high pressure equipment socrates intensive course budapest professor dr.-ing. e. schlücker...
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PAT
High Pressure Equipment
Socrates Intensive Course Budapest
Professor Dr.-Ing. E. SchlückerLehrstuhl Prozessmaschinen und
AnlagentechnikCauerstraße 4
Universität Erlangen-Nürnberg
PAT
From High Blood Pressure to Diamonds
A Survey about HP applications
130 - 80 Torr (0,17 - 0,1 bar)
350 000 bar
Professor Dr.-Ing. E. SchlückerLehrstuhl Prozessmaschinen und
AnlagentechnikCauerstraße 4
Universität Erlangen-Nürnberg
3
PAT
Hocdrucktechnik 18.04.23
What is High Pressure... A question of the point of view ... !
High Blood Pressure is only harmful if it acts to long. Short HBP-Episodes are mostly quite healthy.
Exercises! But long lasting HBP lead to heart diseases =
system gets overloaded.
The Meaning of High Pressure therefore is directly related to the system!
Flow
p
Pump and system damage
Pressure loss increases
Pump has to work harder
4
PAT
Hocdrucktechnik 18.04.23
11000 t on 5 cm²
2 200 000 bar
What is Pressure?
Which pressure is acting when two
elephants are standing on a 10 cent coin ? Which pressure is acting when the
Eifelturm stand upside down m.
4000 bar on a 10 cent coin!
On top of the highest mountain: 0,25 bar,
at the deepest point of the ocean 1000 bar
5
PAT
Hocdrucktechnik 18.04.23
History of High Pressure Technology?
Ktesebios – first double piston pump (Archimedes times) Romans: Pumps for water supplyment Agricola: wooden high pressure pump James Watt 1785: Steam engine Middle ages: Gun barrels Haber Bosch 1918 Nobel Prize Since mid of 20th century
>120000 bar for Diamond
production
6
PAT
Hocdrucktechnik 18.04.23
The Path to the High Pressure Summit
Mount Everest 8848m
The higher, the more important is the equipment
868 bar
Maximal Pressure
0 bar
7
PAT
Hocdrucktechnik 18.04.23
Extraction und Micronisation
Extraction
Maximal Pressure Arome‘s Frangrances
Decaffeination
Up to 700 bar
Micronisation changes liquid into powder
at
300 – 800 bar
Micronisation
8
PAT
Hocdrucktechnik 18.04.23
ExtractionExtraktionsprozesse
Z.B. star-anis at about 200 bar
Maximum:
Saw teeth palm seed oil at 700 bar
Functional Food !!
9
PAT
Hocdrucktechnik 18.04.23
ExtractionExtraction processes
Product basket of a
Extraction plant.
10
PAT
Hocdrucktechnik 18.04.23
MicronisationFrom Liquid to powder
Advantages when used!
Rum-Arome as a powder?
Adhesives (glue) as a powder?
Weidner et. al.
11
PAT
Hocdrucktechnik 18.04.23
Micronisation
22% curcuma on corn starch
59% Strawberry flavor on silicic
acid
79% celery extract on silicic acid
Weidner et. al.
12
PAT
Hocdrucktechnik 18.04.23
High Pressure TechnologyBasic rules for high pressure applications
Optimum Low number of bores, steps in cross section area , notches
and steps in the pressure chamber ! Small pressure loaded areas ! Small number of sealings ! Small enclosed volume ! Smooth surface
? !
p p? !
13
PAT
Hocdrucktechnik 18.04.23
High Pressure TechnologyHigh pressure machines
Bionic application of the „heart“ At high pressure only efficient machines Small pressure loaded surfaces Smooth surfaces No cross section area steps and notches
FLUIDR
Öl VL
Schritt 2
VS
000991 0106b
Diaphragm pumps up to 3000 bar
D
FLUID
R
Schritt 1
VL
VS
000991 0106a
Plunger pumps up to 20 000 bar
14
PAT
Hocdrucktechnik 18.04.23
Liposom-Manufacturing , Homogenisation
Extraction
Maximal Pressure
Micronisation Liposoms
For your health
Food treatment
800 – 1500 bar
15
PAT
Hocdrucktechnik 18.04.23
Liposom-MnaufacturingSmallest particles due dispergation
Liposomold greek
Lipos = grease
Soma = body
grease body
Nach Mayhew, et. al., 1985
1200
800
600
400
200
0
nm
0 200 400 600 800bar
Differenzdruck
mitt
lere
Par
tikel
größ
e
001226 0111 Pressure Difference
Mea
n pa
rtic
le s
ize
16
PAT
Hocdrucktechnik 18.04.23
Heat exchanger
Product
Interaction
chamber
filter
pump
Back flow
Product feed
Liposomen-HerstellungSmallest particles due dispergation
Process
17
PAT
Hocdrucktechnik 18.04.23
Homogenisation of MilkPhysical stability
Shear forces cut drops into
pieces (dispergation)
Test
UHTProd.feed
HEHEHEHEUHTHOMO Vent.
H (septic) V.
H (aseptic)
FV.
001200e 0111
UHTProd.feed
HEHEHEHEUHTHOMO Vent.
