Purpose of the control system of the polyethylene granulator
The SUGP-0.5EX polyethylene granulator control system was developed by Energocomplekt JSC by order of Salavatnefteorgsintez OJSC and is designed to smoothly change the rotation speed of the knife and auger engines and obtain polyethylene pellets of a given size.
The disadvantage of the pre-existing system was its inability to cut granules of polyethylene of the size required by GOST while increasing the productivity of the installation of more than nominal value, which led to a decrease in the grade of the final product due to large pressure beats inside the screw.
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Control system SUGP-0.5EX in the workshop No23 NHZ OJSC "Salavatnefteorgsintez"
The management system provides
- the possibility of separate and joint start-up of first-stage granulator drives from the operator’s remote;
- remote control of the frequency of rotation of both drives together or separately buttons "more", "less" with a set sampling step (N + number of revolutions / min);
- maintenance of the required moment of melt pressure of polyethylene in the working cylinder of the granulator at zero rotation;
- change in the speed of rotation of engines from 0 to 1900 rpm;
- displaying on a digital board the speed of rotation of the auger and cutting knife engines;
- repeatability of set of specified values of speed of rotation of the engine with subsequent bringing of installations to the table form for ease of operation of the operator;
- a high degree of reliability of the units (due to the use of proven pilot operation of imported components);
- increasing production efficiency by increasing the reliability of the equipment;
- twelve types of protection against improper actions of the operator;
- bundling and remote setting of linear speeds simultaneously on 10 granulators, as well as control of production technology as part of the ICS.
Granulator control scheme.
EQUIPMENT COMPOSITION
| Equipment | Food | Kolvo |
| Direct current electric motor drive screws 1850 rpm, 142 kW, explosion-proof with a blown shell | shh. | 1 |
| Direct current electric motor drive cutting knife, 1850 rpm, 3 kW, explosion-proof with a blown shell | shh. | 1 |
| Power cabinet with electric drives, control panel and supply and exhaust ventilation system | shh. | 1 |
| Industrial Controller GE Fanuc | shh. | 1 |
The company’s specialists completely replaced the equipment of the Leonardo type unit (generator-engine) with an alternative one (GeneralElectric DV-300 DC drive for DC engines), which provides energy savings of more than 40 MW per month, and amounted to savings of more than 300,000 rubles per year at 2005 prices.
The developed system provides only high-grade polyethylene granulate due to the precision detachment of the drives, which allows you to create a uniformity of the pressure of the melt of polyethylene in the auger and when cut with a knife, as well as the length of the polyethylene granule at the exit of the filter, corresponding to GOST.
Through the formation of the task in digital form, the accuracy of setting the operation of the engines on both drives of the system is ensured, which allows, without reducing the grade of granulate, to increase the performance of the system over the estimated capabilities by 10%. At a price of 1 kg of polyethylene granule equal to 1 $, the system allows you to produce products in excess of the norm in the amount of $ 335000 per year.
The modernization of the system made it possible to bring the reactor to its design capacity (under the previously existing scheme, the reactor was underloaded), since the increase in productivity led to a decrease in the grade of polyethylene granulate.
The company performs the design, development and supervision of the control system, training of service personnel. Delivery of equipment 3 months from the date of conclusion of the contract and prepayment.