Extrusion Plant Research Articles

Developing a solar PV system for cost-effective electricity reduction in an aluminium extrusion plant

Abstract The demand for solar photovoltaic systems has been steadily increasing over the years, driven by the collective goal to reduce both CO2 emissions and electricity bills in order to foster a sustainable world. Industries with high energy consumption, particularly manufacturing, are actively pursuing the establishment of more sustainable plants to align with net-zero objectives. The primary aim of this project is to design a solar photovoltaic system tailored for an aluminium manufacturing plant, with the intent to curtail electricity consumption and minimize CO2 emissions by harnessing and utilizing energy generated from the photovoltaic system. The comprehensive analysis encompasses meteorological data, daily load demand configuration, photovoltaic array assessment, and simulation of grid-connected inverter sizing through the utilization of PVsyst software. According to the simulation results, the collective operational capacity of the solar photovoltaic system reaches 5240 kWp, effectively meeting 85% of the factory’s maximum demand. To fulfil the plant’s requirements, a total of 12780 panels are necessary. The analysis reveals that this solar system can generate a total of 7,609,690 kWh annually, constituting approximately 26.10% of the total electricity bill for the year 2022, amounting to 29,146,841.28 kWh. The estimated savings from implementing this solar solution amount to around RM 2,701,518 per year. Moreover, the solar system significantly reduces CO2 emissions by an annual total of 4,224.467 tons, contributing to a healthier surrounding environment. The anticipated return on investment, as per the PVsyst projections, is expected to occur within approximately 3.4 years.

Extrusion plant microtube synthesis of micron-sized nitrogen-doped hollow porous carbon nanosheets for high rate and high energy density supercapacitors

Extrusion plant microtube synthesis of micron-sized nitrogen-doped hollow porous carbon nanosheets for high rate and high energy density supercapacitors

ОПТИМІЗАЦІЯ КАСКАДНОЇ СХЕМИ ВИСОКОШВИДКІСНОЇ ЕКСТРУЗІЇ

Plastics are one of the most common materials. Due to its high technical and economical characteristics, this class of materials is used in almost all industries, that is why further growth of the production of plastic products is predicted. Today, the biggest problem in the field of polymer processing by extrusion is to ensure the best possible parameters of resource-energy efficiency of equipment. At the same time, the creating of compounds based on polymers is developing very actively, which requires more flexibility from extrusion lines, since a large number of compositions which differ in their characteristics can be developed on the base of a polymer. The factors listed above have led to cascade extrusion lines become increasingly wide-spread in industry today. Analysis of the extrusion equipment market showed that the schemes with a high-speed double-string extruder at the first stage is more popular. However, the desired mixing quality can be achieved by using a much simpler disc extruder. The article is a review that aims to determine the possibility and feasibility of more efficient arrangement of a cascade scheme for processing composite materials using a disk extruder. Theoretical and experimental studies have shown that melting processes are more efficient in the field of high shear rates at low pressures. Disk extruder is great option for that objective. In this scheme, it is proposed to use a dose feed disk extruder as a homogenizer, and a gear pump as a metering device which allows to reduce pressure and capacity fluctuations before forming device to less than 1%. As a result, it has been determined that the proposed design of the extrusion plant will be more energy efficient than the options on the market and will be able to significantly reduce pressure and performance fluctuations at the inlet to the forming device.

Qualitative and quantitative interdependence of mechanical properties of industrially extruded AA6063 alloy on process parameters and profile characteristics

PurposeThis study aims to investigate and model interrelationships between process parameters, geometrical profile characteristics and mechanical properties of industrially extruded aluminum alloys.Design/methodology/approachStatistical design of experiments (DOE) was applied to investigate and model the effects of eight factors including extrusion ratio, stem speed, billet-preheat temperature, number of die cavities, quenching media (water/air), time and temperature of artificial aging treatment and profile nominal thickness on four mechanical properties (yield strength, ultimate tensile strength, percent elongation and hardness). Experiments were carried out at an actual extrusion plant using 8-in. diameter billets on an extrusion press with 2,200 ton capacity.FindingsMain factors and factor interactions controlling mechanical properties were identified and discussed qualitatively. Quantitative models with high prediction accuracy (in excess of 95%) were also obtained and discussed.Practical implicationsThe obtained results are believed to be of great importance to researchers and industrial practitioners in the aluminum extrusion industry.Originality/valueAll practical and relevant parameters have been used to model all important mechanical properties in a collective manner in one study and within actual industrial setup. This is in contrast to all previous studies where either a partial set of parameters and/or mechanical properties are discussed and mostly under limited laboratory setup.

