Faygo, a Wanplas factory, is a specialized manufacturer of plastic pipe and profile extrusion lines with 22 years of dedicated experience in this field. The company operates three specialized factories, with its pipe and profile facility covering 26,650 square meters in Zhangjiagang City, only two hours from Shanghai airport, and reaches customers across 100 plus exported regions through the Wanplas group network. This article explains how an anti corrosion HDPE chemical パイプ押出ライン is designed and operated for factory acid alkali medium transportation pipelines, and how Faygo configures these lines for stable, fully welded, long service life pipe systems.
Chemical plants, electroplating shops, pharmaceutical sites and mining operations move aggressive liquids every day: dilute sulfuric acid, hydrochloric acid, sodium hydroxide, mixed process waste, organic solvents and abrasive slurries. Carbon steel corrodes, lined steel is costly to maintain, and rigid PVC is limited in temperature and impact resistance. High density polyethylene, particularly PE100 grade HDPE with MRS 10 MPa rating, offers a corrosion free, lightweight and weldable alternative that is produced continuously on a パイプ押出ライン. The following sections cover the media that HDPE resists, why it is chosen, how the material grades and pressure classes work, the full extrusion process, the sizing and cooling technology, quality control, welding, defect troubleshooting, line speed and capacity, maintenance, plant layout, safety and the Faygo line configurations available for this application.
1. Application Scenarios and Chemical Media
An anti corrosion HDPE chemical パイプ押出ライン produces pipe intended to carry aggressive media inside process plants and between plant battery limits. The pipe must survive continuous contact with the medium, resist permeation, keep a smooth bore for flow, and join into a leak free network. HDPE is selected when the medium is corrosive, when weight and installation cost matter, and when a homogeneous welded joint is preferred over flanged metal sections.
The table below summarizes the chemical resistance of HDPE against typical factory media. Resistance ratings are technical, based on the non polar, saturated hydrocarbon structure of polyethylene, and should always be verified against the actual concentration, temperature and exposure time. No brand or formulation name is referenced because the pipe is made from generic PE100 or PE80 grade HDPE compound.
HDPE chemical resistance against common factory media
| Medium | Typical condition | HDPE耐性 | Technical note |
|---|---|---|---|
| 硫酸 (dilute) | up to 60 percent, ambient to 40 C | Excellent | Stable at low to medium concentration |
| Hydrochloric acid | up to 35 percent, ambient | Excellent | Non oxidizer, well tolerated |
| Sodium hydroxide | up to 50 percent, ambient to 60 C | Excellent | ポリオレフィンの水解はない。 |
| Mixed process waste | variable pH, salts | Good | Verify concentration and temperature |
| Aliphatic hydrocarbons | fuel oil, gasoline | Good | Slight swelling at high temperature |
| Aqueous salt solutions | brine, chlorides | Excellent | No chloride stress cracking like steel |
| Aromatic solvents | benzene, toluene | Limited | Swelling and loss of strength |
| Chlorinated solvents | methylene chloride | Not recommended | Severe attack on polyolefin |
| Strong oxidizers | conc. nitric, chromic acid | Not recommended | Oxidative degradation |
| Abrasive slurry | tailings, fly ash | Good | Low friction bore reduces wear |
限定またはお勧めされていない媒体の場合、プラントは専用の耐化学薬品内膜や別のポリマーに切り替える必要があり、エクストラクションサイトは決定的な要素ではありません。HDPEの価値は、工場排出物や中間輸送用途で支配的な水酸化物、アルカリ、塩の大きなファミリーにあります。
Resistance is never absolute; it moves with both concentration and temperature. A medium that is fully tolerated at ambient temperature can attack the polymer at elevated temperature because molecular motion increases and permeation accelerates. Similarly a dilute acid may be safe while the same acid at high concentration becomes aggressive. For this reason the pipe specifier records the worst case concentration and the highest continuous and peak temperature of the duty, then selects the PE grade and the SDR against that envelope. The non polar, saturated carbon chain of HDPE is why it ignores most aqueous corrosives: there is no ester, amide or metal site for acid or alkali to attack, so the material neither dissolves nor hydrolyzes in water based media. This chemical inertness is what makes an anti corrosion HDPE chemical パイプ押出ライン a durable choice for continuous acid alkali service rather than a coated metal compromise.
