding / single dosing
Sieve unit
Raw material
Feeding
Fluid bed
Conveying
..
.... ..
Cellular wheel sluice
Weighing device
Kurtz GmbH
Sept.2002 Al-Ri-us
page 11
l Raw material conveying
Raw material
Conveying
to the weighing unit
l Weighing of batches
Weighing unit
Kurtz GmbH
Sept.2002 Al-Ri-us
page 12
l Feeding into dosing tank

l Feeding into expansion vessel
Side channel fan

Kurtz GmbH
Sept.2002 Al-Ri-us
page 13
l Steaming:
a) Purging of tank
b) Increase of pressure
c) Expansion to required density
Kurtz GmbH
Sept.2002 Al-Ri-us
page 14
l Discharge into the fluid bed

l Stabilization and drying in the fluid bed
Kurtz GmbH
Sept.2002 Al-Ri-us
page 15
l Sieving of pourable beads

l Crushing of lumps
l Pneumatic conveying for intermediate storage
Kurtz GmbH
Sept.2002 Al-Ri-us
page 16
Kurtz GmbH
Sept.2002 Al-Ri-us
page 17
Steam as energy user
Saturated steam
EPS bead
100 C
Heat transfer:
steam on the bead surface
Kurtz GmbH
Sept.2002 Al-Ri-us
page 18
Heat transfer to bead:

Heat softens the polystyrene
Pentane starts to seethe and
to evaporate
Pentane gas leads to
pressure increase in the bead
EPS bead
Pentane
Saturated steam
Kurtz GmbH
Sept.2002 Al-Ri-us
page 19
Result:
Inner pressure leads to
volume increase
of the EPS bead
approx. 0,8 1,8 % pentane

emission (related to batch mass)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 20
Energy Usage During Pre-expanding, Transporting and Storage
Expansion of the bead:

EPS bead
EPS bead
Pentane
Pentane
EPS raw material at

roo temperature
EPS bead
EPS raw material

after steaming.
Pentane starts to seethe
bead starts to expand
Bead expands to required

density
depending on heat
quantity provided
Kurtz GmbH
Sept.2002 Al-Ri-us
page 21
(Vessel and radiation not considered)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 22
Energy supply to beads
..
.... ..
Kurtz GmbH
Sept.2002 Al-Ri-us
page 23
Spec. Heat capacities :

( siehe Wrme-Atlas VDI )
cpEPS = 1,3
[kJ/kg x K]
cpair = 1,0
[kJ/kg x K]
cpsteel = 0,46 [kJ/kg x K]

cpV2A = 0,5
cpAlu
Enthalpy steam (pe):
[kJ/kg x K]
= 0,92 [kJ/kg x K]
with 0,3 bar steam pressure

rsteam = 2238 [kJ/kg]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 24
Temperature difference DTEPS:T1 = Tbeads room temp. = 20 C

T2 = Tsaturated team
= 105 C
DTEPS = T2 T1
DTEPS = 85 C
Investigated density:
SD = 15 [g/l]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 25
Mass EPS:
mEPS = Vvessel net x SD
1 m3
gross
0,8 m3
net
Vvessel net =
80% gross volume
of expansion vessel
Expansion
vessel
Kurtz GmbH
Sept.2002 Al-Ri-us
page 26
Mass EPS:
1 m3 Volume of expansion vessel is:

mEPS = 0,8 m3 x 15 kg/m3
mEPS = 12 kg
Kurtz GmbH
Sept.2002 Al-Ri-us
page 27
Expansion energy EPS: QEPS = mEPS x cpEPS x DTEPS

