Pneumatics for Primary Aluminium. Innovative Products and System Solutions. Catalogue PDE2614SLUK
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1 Pneumatics for Primary Aluminium Innovative Products and System Solutions Catalogue PDE2614SLUK
2 Parker Hannifin Corporation A global, Fortune 300 company with sales of $12.1 billion and over 400,000 customers in 46 countries, Parker Hannifin is the world s leading supplier of motion control components and system solutions serving the industrial, mobile, and aerospace markets. Excellence is imprinted on our corporate DNA. We are the only manufacturer offering customers a choice of hydraulic, pneumatic, electromechanical, or computer motion control. Total Systems Solutions Parker s team of highly qualified applications engineers, product development engineers, and system specialists can turn pneumatic, structural extrusion, and electromechanical products into an integrated system solution. And our Selectable Levels of Integration program provides the components, subsystems, and controlled motion systems for the level of integration you choose. 1st in Delivery, Field Sales and Distribution Parker boasts the industry s largest global distribution network, with more than 8,600 distributors worldwide. With factories located strategically on five continents, we can maintain matchless on-time delivery rates. Expect industry s fastest response and delivery by customer request date when you contact Parker or one of its distributors. Plus, Parker s army of engineers works hand-in-hand with you and your local distributors during the design process to ensure the best products, services, and application performance. Parker Distribution offers the next level in premier customer service. Each location has significant onhand inventory to keep your down time to a minimum. And many distributors have in-house design capability to support your system and subsystem requirements. Training Parker s best-in-class technology training includes hands-on classes, Web-based training, and comprehensive texts for employees, distributors, and customers. Parker also provides computer based training, PowerPoint presentations, exams, drafting and simulation software, and trainer stands. Industry s most comprehensive Web site is your single source for: Product information Downloadable catalogs 3-D design files Training materials Product configuration software RFQ capabilities Parker world headquarters in Cleveland
3 The No.1 Supplier of pneumatics to the world s aluminium smelters Parker Hannifi n has more than 100,000 cylinders in operation in the world s leading smelters. Our experience in the aluminium industry goes back to Parker has equipped machinery in all phases of aluminium production from smelters, casters and extruders through grinders, rolling mills and strip processing lines, and a broad array of fabrication equipment. We understand the special demands of the primary aluminium industry such as high temperatures, strong magnetic fields, electrical arcing, abrasive environments - and we have the answers. Our pneumatic and electromechanical technologies deliver repeatability, accuracy, and rugged dependability for high volume production requirements. Specialised Product Development Our product development has been matched to the very harsh environment found in the reduction cells. Special attention has been paid to: - High temperature environments - Heavy dust laden atmosphere - Abrasive environment - Strong magnetic fi elds - Mechanical damage Parker fulfils the demands from the market With our continuous development in close cooperation with the worlds leading technology suppliers, we offer the market the most up to date specially designed products with the following basic features: Standard High Temperatures - Continuous +150º C (300º F) - Intermittent +200º C (390º F) No additional lubrication Effectively sealed against dust (alumina) Maintenance free operation > 5 years Service life 20 years
4 Crust Breaker Cylinders The C41 Crust Breaker cylinder has been designed to meet the harsh environme nt in an aluminium reduction pot with normal working temperatures up to +150 C (300 F) and intermittently up to C (390 F) which may occur due to anode effects or during the start up of a pot. Options available for Breaker Cylinder: Built-on valves Mechanical latch End position indication - Pneumatic - Electrical Electrical sensing of the bath Electrical insulation Energy saving function Bearings on piston rod and piston of self-lubricating Teflon material (PTFE) reinforced with graphite (piston) and bronze (piston rod) for side load performance. All bearing materials are electrically non conductive. Special attention has been given to the scraper ring function. Two different options are available: 1. A higher temperature resistant self lubricating Teflon scraper ring provides the optimum solution for the crustbreaking cylinders. 