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 boru ekstrüzyon hattı 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 boru ekstrüzyon hattı. 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 boru ekstrüzyon hattı 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
| Orta | 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 | No hydrolysis of polyolefin |
| 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 |
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 boru ekstrüzyon hattı 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
| Material | Kimyasal dayanıklılık to acids/alkalis | Continuous temp ceiling | Density (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 (glass fiber reinforced) | Good, resin dependent | up to 90 C resin dependent | 1.5 to 2.0 | Adhesive or flange, skill dependent | 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 and PE80 Material Grades, SDR and Pressure Classes
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.
Wall thickness is set by the Standard Dimension Ratio, SDR, which is the ratio of outside diameter to wall thickness. A lower SDR means a thicker wall and higher pressure capacity. The pressure class, PN, is the nominal pressure the pipe withstands at 20 degrees Celsius. For PE100, typical pairings are SDR11 with PN16, SDR17 with PN10 and SDR26 with PN6. The same SDR on PE80 yields a lower PN because the allowable stress is smaller. Temperature derating applies: as service temperature rises the allowable pressure falls, so chemical plants operating above 20 degrees Celsius must select a thicker SDR or accept a lower PN.
Material grade and SDR reference
| 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 |
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 boru ekstrüzyon hattı.
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 Boru Ekstrüzyon Process Flow
HDPE boru, bir karıştırılmış granülün eritilmesi, die içinde şekillendirilmesi, boyutların vakum boyutlandırma ile sabitlenmesi ve soğutulması, ardından uzunluğa kesilmesiyle yapılır. PVC'ye kıyasla, HDPE termoplastik bir malzemedir ve korozif gaz salmaz ve güçlü kesme devolatilizasyonuna ihtiyaç duymaz, bu nedenle yüksek hızlı tek şaftli bir extruder standart seçenektir. Aşağıdaki işlem adımları, tam bir kimyasal boru extrüzyon hattına uygulanır.
Process sequence
- Material preparation:HDPE temel reçine, kimliklendirme için bir renk masterbatch ile, işleme ve kullanım sırasında termal oksidasyonla karşılaşan hasarları önlemek için bir antioksidan masterbatch ile karıştırılır. Karışım, sabit çıkış için bir gravimetrik besleyici ile ölçülür.
- Single screw extrusion:yüksek hızlı bir tek şaft extruder, karışımı plastikleştirir. HDPE'nin sürtünme ile değişen viskozitesi nedeniyle, bir dişli tip ölçüm pompası (melt pompası olarak da adlandırılır) silindirden sonra die'ye, pulsuz, sabit bir malzeme akışı sağlar ve bu da şaft hızının değişimiyle bağımsız olarak duvar kalınlığını stabilize eder.
- Spiralli mandrel die:malzeme, bir spiral mandrel die içinde, bir dalga kanalı ile mandrel etrafında sarılır, böylece, birleştirme hatları ortadan kaldırılır ve tam çevre boyunca eşit duvar kalınlığı sağlanır. Die boşluğu, ilk duvarı belirler.
- Vacuum sizing:yeni oluşturulan boru, bir vakum boyutlandırma silindirine girer, burada vakum, dış çapı, kalibre edilmiş, soğutulmuş bakır veya alüminyum bir silindir aracılığıyla, dış çapı ve yuvarlaklığı sabitler. Bir iç soğutma mandreli, deliği kontrol eder.
- 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.
- Coding: an ink jet or laser coder prints the size, grade (PE100), SDR and standard on the pipe surface for traceability.
- Taşıma: a caterpillar haul off grips the pipe and pulls it at the set line speed. Speed stability directly controls wall thickness.
- Cutting: a gezegen kesici or chipless cutter 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.
The combination of a single screw extruder with a gear pump and a spiral mandrel die is the reason HDPE chemical pipe holds tight wall tolerance and a smooth inner surface. This is the configuration Faygo builds into its boru ekstrüzyon hattıs.
