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Source: EREMA 
EREMA RECYCLING NEWS
Edition 2006/2007
(PDF, 1,68 MB, 24 p.) MPR: one
unit does it all (p.12)
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HOME 
Archiv 2006
02.09.2006 New Erema MPR - Multi Purpose Reactor |
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Pre-drying, crystallising and decontaminating PET in one single, compact unit: the new Erema MPR - Multi Purpose Reactor Users are interested in eliminating those issues. With the Multi Purpose Reactor (patent pending), being available as of now in two sizes for throughputs of 500 - 700 and 1000 - 1500 kg/h, Erema offers a wide range of customers a new, innovative product that can help against the problems mentioned above.
The reactor consists of a vacuum vessel in which non-dried amorphous PET raw materials (granulate, bottle flakes or similar) are fed in continuously or semi-continuously through a vacuum lock. Specially shaped rotating tools inside the vessel generate thermal energy that is transferred to the material through friction and create turbulence in the material to prevent clumps forming while it heats up and passes through the crystallisation point. EXTREMELY EFFICIENT, ENERGY SAVING DRYING PROCESS At a constant processing temperature of 200 to 220 oC and a vacuum to below 1 mbar a very efficient, highly accelerated drying process takes place inside the reactor. Let us remember: the laws of physics dictate that the evaporation point of water is just 7 oC at a pressure of 10 mbar, and is minus 2.3 oC at 5 mbar! With as much as 1.5% inherent moisture and moisture peaks of up to 3% brought in on the surface of material - either due to condensation problems in silos, or when using post-consumer material, for example - is evaporated in a flash at the temperatures and pressures inside the reactor. Residual moisture is therefore very effectively eliminated within the shortest possible time. This ensures that moisture peaks in the starting material are effectively eliminated prior to processing in the extruder without having a detrimental, destabilising influence on the downstream extrusion process. The unit is also well insulated so external thermal energy supplies (dried, heated air, for example), are not required. At around 0.1 kW per kg of material processed, the MPR is extremely economical regarding the amount of specific energy consumed. This is around half the power consumption of conventional crystallisers and dryers utilised for the same purpose. The product discharged continuously or semi-continuously through a second chute is crystallised PET material with uniform residual moisture values of below 100 ppm, which is quite sufficient for most applications; in special cases it is also possible to achieve lower residual moisture values by modifying the settings of the unit slightly. The product is then fed direct to the downstream extrusion system. The feed system on the existing extruder needs to be taken into account here. There are several concepts that can be used depending on whether the existing extruder can be fed under vacuum - the ideal situation, or at atmospheric pressure; whether the reactor can be mounted directly above the extruder, or whether due to lack of space it needs to be installed further away. The shorter the path to the extruder the lower the risk of the processed PET material, which emerges from the reactor at between 200 and 220 oC, cooling down or absorbing moisture. UNIQUE SELLING PROPOSITION: FOOD AND DRINK APPROVED The Multi Purpose Reactor for crystallising and pre-drying in vacuum is suitable for various applications throughout the whole PET market.
This will be of special interest in particular to all those potential customers in the PET product or food/drink packaging markets who want to add recycled material to their product portfolio. RETRO-FIT TO EXISTING EXTRUDER FACILITIES The MPR presents a real alternative extending beyond the recycling sector to the whole PET branch in combination with existing extrusion systems for manufacturing bottles, fibres, flat film and other packaging applications. FLEXIBLE Compared to conventional crystallisers and pre-dryers the MPR allows a much quicker change in product. It is therefore especially interesting for companies that process comparatively small batches of each material. The same unit is also able to process new materials that are currently penetrating the market such as PLA, PEN, PET/PE Multilayer etc. MAINTENANCE-FRIENDLY Clogging, sticking, clumping or sintering of the processed PET material are things of the past with the MPR. The small amounts of dust that form during dynamic treatment in the MPR are removed effectively by vacuum through special filter systems. Initial applications have shown that the level of maintenance required with the MPR is much lower than for conventional systems with separate crystallisers and dryers, plus it maintains stable drying conditions. PROVEN IN PRACTICE At Skylight, a Danish PET film
manufacturer where the first MPR prototype has been in operation for over
DEMONSTRATION UNIT AT EREMA'S TECHNICAL CENTRE From the summer of 2006 there will be a full-scale MPR with a capacity of 500 kg/h available for tests and demonstrations at Erema's Technical Centre so customers can obtain a realistic impression of the capabilities of this new Erema technology while processing their own PET materials. Click to contact Your contact persons, in EREMA, pleas.
Related links on IP PETrecycling.cz in English only: More articles on IP PETrecycling.cz:
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