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Pyrolysis Machine Converting Waste Plastic into Oil
ADITYA RECYCLINGBangalore
www.adityahitechmachines.com
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The Project Converting Waste Plastics into Oil
Model => Batch Type ECP-2011
ADITYA RECYCLINGBangalore
www.adityahitechmachines.com
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Depletion of Fossil Energy
High efficiency (average80%) High quality (light oil level)
The Value of Business!
Intensified Regulation of Greenhouse Gas Emissions
Rapid Increase of the need to Improve Nvironmental Pollution
The plan to Overcome New Regulations
Protection of the Earth, the Nation,
the Environment
Creation of New Energy
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Bio Energy
Alternatives for the Future!
Solar Energy Wind Power Generation Energy
Nuclear Energy
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Vinyl Waste
Creation of Renewable energy!
Waste Fishing Net, Fishing Gear
Used Waste Lubricating Oil Wasted Tires
Cracked Oil from Wasted Tire Cracked Oil from Household Waste Vinyl
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The Relative Value of Oil Conversion Projects
# TOE : Tonnage of Oil Equivalent
Refinery Equipment
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Use and Value of Produced Oil from Pyrolysis
Waste Plastics, Waste Oil Conversion to Fuel Oil
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Simple Process, Low Investment
The Best Stability, Safety
The Best Oil Conversion Profitability
Leader of environment-friendly technology, Ecocreation !!
Ecocreation is an environment-friendly
company that cares about future environment of the earth and is a global leading company that opens a new era of low carbon green growth by reducing
CO2 emission for invigoration of resource circulation and prevention of global warming through production of
environment-friendly products.
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폐기물
Oil
Reforming R.P.F( Solid Polymer ) Reforming Waste Plastic
Nitrogen, Atmospheric Pressure Condition Pyrolysis Emulsion ( 380~480℃ Heating Fluid )
Apply liquefaction, Separation TTechnology Based Catalyst
Typical yields : Polymer Waste Kerosene, Diesel more than 80%, Naphtha around 15%, Gas around 3%, CHAR (Coke) around 3%
Pyrolysis Refined Oil
Hybrid Cracking Emulsion Technology
PP(Poly-Propylene), PE( Poly-Ethylene ) PS(Poly-Styrene), PPT( Polyphenylene Terephthalate )
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Process The first pyrolysis of waste and secondary catalytic cracking with catalyst
Operation Type Batch type
Input Plastics PP, PE, PS
Yield Approx. 75 ~ 80 % (It can be different according to the waste plastics type)
Electric Capacity Three-Phases (220V or 380V)
Produced Oil Component
Naphtha, Kerosene & Diesel Fraction
Operating Cost Low operating cost due to the use of recycled oil and waste gas from self production
Safety Less risk of explosion and fire due to nitrogen substitution
It is not necessary to separate, shred and clean the waste plastics.
Plant Size by 12,000mm(W) X 10,000(L) X 7,000(H)
Space required for installation => Variable for capacities Notice => Waterproof / Protection against wind must in roof
Period required for installation by within 10 days site installation
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Power Start ON
Gas Collector ON
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The Main Process Flow Diagram 1
Input
(Waste Plastic) (Compress) (Compressed Stuff)
(Separation/Cooling) (Contact Catalytic Reforming Cracking) (Pyrolysis) (Refining/Storage)
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Catalyst Column secondary catalytic cracking
Primary classification process
Primary cooling process
Storage / Ship
Material Screening Compression
input Material and Melting
Primary fusion
decomposition
Input liquid cracking catalyst
Input coking inhibitor
Decomposition of chlorine compounds, Input inhibitory catalyst
Input GUM inhibitor,
Neutralization reagent
The primary classification, NAPTHA, GAS
Utilization of Process fuel
Environmental Process Dust Collection,
Adsorption of odor
Air emissions
Secondary Classification
Secondary classification NAPTHA, GAS
Vapor catalytic cracking catalyst column
Process Flow Diagram 2 Reactor , Process fuel
Molten Material,
Pressing Heat Supply
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Machine under manufacturing (Currently available daily capacity by 1 ton, 2 tons and 3 tons)
Process Chamber Placement Pictures
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1. Production Process
Section System Configuration / Characteristics Remarks
Heating Furnace( Heater ) Indirectly Heated => Combustion Gas Transfer Heat to the Reactor
High Efficiency =>
Utilize Waste Gas, Apply Waste Heat Recovery System
Automation =>
Autoignition, Automatic Temperature Control Burner System
Safety / Cooling =>
Explosion Prevention, Forced Quick Exhaust Cooling
Using Liquid
Gas Fuel( Option )
Pyrolysis Reactor
Completed the iIspection of B.T.
