Energy For Productivity

Where the energy flows when moulding
Kurtz GmbH
09.09.2002 kb.sme
Survey01.ppt
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 kb.sme
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Page 2
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 kb.sme
Survey01.ppt
Page 3
Energy usage
with batch pre-expanders
when moulding
Kurtz GmbH
09.09.2002 kb.sme
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Page 4

Batch pre-expander
Energy supply
Pre-Expansion Vessel
Raw Material
Sieve
Dampf
Fludi Bed
..
.... ..
Weighing Device
Cellular Wheel Sluice
Kurtz GmbH
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Page 5

Batch pre-expander
Steam usage consists of:

Steam requirement of EPS beads
Steam requirement of expansion vessel
Radiation loss through continuous venting
Kurtz GmbH
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Page 6

Batch pre-expander
Pre-expander steam users

Dampfverbraucher
7%
32%
61%
Dauerentlftung
Material
Verluste
Kurtz GmbH
09.09.2002 kb.sme
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Page 7

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 kb.sme
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Page 8

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 kb.sme
= maximum steam usage!

Survey01.ppt
Page 9

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 kb.sme
Survey01.ppt
Page 10

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

Kurtz GmbH
09.09.2002 kb.sme
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Page 11

Batch pre-expander
Pre-expanders for every throughput requirement!

VSD6300
VSD1000
VSD100

Kurtz GmbH
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Page 12
Energy Usage
with batch pre-expanders
when moulding
Kurtz GmbH
09.09.2002 kb.sme
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Page 13

Shape moulding machine
Energy costs with moulding production

Kostenverteilung
11%
4%
Dampf
7%
Luft
Vakuum
58%
20%
Wasser
Strom
Kurtz GmbH
09.09.2002 kb.sme
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Page 14
Energy usage
Filling air
Steam
Kurtz GmbH
09.09.2002 kb.sme
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Page 15

Air usage with pressure filling
Luft
Luft
Users:
Fill injectors
Pressure fill tank
SAir = VInjector + VVessel

Kurtz GmbH
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Page 16


Air usage during filling depends on:
Tank pressure
Filling time
Fill injector design
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Page 17

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 kb.sme
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Page 18

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 kb.sme
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Page 19


Tank pressure
Filling time
Kurtz GmbH
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Page 20

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 kb.sme
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Page 21


Tank pressure
Filling time
Kurtz GmbH
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Page 22

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 kb.sme
Survey01.ppt
Page 23


Comparison of the loading:
Material quantity
Loading =
Air quantity
Transport capacity of the fillers is considered

Kurtz GmbH
09.09.2002 kb.sme
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Page 24

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 kb.sme
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Page 25

Fill injector influences

Comparison of filling costs
Filling costs = Air costs + Machine costs
Time factor is considered

Kurtz GmbH
09.09.2002 kb.sme
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Page 26


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 kb.sme
Survey01.ppt
Page 27

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 kb.sme
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Page 28
Energy usage
Demoulding air use
Steam
Kurtz GmbH
09.09.2002 kb.sme
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Page 29

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 kb.sme
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Page 30


Demoulding
only with transfer and ejection air
supported by mechanical ejectors
with AZA demoulding support
Kurtz GmbH
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Page 31

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 kb.sme
Survey01.ppt
Page 32

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 kb.sme
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Page 33

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 kb.sme
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Page 34

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 kb.sme
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Page 35
Energy usage
Air
Steam
Kurtz GmbH
09.09.2002 kb.sme
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Page 36

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 kb.sme
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Page 37
Energy usage
Air
Steam saving with the proper mould
Kurtz GmbH
09.09.2002 kb.sme
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Page 38

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 kb.sme
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Page 39

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 kb.sme
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Page 40

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 kb.sme
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Page 41

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 kb.sme
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Page 42
Energy usage
Air
Steam saving with the proper adjustment
Kurtz GmbH
09.09.2002 kb.sme
Survey01.ppt
Page 43