Spider-based FOPID controller design for temperature control in aluminium extrusion process

Abstract Based on the exit temperature in the aluminium extrusion process, the quality of the aluminium bars is obtained in the industries. Control of temperature plays a significant role to obtain the quality of the aluminium bars or rods. Problems are still encountered in the design of proper temperature control schemes in the industries. A new control scheme is presented here, to address the temperature control in the aluminium extrusion process. Spider-based fractional-order PID controller scheme is simulated for the aluminium extrusion plant using MATLAB and its toolbox. It gives the improved result for reducing the time delay, rise time and settling time in the process. Integral square error performance criteria are considered an objective function. The minimization of objective function gives good results. Comparisons of the presented control scheme with the conventional control methods are presented.

The Role of Middle Management and the Mediation of Artifacts in the Process of Organizational Change

The present article proposes a reflection on the skills that organizations and managers need to develop to deal with the processes of change, mediated by artifacts influencing routines. The qualitative descriptive methodology employed was a case study in a plastic extrusion plant, where the change in routine was mediated by several artifacts that played unequivocal roles in the process: as mechanisms for recording information, for communication, for horizontal and vertical alignments, as a means of ensuring the execution of the routine, and as problem-solving facilitators. The results found help to understand how middle management led the change in the organization, acting as a facilitator and articulator of the process, based on the skills of communication, awareness, alignment and proximity, shared vision, and engagement, mediated by various artifacts. These skills favored the creation of a relationship of interdependence and interconnection between multiple agents, and the intelligent use of artifacts, creating autonomy and greater space for spontaneous exchanges. For the organization, it had a positive impact on performance, prompting the reflection that the future of management permeates the manager's capacity for agency to create an environment of interconnection based on communication, respect and mutual trust, where artifacts can play their enabling role.

Estimation of glass lubricant viscosity for hot extrusion of Cr-Ni steel and Ni alloy tubes

Purpose. Estimation of optimal viscosity of a glass lubricant for chromium-nickel steel tube extrusion depending on the deformation resistance, chemical composition of metal and the temperature, degree and rate of deformation. Methodology. To determine the force conditions for tube extrusion, a complex factor of deformation resistance was used, which consists in estimating the value of deformation resistance under the basic process parameters of extrusion plants and its refinement depending on the deviations of heating temperature and wall thickness of billets as well as the degree and rate of deformation from the base conditions. Findings. The dependence of basic values of deformation resistance on the percentage of alloying elements (Ni + Cr) in steels has been found. With the addition of hardening alloying elements (Mo, W, V, Nb) into the alloy steel, its deformation resistance increases in proportion to their percentage. Analytical expressions for calculating the base values of deformation resistance for different extrusion plants have been obtained. Originality. For the first time, the principles governing estimation of the optimal viscosity of glass lubricants based on the chemical composition of steel to be formed, its temperature and the degree and rate of deformation of the blank, thickness of the lubricating layer and geometric dimensions of the tool (die) in hot extrusion of tubes have been established. Practical value. The use of the results of calculation according to the developed method will make it possible to increase the surface quality of tubes manufactured by extrusion and reduce the volume of their subsequent machining.