QEPS = 12kg x 1,3[kJ/kg x K] x 85K
QEPS = 1326 [kJ]
Steam usage per batch::
mDC = QEPS / rsteam

mDC = 1326 [kJ] / 2238 [kJ/kg]
mDC = 0,59 kg
Kurtz GmbH
Sept.2002 Al-Ri-us
page 28
Steam usage per kg EPS:

spec. steam usage = mDC / mEPS
spec. steam usage = 0,59 kg / 12 kg
spec. steam usage = 0,049 kgsteam/kgEPS
l = Energy requirement of beas

l = Vessel and radiation not considered !
Kurtz GmbH
Sept.2002 Al-Ri-us
page 29
Kurtz GmbH
Sept.2002 Al-Ri-us
page 30
One time heating up of

expansion vessel prior
to production start
Kurtz GmbH
Sept.2002 Al-Ri-us
page 31
Temperature difference DTvessel:

T1 = T1_steel = T1_V2A = T1_alu = 20 C
DTvessel = T2 T1
DTvessel = 82 C
Kurtz GmbH
Sept.2002 Al-Ri-us
page 32
Mass expansion vessel:
mlid : 90 kg (aluminium)
mjacket : 280 kg (V2A)
mfloor : 130 kg (steel)
Expansion
vessel
Kurtz GmbH
Sept.2002 Al-Ri-us
page 33
Heating up energy lid:
Qlid = mlid x cpalu x DTvessel

Qlid = 90 x 0,92 x 82 [kJ]
Qlid = 6790 [kJ]
Heating up energy jacket:Qjacket = mjacket x cpV2A x DTvessel

Qjacket = 280 x 0,5 x 82 [kJ]
Qjacket = 11480 [kJ]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 34
Heating up energy floor: Qfloor = mfloor x cpsteel x DTvessel

Qfloor = 130 x 0,46 x 82 [kJ]
Qfloor = 4904 [kJ]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 35
Heating up energy expansion vessel:

Qvessel = Qlid + Qjacket + Qfloor
Qvessel = 6790 [kJ] + 11480 [kJ] + 4904 [kJ]
Qvessel = 23174 [kJ]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 36
Steam requirement vessel: msr = Qvessel / rsteam

msr = 23174 [kJ] / 2238 [kJ/kg]
msr = 10,35 kg
l For heating up the pre-expansion vessel

l One time prior to production start !
Kurtz GmbH
Sept.2002 Al-Ri-us
page 37
Kurtz GmbH
Sept.2002 Al-Ri-us
page 38
l Heating up cooled expansion

vesel to required expansion
temperature
l Heat transfer to beads
Kurtz GmbH
Sept.2002 Al-Ri-us
page 39
Investigated density:
SD = 15 [g/l]
Temperature difference DTEPS:T1 = Tbeads room temp. = 20 C

T2 = Twet steam
= 105 C
DTEPS = T2 T1
DTEPS = 85 C
Kurtz GmbH
Sept.2002 Al-Ri-us
page 40
Temperature difference of vessel between steaming and

discharge DTavessel :
DTavessel = T2 T1
DTavessel = 5 C
Kurtz GmbH
Sept.2002 Al-Ri-us
page 41
Mass EPS with VSD1000: mEPS = Vvessel net x SD

Vgross = 1 m3
Vnet = 0,8 m3
mEPS = 0,8 m3 x 15 kg/m3
mEPS = 12 kg
Mass expansion vessel of VSD1000:
mlid : 90 kg (aluminium);
mjacket : 280 kg (V2A);
mfloor : 130 kg (steel)

Kurtz GmbH
Sept.2002 Al-Ri-us
page 42
Expansion energy EPS:
QEPS = mEPS x cpEPS x DTEPS
Heating up energy lid:
Qlid = mlid x cpalu x DTavessel
Heating up energy jacket: Qjacket = mjacket x cpV2A x DTavessel
Heating up energy floor:
Qfloor = mfloor x cpsteel x DTavessel
Kurtz GmbH
Sept.2002 Al-Ri-us
page 43
Total expansion energy requirement VSD1000:

