Faygo, Wanplas 공장, 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 파이프 압출 라인 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 파이프 압출 라인. 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 파이프 압출 라인 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
| 중간 | Typical condition | HDPE resistance | Technical note |
|---|---|---|---|
| Sulfuric acid (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 | 폴리올레핀의 hydrolysis 없음 |
| 혼합 공정 폐기물 | variable pH, salts | 좋음 | Verify concentration and temperature |
| Aliphatic hydrocarbons | fuel oil, gasoline | 좋음 | 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 | 권장하지 않음 | 폴리올레핀에 대한 심각한 공격 |
| Strong oxidizers | conc. nitric, chromic acid | 권장하지 않음 | Oxidative degradation |
| Abrasive slurry | tailings, fly ash | 좋음 | Low friction bore reduces wear |
For media marked limited or not recommended, the plant should switch to a dedicated chemical resistant lining or a different polymer, and the extrusion line is not the deciding factor. The value of HDPE is exactly in the large family of aqueous acids, alkalis and salts that dominate factory effluent and intermediate transfer duty.
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 파이프 압출 라인 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
| 재료 | Chemical resistance to acids/alkalis | Continuous temp ceiling | 밀도 (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 | 플랜지는 경화제 개스킷의 누출 위험이 있다. 펌프형 PPR, Faygos PP-R 및 PE-RT 파이프 압출 라인을 주 기본 플랫폼으로 사용하고, 다양한 압출기 크기 및 하류 길이에 걸쳐 고객이 실제 시장에서 요구하는 용량에 맞출 수 있도록 제공합니다. 작은 직경 구성에서는 16에서 32 밀리미터의 파이프를 120에서 180 킬로그램/시간 정도의 생산량으로 제조하며, 주택용 배수 및 가벼운 상업용 노출용 수계에 적합합니다. 중급 구성에서는 40에서 110 밀리미터의 파이프를 180에서 420 킬로그램/시간의 생산량으로 제조하여 주택 및 농업 유통에서 사용됩니다. 큰 구성에서는 125에서 160 밀리미터의 파이프를 최대 600 킬로그램/시간의 생산량으로 제조하여 주 배관 및 캠퍼스 규모 네트워크에 적용됩니다. 각 구성은 동일한 제어 철학, 동일한 CE 및 ISO 인증된 빌드 품질, 그리고 동일한 72시간의 사전 납품 테스트 규정을 공유합니다. | Hard |
| FRP (섬유 강화 플라스틱) | 좋음, 수지별 | up to 90 C resin dependent | 1.5~2.0 | 접착제 또는 플랜지, 기술에 따라 다름 | 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 및 PE80 재료 등급, SDR 및 압력 등급
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.
1 바의 압력 변화가 생겨 정원으로부터 행위를 방해하지 않고 행위의 저항이 적을지 여부를 결정합니다. HDPE의 유연성과 열 기합 결합은 이러한 레이아웃을 정원을 성숙시킴에 따라 또는 온실이 다시 구성될 경우에는 쉽게 수정할 수 있게 해줍니다. 이는 무엇보다도 경량 PE 파이프 압출 라인이 관수 공급에 대한 올바른 유상 투자입니다.
재료 등급 및 SDR 참조
| Grade | 압력 (MPa) | Lower reference performance limit (MPa) | SDR example | Resulting PN at 20 C |
|---|---|---|---|---|
| PE80 | 8 | 6.4 | SDR11 기준 | PN12.5 |
| PE100 | 10 | 8.0 | SDR11 기준 | PN16 기준 |
| PE100 | 10 | 8.0 | 목차 | PN10 |
| PE100 | 10 | 8.0 | SDR26 | PN6 |
The extrusion line must hold wall thickness within tight tolerance because the SDR and therefore the PN depend on it. A thin spot is the weakest point in the whole pipeline, so sizing and metering accuracy are the heart of an anti corrosion HDPE chemical 파이프 압출 라인.
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 파이프 압출 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 파이프 압출 라인.
Process sequence
- 재료 준비: 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.
- 단일 스크류 압출: 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:용융은 나선형 맨드렐 다이에서 용융물을 감싸서 용융물을 맨드렐 주위에 감싸고, 용접선을 제거하고 전체 둘레에서 균일한 벽 두께를 제공합니다. 다이 간격은 초기 벽을 설정합니다.