Zeolites as effective desiccants to solve hygroscopicity issue of post-consumer mixed recycled polyolefins

The issue addressed in this study concerns the hygroscopicity of post-consumer mixed recycled polyolefins (PCMP). PCMP commonly incorporate polar contaminants, responsible of their moisture sorption and bad smell; as a consequence, it is necessary to dehumidify the recycled material before processing it. This represents a strong technical limitation, since polyolefin converters are not generally equipped with dehumidification plants, so hindering the future circular economy perspectives for these recycled materials. In order to address this issue, in this study we proposed an easy and innovative solution, alternative to drying and based on the use, never considered before, of zeolites as desiccant additives during PCMP extrusion. At this regard, we prepared, on a pilot scale extrusion plant, several material formulations based on undried PCMP loaded with different amounts and types of zeolites, with and without a compatibilizing agent. The obtained systems were submitted to mechanical tensile test to assess the effectiveness and the technological relevance of the proposed strategy with regard to conventional heat drying and a calcium oxide-based desiccant, specially marketed for processing recycled polyolefins.Results showed that the addition of either type of zeolites at 2 wt% loading has an effective desiccant function during PCMP processing and, with respect to heat drying or calcium oxide desiccant, ensures higher strength of the resultant systems (up to ca. 15% and 40%, respectively). Moreover, the use of the compatibilizing agent improves the mechanical performances until they are a little better than those of the heat dried PCMP.Therefore, in a sustainability perspective of the packaging industry, the proposed strategy can offer a tangible contribution to improve the plastic packaging circularity and to reach the EU plastic recycling targets.

Effect of the ratio of wheat flour and cassava and process parameters on the pellet qualities in low starch feed recipe extrusion

The purpose of the investigation was to study the effects of the ratio of wheat flour and cassava and extrusion process parameters on the physical qualities of low-starch content floating feed in a pilot extrusion plant in order to transfer the production characteristics to scale manufacture. The results show that with an increase of cassava content in formulations, the feed pellet bulk density decreases. When the cassava content is ≥ 54.3 g/kg (wt), the floatability of feed pellet reaches 100 %. The feed pellet hardness depends significantly on the starch sources (P < 0.05). The ratio of wheat flour and cassava in a recipe has significant but irregular impacts on the feed pellet water stability. A wheat flour/cassava ratio (54.3/54.3) was selected as an optimal formulation. For the optimal recipe, a pilot extrusion trial shows that an increase of moisture content and die temperature gives a decrease in the feed pellet bulk density, then an increase in pellet floating possibility. Based on Response Surface Methodology, the optimal parameters for processing the selected recipe are moisture content 32 % (wt), screw speed 247 rpm and die temperature 135 ℃. A theoretical model was also applied to cross-check the results from Response Surface Methodology.

Design and Selective Laser Melting Manufacturing of TPE Extrusion Die

In presented work, extrusion die made by maraging steel used in TPE processing was optimised by means of flow dynamics of the final part. Maraging steel Ni-18 (M300) die were produced by Selective Laser Melting (SLM) using AM125 machine provided by Renishaw. The developed and manufactured extrusion die has not been processed by finishing the process, i.e. grinding, polishing or sandblasting. The tests were carried out using TPE industrial extrusion plant. Moreover, designed extrusion die to decrease weight and save the material; the design was hollow. The presented results indicate that the SLM technique is a promising method for the production in one production process the extrusion dies used in the TPE extrusion process with complex internal walls, with high accuracy, high speed and at low costs and own outlays. Moreover, this technique gives the constructors possibilities to design very complicated shapes of profiles with more than one of the working areas (bubbles) or design co-extrusion dies. Application of SLM technique allows to manufacture air ducts with pipe connectors to fasten an air, hence eliminating from the process expensive and time-consuming electrical discharge machining.

Modernisation of Lighting Systems of a Casting and Extrusion Plant in Krasnoyarsk

The article describes modernisation of the lighting systems of Segal Casting and Extrusion Plant LLC in Krasnoyarsk and technical solutions of its implementation. The parameters of the new lighting system based on Diora Craft LED luminaires are presented and it is shown that replacement of luminaires based on high pressure mercury lamps (HPML) with LED luminaires allows saving 73.5 % of power consumed by lighting with high quality of the light environment established in the shops of the plant. Payback period of such modernisation is 1 year.