Special Material of Explosion Proof,
Anti-Corrosion( SUS )
High Efficiency Catalyst Layer Built-In,
External Apply Coking prevention Technology
Apply Anti-Corrosion( H2S / HCl ) Technology
Pyrolysis Reactor
Splitter / Condenser Apply Splitter,
Condenser Integrated Structure Facility
Adoption of 3( Three-Phase )( Solid,Gaseous,Liquid)
Fractionator
Heat Exchanger
Application System ofAanti-Corrosion Material and
Neutralizing Agent
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2. Process Support
Section System Configuration / Method Option
Cooling Equipment System Apply Water-Cooling Type Cooling System
=> Apply Cooling Water anti-Corrosion System
=> Apply Cooling Water Scale Prevention System
Cooling Air-Cooled Furnace
=> Apply Cooling Heating Medium Reactor by
Cooling Heat Recovery
Separate
Chemical
Nitrogen Injection Safety System Nitrogen Injection Around Process Operation
=> For Cooling
=> The Inhibition of Oxidization
=> Self-Nitrogen Generator can be Adopted
Anti-Corrosion Chemical Injection System
Apply Special Corrosion Inhibitor
( Apply to the Target of Process Cooling Classification System )
=> Prevention of Hydrochloric Acid Corrosion
=> Prevention of Organic Acid Corrosion
Heat Recovery System Recovery
Utilization of Exhaust Waste Heat from Heating Furnace Chimney
=> Recycling of OFF Gas by Economizer System
=> Separate Heating Furnace by Operate Reactor
Option Equipment
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3. Safety and Environmental Equipment
Section System Configuration / Method Remarks
Reactor Explosion Proof Safety System
Satisfy National Safety Standards Material & Facility
Required Government Agencies Verify
Adopt Pressure Relief System in an Emergency
Adopt National Standard Explosion Proof Equipment
Explosion Proof Electrical System
Apply Pipe interlocking Device Against Vibration
Apply Reactor Interlocking Device
Emergency Response System in case of Power Failure
Apply Emergency Private Power Station System
Apply Process Generated Gas Continuous
Processing System
Incineration of OFF-Gas Apply Flare Stack
Option of Small Diesel Generator
Oil Spill Response System Apply Preparing Process for Oil Spill
Loss Prevention System
=> Compliance with Government Standard
Precipitator Deodorizing
Adsorption Removal
Post Processing of Emission Combustion Gas
from Incinerator by Heating Furnace
=> Precipitator, Odor Adsorption Column
=> Precautionary Investment Prepared for Emergency
Facility more than
3 Tons
Process Waste Treatment System Solid Waste Consignment Process for General Landfill
Development of a Separate Solid and Sale
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Characteristic of our Development Process
Section Material
Separation Process Characteristic Remarks
Our Company Process
Polymer Resin of
PP, PE, PS, ABS, etc Complex of Single Substance or Mixture
Excellent Yield
=> Kerosene, Diesel Grade
Excellent Separation Process
High Quality Oil Production
=> Minimize of Wax Component
=> Excellent Low Temperature Fluidity
In the case of Catalytic Cracking of Mixture,
the Process Efficiency of Solid Liquid Mixtures
Is Twice.