Qtotal = QEPS + Qlid + Qjacket + Qfloor
Qtotal = 1326 [kJ] + 591 [kJ] + 980 [kJ] + 364 [kJ]
Qtotal = 3261 [kJ]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 44
Total steam requirement 1 batch VSD1000:

msr = Qtotal / rsteam
msr = 3261 [kJ] / 2238 [kJ/kg]
msr = 1,457 kg
Kurtz GmbH
Sept.2002 Al-Ri-us
page 45
Steam requirement VSD1000 per kg EPS:

rechnerisch:
mD/kg = msr / mEPS

mD/kg = 1,457 kg / 12
mD/kg = 121 gsteam/kgEPS
Kurtz GmbH
Sept.2002 Al-Ri-us
page 46
Steam requirement VSD1000 per kg EPS:

calculation:
ms/kg = 430 gsteamf/kgEPS
Including:
- Heat radiation of vessel
- Radiation during air discharge
(discharge of 75 dm3 pentane + 680 dm3 air)
- Required steam flow to guarantee a fast

and even heat transfer to the beads
Kurtz GmbH
Sept.2002 Al-Ri-us
page 47
Energy requirement in practice:

With densities of:
l 12 14 g/l
l 40 50 g/l
0,35 0,4 [kgsteam/kgEPS]

0,1 0,15 [kgsteam/kgEPS]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 48
Kurtz GmbH
Sept.2002 Al-Ri-us
page 49
Drying and stabilizing of beads

in fluid bed:
Kurtz GmbH
Sept.2002 Al-Ri-us
page 50
Recommendation for fluid bed blower:

l Assuming a tested blowing
speed of
vblow = 0.45 m/s
l Results in a specific air requirement related to the area

of the fluid bed of:
Vspec. ~ 1500 m3air/(h x m2)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 51
l Required total blower air requirement:

Vair_total = Vspec. X lengthfluidbed x widthfluidbed
l Assuming a blower pressure of:

pblower : 20 30 mbar:
Kurtz GmbH
Sept.2002 Al-Ri-us
page 52
Blower capacity for fluid bed:

approx. 1 kW/m2blowing area
Kurtz GmbH
Sept.2002 Al-Ri-us
page 53
Transport of EPS raw material
Kurtz GmbH
Sept.2002 Al-Ri-us
page 54
Raw material conveying:

From the octabin to the weighing unit:
l Pipe screws
l Pneumatic
conveying (suction)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 55
From the weighing unit to the dosing tank

l Pneumatic
conveying (suction)
l Side channel fan
Kurtz GmbH
Sept.2002 Al-Ri-us
page 56
From the dosing tank to the expansion chamber
l Free fall with air

support by side
channel fan
Kurtz GmbH
Sept.2002 Al-Ri-us
page 57
Pipe conveying screws:

l Low energy usage
l Gentle material conveying
l High throughput capacity
Kurtz GmbH
Sept.2002 Al-Ri-us
page 58
Expample: screw placed at 45

kg/h
Lenth
Lnge
1000
6m
8m
500
10 m
0,5
1,0
1,5
kW
Kurtz GmbH
Sept.2002 Al-Ri-us
page 59
Pneumatic conveying (suction):

l Doubled capacity requirement of
conveying screw
l Flexible arrangement possibilities
l Numerous applications
(Discharge support of dosing tank into the expansion
chamber)
(Discharge support of beads into fluid bed)
Kurtz GmbH
Sept.2002 Al-Ri-us
page 60
Example: 3 kW side channel fan [kg/h]