H (septic) V.
H (aseptic)
FV.
001200e 0111
UHTProd.
feed
HEHE
HE
HE
UHTHOMO Vent.
H (septic)V.
H (aseptic)
FV.
001200e 0111
Nach Mayhew, et. al., 1985
1200
800
600
400
200
0
nm
0 200 400 600 800bar
Differenzdruck
mitt
lere
Par
tikel
größ
e
001226 0111
18
PAT
Hocdrucktechnik 18.04.23
Methanol-Injection
Maximal Pressure
ExtractionMicronisation LiposomsMethanolinjection
Against Icing of the injection nozzle at 700
up to 1200 bar
19
PAT
Hocdrucktechnik 18.04.23
Methanol-InjectionOil-/natural gas conveying
From the oil platform to the drilling location i.e. oil platform Gyrfalcon: Oil from a depth of 3000 m Crude oil as a emulsion of oil and water, hydro carbons and
sand At the discharge the mixture expands from 830 to 730 bar Result: hard cooling at a environmental temperature of 4 °C Danger of icing !!! measure: injection of methanol ! Pump for 1000 bar at 400 l/h
20
PAT
Hocdrucktechnik 18.04.23
Methanol-InjectionMethanol Pumps
Diaphragm pumps required – lubrication problems! As small as possible – 1 m2 oil platform für 125 000 €URO ! Classical diaphragm techology to big an not save enough Goal: Plastic diaphragms
001224 0111
21
PAT
Hocdrucktechnik 18.04.23
Methanol-InjectionSimulation of the stress situation
FEM-net of a diaphragm pump head
22
PAT
Hocdrucktechnik 18.04.23
Methanol-InjektionCalcuation results
Pressure
loaded surface
23
PAT
Hocdrucktechnik 18.04.23
Methanol-Injektion
F F
24
PAT
Hocdrucktechnik 18.04.23
Water Jet cutting, Jet Cleaning, Hydroform.
Maximaler Druck
ExtraktionMikronisation LiposomenMethanolinjektion
Water jet cutting
Clean cut beginning at
1500 – 4000 bar
Jet cleaning at 2500 bar
Hydroforming at 1000 – 4000 bar
25
PAT
Hocdrucktechnik 18.04.23
Water Jet cutting, Jet Cleaning, HydroformA great variety of applications
Metall, Stone, Paper, Cake ... Extreme shapes possible No thermal influence
example: steel platen 30 mm, clean cut with 10 mm/min
Stainless Steel
Working Pressure400 / 600 / 800 MPaOrifice0.1 mmFocus0.6 mm / L=50 mmCutting Speed100 mm/min
0
5
10
15
0
5
10
15
mmmm
0
5
10
15
20
25
mm
0
5
10
15
20
25
30
35
mm
0
5
mm
0
5
10
mm
0
5
10
15
mm
View CAluminium
26
PAT
Hocdrucktechnik 18.04.23
Water Jet cutting, Jet Cleaning, HydroformNozzle technique
Water jet is able to wash out steel Jet wear
Additional particles = a liquid saw Main problem: wear
Goal: Avoiding of high wear by increasing pressure up to 4000 bar and more, leaving out particles
27
PAT
Hocdrucktechnik 18.04.23
Water Jet cutting, Jet Cleaning, HydroformHydroforming process for metal deformation
- 4000 bar Special tube based
shapes Large curved parts
3
1
4 4
2
2
4
3
4
A
B
001219 0111
With such a pressure: doing a correct design is not enough!
28
PAT
Hocdrucktechnik 18.04.23
Water Jet cutting, Jet Cleaning, HydroformAutofrettage for increase of the ability for loading
Plastical deformation of the materialp Volumenänderung
p
r
Stresssituation
r
p
t
t
ErhöhteStresssituation
p
t
t
r
p
unbelastet
druckbelastet
t
unloaded
under pressure
29
PAT
Hocdrucktechnik 18.04.23
High pressure polymerisation of Polyethylen
Extraction
Maximal pressure
Micronisation LiposomsMethanol-injection
Water jet cuttingPE-Polymerisation
High value plastics
at about
3000 bar
30
PAT
Hocdrucktechnik 18.04.23
High pressure polymerisation of PolyethylenLD-Polyethylen (branched molekule structure)
System A: storage B, C: Compressors D: Stirred Vessel
Reactor F: H-Exchange G: Separation H: H-Exchange J: Separation K: Gas Recycling
Modifier Comonomerem
Äthylen
PeroxidProdukt (PE)
300 bar
250
0 b
ar
a
c
d
e
f
g
h
i
j
k
l
b 2500 bar
001197e 0111
31
PAT
Hocdrucktechnik 18.04.23
High pressure polymerisation of PolyethylenLD-Polyethylen (branched molekule structure)
Reaction:
Reaction in tube reaktor: up to 3500 m long, pieces 10 m long. Reciprocating positve displacement pump Resistant materials
CH2 + CH2 + .... = CnH2n+2
plus additional chemicals! D
FLUID
R
Schritt 1
VL
VS
000991 0106a
32
PAT
Hocdrucktechnik 18.04.23
High pressure polymerisation of PolyethylenOptimal Materials
Fatigue testing with pulsating internal pressure
1000
800
600
400
200
0
Ver
glei
chss
pann
ung
v
106105 107 108
N / mm2
N
Lastwechselzahl
Spindelöl
Salpetersäure Automatic Autofrettage !!