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 Boru Ekstrüzyon Hattı 20 to 160 mm
Bu satır, PE, PVC ve PP malzemeleri işlenen Faygo boru ekstrüzyon platformunda inşa edilen kol ve başlık boru için yaygın kimyasal tesis çaplarını kapsar. HDPE için yüksek hızlı tek şaftli bir ekstrüder ve ölçüm pompası ile yapılandırılmıştır.
| Parametre | Specification |
|---|---|
| Screw diameter | 65 mm |
| L/D ratio | 33:1 |
| Main motor power | 55 kW |
| Pipe diameter range | 20 to 160 mm |
| Line speed | 0.4 to 8.0 m/min (depends on diameter and wall) |
| Capacity | 150 to 320 kg/h |
| Installed power | 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.
Soğutma uzunluğu 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
Bir antikorozif HDPE kimyasal boru ekstrüzyon hattı, çalışma sırasında kaliteyi, sadece ofis dışı incelemeden değil, kontrol etmek için aletlenmiştir. Barın içindeki eriyik sıcaklığı, HDPE işleme aralığının yaklaşık 200 ila 230 derece Celsius arasında tutulur ve termal bozulmayı önlerken tam plastifikasyon sağlanır. Die'de eriyik basıncı, ekran paketinin tıkanmasını tespit etmek ve çıkışını stabilize etmek için izlenir.
Key quality parameters
| Parametre | Typical target | Why it matters |
|---|---|---|
| Pipe diameter range | 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 | no failure at test pressure | Short term proof of strength |
| Hydrostatic resistance 80 C 165 h | no failure at test pressure | Long term resistance proof |
| Melt flow and OIT | per compound spec | Confirms grade and antioxidant level |
Online inspection devices
- Laser diameter gauge:dış çapı sürekli olarak tarar ve çekme hızını düzeltmek için verilir.
- Ultrasonic wall thickness sensor:borunun dış çapı ve eksenikliği boyunca ölçer ve ince yerler için uyarır.
- Malzeme basıncı ve sıcaklık sensörü:silindir ve die, plastifikasyonu sabit tutmak ve ekran paketinin erken uyarısını sağlamak için.
- First article and type inspection:örnekler kesilir ve ISO 4427 ve GB / T referanslarıyla test edilir ve her üretim parti, izlenebilirlik için kaydedilir.
Borunun hizmette iyi yaşayacağından emin olmak için, boru, granül ve hazır boru üzerinde, malzeme akış indeksi, iki bileşen testi yapılır. Bileşen karışımının işleme sırasında değişmediğinden emin olmak için, büyük bir değişim, bozulma veya yanlış bir parti uyarısı verir. Oksidasyon indüksiyon süresi, OIT, yüksek sıcaklıkta antioksidan paketinin oksidasyona karşı ne kadar süre dayanacağını ölçer ve düşük bir OIT, malzeme dozunun düşük veya malzeme sıcaklığının yüksek olduğu uyarısı verir. Çünkü kimyasal boru, yıllarca sıcak, oksijenle temas eden kuyulara yerleştirilir, OIT, görünümden daha anlamlı bir kalite kapısıdır ve Faygo, çap ve duvar haritası ile birlikte, üretim partisi için OIT'yi kaydeder.
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.
Elektrofüzyon, yerleştirilmiş ısıtma telinin bulunduğu bir kablosunu kullanır; boru uçları kazınılır, yerleştirilir ve enerjilendirilir, böylece bobin her iki yüzeyi de eritir. Onarım, bağlantı ve dar alanlar için tercih edilir. HDPE boru ile pompalar, valfler ve çelik ekipmanlar arasında bağlantı sağlayan flaneli adaptörler, şekillendirilmiş bir HDPE ucu ile gevşek bir çelik arka flanesi birleştirir. Her yöntemde, boru ucu kare şeklinde kesilmeli ve atıklardan arındırılmalıdır, bu nedenle ekstrüzyon hattı kesicisi, yüksek bir karelik toleransı sağlamalıdır.
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 boru ekstrüzyon hattı 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. | Hata | 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 | Wall thickness eccentricity | 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) | Cutter mis set, pipe slipping | Re square cutter, secure haul off grip |
| 13 | Orange peel surface | Melt too cold, die land too long | Raise melt temp, check die land finish |
| 14 | Pipe telescoping in tank | Haul off faster than extruder | Match haul off to output via pump feedback |
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 boru ekstrüzyon hattı; actual figures vary with grade, SDR and cooling water temperature.