IMPROVING PERFORMANCE IN AN ALUMINUM EXTRUSION PLANT USING DISCRETE EVENT SIMULATION: A CASE STUDY

Simulation has been used in many industrial applications for performance improvement. It excels over other system analysis methods in its high flexibility and ability to model system details with high accuracy. In this study, Discrete Event Simulation (DES) is used to improve the performance of an aluminum extrusion plant. A case study is presented in a local factory in which problems are identified, and their effects on efficiency are monitored. The main problem noticed was high production rates with respect to demand rates which resulted in large amounts of work-in-process (WIP) inventory. It was found that the current base system is unstable and suggestions were made to lower production rates in order to stabilize it. Average WIP was reduced by 324% once the system was stabilized with only 1.77% difference in weekly throughput which improved the system considerably. Next, alternatives were suggested to improve throughput and reduce WIP while maintaining stability. The alternative with optimized batch sizes had the best improvement in throughput of 3.54%. The combined model with optimized batch sizes and an added pool for chemical treatment had the most WIP versus other alternatives.

Prediction of liquid nitrogen die cooling effect on the extrusion process parameters by means of FE simulations and experimental validation

The temperature monitoring during aluminum extrusion is a crucial task performed in order to avoid profile defects, to increase the die life and to optimize the process productivity. Among the different available systems used to control the process temperatures, in the last decade, the die cooling through liquid nitrogen has been installed on several extrusion plants. In order to provide extruders and die makers with a modelling tool able to gain a better understanding of the extrusion and die thermal field, a numerical model of the extrusion that accounts for liquid nitrogen cooling has been developed in the present work. A simplified 1D modelling of the cooling channel was used and validated against an experimental investigation previously specifically carried out to evaluate the cooling efficiency in a multi-hollow industrial profile. Results showed a significant impact of the design aspects of channel on the thermal efficiency of the cooling and an important heat removal when the liquid nitrogen cooling is used. A good experimental-numerical agreement was achieved in terms of temperature map and extrusion load both in cooled and uncooled conditions, thus suggesting the reliability of the developed simulation tool and its potential integration in a flexible procedure to be used for die/cooling system design and process optimization.

A computer-aided unit process sustainable modelling for manufacturing processes: case for extrusion process

ABSTRACTSustainable manufacturing assessment is meant to ensure that products are manufactured such that negative environmental impacts are reduced by conserving energy and managing the use of natural resources as well as ensuring economical soundness for the process. The main objective of this work is to introduce sustainable development methodology/models for manufacturing processes. For this purpose, the paper utilizes background data, develops a computer model and presents detailed case studies. This paper will identify and adopt key performance indicators (KPIs) and utilize these to assess the sustainability of extrusion process and their designs. Different manufacturing parameters such as material types, product specifications and manufacturing tools are considered in the process of measuring sustainability. The proposed computer model is verified with data obtain from actual aluminium extrusion plants.

Respiratory Disorders in Aluminum Extrusion Workers

The present study determined the prevalence of work-induced respiratory symptoms among Sudanese extrusion workers in an aluminum (Al) extrusion plant where the health effects of exposure duration, S-Al, and U-Al concentrations were evaluated. A total of 109 workers were enrolled in our study. Ambient Al fumes was estimated using a flame atomic absorption spectrophotometer (Varian, Spectr AA-250).

Study and Analysis of Equipment Availability Using TPM Tools in an Extrusion Plant

Study and Analysis of Equipment Availability Using TPM Tools in an Extrusion Plant

Energy-Exergy Analysis and Carbon (IV) Oxide Emission of an Aluminium Extrusion Plant in Nigeria