Other Company Process
Solid Waste RPF
Low yield
=> The Yield of Naphtha is about
60% at least
Fixed Separation Decline
Low Quality Oil Production
=> Contain Large Amounts of Wax
Very Poor Low Temperature Fluidity
Process Operating Time Is Long
Cause Energy Mass
Consumption form or
Product Quality
Becomes Degraded
It is inevitable that
Light Naphtha Occurs
in Bulk because of
Reflux reaction to
Reduce Wax
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Characteristic of our Development Process
Section Process Operating Condition
Relative Comparison of Operating Hour
( Based 5 Tons Reactor)
Main Products
Our Company Process
Normal Pressure Indirect Heating Type
=> 380~480℃
=> Normal Pressure 0.5 Kgf
( Gassing Pressure Standard )
In case of Solid Liquid
Mixture Process Around 10 hours
( Shorten Operating Hour )
Boiling Point Range
130~385℃ of
Fuel Oil and Similar to Kerosene and Diesel
Other Company Process
Normal Pressure
High Pressure Indirect Heating Type
=> 400~500℃
In case of Solid Single
Material Process
=> 20 hours
=> Prolonged Operating
Hours According to
Reflux Reaction
Fuel Oil Containing Large Amounts of
Waste Naphtha, Gas and Wax
=> Room Temperature
Low Temperature
Fluidity is very Bad
because of Wax Containing
Normal Pressure
High Pressure Indirect Heating Type
450~700℃
In case of Solid Single
Material Process
15 hours
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Characteristic of our Development Process
Section Reactor Process Characteristics Remarks
Our Company Process
Horizontal STOP Reactor
Semi Automatic Medium Sized Reactor
It is possible to Input more than 80% of the Material
=> Equipped with Catalyst Column
Remove Wax and Foreign Material
Apply Technology
=> Apply self Development Isomerization
Catalyst
=> Excellent Thermal Efficiency
=> Coking Prevention and
Easy Operation Management
Isomerization Catalyst As the Catalyst which Changes the Structure of Paraffin with It Changes the Structure of Wax and Makes
It very good Fluidity
Material
Other Company Process
Rotary Fluid Reactor
Limited less than 50% of Raw Material Charging Quantity by Based on Liquid
Law Material
=> Thermal Efficiency is Disadvantage
Heat Loss is Great
=> Coking Management is Difficult
=> Front Coking Phenomenon Occurs At 360°C
=> Concern about Mechanical Durability
Problems According to Reactor Fluid
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Our Competitive Technology
Process Risk Other Company
Existing Technology Our Technology Remarks
Reactor Coking
Extended Maintenance time
=> Heat Transfer Decline
=> No Chemicals to Remove
Independently Developed
Application of Anti Coking and
so Expected a Patent Application
Dramatically Improved Process
As the
Highest Level
of Technology at Home and
Abroad,
No other
Companies
Commercial
Pracactes
Distiller Tube Clogged (Wax / Saponification substance)
Impurities Occur Wax Occurs Frequently Piping Blockage Poor Quality in Winter
Applied Independently Developed Inhibitors for Impurities Occur
=> Expected Patent Application
=> Wax Cracking Catalyst Development => Expected Patent Application
Dramatically Improve Fuel Quality
Product Quality Degradation
Caused by Wax
Product Quality Degradation due to Facility Hydrochloric Acid Corrosionby PVC and Salt
Exposure to Corrosive Hydrochloric Acid,
Difficult for Screening Material -Shorten Equipment Life
-VCM Monomer Occurs and
Fuel Quality Degradation
-Applied VCM Monomer Dechlorination Catalyst Development ( Expected Patent Application)
-Suppress Interference Reaction by Salt (The same patented item)
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Our Competitive Technology
Select Fuel Additive Based On the Same Refineries
Applied Technology
=> Fully Improved Combustion Efficiency
=> Other Functionality
Possible to Provide Leading High
Performance Reforming Catalyst
Facilities due to having Independent Catalyst Development Efforts
Engineering Technique
=> Contribute to Improving Future Productivity
► Profitability
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Pyrolysis Yield according to Material
Material Section Pyrolysis Yield Remarks
Pure PE, PP, PS Standard
=> Except of PVC
• Gas => 2~3%
• Naphtha => Around 15%
• Kerosene & Diesel Fuel
=> More than 80%
• Coke( ASH ) => Below 1~3%
• Distillation Appearance
( Boiling Point )
=> 130 ℃ ~ 385℃
=> In the case of RPF
=> Yield Change Depending
on the Foreign Content
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Our Technical Characteristics
Cost of Equipment Superior Economic Compared to other Company Gas uses Its Own Fuel
Minimize Investment
Maximize Thermal efficiency of Approx. 8 % No limited material is Single Operation of High Molecule and Waste Oil
Minimize Operation Cost
HDPE Standard Diesel Level can be Produced more than 75% of Pyrolysis Oil Minimize 2nd Waste Material => Dangerous Substances like Gas, Naphtha, etc => Generated Gas and Naphtha are used for its Own Fuel.