Typical speed, capacity and energy
| Çap aralığı | Line speed (m/min) | Capacity (kg/h) | Specific energy (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 |
Enerji, çapın büyümesiyle düşer, çünkü metreküplenme pompası ve bıçak, daha verimli noktaya yaklaştıkça ve yüzey / hacim oranı düştüğünde. Servo kontrolü ile çekme ve inverter kontrolü ile yardımcı cihazlar, kWh / kg başına daha fazla enerji düşürür. Enerji, sadece bir fiziksel miktardır; burada bir fiyat belirtilmemiştir.
10. Equipment Maintenance Schedule
Planlanan bakım programı, hat boyunca belirli özelliklerde üretimi sürdürür ve planlanmamış duraklamaları önler. Faygo, makine seviyesinde bir ürün yaşam döngüsü yönetimi yaklaşımını yansıtmak üzere bakımı, vardiya, haftalık ve aylık görevlere ayırır.
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.
- 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.
- 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
Tam bir HDPE kimyasal boru ekstrüzyon hattı uzun olabilir, çünkü soğutma lineer bir alan gerektirir. Küçük hatlar yaklaşık 20 metrekarelik bir alana sığabilirken, uzatılmış soğutma ve bobin istasyonu olan 630 milimetrelik bir hat 30 metreyi aşabilir. Fabrika, düz, yük taşıyabilen bir zemin, die ve yastık değişimleri için yeterli üst boşluk alanı ve dış çıkışta kesme ve yığma için yer gerektirir.
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 | reinforced for heavy pipe |
| Overhead clearance | 4 m | 5 m plus |
Bu rakamlar planlama referanslarıdır; gerçek düzenleme, fabrikada sunulan anahtar teslim destek kapsamında, üç boyutlu atölye çizimi, su ve elektrik tasarımı ve işçi konfigürasyonu ile geliştirilir.
12. Safety, Dust, Noise and Environmental Compliance
HDPE extrüzyon, düşük emisyonlu bir süreçtir, ancak birkaç tehlike kontrol edilmesi gerekir. Masterbatch'in gravimetrik karıştırılması ve beslenmesi, konveyörde ince toz oluşturur, bu nedenle besleme boşluğunda yerel çekme önerilir ve işçiler malzeme işleme sırasında temel toz koruması kullanırlar. Barrel ve die, eritme sıcaklığında çalışır, bu nedenle die yakınında herhangi bir iş için koruma ve kilitlenme gerekir.
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 Boru Ekstrüzyon Hattı 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 Boru Hattı 315 to 630 mm
Bu hat, kimyasal tesis ana hatlarını ve büyük miktarda üretim ve kalın SDR duvarları gerektiren yerel ölçekli transferi sağlar. Büyük çaplı yuvarlaklık için iç basınç boyutlandırma kullanır.
| Parametre | Specification |
|---|---|
| Screw diameter | 120 mm |
| L/D ratio | 33:1 |
| Main motor power | 160 kW |
| Pipe diameter range | 315 to 630 mm |
| Line speed | 0.2 to 3.0 m/min |
| Capacity | 400 to 700 kg/h |
| Installed power | 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
Aşağıdaki tablo, tipik bir müşteri gereksinimini Faygo konfigürasyonuna göre haritalar. Bu, bir başlangıç noktasıdır; son seçim, medya konsantrasyonu, hizmet sıcaklığı ve yerel standartlara bağlıdır.
Selection recommendation
| Medium and duty | Diameter | Target capacity | Recommended Faygo line |
|---|---|---|---|
| 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. Uygulama Endüstrileri ve Son Ürünler
Faygo boru ekstrüzyon hattıs 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
- Kimyasal tesisler: 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.
- Elektrotoplama ve PCB atölyeleri:Asit ve alkali yıkama suyu borusu, etken geri kazanım hatları, HDPE'nin kaplama kimyasına ve düzgün boşluk sınırlamalarına karşı direnç gösterir.