V
e
r
t
i
c
a
l
[m]
Horizontal [m]
2
3
4
2200
2125
1950
1900
2000
1850
1800
1750
1700
Kurtz GmbH
Sept.2002 Al-Ri-us
page 61
Kurtz GmbH
Sept.2002 Al-Ri-us
page 62
Agitator capacity depends on:

l density
l number of revolutions
l diameter of expansion vessel
l volume of expansion vessel
l filling level
Kurtz GmbH
Sept.2002 Al-Ri-us
page 63
Agitator capacity:
l with density of 25 g/l
l installed capacity:
p ~ 0,25 kW/kgmaximum batch weight
Kurtz GmbH
Sept.2002 Al-Ri-us
page 64
Example:
VSD 3000
p = 15 kW/ 60 kg
p = 0,25 kW/kg
Kurtz GmbH
Sept.2002 Al-Ri-us
page 65
Transporting pre-expanded EPS into storage silos
Kurtz GmbH
Sept.2002 Al-Ri-us
page 66
Transporting pre-expanded EPS:

l Preferably in air stream, 6 8 % material share
l Transport via blower:
Dp = approx. 30 50 mbar
l Required capacity of blower depends on density,
pipes and number of pipe bends
Kurtz GmbH
Sept.2002 Al-Ri-us
page 67
l Material feeding usually via cell wheel:

n = 30 40 min-1
l Optimum material flow speed with pipes

100 200 mm :
8 16 m/s
Kurtz GmbH
Sept.2002 Al-Ri-us
page 68
Transport speed:
w = V/A
w = air speed [ m/s ]

V = volume stream [ m3/s ]
A = LW pipe cross section [ m2 ]
Kurtz GmbH
Sept.2002 Al-Ri-us
page 69
Electric energy usage

for the intermediate storage in silos
Kurtz GmbH
Sept.2002 Al-Ri-us
page 70
Use of intermediate storage:

a) Compensation of pressure difference in bead
compared to atmosphere by absorption of air
l Stabilization of bead structure
l Absorbed air acts in subsequent expansion
as additional blowing agent
Kurtz GmbH
Sept.2002 Al-Ri-us
page 71
b) Final drying of beads

l 1 m3 of 20 g/l pre-expanded EPS contains up to
approx. 3 - 6 weight per cent of water
(with 1m3 = 0,6 - 1,2 kg)
l Reduction of bead water content by drying in
fluid bed and intermediate storage in silos
to < 2 weight per cent.
(remaining water approx. 0,2 kg in 1 m3)
Only then further processing in moulding machines

Kurtz GmbH
Sept.2002 Al-Ri-us
page 72
Example drying data:

Drying of 1 m3 pre-expanded EPS beads
with 20 g/l and 10 weight per cent moisture:
rel. moisture of air:
discharged air of silos:
moisture of discharge air:
required blower air quantity:
65%
20 C
80 %
500 m3
65%
30 C
80 %
90 m3
Kurtz GmbH
Sept.2002 Al-Ri-us
page 73
To be observed during drying:

l Boiling point of pentane: 36 C
l Pentane diffusion out of beads into surrounding
atmosphere with high drying temperature and
duration
Lost and no longer expandable EPS beads

Kurtz GmbH
Sept.2002 Al-Ri-us
page 74
Practical storage data

l Depending on material type and density storage
times of 5 48 hours are needed
l The silo air is recommended to be exchanged 6
times per hour
Kurtz GmbH
Sept.2002 Al-Ri-us
page 75
How to dry ?
l Natural ventilation resp. storage
l With medium-sized silos (approx. 1000 m3):
Use explosion safe and slow running axial
fans installed in the immediate floor area.
Capacity:
up to 6000 m3air/h
900 rpm
approx. 1 kW
Kurtz GmbH
Sept.2002 Al-Ri-us
page 76
Electric energy usage during transport

and storage:
l Bead transport into the storage silos:
Capacity and use of blowers depends on the transport
distance and speed
l Bead storage in the silos:
Capacity and use of blowers depends on
- size of storage silos
- air temperature
- material properties of beads
Kurtz GmbH
Sept.2002 Al-Ri-us
page 77
Energy Agenda
Re: Steam consumption Planning Stage
No.
Action required
Stainless steel expansion vessel cp = 0.51, instead of alu cp