Maximize Profitability
Maximize the Stability of Pyrolysis Furnace due to the Secure of Low Pyrolysis Temperature Decomposition of Chlorine Compounds Input Neutralization Catalyst Minimize the Occurrence of Chlorine Gas Causing Equipment Corrosion to Adoption of Anti-Corrosion Minimize Simplify Production Process Facility to Minimize
Minimize Disposal Dangerous Material Stability due to Low temperature Pyrolysis Stable Operation due to Minimize the Occurrence of Wax and Regular Maintenance and Stable Shut down in case of Abnormal Condition and Easy Process Maintenance
Secured Economic Secured Stability
The Best Catalyst Control Technology of the World Liquid Catalytic Cracking, Vapor Catalytic Cracking, Decomposition of Chlorine Compounds, Neutralization Catalyst Technology, Apply Suppression Technology of Wax, Gum, Coking
Facility
Stability
Operation Stability
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Material => Waste Plastics 100%( RPF RDF, Recycling Chip )
Operating Hour is Variable Depending on the Characteristics of Materials
=> Operating Hour is Very Variable Depending on Foreign Content and
Content of the Pure Polymer
It is very General to Operate One Time a Day
( Normal Operating 12 hours )
=> In the case of much Foreign Content
=> ASH Removal Time Occurs by Increasing after Reaction
Recommended Maximum One Time a Day
Our Process Operating Characteristics - Case 2
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기존 상용 촉매
당사 개질 RDF 촉매
RPF PYROYSIS OIL @ ASTM D86
Comparison of Produced Oil based on our Technology
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Hybrid Cracking Process Product Quality
Classification (Red is Standard) Diesel (Oil Company’s Diesel) Waste Lubricating Oil
Cracking Oil (NO Catalyst) Our Pyrolysis Oil of Waste Plastics
Flash Point(℃) Above 40
(Above 30℃ of Pyrolysis Oil ) 30~60 : Variable According to Process
Pour Point(℃) Below 0(Apr. ~ Sep.),
Below -17.5 (Oct. ~ Mar.) -30 -10
Residual Carbon, Wt% Below 0.15 0.17 0.05
ASH, Wt% Below 0.05 0.001 0.001
Distillation 90%, ℃ Below 360 395 350
Centistoke @ 40℃, cSt 2.0~5.8 5.2 2
SULFUR, Wt% Below 0.2 0.08 0.005
Moisture & Precipitate, VOL% Below 0.5 0.07 0.05
Cetane index Above 45 - 40~55
Lubricative, HRRR W.S.D 400 MAX Red Orange B&C 300
@15℃ DENSITY, g/㎤ Above 0.815~below 0.855 0.82~0.84 0.79~0.81
Contents of Heavy Metals
Pb Below 1 ppm None None
Cr Below 1 ppm None None
Cd) Below 1 ppm None None
As) Below 1 ppm None None
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Minimize of Heavy Oil Fraction
Maximize of Kerosene & Diesel Grade
Technology Outline( Catalyst Performance )
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High Molecule PP,PE,PVC
Decomposition & isomerization ,
Reaction of dechlorination
Pour point Below -25℃ Becomes High Quality Fuel
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Technology Outline Infrared Analysis of Kerosene & Diesel at General Gas Station
Aromatics
High Quality Hydrocarbon
High Quality Hydrocarbon
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Technology Outline Infrared Analysis Comparison of Our Catalyst Pyrolysis Oil
Fully meets as Petroleum fuel based on Analysis of the chemical structure
HDPE 촉매 분해유
FT-IR CHART
Hydrocarbon Double Bond Substance
Aromatics High Quality Hydrocarbon
High Quality Hydrocarbon
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RPF(PE ,PS 등) 촉매 분해유
FT-IR CHART
Plasticizer Line C-O Combination
Hydro Carbon Double Bond Substance
Hydro Carbon Aromatic
High Quality Hydro Carbon
High Quality Hydro Carbon
Unrefined Moisture
Fully meets as petroleum fuel based on analysis of the chemical structure
Infrared Analysis Comparison of R.P.F Catalyst Cracking Oil
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Throughput => 3 Tons / day X 20days / Month Operation
Output => Gross 75% Recovery Rate /2500 Liter( Reflected by a Reduction in Fuel use Itself )
Raw Material => Waste Plastic / RPF 100% Handling Economic Evaluation of Refined Oil Production
Leased Plant Standard
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Reasonable Price Range (Based Kerosene KRW 1400) Standard Price => Selling Price of Gas Station Jan. 2012
