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SERI presentation1-5-10

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SERI presentation1-5-10

  1. 1. 1 In-Plant-Materials Optimization Presented By Specialty Elastomer Recovery, Inc. (SERI) SERI
  2. 2. 2 PRESENTATION  Guiding Principals  Process  Polymers Processed  Quality Assurance  Additional Capabilities & Process Development  Suggested Procedure for In “In Process Materials” (IPM) Optimization Practice  Summary
  3. 3. 3 Who is SERI?  Leader in Fine Elastomeric Powder Technology  Process Recovered FKM and High-end elastomeric Materials to a 325 Mesh Powder  ISO Certified  Excellent R&D, Pilot Plant, Laboratory and Customer Support  Unique and Proven Technology  Continual Process and Product Improvements
  4. 4. 4 SERI Manufacturing Facility
  5. 5. 5 SERI
  6. 6. 6 SERI FKM Procesing Line
  7. 7. 7 SERI Warehouse 
  8. 8. 8 Guiding Principles  Assist Material Approval Process  Assist In Collection, Optimization and Implementation  Demonstrate Economic and Value  Successful Long Term Relationship
  9. 9. 9 Objective  Objective is  to Recover,  Reduce,  Reuse,  and fully Recycle IPM Materials in a cost effective, viable, and environmentally sound manner.
  10. 10. 10 CAPABILITIES  Process many cured polymers into precise gradations and surface morphologies.  Strict adherence to QC measures which insure zero contamination.  Includes both virgin and recyclable elastomers.  Finished particle size tailored to customers specific needs.  Finished powder down to a minus 325 mesh particle.  Process is energy efficient, environmentally sound.  Produces highly uniform products with high yields.
  11. 11. 11 The Process 1 Receive Sample(s) 2 Process to a Gradation(s) 3 Lab Evaluations 4 Make Process Adjustments If Necessary 5 Feasibility Finalize Parameters At Mfg. Facilities 6 Begin Collection & Processing 7 Continue ongoing Product/service improvements
  12. 12. 12 Process Quality Assurance– Multi Elastomer Processing  Two manufacturing lines.  Line 1 – Strictly FKM Materials (Black and Colors)  Line 2 – Other High-end Elastomer Materials  Specialized high-pressure rotating steam cleaning system for all pipes in system.  Water flush through grinding and dewatering system.  Optimal equipment engineering design to accommodate thorough and efficient cleanout between every material produced.  Line 1 and Line 2 are contained in separate areas divided by a concrete wall with individual packaging systems.
  13. 13. 13 “In Process Material” (IPM) Optimization Closed Loop IPM Methodology Materials Products Manufacturing Operations IPM Loop Manufacturing Plant Site
  14. 14. 14 Merits of an “IPM” Practice  Waste streams become resources  No Chemistry Changes  No Process Modification  No Material Alterations  Utilization of Existing Resources & Procedures  Internal Cost Savings  Competitive Cost Advantage  Improved Production Performance  Eliminate landfill burdens (cost & liability)
  15. 15. 15 Goal → Recapture “In Process Materials” Present Practice Landfill > In ↓ Out $ IPM Practice IPM Optimization < In ↑ Out $
  16. 16. 16 THE PROCESS  The basic grinding process is called – UltraFineTM  The uniqueness is grinding in fluids, preferably water, with or without additives to achieve precision gradations, uniform chemistry, and surface morphologies  The process when used as a compounding system then becomes an IPMTM process
  17. 17. 17 The UltraFine “IPM” Process Feed Hopper Milling Rare Earth Magnets Conveying Conveying Rare Earth Magnets Slurry Hopper Filtration Conveyor Conveying Packaging Rare Earth Magnets Screening SHIPPING Customers Custom Fine Ground Elastomeric Powders Feed Hopper RECEIVING Customers “IPM” Drying Pollution Control Water Make-up Pump Pump Wet Grinding Note: Heavies & Light Contaminate Ends Removed C o n v e y i n g Conveying
  18. 18. 18 Nature of UltraFineTM Powders High Surface Areas Uniform Chemistry Uniform Gradations Clean Flowable Replaces Costly Polymer Equivalents High Yields Energy & Environmentally Sound