2. Why Choose HDPE for Corrosive Medium Transport
HDPE earns its place in chemical pipelines because it is inert to most aqueous corrosives, it is light enough to handle without cranes at small diameters, it is flexible enough to absorb ground movement, and it forms homogeneous welded joints. Compared with alternative piping materials, HDPE trades some temperature ceiling for much simpler corrosion management and lower lifetime cost of ownership.
Comparison with PVC, PP, steel lined and FRP
| 材料 | 耐化学性に優れる to acids/alkalis | Continuous temp ceiling | 密度（g/cm3） | Joint reliability | Install difficulty |
|---|---|---|---|---|---|
| HDPE(PE100) | Excellent for aqueous acids/alkalis | up to 40 C service, 60 C short | 0.95 | Excellent (butt fusion) | Easy |
| PVC (rigid) | Good, but brittle on impact | up to 60 C | 1.40 | Solvent cement, moderate | Moderate |
| PP | Good, better temp than HDPE | up to 80 C | 0.91 | Welded, good | Moderate |
| Steel with anti corrosion lining | Good if lining intact | high, above 100 C | 7.85 | Flanged, leak risk at gasket | Hard |
| FRP（ガラス繊維強化） | 良好、樹脂に依存 | up to 90 C resin dependent | 1.5 to 2.0 | 粘着剤またはフランジ、スキルに依存 | Hard |
The comparison is material to material, not brand to brand. HDPE wins on corrosion freedom and joint integrity for aqueous acid alkali service at moderate temperature, while PP or lined steel take over when the temperature exceeds the HDPE ceiling. The extrusion line is engineered so the resulting pipe keeps the wall uniformity that makes these properties reliable in the field.
3. PE100およびPE80材質グレード、SDR、および圧力クラス
Polyethylene pipe compounds are graded by their hydrostatic design basis. PE80 and PE100 are the two common grades for pressure pipe, defined by their Minimum Required Strength (MRS) in MPa at 20 degrees Celsius over a 50 year reference life. PE100 grade HDPE with MRS 10 MPa rating provides higher allowable stress than PE80 with MRS 8 MPa, so for the same pressure a PE100 pipe can be thinner walled or a given wall can carry higher pressure.
壁の厚さは標準寸法比率（SDR）で設定されます。SDR は、外径と壁の厚さの比率を意味します。SDR が小さいほど壁は厚くなり、耐压能力は高くなります。圧力等級（PN）は、PE100 では、20℃でパイプが耐える最高圧力を表します。一般的な組み合わせとしては、SDR 11 と PN16、SDR 17 と PN10、SDR 26 と PN6 です。しかし PE80 では、同じ SDR で低い PN が得られます。これは、許容応力が小さいためです。温度誤差適用：使用温度が上がるにつれて、許容圧力は低下します。そのため 20℃を超える温度で動作する化学工場は、より厚い SDR を選択するか、低い PN を受け入れる必要があります。
材質グレードおよびSDR参照
| Grade | MRS (MPa) | Lower reference performance limit (MPa) | SDR example | Resulting PN at 20 C |
|---|---|---|---|---|
| PE80 | 8 | 6.4 | SDR11 | PN12.5 |
| PE100 | 10 | 8.0 | SDR11 | PN16 |
| PE100 | 10 | 8.0 | SDR17 | PN10 |
| PE100 | 10 | 8.0 | SDR26 | PN6 |
圧延ラインでは、壁厚を厳密な許容範囲内に保つ必要があります。これは、SDRとそれによるPNがそれに依存するためです。薄い部分はパイプ全体の最も弱い部分であり、サイジングと計量の正確さが腐食防止HDPE化学パイプ圧延ラインの重要な要素です。
The MRS values are derived from a 50 year design life at 20 degrees Celsius, which is the reference basis used across the pipe industry. In real chemical plants the service temperature is often above 20 degrees Celsius, and polyethylene loses allowable stress as temperature rises. A practical way to apply this is to compute the pressure capability at the actual temperature and then choose an SDR that leaves a safety margin, rather than selecting PN at 20 degrees Celsius and hoping the margin covers the heat. For example a line running near 40 degrees Celsius should use a thicker SDR than the same line at ambient, or accept a lower continuous pressure. The extrusion line supports this discipline by holding the wall so uniformly that the rated SDR is real along the entire pipe length, not just at a sampled point.