- Vacuum sizing:막 형성된 파이프는 진공 크기 슬리브에 들어갑니다. 진공은 외부 직경을 맞춤형, 냉각된 구리 또는 알루미늄 슬리브에 맞춰서 당기고, 외부 직경과 원형을 고정시킵니다. 내부 냉각 맨드렐은 보어를 제어합니다.
- 스프레이 또는 침수 냉각: the pipe passes through multiple cooling tanks with spray nozzles or immersion baths held at staged temperatures. Gradual cooling controls crystallization and residual stress.
- Coding: an ink jet or laser coder prints the size, grade (PE100), SDR and standard on the pipe surface for traceability.
- Haul off:캐터필러 헤드는 파이프를 잡은 다음 설정된 속도로 당겨줍니다. 속도 안정성은 벽 두께를 결정합니다.
- Cutting: a 행성형 절단기 or chipless cutter severs the pipe at the set length with a square end. Large coils may be wound instead of cut.
- 쌓기 또는 감싸기: pipes are discharged to a tipping table or wound onto a reel for small diameters.
단일 스크류 엑스트루더, 기어 펌프 및 나선형 맨델 다이프로의 조합은 HDPE 화학 파이프가 단단한 벽 허용값과 매끄러운 내면 표면을 유지하는 이유입니다. 이는 Faygo가 파이프 압출 라인에 구축한 구성입니다.
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 파이프 압출 라인 20 to 160 mm
이 라인은 PE, PVC 및 PP 재료를 처리하는 Faygo 파이프 압출 플랫폼을 기반으로 브랜치 및 헤더 파이프의 주요 화학 공장 직경을 다룹니다. HDPE를 위해 고속 단일 스크류 압출기와 측정 펌프가 구성되어 있습니다.
| 매개변수 | 사양 |
|---|---|
| 스크류 직경 | 65mm |
| L/D 비율 | 33:1 |
| 주 모터 출력 | 55 kW |
| 파이프 직경 범위 | 20 to 160 mm |
| 라인 속도 | 0.4 to 8.0 m/min (depends on diameter and wall) |
| Capacity | 150 to 320 kg/h |
| 설치된 전력 | approx. 110 kW |
5. 진공 크기 조정 및 냉각 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 파이프 압출 라인 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. 녹는 압력 is monitored at the die to detect screen pack blockage and to stabilize output.
Key quality parameters
| 매개변수 | 일반적인 대상 | 왜 중요한가요? |
|---|---|---|
| 파이프 직경 범위 | 20 to 630 mm | Covers branch to trunk chemical lines |
| 벽 두께 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 |
| 수압 저항성 20 C 100 h | 시험 압력에서 파손이 없습니다. | Short term proof of strength |
| 수압 저항성 80 C 165 h | 시험 압력에서 파손이 없습니다. | Long term resistance proof |
| Melt flow and OIT | per compound spec | Confirms grade and antioxidant level |
Online inspection devices
- Laser diameter gauge: 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.
- 녹는 압력 and temperature transducer: at the barrel and die, for stable plasticizing and early screen pack warning.
- 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
The corrosion freedom of HDPE is only useful if the joints are as durable as the pipe. Three jointing methods dominate chemical pipeline work. Butt fusion joins two pipe ends by heating them on a mirror plate, then pressing them together so the melt fuses into one homogeneous wall. For PE100 pipe above about 63 millimeters this is the standard, and the joint can reach the full strength of the pipe when the ends are square and clean.
Electrofusion uses a coupler with embedded heating wire; the pipe ends are scraped, inserted and energized so the coil melts both surfaces. It is preferred for repairs, tie ins and confined spaces. Flange adapters connect HDPE pipe to pumps, valves and steel equipment, combining a molded HDPE stub end with a loose steel backing flange. For all methods the pipe end must be cut square and free of debris, which is why the extrusion line cutter must hold a tight squareness tolerance.
