Lowering the cost/pipe length is a primary goal in pipe extrusion. Modern extrusion lines aim for reduced maintenance and energy consumption. Specific extrusion energy, measured in Wh/kg, differs significantly between PVC and Polyolefins (PO). Drive energy for PO is approximately three times higher than for PVC.
Energy costs per pipe length are influenced by the efficiency of extruders and plant equipment, material saving technologies (processing less material for the same pipe length), and replacing polymer with air or filler. For a typical extrusion site, energy costs can be around $75,-/ton. The energy needed for manufacturing is part of the overall Life Cycle Analysis (LCA).
Energy Costs Breakdown:
Drive: 65%
Heating: 10%
Mixers, pumps, coolers, etc.: 25%
Technologies like Multilayer (foam/high filled/recycled core) pipe extruders and dies, Direct Addition of fillers, and Gravimetrics and scanners contribute to material saving. Gravimetrics and scanners can save 1-2% dry blend, leading to a payback time shorter than 1 year.
Technical Specifications Notes
While no specific table is provided, the source indicates typical specific energy values:
PVC: Approx. 80-100 Wh/kg (excl. die), Die adds 15-25 Wh/kg.
PO: Approx. 3x higher drive energy than PVC.
FAQ Section
How does reducing specific energy consumption impact the overall cost of plastic pipes?
Reducing specific energy consumption directly lowers energy costs per pipe length. Combined with material saving technologies like gravimetrics or using fillers/foam, it significantly contributes to achieving the lowest cost per meter of pipe. Lower energy use also aligns with sustainability goals and LCA considerations.
Are there material differences that affect specific energy requirements?
Yes, Polyolefins (PO) require significantly more drive energy for extrusion (approx. 3x more) compared to PVC. The processing characteristics of PVC as a rubber-like solid versus PO as a real melt also influence energy input.
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Nick Belshof