4. HDPE Chemical パイプ押出 Process Flow
HDPE pipe is made by melting a compounded granulate, shaping it in a die, fixing the dimensions by vacuum sizing and cooling, then cutting to length. Unlike PVC, HDPE is a thermoplastic that does not release corrosive gas and does not need strong shear devolatilization, so a high speed single screw extruder is the standard choice rather than a twin screw extruder. The process steps below apply to a complete chemical パイプ押出ライン.
Process sequence
- Material preparation: HDPE base resin is blended with a color masterbatch for identification and an antioxidant masterbatch to protect against thermal oxidative degradation during processing and service. The blend is metered by a gravimetric feeder for stable output.
- Single screw extrusion: a high speed single screw extruder plasticizes the compound. Because HDPE viscosity varies with shear, a gear type metering pump (also called a melt pump) is fitted after the barrel to deliver pulse free, constant melt flow to the die, which stabilizes wall thickness independent of screw speed fluctuation.
- Spiral mandrel die:溶融物はスパイラルマンドレルダイに入り、そこで螺旋形のチャネルが溶融物をマンドレルの周りに巻き、溶接ラインを排除し、全周面の均一な壁厚を実現します。ダイの隙間で初期の壁が設定されます。
- Vacuum sizing:成形されたパイプは真空サイジングスリーブに入り、真空が外側を調整し、調整された、水冷式の銅またはアルミニウムスリーブに外径と円周率を固定します。内部冷却マンドレルがボアを制御します。
- Spray or immersion cooling: the pipe passes through multiple cooling tanks with spray nozzles or immersion baths held at staged temperatures. Gradual cooling controls crystallization and residual stress.
- コーディング: an ink jet or laser coder prints the size, grade (PE100), SDR and standard on the pipe surface for traceability.
- Haul off: a caterpillar haul off grips the pipe and pulls it at the set line speed. Speed stability directly controls wall thickness.
- カット： a planetary cutter or チップレスカッター severs the pipe at the set length with a square end. Large coils may be wound instead of cut.
- Stacking or coiling: pipes are discharged to a tipping table or wound onto a reel for small diameters.
シングルスクリューエキストラーダにギアポンプとスパイラルマンドレルダイを組み合わせることで、HDPE化学パイプは厚みの許容範囲内でしっかりと圧縮され、内面が滑らかに仕上がります。これは、Faygoがパイプエキストラダーラインに組み込んでいる構成です。
The single screw itself uses a barrier or mixing section to complete plasticizing at a controlled melt temperature, because HDPE has a narrow safe window and overheating causes oxidative degradation that shows as yellowing and gel. The barrel is divided into feed, compression and metering zones, each with its own temperature set point, and the melt pressure is read at the barrel exit so the screen pack and filter are changed before pressure spikes. Placing the gear pump after the barrel decouples output stability from screw pulsation: the pump delivers a constant volumetric flow to the die even as screw speed or back pressure varies, which is the single biggest contributor to uniform wall thickness on a high speed line. The energy cost of the pump is small next to the scrap it prevents.
