naMichael Kelly, Allied PhotoChemical, naDavid Hagood, Finishing Technology Solutions
Fungidzira uchikwanisa kubvisa anenge ese maVOCs (Volatile Organic Compounds) mupombi uye chubhu yekugadzira maitiro, akaenzana zviuru gumi zvemapaundi eVOC pagore. Fungidzira zvakare kugadzira nekukurumidza nekumhanya nekuwedzera uye mutengo wakaderera pachikamu / mutsara tsoka.
Magadzirirwo ekugadzira akasimba akakosha kutyaira uchienda kune inoshanda uye yakagadziridzwa kugadzira mumusika wekuNorth America. Sustainability inogona kuyerwa nenzira dzakasiyana siyana:
Kuderedzwa kweVOC
Kushandisa simba kushoma
Optimized vashandi vevashandi
Inokurumidza kugadzira kubuda (yakawanda ine zvishoma)
Kunyanya kushandiswa kwemari
Uyezve, akawanda masanganiswa epamusoro
Nguva pfupi yadarika, mugadziri anotungamira wechubhu akagadzira hurongwa hutsva hwekushanda kwayo kwekupfeka. Mapuratifomu emugadziri ekutanga ekuenda-kuvharisa aive akavakirwa mvura, ayo akakwira muVOCs uye anoitika achibvira moto zvakare. Iyo inogoneka yekuputira chikuva iyo yakaitwa yaive 100% solids ultraviolet (UV) yekupfekedza tekinoroji. Muchinyorwa chino, dambudziko rekutanga remutengi, iyo UV yekuvhara maitiro, kuvandudzwa kwemaitiro ese, kuchengetedza mutengo uye kuderedzwa kweVOC kunopfupikiswa.
Coating Operations muTube Manufacturing
Mugadziri aishandisa nzira yekubatisa yemvura inosiya tsvina, sezvinoratidzwa mumifananidzo 1a uye 1b. Haina kungoita chete kuti maitiro aite zvakaraswa zvekupfeka zvinhu, zvakagadzirawo njodzi yepasi pechitoro iyo yakawedzera kuratidzwa kweVOC uye njodzi yemoto. Uye zvakare, mutengi aida yakagadziridzwa coating performance kana ichienzaniswa neyazvino mvura yakavakirwa coating operation.
Nepo nyanzvi dzakawanda dzeindasitiri dzichienzanisa zvakananga machira emvura kune UV machira, uku hakusi kuenzanisa kwechokwadi uye kunogona kutsausa. Iyo chaiyo UV yekupotera ndeye subset yeUV yekupfeka maitiro.
Mufananidzo 1. Basa rekuita chirongwa
UV inzira
UV inzira inopa zvakakosha zvakatipoteredza, kuvandudzwa kwemaitiro ese, kuvandudzwa kwekuita kwechigadzirwa uye, hongu, pamutsara tsoka yekumisikidza kuchengetedza. Kuti ubudirire kuita chirongwa cheUV chekupotera, UV inofanirwa kutariswa senzira ine zvinhu zvitatu zvikuru - 1) mutengi, 2) UV application uye kurapa yekubatanidza michina uye 3) coatings tekinoroji shamwari.
Ese ari matatu aya akakosha pakuronga kwakabudirira uye kuita kweUV coating system. Saka, ngatitarisei iyo yakazara chirongwa chekuita chirongwa (Mufananidzo 1). Kazhinji, kuedza uku kunotungamirwa ne UV coating tekinoroji shamwari.
Kiyi kune chero purojekiti yakabudirira kuve yakatsanangurwa zvakajeka matanho ekuita, ane yakavakirwa-mukati kuchinjika uye kugona kuchinjika kune akasiyana marudzi evatengi uye mashandisiro avo. Aya matanho manomwe ekubatanidzwa ndiwo hwaro hwekubudirira kweprojekiti yekubatana nemutengi: 1) hurongwa hwese hwekukurukurirana; 2) ROI hurukuro; 3) zvinyorwa zvechigadzirwa; 4) kutsanangurwa kwemaitiro ese; 5) miedzo yemuenzaniso; 6) RFQ / yakazara purojekiti yakatarwa; uye 7) kuenderera mberi kwekukurukurirana.
Aya matanho ekubatanidzwa anogona kuteverwa seri, mamwe anogona kuitika panguva imwe chete kana anogona kuchinjana, asi ese anofanirwa kupedzwa. Uku kuchinjika kwakavakirwa-mukati kunopa mukana wepamusoro wekubudirira kune vatori vechikamu. Mune zvimwe zviitiko, zvingave zvakanakisa kuita nyanzvi yeUV maitiro sechishandiso chine yakakosha indasitiri ruzivo mune ese marudzi tekinoroji yekupotera, asi zvakanyanya kukosha, yakasimba UV maitiro ekuita. Iyi nyanzvi inogona kufambisa nyaya dzese uye kuita senge isina kwayakarerekera sosi yekuongorora nemazvo uye zvakaringana matekinoroji ekuputira.
