CDS R-O2 Presentation - Ceramics & Refractories

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CDS have a patented R-O2 technology that uses dry super heated steam to dry ceramic based products in a far shorter time using less energy

CDS have a patented R-O2 technology that uses dry super heated steam to dry ceramic based products in a far shorter time using less energy

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  • 1. CDS GROUP R−O2 Drying Presentation for Refractories, advanced ceramics & allied products.
  • 2. CDS GROUP ˆthe history˜ Privately owned and formed in 1983. Based in Stoke−on−Trent, England. 80 people employed throughout the CDS Group, covering: ˘Sales ˘Design ˘Engineering ˘Fabrication, and Installation ˘Commissioning Annual Group Turnover of $20,000,000.00 US Dollars. Accredited to ISO 9001/2000.
  • 3. CDS GROUP ˆthe team˜
  • 4. CDS GROUP ˆcapabilities ˜ Design, consultation and feasibility study. From small scale engineering design to full ˆturnkey˜ packages. Flexibility of contract structure. ˘ Complete Supply from the UK. ˘ Local manufacture and equipment supply. Complete installation and commissioning service. After sales service from the UK. Research & Development facilities.
  • 5. What is R−O2 Drying? R−O2 Drying is a method of drying which uses dry superheated steam at atmospheric pressure to perform the drying process. R−O2 Drying is safe to operate, easy to control (only temperature is controlled & not humidity) & offers ultra fast drying times with high thermal efficiencies. R−O2 Drying Advantages include: Reduction in process drying times Reduction of energy requirements High thermal efficiency Smaller Footprint required Minimal exhaust emissions to atmosphere. Traditional stack is not needed. Energy recovery potential Virtual elimination of the potential explosion and or product combustion risk
  • 6. How Does Steam Replace air? The steam is generated from the moisture contained only within the product. When water boils & becomes steam its volume increases by a factor of 1,670. As the water evaporates, each Kg of water occupies a volume of 1.67 m3 R−O2 Dryers operate on full recirculation so no new air is required to enter the system. As both the recirculation mix and the product get hotter, 1.67m3 of increasingly humid air is vented as each Kg of water is evaporated. This process continues until the Dryer is virtually free of air which is replaced with dry superheated steam.
  • 7. How Does Steam Replace air?
  • 8. How Does Steam Replace air?
  • 9. What is the R−O2 Drying Cycle? The R−O2 drying cycle consists of only 2 phases: − The Warm Heat Up Phase − between ambient and 100°C. − The Drying Phase − Above 100°C. During the Warm Up Phase the small amount of water evaporated from the product effectively raises the humidity level. This suppresses undue evaporation and allows the product to be rapidly heated to 100°C without rapid shrinkage.
  • 10. What is the R−O2 Drying Cycle? Additional heating further heats the product and evaporates the remaining water, while the additional steam generated from the moist product continues to be vented from the chamber. Heating continues until the product is dry at which stage ambient air is introduced into the dryer to cool both chamber and products. In summary, the combination of the rapid heating during the warm up phase and rapid moisture removal during the drying phase allows R−O2 drying to achieve such substantial reductions in drying times against conventional techniques.
  • 11. What is the R−O2 Drying Cycle?
  • 12. What is the R−O2 Drying Cycle?
  • 13. Temperature profile in a Continuous R−O2 Dryer
  • 14. What Are The Advantages of R−O2 Drying? As the Specific Heat of steam is twice that of air, less Fan power is required to supply a given amount of heat to the moist product. R−O2 Drying is more energy efficient because, not only is fresh air excluded from the process (which in conventional Dryers needs heating), most of the Dryers heat input can be usefully re−cycled, and is typically around 80% of the total heat input. In summary R−O2 Drying is a SAFE Drying Method is more energy efficient and offers vastly reduced drying times.