Faygo PE / HDPE パイプ押出ライン 20 to 160 mm
This line covers the dominant chemical plant diameters for branch and header pipe, built on the Faygo pipe extrusion platform that handles PE, PVC and PP materials. It is configured for HDPE with a high speed single screw extruder plus metering pump.
| パラメータ | 仕様書 |
|---|---|
| Screw diameter | 65mm |
| L/D ratio | 33:1 |
| メインモーターの出力 | 55 kW |
| パイプの口径の範囲 | 20 to 160 mm |
| ライン速度 | 0.4 to 8.0 m/min (depends on diameter and wall) |
| Capacity | 150 to 320 kg/h |
| インストール電力 | approx. 110 kW |
5. Vacuum Sizing and Cooling Technology
Dimension control of HDPE pipe depends almost entirely on the sizing and cooling section. The vacuum sizing sleeve is a precision bored, water jacketed cylinder with vacuum slots. When the hot pipe enters, vacuum draws the soft melt against the sleeve wall so the outside diameter is locked to the sleeve bore while internal cooling water chills the contact layer. The result is a pipe with accurate outside diameter, good roundness and a glossy surface.
For larger diameters, internal pressure sizing is used. A sealed internal cooling mandrel is pressurized with water or air so the pipe is pushed outward against the sizing sleeve from inside, which improves roundness and cools the bore faster. This internal cooling method suits large diameter HDPE chemical pipe where wall thickness is high and external cooling alone is too slow.
Cooling length and line speed must be matched. If the pipe leaves the cooling section before its core solidifies, it will ovalize or sag under its own weight. Multi stage temperature control, starting cooler at the die end and slightly warmer downstream, reduces thermal shock, limits internal stress and improves impact toughness. Residual stress is checked by the longitudinal reversion test, where a cut ring is heated in a bath and its length change is measured.
The vacuum sizing sleeve is normally made from a low friction, heat conducting metal such as copper or aluminum alloy, with a mirror finished bore that transfers its geometry straight to the pipe surface. The vacuum level is tuned to the wall thickness: thin wall pipe needs gentle vacuum to avoid collapse, thick wall pipe needs enough vacuum to seat the melt against the sleeve through its full circumference. Between production runs the sleeve is cleaned and descaled because mineral deposit from the cooling water is the most common cause of out of round pipe. For internal pressure sizing the sealed mandrel is fed with tempered water so the bore cools from inside while the outside is held by the sleeve, which is especially effective on large diameter chemical trunk pipe where the wall is thick and external cooling alone would leave a soft core.
6. Key Process Parameters and Online Quality Control
An anti corrosion HDPE chemical パイプ押出ライン is instrumented so that quality is controlled during running, not only by off line inspection. The melt temperature in the barrel is kept in the HDPE processing window of roughly 200 to 230 degrees Celsius to avoid thermal degradation while ensuring full plasticizing. 溶融圧力 is monitored at the die to detect screen pack blockage and to stabilize output.
Key quality parameters
| パラメータ | Typical target | Why it matters |
|---|---|---|
| パイプの口径の範囲 | 20 to 630 mm | Covers branch to trunk chemical lines |
| Wall thickness tolerance | per ISO 4427 tolerance table | Sets SDR and PN reliability |
| Roundness | within diameter tolerance band | Needed for leak free joints |
| Inner surface roughness | smooth, low Ra | Reduces flow loss and fouling |
| Longitudinal reversion | within standard limit | Indicates residual stress |
| Hydrostatic resistance 20 C 100 h | 試験圧力で故障しません | Short term proof of strength |
| Hydrostatic resistance 80 C 165 h | 試験圧力で故障しません | Long term resistance proof |
| Melt flow and OIT | per compound spec | Confirms grade and antioxidant level |
Online inspection devices
- レーザー直径ゲージ： scans the outside diameter continuously and feeds the haul off speed to correct drift.
- Ultrasonic wall thickness sensor: measures wall and eccentricity around the pipe, warning on thin spots.
- 溶融圧力 and temperature transducer:バレルとダイで、安定した可塑化と早期のスクリーンパック警告のために
- First article and type inspection: samples are cut and tested per ISO 4427 and GB/T references, and each production lot is recorded for traceability.