Danho 1. Hurukuro Yenzira Yese
Apa ndipo panotsinhaniswa ruzivo rwekutanga maererano nemaitiro emutengi azvino, ane tsananguro yakajeka yemagadzirirwo azvino uye zvakanaka / zvakaipa zvinotsanangurwa zvakajeka. Muzviitiko zvakawanda, chibvumirano chekusaburitsa pachena (NDA) chinofanira kunge chiripo. Zvadaro, zvinotsanangurwa zvakajeka zvinangwa zvekuvandudza maitiro zvinofanira kuonekwa. Izvi zvinogona kusanganisira:
Sustainability - VOC kuderedza
Kuderedza basa uye optimization
Hunhu hwakavandudzwa
Kuwedzera kumhanya kwemutsara
Floor nzvimbo kuderedza
Ongororo yemitengo yemagetsi
Kuchengetedzwa kweiyo yekuvhara system - spare parts, nezvimwe.
Tevere, chaiwo metrics anotsanangurwa zvichienderana neaya akaonekwa maitiro ekuvandudza.
Nhanho 2. Kudzoka-pa-Investment (ROI) Kukurukurirana
Zvakakosha kunzwisisa ROI yeprojekti pamatanho ekutanga. Nepo iyo nhanho yeruzivo isingadi kuve iyo nhanho inozodikanwa kubvumidzwa kweprojekiti, mutengi anofanira kuve neyakajeka yemitengo yazvino. Izvi zvinofanirwa kusanganisira mutengo pachigadzirwa, pamutsara tsoka, nezvimwe; mari yemagetsi; pfuma yeuchenjeri (IP) mari; mari yehutano; mushandisi / mari yekugadzirisa; mari yekusimudzira; uye mutengo wemari. (Kuti uwane ROI Calculator, ona panoperera chinyorwa ichi.)
Danho 3. Product Specification Hurukuro
Sezvinei nechero chigadzirwa chinogadzirwa nhasi, zvakakosha zvechigadzirwa zvinotsanangurwa muhurukuro dzekutanga dzeprojekiti. Nezve mashandisirwo ekuputira, izvi zvigadzirwa zvakasimukira nekufamba kwenguva kuti zvizadzise zvinodiwa zvekugadzira uye kazhinji hazvisi kusangana nemaitiro emutengi aripo. Tinozvidaidza kuti "nhasi vs. mangwana." Icho chiitiko chekuenzanisa pakati pekunzwisisa zvazvino zvigadzirwa zvechigadzirwa (izvo zvingave zvisiri kusangana neazvino coating) uye kutsanangura zvidikanwi zvenguva yemberi zvinogoneka (izvo zvinogara zviri kuenzanisa chiitiko).
Danho 4. Zvose Zvakatsanangurwa Maitiro
Mufananidzo 2. Kuvandudzwa kwemaitiro kunowanikwa kana uchifamba kubva pamvura-yakadzika nzira kuenda kune UV-coating process.
Mutengi anofanira kunyatsonzwisisa uye kutsanangura maitiro ezvino, pamwe chete nezvakanaka uye zvakashata zvemaitiro aripo. Izvi zvakakosha kuti UV masisitimu anobatanidza kuti anzwisise, saka zvinhu zviri kufamba zvakanaka uye izvo zvisiri izvo zvinogona kutariswa mukugadzirwa kweiyo UV system itsva. Apa ndipo apo maitiro eUV anopa mabhenefiti akakosha anogona kusanganisira kukurumidza kwejasi, kuderedzwa kwenzvimbo yepasi, uye tembiricha uye humidity kudzikiswa (ona Mufananidzo 2). Kushanya pamwe chete kunzvimbo yekugadzira yemutengi kunokurudzirwa zvakanyanya uye kunopa chimiro chikuru chekunzwisisa zvinodiwa nevatengi uye zvinodiwa.
Nhanho 5. Kuratidzira uye Kuedza Kunomhanya
Iyo yekuvharisa yekuvharisa nzvimbo zvakare inofanirwa kushanyirwa nemutengi uye UV masisitimu ekubatanidza kubvumira munhu wese kutora chikamu mukuenzanisa kwemutengi weUV yekuvhara maitiro. Munguva iyi, mazano matsva akawanda uye mazano achabuda apo zvinotevera zviitwa:
Simulation, samples uye kuyedza
Benchmark nekuyedza yemakwikwi ekubatisa zvigadzirwa
Ongorora maitiro akanakisa
Ongorora maitiro ekupa zvitupa
Sangana nevanobatanidza UV
Gadzira hurongwa hwekuita hwakadzama uchienderera mberi
Nhanho 6. RFQ / Yese Kutsanangurwa kweProjekiti
Gwaro reRFQ remutengi rinofanirwa kusanganisira ruzivo rwese rwakakodzera uye zvinodiwa zveiyo itsva UV yekupotera mashandiro sekutsanangurwa kwazvinoitwa muhurukuro dzekuita. Gwaro rinofanirwa kubatanidza maitiro akanakisa akaonekwa neUV coating tekinoroji kambani, iyo inogona kusanganisira kudziyisa iyo coating kuburikidza nemvura-jacket heat system kune pfuti tip; tote kupisa uye kusagadzikana; uye zvikero zvekuyeresa coating coating.
