Specific Energy Consumption in Pipe Extrusion

Optimizing Energy Use in Plastic Pipe Production

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