Two compound tests confirm the pipe will age well in service. The melt flow index, measured on the granulate and on the finished pipe, confirms the grade has not changed during processing; a large shift would signal degradation or a wrong lot. The oxidation induction time, OIT, measures how long the antioxidant package resists oxidation at an elevated temperature, and a short OIT warns that the masterbatch dose was low or the melt ran too hot. Because chemical pipe often sits in warm, oxygen exposed trenches for decades, OIT is a more meaningful quality gate than appearance alone, and Faygo records it for the production lot alongside the diameter and wall map.
7. Welding and Jointing of HDPE Chemical Pipe
HDPEの腐食性は、接合部がパイプと同じ耐久性を持っている場合にのみ有効です。化学パイプ作業では、3つの接合方法が主流です。バット融合は、パイプの両端を鏡板上で加熱し、その後それを圧着して溶融を融着させることで行われます。PE100のパイプが約63ミリメートルを超える場合、これは標準であり、端が正方形で清潔である場合、接合部はパイプの最大強度に達することができます。
エレクトロフュージョンでは、埋め込まれた加熱線を備えたカプラーを使用し、パイプの端部を削り、挿入し、電流を通すことで、コイルが両面を溶かします。修理、接続、狭いスペースに最適です。フレングアダプターは、HDPEパイプをポンプ、バルブ、および鋼製機器に接続し、成形されたHDPEのストブエンドと緩やかな鋼製バックフレングを組み合わせます。すべての方法において、パイプの端部は正方形にカットされ、ゴミが無いようにする必要があります。そのため、押出ラインカッターは、正確な正方形の許容範囲を保持する必要があります。
8. Common Defects and Countermeasures
Even a well built line produces defects if process settings drift. The table below lists the common defects on an HDPE chemical パイプ押出ライン with their likely causes and remedies. It is the field checklist Faygo supplies with each line and trains operators to use.
Defect troubleshooting table
| No. | 瑕疵 | Likely cause | Countermeasure |
|---|---|---|---|
| 1 | Roundness out of tolerance | Vacuum too low, sleeve worn, cooling uneven | Raise vacuum, re bore or replace sleeve, balance spray |
| 2 | 壁厚の偏心率 | Die gap uneven, mandrel off center | Adjust die bolts, center mandrel, check ultrasonic data |
| 3 | Surface yellowing or burn | Melt over 230 C, dwell in barrel | Lower barrel temp, raise screw speed, add antioxidant |
| 4 | Inner wall scratches | Internal mandrel or cooling pipe scored | Polish or replace internal mandrel, clean cooling path |
| 5 | Sizing not round | Sleeve scaling, vacuum leak | Descale sleeve, seal vacuum chamber |
| 6 | Cooling insufficient, deformation | Line speed too high, water flow low | Slow line, raise cooling water flow and staging |
| 7 | Unclear coding | Ink low, surface wet, head offset | Refill ink, dry surface, align coder |
| 8 | Cut surface bevel | Cutter not square, blade worn | Square the cutter, replace blade, check clamp |
| 9 | Gels or fisheye (晶点/凝胶) | Crosslinked particles, dirty melt | Improve screen pack, clean barrel, check resin |
| 10 | Color variation | Masterbatch dose unstable | Calibrate gravimetric feeder, mix resin lot |
| 11 | Longitudinal reversion over limit | Quench too fast, high internal stress | Stage cooling temps, slow haul off slightly |
| 12 | Uneven pipe end (port not flat) | カッターが誤って設定され、パイプがスリップしている | カッターを再度正しく設定し、ハウルオフグリップを固定する |
| 13 | オレンジの皮の表面 | Melt too cold, die land too long | Raise melt temp, check die land finish |
| 14 | Pipe telescoping in tank | Haul off faster than extruder | ハウルオフを出力に合わせて調整する（ポンプフィードバックによる） |
9. Line Speed, Capacity and Energy Consumption
ラインの速度と容量は、パイプの直径と壁の厚さによって異なります。大きな太いパイプでは溶融物が多く、冷却時間も長くなります。小径の薄い壁のパイプは速く走りますが、630ミリメートルのトランクパイプはゆっくりですが、高い質量出力を実現します。表はHDPE化学パイプ押出ラインの典型的な参考値ですが、グレード、SDR、冷却水の温度によって実際の値は異なります。
典型的な速度、容量、エネルギー
| 直径の範囲 | Line speed (m/min) | Capacity (kg/h) | 具体的なエネルギー（kWh/kg） |
