pellcon3® process for plastic manufacturing and compounding
Selecting a pneumatic conveying system design is important for economic and reliable operation of any plastics manufacturer or compounder. Poorly designed systems lead to plant-wide inefficiencies and high maintenance costs. When designing pneumatic conveying systems, many design parameters must be considered. The length of the system, numbers of elbows and varying material properties all have a significant influence on the determination and sizing of a pneumatic conveying system.
For plastics manufacturing companies or compounders, the quality of the plastic pellets, prior to packaging, is most important. High contents of dust and streamers or angel hair in plastic pellets lead to rejects and lower market prices. The aim of each plastics manufacturer or compounder is the production of the highest quality resin grade with low dust content and no angel hair, at the lowest possible production cost. In order to help customers to achieve this goal, Pelletron developed a new economical conveying process, trade named pellcon3®, based on three major process components.
STRANDPHASE® is a conveying technology for gentle conveying of granular products. Moderate velocities prevent breakage and attrition of the conveyed product, keeps the generation of dust at a very low level and prevents the creation of long angel hair. STRANDPHASE® does not need special pipe supports or additional steel construction. Most importantly, STRANDPHASE® does not create fine micro-dust, seen in dense phase systems, or long streamers, created in dilute phase systems. In many cases, the pipe diameters are smaller in comparison with dense phase systems. Because of these advantages, the investment costs for large scale STRANDPHASE® systems are much lower than slow motion dense phase systems. In summary, STRANDPHASE® systems guarantee a high quality of the resins, are easy to operate, easy to maintain and low in investment costs.
Pellbow® is a special patented pipe elbow. The design resembles a standard short-radius elbow with a large expanded chamber between the inlet and discharge of the elbow. The soft impact of pellets in the slurry zone and the low wall friction eliminates the creation of streamers. Its pressure loss is only slightly higher than that of standard long- and short- radius elbows. The nature of the design eliminates the build-up of product within the elbow. A complete purge is accomplished simply by using the same conveying air volume and pressure.
DeDuster® is the dust and angel hair removal unit. Regardless of conveying method used, friction is generated by the velocity and pressure. This results in attrition of the conveyed product. The DeDuster® unit removes dust particles providing high quality resin with remaining dust contents below 50PPM. No other dust removal unit can reach this cleaning efficiency.
Existing dense phase and dilute phase systems may be upgraded to incorporate pellcon3® technology.
Upgrading an existing system to pellcon3® provides a quick return of investment. Besides the savings of 20% to 30% compared to dense phase conveying at new plant installations, pellcon3® provides lower operation costs and better product quality, which results in higher resin market prices.