Energy security, cost of production and environmental constraints have necessitated the need for proper energy utilisation in the manufacturing industries. This work analysed energy and production data from an aluminium extrusion plant in Lagos, Nigeria for energy efficiency, exergy efficiency (or process efficiency), energy cost per unit of production, CO2 emission and pollution rate index. The input-output energy analysis method was used to estimate the embodied energy intensity. The pollution rate, energetic and exergetic efficiencies were estimated from the exergy analysis. The CO2 emission was estimated from IPCC guideline on greenhouse inventories and the energy cost of unit produce was estimated from energy cost accounting method. The five-year average thermal and electrical utilisation ratio was 45/55, which deviated from the 70:30 of the global best practices. The embodied energy intensity for the five years’ ranges between 2.31 - 162.3 GJ/t which is in excess of the recommended range of (2.9 - 3.2 GJ/t). The mean energy efficiency for the five year was 79.4% and the mean exergetic efficiency was 57.8% indicating that production was well managed (>50%) with energy wastages very high in boiler energy conversion. The total energy used was 16 MJ and CO2 emitted is 1.01 × 1011 g during the study period. The average pollution rate index for the plant was 0.8695 indicating that the plant is negatively impacting the environment due to technological limitation of the energy conversion process employed in the manufacturing plant. The study reveals a distortion of the recommended best practice in energy balance ratio which accounted for the high average cost of production (N 4418.3/t); process efficiency was generally low thereby negatively affecting industrial output for the company.

The worm-gear extruder during processing the polymeric materials

The paper presents the analysis of the main schemes of extrusion plants, and the main parameters that affect the performance pulsation in worm extruder without gear pumps.It is considered analysis and experimental research of productivity and its fluctuations in the classic worm extruder and in the same extruder with gear pump

Retrofitting industrial in electrical motor type: A matter of energy efficiency and reduction of maintenance

This report aims to identify, in terms of economic and technical aspects, an electric motor whose characteristics meet a proposed replacement of a direct current (DC) motor in an aluminum extrusion plant, whose preventive maintenance has in the last years, the problem of technical and operational orders. Data relating to the preventive maintenance of motors in operation were used to estimate the performance of an induction motor in combination with an inverter for speed and torque control. The advantages were determined, and the investment costs can be reduced by maintenance. It was observed that the market offers an innovative solution by the use of a permanent magnet synchronous motor (PMSM), which is a brushless, alternating current (AC) motor, with reduced dimensions, and offers the same power as a three-phase induction motor (TPIM). Joule losses in the rotor are negligible because the rotor is fit internally with rare-earth-doped neodymium-iron-boron permanent magnets, which also minimizes motor temperature, thereby increasing its useful life. Estimates determined that the gains derived from preventive maintenance would be even greater than those expected for the induction motor. Simulations conducted in MATLAB showed that, in terms of energy efficiency, the PMSM is presently the most appropriate replacement for the DC motor. Key words: Brushless, permanent magnets, preventive maintenance, retrofitting, electric motor.

Investigation of the process energy demand in polymer extrusion: A brief review and an experimental study

Extrusion is one of the fundamental production methods in the polymer processing industry and is used in the production of a large number of commodities in a diverse industrial sector. Being an energy intensive production method, process energy efficiency is one of the major concerns and the selection of the most energy efficient processing conditions is a key to reducing operating costs. Usually, extruders consume energy through the drive motor, barrel heaters, cooling fans, cooling water pumps, gear pumps, etc. Typically the drive motor is the largest energy consuming device in an extruder while barrel/die heaters are responsible for the second largest energy demand. This study is focused on investigating the total energy demand of an extrusion plant under various processing conditions while identifying ways to optimise the energy efficiency. Initially, a review was carried out on the monitoring and modelling of the energy consumption in polymer extrusion. Also, the power factor, energy demand and losses of a typical extrusion plant were discussed in detail. The mass throughput, total energy consumption and power factor of an extruder were experimentally observed over different processing conditions and the total extruder energy demand was modelled empirically and also using a commercially available extrusion simulation software. The experimental results show that extruder energy demand is heavily coupled between the machine, material and process parameters. The total power predicted by the simulation software exhibits a lagging offset compared with the experimental measurements. Empirical models are in good agreement with the experimental measurements and hence these can be used in studying process energy behaviour in detail and to identify ways to optimise the process energy efficiency.