8. Common Defects and 방지 조치s
Even a well built line produces defects if process settings drift. The table below lists the common defects on an HDPE chemical 파이프 압출 라인 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. | 결함 | 유력한 원인 | 방지 조치 |
|---|---|---|---|
| 1 | 허용치 밖의 둥근도 | Vacuum too low, sleeve worn, cooling uneven | Raise vacuum, re bore or replace sleeve, balance spray |
| 2 | 벽 두께 편심도 | 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 | 냉각이 부족하여 변형이 발생합니다. | Line speed too high, water flow low | Slow line, raise cooling water flow and staging |
| 7 | Unclear coding | 잉크가 부족하고 표면이 젖어 있으며 헤드가 위치를 벗어나 있습니다. | Refill ink, dry surface, align coder |
| 8 | Cut surface bevel | Cutter not square, blade worn | 커터를 정사각형으로 만들고 블레이드를 교체하고 클램프를 확인하십시오. |
| 9 | Gels or fisheye (晶点/凝胶) | Crosslinked particles, dirty melt | Improve screen pack, clean barrel, check resin |
| 10 | 색상 변화 | Masterbatch dose unstable | Calibrate gravimetric feeder, mix resin lot |
| 11 | Longitudinal reversion over limit | 냉각이 너무 빨라 내부 응력이 높습니다. | Stage cooling temps, slow haul off slightly |
| 12 | Uneven pipe end (port not flat) | Cutter mis set, pipe slipping | Re square cutter, secure haul off grip |
| 13 | Orange peel surface | 용융이 너무 차가워지면 다이 랜드가 너무 오래 지속됩니다. | Raise melt temp, check die land finish |
| 14 | Pipe telescoping in tank | Haul off faster than extruder | 펌프 피드백을 통해 하우 오프를 출력과 일치시킵니다. |
9. Line Speed, Capacity and Energy Consumption
Line speed and capacity depend on pipe diameter and wall, because a large thick pipe needs more melt and more cooling time. Small diameter thin wall pipe runs fast, while a 630 millimeter trunk pipe runs slowly but delivers high mass output. The table gives typical reference values for an HDPE chemical 파이프 압출 라인; actual figures vary with grade, SDR and cooling water temperature.
Typical speed, capacity and energy
| 직경 범위 | Line speed (m/min) | Capacity (kg/h) | 특정 에너지 (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 |
특정 에너지 falls as diameter grows because the metering pump and screw run closer to their efficient point and the surface to volume ratio drops. Servo driven haul off and inverter controlled auxiliaries further lower the kWh per kilogram. Energy is a physical quantity only; no price is stated here.
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:진공 크기 슬리브를 검사하고 청소하고 기어 펌프 커플링을 확인하고 커터 블레이드의 날카로움과 직각성을 확인하십시오.
- Per month: 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.
- 분기마다: 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
A complete HDPE chemical 파이프 압출 라인 is long because cooling takes linear space. Small lines fit within roughly 20 meters, while a 630 millimeter line with extended cooling and a coil station can exceed 30 meters. The plant needs a flat, load bearing floor, sufficient overhead clearance for die and sleeve changes, and space at the outfeed for cutting and stacking.
Utility reference
| Utility | 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 | 무거운 파이프를 위해 강화되었습니다. |
| Overhead clearance | 4 m | 5 m plus |
이 수치는 계획 참조입니다. 정확한 레이아웃은 팍스코리아가 턴키 지원의 일환으로 제공하는 공장 설계 서비스에서 개발됩니다. 여기에는 3차원 작업실 도면, 전기 및 수도 설계, 작업자 구성 등이 포함됩니다.
12. Safety, Dust, Noise and Environmental Compliance
HDPE 압출은 저배출 공정이지만 몇 가지 위험 요소가 통제해야 합니다. 마스터 배치를 중량 측정 방식으로 혼합하고 공급하면 호퍼에서 미세 먼지가 생성되므로 공급구에서 지역 추출이 권장되며 재료 취급 시 작업자는 기본적인 먼지 보호 장비를 착용해야 합니다. 배럴과 다이기는 용융 온도에서 작동하므로 다이어 근처에서 작업할 때는 가드와 잠금 장치가 필요합니다.
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 Chemical 파이프 압출 라인 Series
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
이 라인은 화학 공장 본선 및 도시 규모의 이송에 필요한 높은 질량 출력을 제공하며 두꺼운 SDR 벽을 필요로 합니다. 이 라인은 내부 압력 크기를 사용하여 큰 지름의 원형도를 제공합니다.
| 매개변수 | 사양 |
|---|---|
| 스크류 직경 | 120 mm |
| L/D 비율 | 33:1 |
| 주 모터 출력 | 160 킬로와트 |
| 파이프 직경 범위 | 315 to 630 mm |
| 라인 속도 | 0.2 to 3.0 m/min |
| Capacity | 400 to 700 kg/h |
| 설치된 전력 | approx. 280 kW |
두 라인은 운영자가 자유롭게 매개 변수를 설정하고 실시간으로 조정할 수 있는 팍스코리아의 지능형 제어 시스템을 공유합니다. 이 시스템은 신뢰성을 위해 국제적으로 공급되는 전기 부품을 사용합니다. 모든 라인은 CE 및 ISO 인증을 받았으며 배송 전에 72시간 연속 작동 테스트를 통과합니다.