= 0.92 [kJ/kg x K].
Complete insulation of expansion vessel against heat
radiation
2
3
Done
Draw blowing air for filling and discharge from the warm air
zone in the lid area of the pre-expander.
Kurtz GmbH
Sept.2002 Al-Ri-us
page 78
Energy Agenda
Re: Steam consumption - Production
No.
Action required
Proper adjustment of passage through the by-pass valve for

discharge of air, pentane and exhaust steam.
Select saturated steam temperature according to the material
to be processed.
Done
3
4
5
6
7
Kurtz GmbH
Sept.2002 Al-Ri-us
page 79
Energy Agenda
Re: Steam consumption - maintenance
No.
Action required
Done
Regular control of steam and condensate installation
Tightness control at material inlet and outlet
Check steam inlet in floor area (slotted metal sheet of wedge

wire system) regularly concerning free passage.
4
5
6
7
Kurtz GmbH
Sept.2002 Al-Ri-us
page 80

Energy Consumption Preexpanding

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Energy Consumption Preexpanding

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Energy Usage During

Energy Usage During Pre-expansion, Transporting and Storage

Energy Usage During Pre-expansion, Transporting and Storage

Energy Usage During Pre-expansion, Transporting and Storage

Energy Usage During Pre-expansion, Transporting and Storage

Conditioned for final product

Energy Usage During Pre-expansion, Transporting and Storage

Conditions for the pre-expansion process:

Energy Usage During Pre-expansion, Transporting and Storage

l Second pass expanders

Energy Usage During Pre-expansion, Transporting and Storage

This presentation is limited to:

Examination of Energy Balance Sheet

Energy Usage During Pre-expansion, Transporting and Storage

Why limitation to batch pre-expansion

l Low densities in large quantities

Energy Usage During Pre-expansion, Transporting and Storage

l Almost universally usable pre-expanders

Energy Usage During Pre-expansion, Transporting and Storage

Cellular wheel sluice

Energy Usage During Pre-expansion, Transporting and Storage

l Raw material conveying

to the weighing unit

Energy Usage During Pre-expansion, Transporting and Storage

l Feeding into dosing tank

Side channel fan

Energy Usage During Pre-expansion, Transporting and Storage

Energy Usage During Pre-expansion, Transporting and Storage

l Discharge into the fluid bed

Energy Usage During Pre-expansion, Transporting and Storage

l Sieving of pourable beads

Energy Usage During Pre-expansion, Transporting and Storage

Energy Usage During Pre-expansion, Transporting and Storage

Steam as energy user

Energy Usage During Pre-expansion, Transporting and Storage

Heat transfer to bead:

Energy Usage During Pre-expansion, Transporting and Storage

approx. 0,8 1,8 % pentane

Energy Usage During Pre-expanding, Transporting and Storage

Expansion of the bead:

EPS raw material at

EPS raw material

Bead expands to required

Energy Usage During Pre-expansion, Transporting and Storage

(Vessel and radiation not considered)

Energy Usage During Pre-expansion, Transporting and Storage

Energy supply to beads

Energy Usage During Pre-expansion, Transporting and Storage

Spec. Heat capacities :

cpsteel = 0,46 [kJ/kg x K]

Enthalpy steam (pe):

with 0,3 bar steam pressure

Energy Usage During Pre-expansion, Transporting and Storage

Temperature difference DTEPS:T1 = Tbeads room temp. = 20 C

Energy Usage During Pre-expansion, Transporting and Storage

mEPS = Vvessel net x SD

Energy Usage During Pre-expansion, Transporting and Storage

1 m3 Volume of expansion vessel is:

Energy Usage During Pre-expansion, Transporting and Storage

Expansion energy EPS: QEPS = mEPS x cpEPS x DTEPS

mDC = QEPS / rsteam

Energy Usage During Pre-expansion, Transporting and Storage

Steam usage per kg EPS: