EUROMAP Extrusion Blow Moulding Machines Determination of Machine Related Energy Efficiency Class. Version 1.0, January pages

Transcription

1 EUROMAP 46.1 Extrusion Blow Moulding Machines Deterination of Machine Related Energy Efficiency Class Version 1.0, January pages This recoendation was prepared by the Technical Coission of EUROMAP. EUROMAP Technical Coission c/o VDMA FV KuG Lyoner Str. 18 DE Frankfurt a Main Phone + 49 (69) Fax + 49 (69) euroap@vda.org

2 Contents Page 1 Introduction Scope and application References Definitions Total energy consuption Total specific energy consuption Subsystes energy consuption (optional) Ready-to-operate achine Idle power Energy consuers Measuring ethod Measuring equipent Test aterial Melt quality Measureent operating conditions Tests for energy consuption easureent Energy classes Reporting... 9 Appendix A Appendix B EUROMAP 46.1 Page 2 of 13

3 1 Introduction 1.1 Scope and application This recoendation specifies the procedure for easuring and calculating the absolute/specific energy consuption of Extrusion Blow Moulding (EBM) achines. The goal is to establish a coparison ethod aong achines in order to provide a classification based on the energy efficiency regardless of tools or custoer/product related factors, which ay influence the energy consuption. This recoendation deals with EBM achines 1 : for the processing of theroplastics; with one or ore extruders with electrical barrel and head heating; with one or ore shuttles; which are able to process Polyethylene (PE) (see test aterial); for continuous or interittent extrusion (see accuulator head). For the deterination of the absolute/specific energy consuption of coplex installations as well as for easuring the energy consuptions according to custoer/product specification, EUROMAP 46.2 requireents shall also be used. This recoendation enables the evaluation of the energy consuption of basic achines regardless of ancillary oveents, ancillary equipent or auxiliary units, so that the energy efficiency of the ain units should be ascertainable. All the energy/power values defined and used further on are "achine related". The procedure to easure the specific energy consuption of achines with liquid cooling systes (barrel, otor and drive, oil) is described in Appendix A. The procedure to easure the specific energy consuption of achines with accuulator head is described in Appendix B. 1.2 References Short nae Title Version EUROMAP 46.2 Extrusion Blow Moulding Machines Deterination of Product Related Energy Consuption IEC Electricity etering equipent (a.c.) Particular requireents Part 22: Static eters for active energy (classes 0,2 S and 0,5 S) Machines with pneuatic driven shuttles are excluded by this recoendation EUROMAP 46.1 Page 3 of 13

4 2 Definitions 2.1 Total energy consuption Consider the power diagra of Fig. 1, representing the power consuption of a achine obtained by using a easuring ethod/instruent as specified in Sect. 4. apparent power [kva] reactive power [kvar] effective (active) power [kw] Figure 1: Power diagra ϕ The achine total energy consuption E tot [kwh] in a given tie interval ΔT is defined as: E tot = P T [kwh] where P is the ean active power supplied to the achine in the tie interval ΔT. 2.2 Total specific energy consuption The achine specific energy consuption E sp is defined as the energy consuption E tot in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E sp = E tot 2.3 Subsystes energy consuption (optional) Siilarly to the previous definitions, the following energy consuption values can also be easured Extruder otor and drive energy and specific energy consuption The extruder otor and drive energy consuption E [kwh] in a given tie interval ΔT is defined as: E = P T [kwh] where P is the ean active power supplied to the otors in the tie interval ΔT. Accordingly, the extruder otor and drive specific energy consuption E sp is defined as the extruder otor energy consuption E in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E sp = E In achines with ultiple extruders, the contributions of all otors and drive shall be added Barrel and head theroregulation syste energy and specific energy consuption The barrel and head theroregulation syste energy consuption E th [kwh] in a given tie interval ΔT is defined as: E th = P th T [kwh] EUROMAP 46.1 Page 4 of 13

5 where P is the ean active power supplied to the theroregulation syste in the tie interval ΔT. The barrel and head theroregulation syste specific energy consuption E spth is defined as the extruder theroregulation energy consuption E th in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spth = E th In achines with ultiple extruders, the contributions of all extruders shall be added Extruder energy and specific energy consuption The extruder energy consuption E ex [kwh] in a given tie interval ΔT is defined as: E ex = P ex T [kwh] where P ex is the ean active power supplied to the extruder in the tie interval ΔT. If E th and E are easured over the sae tie interval ΔT, E ex can be calculated as: E ex = E th + E [kwh]. The extruder specific energy consuption E spex is defined as the extruder energy consuption E ex in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spex = E ex E spex can be calculated by: E spex = E spth + E sp In achines with ultiple extruders, the contributions of all extruders shall be added Foring syste energy and specific energy consuption The foring syste energy consuption E f [kwh] in a given tie interval ΔT is defined as: E f = P f T [kwh] The foring syste specific energy consuption E spf is defined as the foring energy consuption E f in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spf = E f kwh In achines with ultiple shuttles, the contributions of all shuttles shall be added. In the case of achines with oving parisons, the foring syste energy consuption refers to the energy consuption to ove the parison (and, possibly, the shuttle) Relation between the total energy consuption and the subsystes energy consuption - The total (specific) energy consuption can be calculated by: E tot = E th + E + E f [kwh] E sp = E spth + E sp + E spf EUROMAP 46.1 Page 5 of 13

6 For Machines using liquid cooling systes the related energy consuption shall be deterined according to Appendix A. The resulting cooling energy consuption (i.e. E barr, E oil, etc [kwh]) and cooling specific energy consuption (i.e. E spbarr, E spoil, etc ) shall be added to the total energy consuption E tot respectively to the total specific energy consuption E sp defined in Sect For Machines using extruders with accuulator head the related energy consuption shall be deterined according to Appendix B. The resulting accuulator head energy consuption E acc [kwh] and accuulator head specific energy consuption E spacc shall be added to the total energy consuption E tot respectively to the total specific energy consuption E sp defined in Sect Ready-to-operate achine All units (i.e. possibly required ancillary units, inverters, electronic control syste and their cooling devices, ) required for the ain achine oveents (ould closing/opening, ould backward and forward oveents, bobbing, etering, screw otors and drives, etc.) are ready-to-operate. The hydraulic syste, if any, shall be always switched on and at the operating pressure. The barrel heating is switched off. 2.5 Idle power The idle power P i [kw] is the ean power consuption of the ready-to-operate achine easured in the conditions specified in Sect Energy consuers The following shall be included: electric otors and drives of the extruders (included otor and drive liquid cooling, if any); electric heating of barrels and heads (including barrel (liquid or air) cooling syste, if any); electric otor and drives for all axis oveents in the foring process (shuttle or parison); accuulator head for the production of discontinuous parisons (if any); pup and drive for the hydraulic power generation (if any); oil cooling syste (if any); control syste electronics; internal aintenance devices (supplied by the achine anufacturer), e.g. cooling of electrical coponents, grease systes, cooling of the hydraulic oil. The following shall be excluded: ancillary equipent, e.g. conveyors, etering equipent, pick and place devices; external supply of fluids related to ould cooling or blowing syste; gearbox cooling, if any; pup and drive of the barrel, otor etc cooling systes, if any; aterial transport/iproveent of the aterial properties (e.g. dryers) EUROMAP 46.1 Page 6 of 13

7 4 Measuring ethod 4.1 Measuring equipent The power easureents shall be perfored using instruentation copliant to the IEC faily of international standards. More specifically, the instruentation shall be certified accordingly to IEC :2003 (Static eters for active energy - classes 0,2 S and 0,5 S). The easureent devices should be positioned at the ain power supply input. 4.2 Test aterial The tests shall be carried out with virgin PE-HD with density / MFR (accordance to ISO 1133) = 8-10 g/10 inutes (at 21,6 kg and 190 C), not dried and not preheated, at an abient teperature below 30 C. 4.3 Melt quality The elt shall show no visual inhoogeneity or degradation. 4.4 Measureent operating conditions The barrel teperature of all zones (except the cooled ones) shall be within ±10 C of the set-point value. The achine is in a stable condition, i. e.: stable autoatic operation without the necessity of anual intervention for at least 15 in; the barrel has been at set-point teperature for at least 15 in; stable oil teperature (for hydraulic achines) has been reached and aintained for at least 15 in. The tests are intended to be perfored without any ould. It is therefore necessary to guarantee the target claping force (see Table 1) during the ould closure. The tests shall be perfored at the conditions reported in Table 1. Paraeter Mould claping force Bobbing speed Shuttle and ould closing / opening speed Shuttle and ould oveent speed Shuttle and ould acceleration / deceleration Table 1 - Machine paraeters during tests Value 90% of axiu value 90% of axiu value 90% of axiu value 90% of axiu value 90% of axiu value Shuttle and ould displaceents 90% of axiu value Blowing tie (1) s T b = kn F cax s s kn F cax + 28 s Extruder(s) total throughput 90% of axiu value (2) Barrel set-point teperatures (all zones except the cooled ones) 190 C when F cax < 200 kn when F cax 200 kn (1) (2) The blowing tie is defined as a function of the noinal axiu ould claping force F cax [kn] The total throughput ust be 90% and the different coponents ust be in the correct copound proportion. EUROMAP 46.1 Page 7 of 13

8 4.5 Tests for energy consuption easureent The following tests shall be perfored in order to easure the energy values defined in Sect and in Sect Test 0 - easureent of E tot, E sp The goal of this test is to easure the total and specific energy consuption of the achine. Since the foring part is not equipped with any ould, the extruded elt shall be separately collected for weighing. The total energy consuption E tot as defined in Sect. 2.1 shall be easured at the conditions reported in Sect. 4.4, provided that the following constraint are all verified: ΔT 10 in; extruded ass 5 kg; at least 10 cycles are perfored. The collected extruded ass shall be weighed and E sp deterined as defined in Sect Test 1 - easureent of P i With the achine at the conditions described in Sect. 2.4, the ean supplied power P i over a tie interval ΔT i 5 in shall be easured. The following tests can be optionally perfored in order to easure the energy values defined in Sect Test A (optional) - easureent of extruder related energy consuptions The goal of this test is to easure the energy consuption of the extruder. For this purpose, if it is not possible to easure it separately fro the foring process, it shall be provided that the foring section shall be switched off (no ould oveents). In hydraulic achines the pup shall be switched off. The extruded elt shall be separately collected for weighing. The extruder energy consuption E ex as defined in Sect shall be easured at the conditions reported in Sect. 4.4, provided that the following constraint are all verified: ΔT 10 in; extruded ass M 5 kg The collected extruded ass shall be weighed and E spex deterined as defined in Sect Other optional easureents If the subsystes are equipped with separate power supplies, it is recoended to separately easure the electric otor energy consuptions E, E sp and the theroregulation energy consuptions E th, E spth with the sae constraints as above: ΔT 10 in and 5 kg. Test B (optional) - easureent of foring section related energy consuptions The goal of this test is to easure the energy consuption related to the oveents of the foring section. To this ai, if it is not possible to easure it separately fro the extruder, it shall be provided that the extruder otor and theroregulation syste are switched off. EUROMAP 46.1 Page 8 of 13

9 The foring syste energy consuption E f as defined in Sect shall be easured at the conditions reported in Sect. 4.4, provided that the following constraint are all verified: ΔT 10 in; at least 10 cycles are perfored The specific energy E spf shall be calculated according to the following: E spf = E f T A M T where is the extruded ass collected in a tie interval ΔT A (for instance in the previous experient - test A). 5 Energy classes According to the deterined specific energy consuption the achine shall be assigned to one of the following classes: Table 2 - Efficiency classes Class Specific energy consuption E sp 1 > A plus ("+") shall be added to the class, if the deterined idle power is less than 1 kw. 6 Reporting Table 3presents the andatory report for classification. If this report is not provided, the achine is considered in a worse energy efficiency class. In Table 4, the report on optional easureents is presented. This table too could only be partially filled. Notice that, if Test A and Test B are perfored the inforation for Test 0 can be obtained fro the. EUROMAP 46.1 Page 9 of 13