Nhanho 7. Kukurukurirana Kunoramba Kuripo
Nzira yekukurukurirana pakati pevatengi, UV musanganisi uye UV coatings kambani yakakosha uye inofanirwa kukurudzirwa. Tekinoroji nhasi inoita kuti zvive nyore kwazvo kuronga uye kutora chikamu mune yakajairwa Zoom / musangano-mhando mafoni. Hapafanirwe kuve nekushamisika kana UV mudziyo kana system iri kuiswa.
Mibairo Yakazadzikiswa nePipe Manufacturer
Nzvimbo yakakosha yekutariswa mune chero UV yekuputira purojekiti ndeyese mari yekuchengetedza. Muchiitiko ichi, mugadziri akaona kuchengetedza munzvimbo dzinoverengeka, kusanganisira mari yemagetsi, mutengo wevashandi uye zvekupfeka zvinobatika.
Mari Yemagetsi - Microwave-powered UV vs. Induction Heating
Mune akajairwa emvura-yakadzika majeti masisitimu, panodiwa pre- kana post-induction kudziyisa kwechubhu. Induction heaters anodhura, ane-high-energy vatengi uye anogona kuve neakakosha nyaya dzekugadzirisa. Pamusoro pezvo, mushonga wemvura waida 200 kw induction heater simba rekushandisa maringe ne90 kw inoshandiswa nemarambi emicrowave UV.
Tafura 1. Kuchengeta mari inopfuura 100 kw/awa uchishandisa 10-lambi microwave UV system maringe ne induction heat system.
Sezvinoonekwa muTable 1, mugadziri wepombi akaona kuchengetedza kudarika 100 kw paawa mushure mekushandisa tekinoroji yeUV yekupotera, ukuwo ichidzikisa mutengo wemagetsi neinopfuura $71,000 pagore.
Mufananidzo 3. Mufananidzo wegore negore mari yekuchengetedza magetsi
Kuchengetwa kwemari kweiyi kuderedzwa kwesimba rekushandisa kwakafungidzirwa zvichienderana nemutengo unofungidzirwa wemagetsi pa14.33 cents/kWh. Iyo 100 kw / awa kudzikiswa kwekushandiswa kwesimba, yakaverengerwa pamusoro pemashifiti maviri kwemavhiki makumi mashanu pagore (mazuva mashanu pasvondo, maawa makumi maviri pashift), inoguma nekuchengetwa kwe $71,650 sezvakaratidzwa mumufananidzo 3.
Kuderedza Mutengo Webasa - Vashandisi uye Maintenance
Sezvo masangano ekugadzira achiramba achiongorora mutengo wavo wevashandi, maitiro eUV anopa yakasarudzika mari ine chekuita neanoshanda uye kugadzirisa maawa emurume. Nekuputira kwemvura, iyo yakanyorova yakanyorova inogona kuomesa yakadzika pamvura yekushandisa, iyo inozopedzisira yabviswa.
Vashandi venzvimbo yekugadzira vakapedza maawa makumi maviri nemasere pasvondo vachibvisa / kuchenesa iyo yakavakirwa mvura kubva mumidziyo yayo yepasi.
Pamusoro pekuchengetedza mari (inofungidzirwa kuti maawa makumi maviri nemasere ekushanda x $36 [mutoro unorema] paawa = $1,008.00 pavhiki kana $50,400 pagore), zvinodikanwa zvebasa remuviri zvevashandi zvinogona kuodza mwoyo, kutora nguva uye kunze-kurudyi kune ngozi.
Mutengi akananga kucheneswa kwekuvhara kwekota yega yega, nemari yevashandi yemadhora zviuru zana nemakumi mapfumbamwe pakota, pamwe nemitengo yekubvisa coating iyo yakaitwa, pamari inosvika zviuru zviviri nemazana mashanu. Mari yese yakachengetwa pagore yakaenzana ne$10,000.