Economic Evaluation of Refined Oil Production
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[ The Purpose of Emulsified Recycle Business ] 1. Reduce Emission Amount of Co2 { Reduce by Approx. ¼ Compared to Incineration Treatment } 2. Reduce Incineration Treatment or Reclaiming Disposal Cost 3. Create a New Business and Profit by Selling Recycled Oil 4. Thorough Information Management of Wastes
[ The Purpose of Product ] ▶ Fuel for Diesel => Industrial fuel, Agricultural Boiler, Incinerator, Diesel engine generator, Vessel& heavy machinery fuel, etc ▶ Residue is Available as a Heating Fuel for Cement Furnace Fuel, Heating Fuel of Iron Works and Foundry{ Cokes 4500Kcal }
[ Recommend Type of Business ] Main Agent of Administration( City ) Recycling Resources Enterprise => Recycle Center, Plastics Recycling Resources Enterprise, Mineral Resources Enterprise Waste Disposal Enterprise => General Waste, Industrial Waste, Agricultural Waste Plastics Industry Product processing industry, Film printing industry Chemical Industry Polymer Ingredient Manufacturing Industry Chemicals Industry
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Q&A about Catalytic Cracker of Waste Plastics
Q.1. What is the Characteristic of this Device? A ① Low Operation Cost due to Pyrolysis using the Fuel of Recycled Oil and Waste Gas. ② This Device Realized Low Cost Compared to Former Emulsification Device Q.2. What is the Processing Capacity of this Device? A ① Processing Capacity => 1.000kg, 2.000kg, 3.000kg, 4.000kg, 5.000kg / Day Q.3. What is the Processing Progress of this Device? A ① Input a Batch of Waste Plastics in the Preprocessing Stage. ② Heat the Raw Materials of Waste Plastics and Gasify Inside a Furnace. ③ Obtained Cracked Gas is Reformed into Gasoline Grade and Diesel Grade by a Catalyst Column and save in each Cracked Oil Tank Q.4. What is different from General Method until now? A ① Existing Emulsification Device Safety Matter Operation Cost and our Emulsification device needs a Gaseous Reforming Catalyst and there is No Risks of Explosion and Fire because of using Nitrogen and Low Operation Cost by using the Fuel of our Own Produced Recycled Oil and Gas
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Q&A about Catalytic Cracker of Waste Plastics
Q.5. What is the Influence on Safety and Environment? A ① Block the Emission of Harmful Gas with the Installation of Gas Washer and Storage Tank ② Not necessary of Measures and like a Silencer and etc Specially even though there are Operation Sounds like Motor Sounds and Cooling Pump Sounds, etc ③ Not necessary of Measures because we perceive almost No Vibrations even though we are near to the Device ④ It is possible for draining and Waterproofing Entirely without Polluting because Drainage is only for Circulating Cooling Water
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Vitalization of Regional Economy through Regional
Energy Supply
Creation for Clean Streets And Clear Regional Society
Environment
Change of Environmental Friendly Awareness by Region
Name of Parts
Fuel Gas Storage Tank 1EA
Burner 1EA Spiral Heat Exchanger 2EA
Damper Noxious Gas Neutralizing Tank
1EA
Catalyst Reforming Column
1EA Cooling Tower
Collect Wax Column 1EA Fuel Heater 2EA
Naphtha Separation Tank
1EA Nitrogen Generator 1EA
Overpressure Gas Tank 1EA Gas Vein Pump 1EA
Naphtha Tank 1EA Micro Pressure Gauge
Diesel Grade Storage Tank 1EA Micro Thermometer
Gasoline Grade Storage Tank 1EA Valves & Pipes
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Relay Part
Electricity is used to Operate Burner Pump & Lamp and to Measure the Gauge
Maximum Load => 2.2 kw( Based on 1 Ton ) Average Electric Consumption => 1 ~ 2 kw / hr Average Daily Operating Hours => 10 ~ 12 hours/day
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Relay Part Main Control Panel
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Relay Part Main Control Panel
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Relay Part Main Control Panel
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Main Device Status Indirect Heating Furnace & Burner