10 Table 3 - Mandatory tests report for Test 0,1 - Machine consuption, idle power Cycle tie Blow tie Cycle nuber # Measureent tie ΔT [in:s] Extruded ass M Total energy consuption E tot Liquid cooling energy consuption (if applicable) Specific energy consuption E sp Idle Power P i Idle easureent tie ΔT i Efficiency class [s] [s] [kg] [kwh] [kwh] [kw] [in:s] Table 4 - Optional tests report for Test A - Extruder related consuption Measureent tie ΔT [in:s] Extruded ass M [kg] Extruder energy consuption E ex [kwh] Extruder specific energy consuption E spex Extruder otor energy consuption E [kwh] Extruder otor specific energy consuption E sp Extruder theroregulation syste energy consuption E th [kwh] Extruder theroregulation syste specific energy consuption E spth Barrel cooling specific energy consuption E spcool Accuulator head specific energy consuption E spacc Test B - Foring process related consuption Measureent tie ΔT [in:s] Cycle nuber # Foring energy consuption E f [kwh] Foring specific energy consuption E spf EUROMAP 46.1 Page 10 of 13

11 Appendix A When considering achines with liquid cooling systes, the cooling power P cool [kw] shall be calculated using the achine noinal values, according to the following equation P cool = 10 3 ρwc v (T out T in ) [kw] (1) where: T in [K] is the cooling liquid input teperature (can possibly be easured - see Sect. 4.4); T out [K] is the cooling liquid output teperature (can possibly be easured - see Sect. 4.4); ρ [ kg 3] is the cooling liquid density; c v [ J kg K ] is the cooling liquid specific heat; w [ 3 ] is the cooling liquid voluetric flow (can possibly be easured - see Sect. 4.4). s Equation1 can be used for the calculation of the energy consuption of a cooling syste. The barrel cooling energy consuption E barr [kwh] in a given tie interval ΔT is defined as: E barr = P barr T [kwh] where P barr is coputed according to Eq. 1. The barrel cooling specific energy consuption E spbarr is defined as the barrel cooling energy consuption E cool in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spcool = E cool The oil cooling energy consuption E oil [kwh] in a given tie interval ΔT is defined as: E oil = P oil T [kwh] where P oil is coputed according to equation 1. The oil cooling specific energy consuption E spoil is defined as the oil cooling energy consuption E oil in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spoil = E oil This procedure can be extended to otor and drives cooling systes. The energy consuption of liquid cooling pup drives, if any, can be neglected. EUROMAP 46.1 Page 11 of 13

12 Appendix B When considering achines with accuulator head, additional tests shall be perfored at the following conditions: 1) The extruder shall be at the operating conditions specified in Sect ) The polyer ass for each cycle shall correspond to at least 70% of the head noinal volue value. 3) The ejection speed shall be at the value necessary to extrude at least 70% of the head noinal volue value in 10 s. 4) The hydraulic circuit pressure shall be: at the noinal value at the noral achine operating conditions, when the head does not have an independent hydraulic plant. at the iniu value to satisfy the previous constraint 3, when the head has an independent hydraulic plant. 5) The polyer teperature shall not be greater than the extruder teperature specified in Sect ) The die s opening shall not be larger than 10. 7) At least 10 cycles are perfored. The accuulator head energy consuption E acc [kwh], in a given tie interval ΔT, is defined as: E acc = P acc T [kwh] being P acc [kw] the ean power consuption over the considered tie interval. The accuulator head specific energy consuption E spacc is defined as the accuulator head energy consuption E acc in a given tie interval ΔT divided by the extruded ass in the sae tie interval ΔT: E spacc = E acc EUROMAP 46.1 Page 12 of 13

13 EUROMAP Europäisches Koitee der Hersteller von Kunststoff- und Guiaschinen European Coittee of Machinery Manufacturers for the Plastics and Rubber Industries Coité Européen des Constructeurs de Machines pour Plastiques et Caoutchouc Coitato Europeo Costruttori Macchine per Materie Plastiche e Goa See you again Copyright by EUROMAP EUROMAP 46.1 Page 13 of 13