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 kb.sme
Survey01.ppt
Page 44

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 kb.sme
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Page 45

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 kb.sme
Survey01.ppt
Page 46

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 kb.sme
Survey01.ppt
Page 47

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 kb.sme
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Page 48
Energy usage
Air
Steam saving with the proper steam

chamber
Kurtz GmbH
09.09.2002 kb.sme
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Page 49


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 kb.sme
Survey01.ppt
Page 50

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 kb.sme
Survey01.ppt
Page 51

Example calculation:
100 mm spacer frame is not removed
Saving potential approx. 30.000 p.a.
Kurtz GmbH
09.09.2002 kb.sme
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Page 52
Energy usage
Energy saving with the proper production

method
Kurtz GmbH
09.09.2002 kb.sme
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Page 53

Comparison of production process
Selection of the production process

Vacuum technology
LTH- Classic
LTH- Eco
Kurtz GmbH
09.09.2002 kb.sme
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Page 54

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 kb.sme
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Page 55

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 kb.sme
Survey01.ppt
Page 56

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 kb.sme
Survey01.ppt
Page 57

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 kb.sme
Survey01.ppt
Page 58

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 kb.sme
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Page 59

Determination of producion costs
Company-specific data
Machine-specific data
Mould-specific data
Process-specific data
Kurtz GmbH
09.09.2002 kb.sme
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Page 60

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 kb.sme
Survey01.ppt
Page 61

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 kb.sme
Survey01.ppt
Page 62
Energy for Productivity

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 kb.sme
Survey01.ppt
Page 63

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 kb.sme
Survey01.ppt
Page 64

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 kb.sme
Survey01.ppt
Page 65

Energy For Productivity

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Where the energy flows when moulding

Shape moulding production, energy-wise

l Energy usage in shape moulding

l Comparison of shape moulding production methods

Shape moulding production, energy-wise

Shape moulding production, energy-wise

with batch pre-expanders

Shape moulding production, energy-wise

Cellular Wheel Sluice

Shape moulding production, energy-wise

Steam usage consists of:

Shape moulding production, energy-wise

Pre-expander steam users

Shape moulding production, energy-wise

Influence of continuous venting

low densities are not achievable

Goal: increased steam concentration in the steam-air

Shape moulding production, energy-wise

Dam pfverbrauch [kg/Zyklus]

Steam usage and density

minimum density = maximal expansion

= maximum steam usage!

Shape moulding production, energy-wise

Usage and weighed-in quantity

spez. Dampfverbrauch [kg/kg]

Masse EPS [kg]

Always use your full capacity!

Shape moulding production, energy-wise

Usage and weighed-in quantity

specific steam usage:

spez. Dampfverbrauch [kg/kg]

Masse EPS [kg]

the specific steam usage sinks with increased capacity usage

Always use your full capacity!

Shape moulding production, energy-wise

Pre-expanders for every throughput requirement!

Always use your full capacity!

Shape moulding production, energy-wise

with batch pre-expanders

Shape moulding production, energy-wise

Energy costs with moulding production

Shape moulding production, energy-wise

Shape moulding production, energy-wise

Air usage with pressure filling

SAir = VInjector + VVessel

Shape moulding production, energy-wise

Air usage with pressure filling

Shape moulding production, energy-wise

Comparison of air quantities with increased tank pressure

Shape moulding production, energy-wise

Comparison of total air usage with increased tank pressure

Air usage increases with tank pressures over 1 bar!

Shape moulding production, energy-wise

Air usage with pressure filling

Shape moulding production, energy-wise

Influence of increased tank pressure on filling time

The higher the tank pressure, the faster the filling!

Shape moulding production, energy-wise

Air usage with pressure filling

Shape moulding production, energy-wise

Choice of fill injectors

Shape moulding production, energy-wise

Choice of fill injectors