|---|---|---|---|
| 20 to 63 mm | 2.0 to 12.0 | 80 to 180 | 0.35 to 0.55 |
| 75 to 160 mm | 0.4 to 8.0 | 150 to 320 | 0.30 to 0.45 |
| 315 to 630 mm | 0.2 to 3.0 | 400 to 700 | 0.28 to 0.40 |
直径が大きくなると、メーターポンプとスクリューが効率的な点に近づくため、比表面積／体積比が低下するため、特定のエネルギーは低下します。エネルギーは物理量だけであり、価格はここで示されていません。
10. Equipment Maintenance Schedule
A planned maintenance schedule keeps the line producing in spec pipe and avoids unplanned stoppage. Faygo organizes maintenance into shift, weekly and monthly tasks, mirroring a product lifecycle management approach on the machine level.
Maintenance tasks by interval
- Per shift: clean the die lip and vacuum sleeve area of dust and melt smear, check haul off belt tension, verify coder ink and cooling water clarity, log melt pressure and temperature.
- Per week: inspect and descale the vacuum sizing sleeve, check the gear pump coupling, clean the screen pack area, confirm cutter blade sharpness and squareness.
- 月ごとに： calibrate temperature controllers against a reference probe, inspect the screw and barrel for wear, lubricate the haul off gearbox, verify the laser gauge against a standard ring, review the ultrasonic wall map history.
- Per quarter: full barrel and screw inspection, replace worn sleeve or mandrel, check electrical terminals and grounding, validate the cooling tower and water treatment.
Water quality in the cooling circuit matters: hardness scale inside the sizing sleeve degrades roundness, so a softened or filtered loop is recommended. Records of each task support traceability and help predict part replacement before failure.
11. Plant Layout and Utility Requirements
完全なHDPE化学パイプ押出ラインは、冷却のために直線的なスペースが必要になるため、長くなります。20メートル程度の小さなラインは、冷却とコイルステーションが拡張された630ミリメートルのラインよりも小さくなります。工場には、床が平坦で荷重を支えることができ、ダイとスリーブの交換のために十分な天井高さがあり、出力側にカットと積み重ねのためのスペースが必要です。
Utility reference
| 設備 | Small line | Large line |
|---|---|---|
| Line length | 18 to 22 m | 30 plus m |
| Power supply | approx. 150 kVA | approx. 400 kVA |
| Cooling water | 8 to 15 m3/h | 25 to 45 m3/h |
| Floor load | standard industrial | reinforced for heavy pipe |
| Overhead clearance | 4 m | 5 m 以上 |
These figures are planning references; the exact layout is developed in the factory design service that Faygo offers as part of its turnkey support, including three dimensional workshop drawing, water and electricity design, and worker configuration.
12. Safety, Dust, Noise and Environmental Compliance
HDPE extrusion is a low emission process, but a few hazards need control. The gravimetric blending and feeding of masterbatch creates fine dust at the hopper, so local extraction at the feed throat is recommended and operators wear basic dust protection during material handling. The barrel and die run at melt temperature, so guarding and lockout are required for any work near the die.
Noise comes mainly from the haul off and cutter; enclosures and hearing protection keep the work area within occupational limits. Coolant is recycled through a closed loop with filtration, so water use stays low and warm water can be recovered for plant heating. For pipes intended for food grade or potable contact, the compound path follows restricted substance controls aligned with RoHS and REACH routes, using only registered additives and documenting the formulation. These are plain text references to the control frameworks, not certification claims.
