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Vem case studies - Premix system


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Vem case studies - Premix system

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Vem case studies - Premix system

  1. 1. VEM CASE STUDIES:PREMIX SYSTEM Vem presents its new state-of-the-art system for 1 VEM CASE STUDIES – raw material consumption optimization. PREMIX SYSTEM
  2. 2. FOREWORDThis technology was developed to reduce resinconsumption in the core, as well as improvingthe mixing of resin and sand, especially whenthe sand granulometry is not exactly to VEM’sspecifications.The premix system is convenient for theproduction of pipe with a minimum wallthickness of 10mm. The premix pipe does not Photo 1: China premix in production, first release.have the same design as that of a standardpipe: there is no chop in the core and there OUR TESTS stare three different resin dosing systems: 1 The first test was performed in a plant in Chinaskin, premix mortar core and finally the 2nd in 2009 with the first version of premixskin. machine, visible in photo no. 1 above.The mortar core is made of a polypropylene The pipe produced was ND800 NP6 ST10000veil that contains the resin mixed with the and the laboratory test results were aligned tosand; afterwards the premix “sausage” is the pipe design program. The composition waswound onto the mandrel. in accordance with the pipe design expectedThe premixing machine has two different data, as indicated in the following table:extruders, depending on the wall thickness.The second one is useful when the corethickness is > 25 mm, for example: STANDARD SAND PREMIX RAW MATERIALS SYSTEM(%) SYSTEM(%) - ND 2000 NP 10 SN 10.000 (25,87mm) - ND 2300 NP 10 SN 7.500 (25,46mm) Sand 54 66 - ND 3000 NP 10 SN 5.000 (26,50mm) Hoop 7.9 7.4The old release had the static mixer fixed on Chop 6.8 2.9the premix structure. As you can see from the Resin 30.4 23.6picture, the device was designed to guarantee Total resin 27.13 22.14the minimum gap from extruder output and Kg/mthe pipe on production. 2 VEM CASE STUDIES – PREMIX SYSTEM
  3. 3. The variation from design was: L.O.I DEV (%) Resin 1.1 Sand 0.5 Chop -0.8 Hoop -2,85 Photo 2: Turkey release premixThe second test was performed in Turkey L.O.I. DEV (%)where a ND1300 NP6 SN2500 was produced. Resin 0,43The system was stable enough to produce a Sand 1,96very well compacted pipe core, thanks to a Chop 0,02second compaction roller together with Hoop -2,85controlled vibration. Stiffness respected thedesign values, namely 3365,58Pa at 5% ofdeflection. The following tables and picturesexplain the above: RAW STANDARD SAND PREMIX SYSTEM(%) SYSTEM(%) MATERIALS Sand 40 47 Hoop 20 20.2 Chop 9.3 6.5 Resin 30.3 25.4 Total resin 40 35 Kg/m Photo set 3: see the optimum compaction thanks to the second compaction roller and vibration 3 VEM CASE STUDIES – PREMIX SYSTEM
  4. 4. A third test was done in Turkey on DN2000 The last test was performed in Syria, where aNP6 SN2500 and the L.O.I. result showed good ND1200 NP6 SN10.000 pipe was made. Thevalues from a composition point of view and production was very smooth and thevariation from design: laboratory results showed successful values. L.O.I. DEV (%) Resin 1,55 Sand -1,66 Chop -2,22 Hoop 2,23VEM decided to further develop the Photo 4: Syrian version, premix on trolley and premix guidetechnology to obtain a more user friendlysystem: The 2010 release is more user friendly from an 1) Use of a different veil: larger and installation point of view: installation and stronger. removal can be performed in less than 1 hour 2) Use of a forming mouth piece to close thanks to the fast connections and mechanical the sausage and an auto-tensioning facilities. device to make the process stable. 3) Changing of premix position: easier to put it into operation. From a production point of view, the ND1200 4) Chopper plate conveyors. NP6 SN10.000 pipe was designed as shown 5) Use of a larger core area and a second below, where we have also indicated the compaction roller. expected and actual values: 6) Changing of static mixer position from premix structure to the chopper bridge. 4 VEM CASE STUDIES – PREMIX SYSTEM
  5. 5. PIPE DESIGN ACTUAL EXPECTED Resin LOI 23 23,72 (%) Sand (%) 64,7 64,71 Hoop 9,3 9,94 (%) Photo 5: well compacted core Chop (%) 2,9 3,56 Thickness Mm 23,84 23,23 CONCLUSIONS Stiffness 5% Pa 10000 10605 deflection The premixing system allows the production of Axial tensile N/mm 280 354 an extremely competitive pipe thanks to a Hoop tensile N/mm 1448 1669 reduced consumption of resin, approximately between 15 and 20% in the core, dependingCircumference mm atelongation on 6,4 2,5 on the pipe recipe, with good mechanical test 1xNP Hydrotest results. mm at 14 5,7 2xNP Since the case studies carried out in Turkey and Syria, VEM continued to develop the premixing system and we are proud to now show you a photo of the latest version:The good compaction of the mortar core isshown in the photo number 5. A combinationof pressure compaction roller, gravity rollerand vibration in different points contributed tothis excellent result. Photo set 6: Premix last release, 2011 version 5 VEM CASE STUDIES – PREMIX SYSTEM