  19. 19. 19 Rubber Material: FKM Compound with 25% SERI 170 mesh Regrind Material PROPERTIES: Unit Results Results Test Pieces 214 Orings No Regrind 25% FKM Regrind Original Hardness, Shore A (ASTM Slab) point 75 75 Properties Hardness, I.R.H.D. point 70 71 Tensile Strength MPa 14.0 13.9 Ultimate Elongation % 251 236 Modulus @ 100% Elongation,Mpa % 6.3 7.2 Heat Aging Change in Hardness, Shore A point 0 +1 Change in Tensile Strength % +39.9 +40 250°C x 70 hrs. Change in Ultimate Elongation % -19.1 -21.8 Immersion in Liquid Change in Hardness point -2 -1 Fuel C Tensile Strength % -7.7 -9.6 Ultimate Elongation % +1.9 -1.8 23°C x 70 hrs. Change in Volume % +2.8 +2.2 Immersion in Liquid Methanol Change in Volume % +3.7 +3.0 23°C x 24 hrs. Compression Set Compression = 25% % 17 16 175°C x 22 hrs. SERI
  20. 20. 20 HNBR Compound with 25% SERI 170 Mesh Regrind Material PROPERTIES: Unit Results Results Test Pieces ASTM Dumbells No Regrind 25% HNBR Regrind Original Hardness, Duro A point 73 73 Properties Tensile Strength MPa 29.30 29.4 Ultimate Elongation % 225 238 Tear Die B kN/m 21.43 25.06 Heat Aging Change in Hardness point +1 +1 Change in Tensile Strength % +7.4 +2.7 120°C x 70 hrs. Change in Ultimate Elongation % +1.3 -2.1 Immersion in Liquid Change in Hardness point -10 -11 Fuel C Tensile Strength % -70.3 -61.0 Ultimate Elongation % -47.6 -42.4 30°C x 48 hrs. Change in Volume % +37.7 +37.3 Immersion in Liquid Change in Hardness point -10 -12 Fuel C +M10 Tensile Strength % -71.3 -75.0 Ultimate Elongation % -52.4 -53.5 30°C x 48 hrs. Change in Volume % +56.7 +56.9 Immersion in Liquid Change in Hardness point -10 -11 Fuel C +E20 Tensile Strength % -71.6 -72.3 Ultimate Elongation % -51.1 -54.5 30°C x 48 hrs. Change in Volume % +53.9 +53.7 Immersion in Liquid Change in Hardness point -8 -9 Fuel C +MTBE15 Tensile Strength % -67.9 -66.7 Ultimate Elongation % -48.4 -47.2 30°C x 48 hrs. Change in Volume % +36.0 +36.4 Compression Set Compression = 25% % 10.6 11.0 120°C x 70 hrs. Plied Slabs SERI
  21. 21. 21 Dynamics of the UltraFineTM Wet Grind System Precision Intimate Grinding in a Fluid System Customer Specialty Polymer(s) Precision Tailored Ground UltraFineTM Powder Light End Contaminates Removed Heavy End Contaminates Removed
  22. 22. 22 Custom Tolling - UltraFine™ “IPM” Flow Loop Customer –Facility 1. Collecting Source Separated Materials 2. Labeling 3. Shipment SERI RECEIVING 4. Receiving 5. Storage 6. Production Scheduling UltraFine PROCESSING 7. Primary Reduction 8. UltraFine Grinding 9. Precision Screening SERI PACKAGING 10. Drying 11. Packaging/pre-weigh 12. Warehousing SERI SHIPPING 13. Product Certification 14. Final QA/QC 15. Material Balance 16. Shipment (Round-Robin)
  23. 23. 23 Present to Future Practice Customer IPM Converted to CG- FKM-170 UltraFine Powder Back to High Quality New Parts
  24. 24. 24 The Benefit Maintain Product Properties EconomicValue,$ IPM Value, Time Landfilling, $ Losses, Stop Generally Improved Manufacturing Experiences and Significant Economic Benefit Transition
  25. 25. 25 Future Improvements FKM Teflon Aflas FQM New Specialty Development in Time Savings/Profit
  26. 26. 26 SUMMARY OF SERI’S SERVICES TO CUSTOMERS  Established  Certified For Quality and Methodology  Professional Staff and Services  Confidentiality  Precision Grinding to Produce Specified High Quality UltraFineTM Powders  Partnering for Future Innovation and New Developments
  27. 27. 27 Result  Reduced Material Costs  Capture Lost Opportunity Value  Improve Production  Leading Edge Opportunity  Improve Product Margins  Maintain Competitive Edge
  28. 28. 28 Thank You An “IPM” Partnership SERI
  29. 29. 29 Shipping Area
  30. 30. 30 Receiving Area
  31. 31. 31 Back of Manufacturing Facility
  32. 32. 32 Manufacturing Facility
  33. 33. 33 SERI Manufacturing Facility
  34. 34. 34 Direct line to the power company

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