13. Faygo HDPE化学パイプ押出ラインシリーズ
Faygo builds its chemical pipe lines on the same pipe extrusion platform that covers 12 to 575 millimeter diameter PE, PVC and PP pipe with wall thickness up to 6.5 millimeters, used across water supply, drainage, gas, communication and agricultural irrigation. For HDPE chemical duty the lines are specified with a high speed single screw extruder, metering pump, spiral mandrel die and vacuum sizing, plus the online inspection package described above. Below are two representative configurations.
Faygo Large Diameter HDPE Pipe Line 315 to 630 mm
This line serves chemical plant trunk lines and municipal scale transfer where high mass output and thick SDR walls are needed. It uses internal pressure sizing for large diameter roundness.
| パラメータ | 仕様書 |
|---|---|
| Screw diameter | 120 mm |
| L/D ratio | 33:1 |
| メインモーターの出力 | 160 kW |
| パイプの口径の範囲 | 315 to 630 mm |
| ライン速度 | 0.2 to 3.0 m/min |
| Capacity | 400 to 700 kg/h |
| インストール電力 | approx. 280 kW |
Both lines share the Faygo intelligent control system that lets operators set parameters freely and adjust them in real time, with internationally sourced electrical components for reliability. Every line is CE and ISO certified and passes a 72 hour continuous operation test before delivery.
14. Requirement to Model Selection Recommendation
The table below maps a typical customer requirement to a recommended Faygo configuration. It is a starting point; final selection also depends on the medium concentration, service temperature and local standard.
Selection recommendation
| Medium and duty | Diameter | Target capacity | おすすめのFaygoライン |
|---|---|---|---|
| Dilute acid or alkali, branch line | 20 to 63 mm | 80 to 180 kg/h | Faygo 20 to 160 mm HDPE line, small config |
| Process wastewater, plant header | 75 to 160 mm | 150 to 320 kg/h | Faygo 20 to 160 mm HDPE line, upper config |
| Trunk chemical transfer, high volume | 315 to 630 mm | 400 to 700 kg/h | Faygo 315 to 630 mm large diameter HDPE line |
| Abrasive slurry (tailings) | 110 to 315 mm | 200 to 500 kg/h | Faygo line with thicker SDR and wear resistant sizing |
15. 適用分野 and End Products
Faygo パイプ押出ラインs serve the industries below with concrete end products. These are the real application areas from the Faygo profile, mapped to anti corrosion HDPE chemical pipe end uses.
Industry to end product
- Chemical plants: dilute sulfuric acid and hydrochloric acid transfer pipe, sodium hydroxide return lines, mixed process waste headers, all made from PE100 grade HDPE with MRS 10 MPa rating.
- Electroplating and PCB workshops: acidic and alkaline rinse water pipe, etchant recovery lines, where HDPE resists the plating chemistry and the smooth bore limits scaling.
- Pharmaceutical and food grade: purified water and clean medium pipe built on a RoHS and REACH aligned compound path for contact duty, with full traceability.
- Mining: tailings slurry pipe and process water lines, where low friction bore and abrasion resistance extend service life.
- Agriculture and garden irrigation: PE drip and sprinkler pipe systems that double as mild fertilizer solution lines, benefiting from HDPE corrosion freedom.
- Municipal engineering:大径のHDPEガスおよび水パイプ、非化学物質であるが圧力が重要な用途に適した同プラットフォーム。
16. サービスとサポート
Faygo, a Wanplas factory, supports every anti corrosion HDPE chemical パイプ押出ライン through the full lifecycle. Each line is run through a 72 hour continuous operation test before shipment to confirm stable extrusion, accurate sizing, steady haul off and square cutting. Engineers assist with installation and commissioning at the customer site, and operators receive training on setup, troubleshooting and maintenance using the defect table above.