- 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.
- Madencilik:atık çamur borusu ve proses suyu hatları, düşük sürtünme çapı ve aşınmaya dayanıklılık sayesinde hizmet ömrünü uzatır.
- Tarım ve bahçe sulaması: 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. Service and Support
Faygo, a Wanplas factory, supports every anti corrosion HDPE chemical boru ekstrüzyon hattı 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.
Sıkça Sorulan Sorular
HDPE, asit ve alkali ortamlı boru hatları için PVC veya çelikten neden tercih edilir?
HDPE, çeşitli konsantrasyonlarda asitler, alkali ve tuzlu çözeltilerle reaksiyona girmez ve iç kaplamaya veya katodik korumaya ihtiyaç duymaz. PVC daha ucuzdur ancak sıcaklık ve darbe dayanımı sınırlıdır, diğer yandan çelikte, klorür ortamlarında çökme meydana gelir. HDPE, aynı zamanda but fusion yoluyla tamamen homojen, sızıntısız bir bağlantıya dönüştürülebilir.
HDPE kimyasal boru için hangi extruder tipi kullanılır, tek şaftlı mı yoksa çift şaftlı mı?
HDPE boru genellikle, istikrarlı, pulsuz bir erimiş malzeme sağlayan dişli tip ölçüm pompasıyla donatılmış yüksek hızlı tek dişli ekstrüderde üretilir. PVC toz karıştırılması ve sert PVC boru için çift dişli ekstrüderler kullanılır, çünkü PVC güçlü kesme ve devalülasyon olmadan bozulur. HDPE için tek dişli + dişli pompa kombinasyonu, en iyi çıkış istikrarı ve duvar kalınlığı kontrolünü sağlar.
Ekstrüzyon sırasında boru çapı ve duvar kalınlığı nasıl kontrol edilir?
Spiral bir mandrel die, eriyi çevre boyunca eşit olarak dağıtır, ardından bir vakum boyutlandırma silindiri, vakum altında dış çapı kalibre ederken bir kapalı iç soğutma mandreli, yuvarlaklık ve eksenel sapma içindeki tolerans bandlarında ISO 4427 referanslarına göre boru çapını kontrol eder.
Kimyasal taşımacılık hatları için hangi basınç sınıfı seçilmelidir?
Basınç sınıfı, PE derecesi, SDR (standart boyut oranı) ve hizmet sıcaklığına göre belirlenir. PE100 için, SDR11, genellikle 20 derece santigrat sıcaklıkta PN16, SDR17, PN10 ve SDR26, PN6'yı sağlar. Kimyasal tesisler, çalışma sıcaklığında gerekli basınç marjını elde eden SDR'i seçmeli ve medya konsantrasyonunu malzeme direnci tablosuna göre kontrol etmelidir.
HDPE kimyasal boru için hangi kaynaklama yöntemleri önerilir?
Butt fusion, yaklaşık 63 milimetre çapındaki boru boru bağlantıları için standarttır ve boru kendisi kadar güçlü bir bağlantı oluşturur. Elektrofusion bağlantıcılar, onarım, bağlanma ve dar alanlar için kullanılırken, flans adaptörleri HDPE boruyu valflere ve pompalara bağlar. Yuvarlak, temiz boru uçları, tam güçte butt fusion bağlantıları için önemlidir.
Bir HDPE boru hattı sevk edilmeden önce hangi kalite testleri yapılır?
Faygo, teslimat öncesinde her hatta 72 saat süren bir sürekli çalışma testi yapar ve ekstruder istikrarını, vakum boyutlandırma doğruluğunu, çekme hızının takibi ve kesici düzlüğünü kontrol eder. Örnek borular, ISO 4427 ve GB / T referanslarına göre çap, duvar kalınlığı, yuvarlaklık, uzunluksal dönüşüm ve hidrostatik direnci açısından incelenir ve hat, izlenebilir bir üretim kaydı ile belgelendirilir.
Sonuç
An anti corrosion HDPE chemical boru ekstrüzyon hattı 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.