2. For applications where the cylinder is exposed to extreme temperature or heavily polluted air, the cylinder can be equipped with a metallic rod wiper in combination with a Teflon scraper ring. Specification for materials End cover: Aluminium, black anodized Cylinder barrel: Aluminium, anodized Piston: Aluminium, anodized Tie rod: Steel, Zinc plated Piston rod: Steel, hard chromium plated Bearings piston: PTFE (Teflon) reinforced with graphite piston rod: PTFE (Teflon) reinforced with bronze Seals: Viton (Fluoric rubber) Scraper ring PTFE (Teflon) combined with Viton or - Metallic rod wiper combined with a PTFE (Teflon) scraper ring. The cylinders are designed to operate in a point feeder on an aluminium reduction cell for the complete life of the cell. Performance Data Double acting cylinder according to ISO 6431 with adjustable cushioning at both ends. Bore mm: Piston rod diameter mm: 32 32/40 40/50 40/50/70 Stroke: According to requirement from the client Connection ports BSP or NPT: ½ ½ ¾ ¾ Maximum working pressure 10 Bar (145 PSI) Temperature range: Working temperature: +150 C (+300 F) Max. intermittent temperature: +200 C (+390 F)
5 Intelligent Crustbreaking Breaking The force required for breaking is related to the hardness of the crust; the full force is only required occasionally. The Intelligent Crustbreaking Cylinder solution has made it possible to distinguish between different crusts. In the front end cover of the cylinder, an integrated sensor detects when the chisel has reached it s extended position. The power valve is then immediately switched and the air supply to break is reversed. With no crust or a very thin one, the extended position is reached using approximately 30% of the available air pressure. When encountering a harder crust, the air pressure increases up to the required force to break, which is somewhere between the no crust force and the full available force. The cylinder is able to sense the hardness of the crust and only uses as much energy as required. Controlling the Process In case the cylinder does not have enough force to break the crust, the signal from the end sensor will be missing. The lack of feed back signal can be registered by a pot control system and the problem can be dealt with in the most effective way. The Alumina Concentration in the bath can be kept stable, avoiding undesired anode effects. Leakage control In case of a pressure loss inside the cylinder resulting in the chisel moving slightly down, the sensor compensates the pressure drop, lifts the chisel and shuts off the air supply again. The pressure drop can be registered by the control system enabling preventive actions from the maintenance department. Retracting As soon as the chisel has left the crust only a very low pressure is required to lift a chisel with a weight of approximately 100kg. The critical phase is when friction or an elephant leg prevents the chisel from being released from the crust at a low pressure. In this case the force will automatically built up to release the chisel, but as soon as the chisel has cleared the crust, it will continue to retract at a low air pressure. When reaching the upper position, the sensor in the rear end-cover instantly shuts off the air supply. Prolonged Service Life The time that the chisel is exposed to the high temperatures by each break cycle can be reduced to a minimum. This not only extends the service life of the chisel but also the cylinder, as less heat will be transmitted through the piston rod. Lower pressure operation with limited pressure peaks and reduced exposure to high temperatures, contributes to Parker s strategy of offering a service life of the crustbreaker cylinders corresponding to the life of the cathode. When the job is finished, the air supply is shut off and no unnecessary compressed air is consumed.
6 Intelligent Crustbreaking 70% Save up to 70% of your compressed air consumption and get better control in the process! Breaking The cylinder is able to sense the hardness of the crust and only uses as much energy as required. Retracting When the job is finished, the air supply is shut off and no unnecessary compressed air is consumed. Controlling the process The Alumina Concentration in the bath can be kept stable, avoiding undesired anode effects. Leakage control The pressure drop can be registered by the control system enabling preventive actions from the maintenance department. Prolonged service life Lower pressure operation with limited pressure peaks and reduced exposure to high temperatures, contributes to Parker s strategy of offering a service life of the crustbreaker cylinders corresponding to the life of the cathode.