The Wanplas group service policy applies: USD 500 free parts per year, free replacement of damaged parts within warranty, 24/7 online technical support, and remote monitoring of the control system so abnormalities can be analyzed from the factory. Faygo also welcomes open factory visits for inspection and runs a factory consulting service covering water and electricity design, three dimensional workshop layout, worker configuration and training, new factory construction as a turnkey project, old machine replacement with minimal downtime, and capacity expansion by optimizing bottlenecks. The end to end service covers selection, design, manufacturing, installation, commissioning, training and maintenance.
よくある質問
Why is HDPE preferred over PVC or steel for acid and alkali medium pipelines?
HDPEは、広範な希薄な酸、アルカリ、および塩水溶液に対して腐食しにくく、内部ライニングや陰極保護が不要です。PVCは安価ですが、温度と耐衝撃性に制限があり、鋼材には継続的な腐食防止の内部ライニングが必要で、塩化物媒体では腐食が発生します。HDPEは、完全に均質で漏れのない接合部をバット融合で形成できます。
What extruder type is used for HDPE chemical pipe, single screw or twin screw?
HDPE pipe is normally produced on a high speed single screw extruder equipped with a gear type metering pump for stable, pulse free melt delivery. Twin screw extruders are used for PVC powder compounding and rigid PVC pipe because PVC degrades without strong shear and devolatilization. For HDPE the single screw plus gear pump combination gives the best output stability and wall thickness control.
How is pipe diameter and wall thickness controlled during extrusion?
A spiral mandrel die distributes melt evenly around the circumference, then a vacuum sizing sleeve calibrates the outside diameter under vacuum while a sealed internal cooling mandrel controls the bore. レーザー直径ゲージ and ultrasonic wall thickness sensors give closed loop feedback to the haul off speed and extruder rpm, holding roundness and eccentricity inside the tolerance bands of ISO 4427.
Which pressure class should be selected for a chemical transport pipeline?
Pressure class is set by the PE grade, the SDR (standard dimension ratio) and the service temperature. For PE100, SDR11 typically serves PN16 at 20 degrees Celsius, SDR17 serves PN10 and SDR26 serves PN6. Chemical plants should select the SDR that yields the required pressure margin at the operating temperature, and verify the medium concentration against the material resistance table.
What welding methods are recommended for HDPE chemical pipe?
Butt fusion is the standard for pipe to pipe joints in diameters above roughly 63 millimeters, producing a joint as strong as the pipe itself. Electrofusion couplers are used for repairs, tied ins and confined spaces, while flange adapters connect HDPE pipe to valves and pumps. Square, clean pipe ends are essential for full strength butt fusion joints.
What quality tests are performed before an HDPE pipe line ships?
Faygo runs a 72 hour continuous operation test on every line before delivery, checking extruder stability, vacuum sizing accuracy, haul off tracking and cutter squareness. Sample pipes are inspected for diameter, wall thickness, roundness, longitudinal reversion and hydrostatic resistance per ISO 4427 and GB/T references, and the line is documented with a traceable production record.
結論
An anti corrosion HDPE chemical パイプ押出ライン turns PE100 grade HDPE with MRS 10 MPa rating into a continuous, weldable, corrosion free pipeline for factory acid alkali medium transport. The winning combination is a high speed single screw extruder with a metering pump, a spiral mandrel die for uniform wall, vacuum sizing with controlled cooling, and online laser and ultrasonic inspection that locks diameter and wall thickness to the SDR that defines the pressure class. With proper grade selection, butt fusion jointing and the defect troubleshooting discipline described here, the pipe serves chemical, electroplating, pharmaceutical, mining and irrigation duty with long, low maintenance life.
Faygo, a Wanplas factory with 22 years of pipe extrusion experience and three specialized factories, offers HDPE chemical pipe lines from 20 to 630 millimeter diameter, each tested for 72 hours before shipment and backed by the Wanplas group service promise including USD 500 free parts per year and open factory visits. If you are planning a chemical medium pipeline project, send your medium, diameter, wall, capacity and site conditions, and our engineers will propose a tailored line configuration, arrange a factory audit, and run a sample trial so you can verify pipe quality before committing.