!!
0 10 20 30 40%
Dehnung
0
200
400
600
800
1000
N / mm2
Spa
nnun
g
1.4462
001222 0111
1.4462
RP 0,2
Rm
Notch factor ca. 2,8
Spindloil
Nitric acid
Load cyclesstrain
Van
Mis
es S
tres
s
33
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisation
Extraction
Maximal Pressure
Micronisation LiposomsMethanol-Injektion
WasserstrahlschneidenPE-Polymerisation Water Jet CuttingPE-Polymerisation
HP-Sterilisation
Alternative to hot sterilisation ?
Up to 8000 bar
34
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisationCreatures under high pressure
35
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisationcareful alternative to hot sterilisation
1914: Nobel price winner Bridgeman – egg white coagulates at 7000 bar similar to > 50°C
At 5000 – 6000 bar lethality of all life forms
At pressure > 6000 bar it is possible to sterilize
Advantage: - Vitamins and proteins don‘t get destroyed- Aroma stays - Allergens are not added
Disadvantage: - high technical effort, long pressure load time- 2 - 3 more expensive than hot sterlized products
36
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisationAlternative to hot sterilisation
High product safety
Problem: ecconomic !
Food varmints
Kill at 8000 bar
55 KJ/Kg
125,4 KJ/Kg from 20 up to 50°C (water)
Especially sucessful in Japan
Here Autofrettage sometimes is not enough!
37
PAT
Hocdrucktechnik 18.04.23
D+X
High pressure sterilisationShrinking
Shrinking generates at the inside of a cylinder compression stress
D
unbelastet
druckbelastet
t
unloaded
under pressure
38
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisation
Flüssiges Lebensmittel
K. Hori et al., Mitsubishi Heavy Ind., Hiroshima 1992
1
23
45
Trinkwasser1
Niederdruckpumpe2
Hochdruckpumpe (4000 bar)3
Kolben4
Hochdruckbehälter5
(Fruchtsaft)
150598_3.dsfPlant – quasi continual
39
PAT
Hocdrucktechnik 18.04.23
High pressure sterilisation
Sucessful applications for a lot of food Increase of the stability from 4 days up to 4 weeks
careful alternative to hot sterilsation
40
PAT
Hocdrucktechnik 18.04.23
High Pressure Cristallisation
Extraction
Maximum Pressure
Micronisation LiposomsMethanol-Injektion
Water Jet CuttingPE-Polymerisation
High Pressure Cristallisation High Pressure Steril.
Galliumnitrit-crystals
in highest quality up to
15000 bar
Autofrettage up to 13000 bar
41
PAT
Hocdrucktechnik 18.04.23
High Pressure CristallisationWhy?
Optimal Pressure (> 10 kbar) - reactands homogen in stoichiometric ratio
Pressure gerates optimal growing conditions Growing velocitiy is increasing
with pressure
15000 bar
1500 °C
N2
GaN2
Ga
42
PAT
Hocdrucktechnik 18.04.23
High Pressure CristallisationHigh Pressure – to high for common steel
Hard metal segments as stress reducer (pressure transformer) Seal made out of metal – self sealing principle
Stahl
Weich-Metall
Kunststoff
O-Ring
Kunststoff
Weich-Metall
Stahl
Anti-Rutsch-Ring
Weichmetall oderKunststoff
Anti-Rutsch-Ring
Stahl
a)
b)
alternativ
pR1
R2
1
2
=
R2
R1
p
R3
1
2
R4
43
PAT
Hocdrucktechnik 18.04.23
Diamond-Manufacturing
Extraction
Artificial Diamonds with
more than
100 000 bar
Micronisation LiposomsMethanol-Injektion
WasserstrahlschneidenPE-Polymerisation
Maximum Pressure Diamond Manufacturing
Water Jet CuttingPE-Polymerisation
High Pressure Kristallisation High Pressure Steril.
44
PAT
Hocdrucktechnik 18.04.23
Diamond-ManufacturingTools / Process
No Fluid! Compression of powder
Tetrahedral Press
bis 120 000 bar!
Opposed Anvil Apparatus
bis 350 000 bar!
GraphiteNickel
Maximum Size:
1 Carat
(0,2 Gramm)
45
PAT
Hocdrucktechnik 18.04.23
Cheers - We reached the Maximum!
Welcome to the Pressure Summit!
46
PAT
Hocdrucktechnik 18.04.23
Maximum Pressure
Minimum Pressure
?Pressure influences:
Density/Molekule Distance
Diffusion Behavior
Energy Density
etc...
Future?
47
PAT
Hocdrucktechnik 18.04.23
Future?
Pressure as a modelling
parameter
Modelling functional boundary layers
Generation of Functional Particle Systems
Nano Particle Behavior in Gases
Diffusion of Gas into Metals
Idea