Indirect Heating Furnace & Burner
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Melting Pyrolysis Reactor Main Device Status
Melting Pyrolysis Reactor
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Main Device Status DUFJ
Various Tank
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Main Device Status
Power Start ON
Gas Collector ON
Various Tank
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Main Device Status
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Main Device Status
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Main Device Status ( Sight Glass )
Sight Glass
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Other Major Device
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Other Major Device
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Other Major Device
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Nitrogen Generator Gas Compressor
Despite being compact in size and light in weight vertical Air Cooled Oil Free Reciprocating Compressor is as Highly reliable as any industrial version used in utility supply plants and the product is used to Supply High Pressure Gas as required by increasing and the Pressure of a Low Pressure Gas operation speed of Compressor It should not operate at 820rpm or Higher or at 200 rpm or Lower
Electricity Single Phase AC 220V 50 / 60Hz
Specification
Flow 98% by the purity of the Nitrogen Generated( Nm3/hr )
Discharge Pressure of the Nitrogen Generated( kg/㎠g )
Inflow Air Volume( nm3/hr )
Inflow air Generated( kg/㎠g )
Voltage ( V, AC )
Frequency(Hz)
Number of Phase
Current( Ampere )
Discharge Port Diameter of the Nitrogen Generated( PT )
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Burner
Technical and Functional Features • Diesel Burner / Oil Burner, OFF GAS Incineration Burner • Single Stage Operation( ON / OFF ) • Compatible with Any type of Combustion Chamber • High Pressure Mechanical Atomization of Fuel using Nozzle • Ability to Obtain Optimal Combustion Values by Regulating Combustion Air and Blast Pipe • Maintenance Facilitated by the fact that the Atomization unit can be removed without having to remove the Burner from the Boiler • Manual Air Flow Adjustment
Technical Data
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No. ITEM UNIT CONTENT
1 Inner Volume M³ 1.0
2 Name of the Fluid to be used Air
3 Design Pressure Mpa G 0.97
Temperature ℃ 60
4 Operation
Pressure Mpa G 0.88
Temperature ℃ AMB.
5 Inner Diameter of fuselage mm I.D 898.4 x 1264h
6 Corrosion Tolerance mm 1.0
7 Radiation Inspection(S/H) NO / N.A
8 Welding Efficiency
Fuselage % 70
Flat End Plate % 85
9 Post Heat Treatment NO
10 Used Material
Fuselage and Flat End Plate SS400
Support SS400
Anchor Bolt SS400
11 Permissible Stress
Fuselage and Flat End Plate N/㎟ 100
Support N/㎟ 100
Anchor Bolt N/㎟ 61
12 Water-Pressure Test Pressure Mpa G 1.261
13 Wind Load/Earthquake Load ㎧ 45/ZONE 2A(1.15)
14 Weight
In installation Kg 383
In operation Kg 383
In Water-Pressure Kg 1393
15 Installation Place OUTDOOR
No. ITEM UNIT CONTENT
1 Inner Volume M³ 2.0
2 Name of the Fluid to be used Air
3 Design Pressure Mpa G 0.97
Temperature ℃ 60
4 Operation
Pressure Mpa G 0.882
Temperature ℃ AMB.
5 Inner Diameter of fuselage mm I.D 1130 x 1584h
6 Corrosion Tolerance mm 1.0
7 Radiation Inspection(S/H) NO / N.A
8 Welding Efficiency
Fuselage % 70
Flat End Plate % 85
9 Post Heat Treatment NO
10 Used Material
Fuselage and Flat End Plate SS400
Support SS400
Anchor Bolt SS400
11 Permissible Stress
Fuselage and Flat End Plate N/㎟ 100
Support N/㎟ 100
Anchor Bolt N/㎟ 61
12 Water-Pressure Test Pressure Mpa G 1.261
13 Wind Load/Earthquake Load ㎧ 45/ZONE 2A(1.15)
14 Weight
In installation Kg 739
In operation Kg 739
In Water-Pressure Kg 2794
15 Installation Place OUTDOOR
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Patent Status
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Certificate of Test for Pyrolysis Oil
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Thanks So Much to You
New Technology by Ecocreation Industries keeps running forward for more Clear and Cleaner World
ADITYA RECYCLINGBangalore
www.adityahitechmachines.com