7 Parker s Intelligent Crustbreaking System Air consumption diagram 6,0 5,0 4,0 (bar) 3,0 2,0 1,0 0,0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 Breaking Inlet pressure : 8 bar Retracting (S) What does this mean for a smelter with 1000 crustbreaker cylinders? - Bore: 200mm / 8 inches - Stroke: 500mm / 20 inches - Pressure: 7 bar / 100psi Intelligent Crustbreaker Cylinder provides up to 70% saving in compressed air Based on proven technology from the C40 series Complete working unit Provides information on: - If the crust is broken - If the chisel has left the bath - If the cylinder is fully retracted - Air leakage Maintenance free service life corresponding to life of the cathode. More than 20,000 Intelligent Crustbreaker Cylinders in operation since With breaking every 2 minutes the normal air consumption is 66 million m 3 / 2.3 billion ft 3. With Parker s Intelligent Crustbreaking System it means you can achieve air savings of approximately %! Air consumption is then reduced to 20 million m 3 / 1.6 billion ft 3 saving 45 million m 3. What is the potential saving in YOUR smelter? Check YOUR annual saving at Click on Applications/Primary Aluminium
8 Feeder Cylinder The C41 Feeder cylinders are designed to operate in a point feeder on an aluminium reduction cell for 5 years without repair or maintenance. Special attention has been given to the function of the Viton scraper ring. Specification for materials End cover: Aluminium, black anodized Cylinder barrel: Aluminium, anodized Piston: Aluminium, anodized Tie rod: Integrated Piston rod: Steel, hard chromium plated Bearings: PTFE (Teflon) reinforced with graphite Seals: Viton (Fluoric rubber) Scraper ring Viton (Fluoric rubber) Performance Data Double acting cylinder according to ISO 6431 with adjustable cushioning at both ends. Bore mm: Piston rod diameter mm: Stroke: According to requirement from the client Connection ports BSP or NPT: ¼ ¼ 3 /8 3 /8 Control Valve VF45 The VF45 valve is specially design for the applications in the aluminium industry. Resistant to high temperatures and sealed against dust. The valve design is of poppet seat type for non-lube operation. All materials are non magnetic to avoid jeopardizing the function under the influence of strong magnetic fields. The control valve may be simply removed from the ISO Size 4 subbase without disconnecting any pipework to cylinder, air supply or exhaust. The valve is available with air or electrical actuation and spring return. VF45 valves are designed to operate for a minimun of 5 years without additional lubrication or maintenance with an operating frequency for each control valve of a maximum 600 cycles during a 24 hour period. Maximum working pressure 10 Bar (145 PSI) Temperature range: Working temperature: C ( F) Max. intermittent temperature: C ( F) Specification for materials Control valve Valve body: Aluminium End caps: Aluminium Internal parts: Aluminium Seals: Viton (Fluoric rubber) Dynamic O-rings with Glide rings Bearings, Glide rings: PTFE (Teflon) reinforced with graphite Spring: Stainless steel Lubricant: Graphite powder with Silicon oil Solenoid valve Valve body: Duroplastic epoxy resin, non organic reinforcement Coil: Copper wire coated with W200 acc. to DIN Plunge: Stainless steel, low magnetic Cable connector: Polyamid plastics Base: Brass Subbase, interface ISO 5599/1 size 4 Subbase Aluminium Performance Data Control valve Directional control valve 5 port, 2 way valve of poppet type. Maximum working pressure 10 Bar (145 PSI) Minimum signal pressure 3,5 Bar (50 PSI). For el. actuated valves minimum working pressure 3,5 Bar (50 PSI) Temperature range (air actuated valve): Working temperature +150ºC (300ºF) Max. Intermittent temperature +200ºC (390ºF) Temperature range (el. actuated valve): Working temperature +120ºC (250ºF) Max. Intermittent temperature +160ºC (320ºF) Flow capacity: Lit. / min. at 6 Bar (87 PSI) and 1 Bar (14,5 PSI) pressure drop Medium: Air, non lubricated 15 µ Operating environment: Heavy aluminia dust atmosphere Strong magnetic fields Solenoid valve Protection class: IP 65 Voltage: Available in all common AC and DC voltages Subbase, interface ISO 5599/1 size 4 Connection ports: BSP or NPT ½, BSP or NPT ¾
9 Accessory Products Air preparation Air preparation plays a central role in pneumatic installations. In fact is the key factor for trouble free operation. Air preparation units filter out all damaging particles down to the smallest contaminants. Dust, rust particles and condensation residue are examples of contaminants which might otherwise wear out moving parts prematurely, shortening service life. The correct air preparation system also ensures correctly regulated air pressure and downstream lubrication when necessary. The unique Moduflex air preparation system offers a wide selection of products, port sizes, combinations and accessories for the efficient control of compressed air. - Fully modular & body ported 1/8 up to 1" - Combinations assembled in seconds, without tools - One piece fi lter element cartridge - Rugged one piece aluminium bodies - Full range of accessories Fluid Connectors & Hoses The leaders in dry technology for the fluid power industry, the Parker Fluid Connectors Group is your single source for high-quality tube fittings, pressure hose and hose fittings, thermoplastic tubing, brass fittings and valves, quick-disconnect couplings and assembly tools. Products are available for shipment 24 hours a day, supported by 49 manufacturing facilities throughout the world, a global distribution network and 25 company-owned stocking service centres. We offer a wide range of fittings and non-conductive hoses used in all the major aluminium smelters all over the world.