Coating Savings - Waterbased vs. UV
Kugadzirwa kwepombi panzvimbo yevatengi kwaive 12,000 matani pamwedzi we9.625-inch-diameter pombi. Pachidimbu, izvi zvinoenzana ne570,000 mutsara tsoka / ~ 12,700 zvidimbu. Maitiro ekunyorera tekinoroji yeUV yekupotera tekinoroji yaisanganisira yakakwira-vhoriyamu / yakaderera-kudzvanya pfuti yekupfapfaidza ine yakajairika chinangwa ukobvu hwe1.5 mils. Kurapa kwakaitwa kuburikidza nekushandisa Heraeus UV microwave marambi. Mari yekuchengeta mumachira uye mutengo wekufambisa / wemukati wekubata unopfupikiswa muTable 2 ne3.
Tafura 2. Coating cost comparison - UV vs. waterbased coatings per linear foot
Tafura 3. Kuwedzera mari kubva kune yakaderera mutengo wekufambisa uye kuderedzwa kwekubata kwezvinhu panzvimbo
Uye zvakare, zvimwe zvekuwedzera uye mari yevashandi kuchengetedza uye kugona kwekugadzira kunogona kuitika.
UV mabhanhire anodzoreredzwa (waterbased coatings haasi), achibvumira kanokwana 96% kunyatsoshanda.
Vashandi vanopedza nguva shoma vachichenesa uye kuchengetedza zvishandiso zvekushandisa nekuti UV yekupotera haiome kunze kwekunge yakafumurwa kune yakakwira-yakanyanya UV simba.
Kumhanyisa kwekugadzira kunokurumidza, uye mutengi ane mukana wekuwedzera kumhanya kwekugadzira kubva ku100 tsoka paminiti kusvika 150 tsoka paminiti - kuwedzera kwe50%.
Iyo UV process yemidziyo inowanzo ine yakavakirwa-mukati yekumhanyisa kutenderera, iyo inoteedzerwa uye yakarongwa nemaawa ekugadzira kumhanya. Izvi zvinogona kugadziriswa zvinoenderana nezvinodiwa nemutengi, izvo zvinoita kuti vanhu vashoma vanodiwa pakuchenesa system.
Mumuenzaniso uyu, mutengi akaona mari yekuchengetedza yemadhora zviuru zana nemakumi maviri nenomwe pagore.
Kuderedzwa kweVOC
Kuitwa kweUV coating tekinoroji zvakare kwakaderedza VOCs, sezvinoonekwa muMufananidzo 4.
Mufananidzo 4. VOC kuderedzwa semugumisiro weUV coating kushandiswa
Mhedziso
UV yekupotera tekinoroji inobvumira mugadziri wepombi kuti abvise maVOC mukushanda kwavo kwekupfekedza, ukuwo achiunza yakagadzikana yekugadzira maitiro anovandudza kugadzirwa uye kuita kwese kwechigadzirwa. UV yekuvhara masisitimu zvakare inofambisa yakakosha mari yekuchengetedza. Sezvakatsanangurwa muchinyorwa chino, mari yese yemutengi inodarika $1,200,000 pagore, uye yakabviswa pamusoro pe154,000 lbs yeVOC emissions.
Kuti uwane rumwe ruzivo uye kuwana ROI Calculator, shanya www.alliedphotochemical.com/roi-calculators/. Kuti uwane mamwe maitiro ekuvandudza uye iyo ROI Calculator muenzaniso, shanya www.uvebtechnology.com.
SIDEBAR
UV Coating process Sustainability / Environmental Advantages:
Hapana Volatile Organic Compounds (VOCs)
Hapana Zvinosvibisa Mhepo Ine Ngozi (HAPs)
Zvisingatsvi
Hapana zvinonyungudutsa, mvura kana mafirita
Hapana humidity kana tembiricha yekugadzira nyaya
Yakazara Maitiro Kuvandudza Inopihwa neUV Coatings:
Inokurumidza kugadzira inomhanya inokwira ye800 kusvika 900 tsoka paminiti, zvichienderana nehukuru hwechigadzirwa
Diki diki tsoka isingasviki 35 tsoka (mutsara kureba)
Minima work-in-process
Instant yakaoma pasina post-cure zvinodiwa
Hapana nyaya dzekudzika kwemvura dzakanyorova
Hapana gadziriso yekupfeka kune tembiricha kana humidity nyaya
Hapana yakakosha kubata / kuchengetedza panguva yekuchinja shanduko, kugadzirisa kana kuvhara kwevhiki
Kuderedzwa kwemari yevashandi inoenderana nevashandisi uye kugadzirisa
Kugona kudzoreredza overspray, refilter uye kudzoreredza mucoating system
Yakavandudzwa Chigadzirwa Kuita neUV Coatings:
Kuvandudza humidity test results
Great salt fog test results
Kugona kugadzirisa coating hunhu uye ruvara
Majasi akajeka, simbi uye mavara aripo
Yakaderera pamutsara tsoka yekupfekedza mitengo sezvakaratidzwa neROI karukureta:
Nguva yekutumira: Zvita-14-2023