  • 15. Schematic Flow Diagram R−O2 Drying Process
  • 16. Isometric Drawing of a Typical R−O2 Drying Chamber
  • 17. R−O2 Drying Chambers
  • 18. R−O2 Drying Chambers
  • 19. R−O2 Drying Chambers
  • 20. R−O2 Drying Chambers
  • 21. R−O2 Continuous Systems
  • 22. R−O2 Continuous Systems
  • 23. R−O2 Dryer in pre−build stage
  • 24. R−O2 Processing Systems
  • 25. R−O2 Processing Systems
  • 26. Examples of Products Dried Refractory Blocks Refractory Bricks Refractory Bricks Fire Backs
  • 27. Examples of Products Dried Tableware Silicon Carbide Tubes De-Nox Catalyst Automotive Catalyst
  • 28. Examples of Products Dried Fibre pressed Shapes Steel Refractory Dart heads
  • 29. Examples of Products Dried Sanitaryware Fibre Boards Insulators Fibre Boards
  • 30. Examples of Products Dried Slide Gate Products Refractory Shapes Formed Fibre Shapes Crucibles
  • 31. Examples of Products Dried Fused Silica Crucibles Fused Silica Rollers Refractory Block for the float Glass Industry
  • 32. R−O2 Research & Development Facilities
  • 33. R−O2 Trial Plants We have extensive testing facilities located in Stoke− on−Trent, UK. These facilities consist of a wide range of R−O2 processing equipment which allows us to carry out trials on almost any type of product, producing trial−sized quantities of up to 1,000 kg/hr.
  • 34. R−O2 Trials Batch Dryer
  • 35. R−O2 Trials Chamber Dryer R−O2 Trials Batch Dryer
  • 36. R−O2 Process Control Systems
  • 37. R−O2 Process Control Systems
  • 38. R−O2 Process Control Systems
  • 39. R−O2 Control Cabinets
  • 40. R−O2 Technology Independent Verification
  • 41. End User Proximate Energy Savings Independent Bodies found Potential End User Proximate Energy Savings of 45% when using R−O2 Technology: (556 Development of an Energy Efficient System to Reduce the Cost of Drying Food and Food Waste WREEED, CORDIS RTD− Projects / European Communities FP5 Project Record)
  • 42. Independent Verification `Energy Efficiency Best Practice Programme (UK) Future Practice Final Report 58 by ETSU, Harwell, Didcot, OX11 0RA, acting on behalf of the DETR 1997. Found: R−O2 Drying offers energy consumption savings over industry survey averages of between 60% and 85%. `R−O2 Drying for Ceramic Products Ceram Research Report KAIR−IV Final Project Report, J. Fifer (Project Manager) and T. Evans (Report) 1996: Found: Savings relating from shorter cycle times and or reduced product damage; Savings achievable by full re−use of the R−O2 Dryers exhausted steam energy and or use of its flue gas energy CERAM
  • 43. More Independent Verification `556 Development of an Energy Efficient System to Reduce the Cost of Drying Food and Food Waste (WREED) CORDIS RTD−PROJECTS / © European Communities FP5 Project Record. Found: the potential to save up to 75% of the current energy loss. Utilising a non− pressure steaming approach, with a unique sealing method for continuous production with features for maximised energy efficiency. `R−O2 Drying Trials for Calcium Silicate Boards, Cape Calsil Systems Ltd 1999. Found: using superheated steam as the heat transfer medium, enhanced heat transfer performance, relative to air and because R−O2 drying has the added virtue of virtual `no air being present, there is an enhanced product quality. Cape Calsil Systems Ltd
  • 44. R−O2 References Worldwide Dutch Govt Kermansavi Calortec Se−Shin Palmex R.S.I. Morgan Matroc Kanthal Cookson Mathey Vesuvius Ideal Standard Parkinson Spencer Refractories IFGL & MIR Global Dyson Refractories Incesa Standard Harbison Walker Villeroy & Boch Morganite Crucible Kohler Sanimex Morgan Thermal Steelite plc Hepworth Refractories Dudson plc Carborundum Vista Alegra Ceradyne Pfalzgraph Norton Ceramics Harbison Walker Diamond Refractories Swell Corporation Acme Marls American Standard Aguascalientes Cape Insulation Jacob Delafon CERAM Celtek ECU Promat Doncasters National Metalurgical Laborities Skamol Marine System Technology
  • 45. CDS GROUP Where there is NO COMPROMISE when it comes to . QUALITY & RELIABILITY