10 References in the Aluminium Industry Intelligent Crust Breakers Name Country Technology Installation / Operation Mostar Bosnia Pechiney/VAW 2001 Hydro Rheinwerk Germany VAW 1997 Alcan Iceland Alusuisse Nordural Iceland VAW/Hydro Elkem Mosjoen Norway Alcoa 2001 Hydro Sunndal Norway Hydro 2001 Alro Romania Pechiney Alcan Switzerland Alusuisse 2003 Alba Bahrain Pechiney 2004 Balco India Gami 2006 Dubal UAE Dubal 2006 Qatalum Quatar Hydro 2009 Emal UAE Dubal 2009 Crust Breakers & Feeder Cylinders Name Country Name Country Aluminij Mostar Alcan Hydro Aluminium Alcan Alcoa Nordural Aldel Elkem Hydro Aluminium Soral Alro Rusal Alcoa Kubal Alcan Alcan Aluar Albras Alcoa Alcan Bosnia France Germany Iceland Iceland Iceland Netherlands Norway Norway Norway Romania Russia Spain Sweden Switzerland UK Argentina Brazil Brazil Canada Alcoa Elkem Alcoa Alcasa Venalum Alcan Alcoa Hydro Aluminium Alba Lanzhou Egypt Aluminium Balco Malco Nalco Hormozal Almhdi Iralco NZAS Dubal Canada Surinam USA Venezuela Venezuela Australia Australia Australia Bahrain China Egypt India India India Iran Iran Iran New Zealand UAE H H H H H H H H Intelligent Crust Breaker Cylinders Crust Breaker and Feeder Cylinders
11 Parker s Motion & Control Technologies At Parker, we re guided by a relentless drive to help our customers become more productive and achieve higher levels of profitability by engineering the best systems for their requirements. It means looking at customer applications from many angles to find new ways to create value. Whatever the motion or control technology need, Parker has the experience, breadth of product and global reach to consistently deliver. No company knows more about motion and control technology than Parker. For further information call AEROSPACE Aircraft engines Business & general aviation Commercial transports Land-based weapons systems Military aircraft Missiles & launch vehicles Regional transports Unmanned aerial vehicles Flight control systems & components Fluid conveyance systems Fluid metering delivery & atomization devices Fuel systems & components Hydraulic systems & components Inert nitrogen generating systems Pneumatic systems & components Wheels & brakes CLIMATE CONTROL Agriculture Air conditioning Food, beverage & dairy Life sciences & medical Precision cooling Processing Transportation CO 2 controls Electronic controllers Filter driers Hand shut-off valves Hose & fittings Pressure regulating valves Refrigerant distributors Safety relief valves Solenoid valves Thermostatic expansion valves ELECTROMECHANICAL Aerospace Factory automation Life science & medical Machine tools Packaging machinery Paper machinery Plastics machinery & converting Primary metals Semiconductor & electronics Textile Wire & cable AC/DC drives & systems Electric actuators, gantry robots & slides Electrohydrostatic actuation systems Electromechanical actuation systems Human machine interface Linear motors Stepper motors, servo motors, drives & controls Structural extrusions FILTRATION Food & beverage Industrial machinery Life sciences Marine Mobile equipment Oil & gas Power generation Process Transportation Analytical gas generators Compressed air & gas filters Condition monitoring Engine air, fuel & oil filtration & systems Hydraulic, lubrication & coolant filters Process, chemical, water & microfiltration filters Nitrogen, hydrogen & zero air generators FLUID & GAS HANDLING Aerospace Agriculture Bulk chemical handling Construction machinery Food & beverage Fuel & gas delivery Industrial machinery Mobile Oil & gas Transportation Welding Brass fittings & valves Diagnostic equipment Fluid conveyance systems Industrial hose PTFE & PFA hose, tubing & plastic fittings Rubber & thermoplastic hose & couplings Tube fittings & adapters Quick disconnects HYDRAULICS Aerospace Aerial lift Agriculture Construction machinery Forestry Industrial machinery Mining Oil & gas Power generation & energy Truck hydraulics Diagnostic equipment Hydraulic cylinders & accumulators Hydraulic motors & pumps