PRODUCTION | ENERGY MANAGEMENT
Above: Farrel Pomini’s Compact Processor continuous mixers are claimed to offer reduced energy consumption and operating cost
Compeo features a unique process chamber where elements of very different geometry and shape can be combined,” he says. “The combination of two, three and four flight elements in the primary melting and mixing zones, for instance, can significantly improve the processing effectiveness and thus reduce losses. Another development of the Compeo series is a high energy density electric heating system with a water evaporation cooling system. Particularly for high temperature com- pounding applications like filled engineering plastics, such a system can drastically reduce thermal losses when compared to a liquid oil heating system.”
Right: Farrel Pomini says its latest Synergy control system is helping customers optimise their operations
Energy incentives Kudrass sees energy efficiency playing an increas- ingly important role in compounding plant decisions. “As the unit cost of energy increases, the economic incentive for optimising energy efficiency in polymer compounding will also increase. As a result of this, energy management considerations are playing a growing role in the development of processing aids, in the design of processing machinery and in layout of compounding plants,” he says. And with energy costs likely to rise, he advises
that cost-versus-benefit calculations for energy efficiency optimisation are not made based on present energy costs, but on the basis of likely future expenses. “Such predictions can be difficult to make, but even benefit calculations with con- servative future cost estimates usually yield much higher return on investments than those using current energy prices.” According to Paul Lloyd, President & Business
Unit Director at Farrel Pomini, the big energy user in any compounding plant is the compounding process itself. “A good energy management strategy in the plastics compounding plant starts with the
34 COMPOUNDING WORLD | February 2021
www.compoundingworld.com
equipment choice,” he says. “Different types of compounding equipment have distinct levels of heat generation and energy efficiency. Selecting an energy efficient compounder, such as a Compact Processor [the type of machine manufactured by the company], can result in 10-15% lower energy consumption during the primary mixing process.” In addition to equipment selection, plant layout and philosophy are important, he says, pointing out that good design can save space, reduce distances for the material to travel throughout the process, and significantly reduce power needs. According to Lloyd, there are a number of points to consider for efficient energy use. These include: n Selecting the most appropriate equipment and making sure it is maintained properly and running efficiently;
n Seeking out opportunities for upgrades. A more energy efficient motor, for example, can provide a rapid return on investment and have a signifi- cant impact on energy consumption;
n Training staff to a high level to ensure equipment is run correctly, without waste or unnecessary consumption;
n Consulting with equipment specialists to ensure process parameters are optimised to achieve better energy efficiency. “One of our more recent developments that has
a large impact on a customer’s compounding operation is the Farrel Pomini Synergy control system. This is a very user-friendly, visually driven platform and provides integrated control of the mixer, feeder, upstream and downstream equip- ment,” says Lloyd. “We also conduct a significant amount of development work on the coatings we use on major wear components, such as rotors and the mixing chamber. One special wear coating for the mixing chamber liner has the potential to increase the throughput rate without any increase in power.
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IMAGE: FARREL POMINI
IMAGE: FARREL POMINI
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