14. Requirement to Model Selection Recommendation
아래 표는 일반적인 고객 요구 사항을 팍스코리아 구성으로 매핑합니다. 이는 시작점이며 최종 선택은 매체 농도, 서비스 온도 및 현지 표준에 따라 결정됩니다.
Selection recommendation
| Medium and duty | Diameter | Target capacity | 추천되는 Faygo 라인 |
|---|---|---|---|
| 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 20~160mm HDPE 라인, 상부 구성 |
| 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. 응용 분야 및 최종 제품
Faygo 파이프 압출 라인s 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.
산업에서 최종 제품까지
- Chemical plants:황산과 염산 이송 파이프, 나트륨 히dro아산염 반환 라인, 혼합 공정 폐기물 헤더는 모두 PE100 등급 HDPE로 제작되었으며 MRS 10 MPa 등급을 받았습니다.
- Electroplating and PCB workshops:산성 및 알칼리성 세척 물 배관, 에탄트 회수 라인 등에서 HDPE는 도금 화학물질에 강하며 원활한 내부 직경은 부식 방지 기능을 제공합니다.
- 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: large diameter HDPE gas and water pipe, the same platform adapted for non chemical but pressure critical duty.
16. 서비스 및 지원
Faygo, Wanplas 공장, supports every anti corrosion HDPE chemical 파이프 압출 라인 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.
자주 묻는 질문
Why is HDPE preferred over PVC or steel for acid and alkali medium pipelines?
HDPE는 광범위한 희석된 산, 알칼리 및 염수 용액에 대해 부식되지 않으며 내부 내장재 또는 음극 보호가 필요하지 않습니다. PVC는 저렴하지만 온도와 충격 강도가 제한되어 있으며, 강철은 지속적인 내식성 내장재가 필요하고 염화 매체에서 부식됩니다. HDPE는 butt fusion을 통해 완전히 균질하고 누출이 없는 결합을 형성합니다.
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?
나선형 맨드렐 다이(mandrel die)는 용융물을 원주 둘레에 균일하게 분배한 다음 진공 크기 슬리브가 진공 상태에서 외부 지름을 조절하고 밀폐된 내부 냉각 맨드렐이 지름을 제어합니다. 레이저 지름 게이지와 초음파 벽 두께 센서는 ISO 4427의 허용 범위 내에 원형도와 편심도를 유지하기 위해 하우 오프 속도와 압출기 rpm, 라운드도 및 진동도를 닫는 루프 피드백을 제공합니다.
Which pressure class should be selected for a chemical transport pipeline?
압력 등급은 PE 등급, SDR(표준 치수 비율), 서비스 온도에 따라 결정됩니다. PE100의 경우 SDR11은 일반적으로 20도 섭씨에서 PN16을, SDR17은 PN10을, SDR26은 PN6을 제공합니다. 화학 공장은 필요한 압력 마진을 운영 온도에서 얻는 SDR를 선택하고 매체 농도를 PE 저항 표에 따라 확인해야 합니다.
HDPE 화학 파이프에 대해 어떤 용접 방법을 추천하나요?
butt fusion은 대략 63 밀리미터 이상의 직경의 파이프 간 접합을 위한 표준으로, 파이프 자체만큼 강한 접합을 생성합니다. 전기 용접 커플러는 수리, 연결 및 제한된 공간에 사용되며, 플랜지 어댑터는 HDPE 파이프를 밸브 및 펌프에 연결합니다. 정사각형으로 깔끔하게 마무리된 파이프 끝은 완전한 강도 butt fusion 접합을 위해 필수적입니다.
What quality tests are performed before an HDPE pipe line ships?
Faygo는 모든 라인에서 배송 전에 72시간 연속 작동 테스트를 진행하며, 압출기 안정성, 진공 사이즈 정확도, 운송 배송 추적 및 커터 평면성을 검사합니다. 샘플 파이프는 ISO 4427 및 GB/T 기준에 따라 지름, 벽 두께, 라운드함, 장방향 반전 및 수압저항 등을 검사하며, 생산 기록을 추적하고 라인에 기록합니다.
결론
An anti corrosion HDPE chemical 파이프 압출 라인 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, Wanplas 공장 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.