Hydraulic systems Hydraulic valves & controls Power take-offs Rubber & thermoplastic hose & couplings Tube fittings & adapters Quick disconnects PNEUMATICS Aerospace Conveyor & material handling Factory automation Life science & medical Machine tools Packaging machinery Transportation & automotive Air preparation Brass fittings & valves Manifolds Pneumatic accessories Pneumatic actuators & grippers Pneumatic valves & controls Quick disconnects Rotary actuators Rubber & thermoplastic hose & couplings Structural extrusions Thermoplastic tubing & fittings Vacuum generators, cups & sensors PROCESS CONTROL Chemical & refining Food, beverage & dairy Medical & dental Microelectronics Oil & gas Power generation Analytical sample conditioning products & systems Fluoropolymer chemical delivery fittings, valves & pumps High purity gas delivery fittings, valves & regulators Instrumentation fittings, valves & regulators Medium pressure fittings & valves Process control manifolds SEALING & SHIELDING Aerospace Chemical processing Consumer Energy, oil & gas Fluid power General industrial Information technology Life sciences Military Semiconductor Telecommunications Transportation Dynamic seals Elastomeric o-rings EMI shielding Extruded & precision-cut, fabricated elastomeric seals Homogeneous & inserted elastomeric shapes High temperature metal seals Metal & plastic retained composite seals Thermal management
12 Parker Worldwide AE UAE, Dubai Tel: parker.me@parker.com AR Argentina, Buenos Aires Tel: AT Austria, Wiener Neustadt Tel: +43 (0) parker.austria@parker.com AT Eastern Europe, Wiener Neustadt Tel: +43 (0) parker.easteurope@parker.com AU Australia, Castle Hill Tel: +61 (0) AZ Azerbaijan, Baku Tel: parker.azerbaijan@parker.com BE/LU Belgium, Nivelles Tel: +32 (0) parker.belgium@parker.com BR Brazil, Cachoeirinha RS Tel: BY Belarus, Minsk Tel: parker.belarus@parker.com CA Canada, Milton, Ontario Tel: CH Switzerland, Etoy Tel: +41 (0) parker.switzerland@parker.com CL Chile, Santiago Tel: CN China, Shanghai Tel: CZ Czech Republic, Klecany Tel: parker.czechrepublic@parker.com DE Germany, Kaarst Tel: +49 (0) parker.germany@parker.com DK Denmark, Ballerup Tel: parker.denmark@parker.com ES Spain, Madrid Tel: parker.spain@parker.com FI Finland, Vantaa Tel: +358 (0) parker.finland@parker.com FR France, Contamine s/arve Tel: +33 (0) parker.france@parker.com GR Greece, Athens Tel: parker.greece@parker.com HK Hong Kong Tel: HU Hungary, Budapest Tel: parker.hungary@parker.com IE Ireland, Dublin Tel: +353 (0) parker.ireland@parker.com IN India, Mumbai Tel: IT Italy, Corsico (MI) Tel: parker.italy@parker.com JP Japan, Tokyo Tel: +(81) KR South Korea, Seoul Tel: KZ Kazakhstan, Almaty Tel: parker.easteurope@parker.com LV Latvia, Riga Tel: parker.latvia@parker.com MX Mexico, Apodaca Tel: MY Malaysia, Shah Alam Tel: NL The Netherlands, Oldenzaal Tel: +31 (0) parker.nl@parker.com NO Norway, Ski Tel: parker.norway@parker.com NZ New Zealand, Mt Wellington Tel: PL Poland, Warsaw Tel: +48 (0) parker.poland@parker.com PT Portugal, Leca da Palmeira Tel: parker.portugal@parker.com RO Romania, Bucharest Tel: parker.romania@parker.com RU Russia, Moscow Tel: parker.russia@parker.com SE Sweden, Spånga Tel: +46 (0) parker.sweden@parker.com SG Singapore Tel: SK Slovakia, Banská Bystrica Tel: parker.slovakia@parker.com SL Slovenia, Novo Mesto Tel: parker.slovenia@parker.com TH Thailand, Bangkok Tel: TR Turkey, Istanbul Tel: parker.turkey@parker.com TW Taiwan, Taipei Tel: UA Ukraine, Kiev Tel parker.ukraine@parker.com UK United Kingdom, Warwick Tel: +44 (0) parker.uk@parker.com US USA, Cleveland Tel: VE Venezuela, Caracas Tel: ZA South Africa, Kempton Park Tel: +27 (0) parker.southafrica@parker.com European Product Information Centre Free phone: (from AT, BE, CH, CZ, DE, DK, ES, FI, FR, IE, IT, NL, NO, PL, PT, RU, SE, UK, ZA) 2009 Parker Hannifin Corporation. All rights reserved. Parker Hannifin Ltd Pneumatic Division Europe The Collins Centre, Lichfield South Lichfield, Staffs. WS14 0QP. UK Tel.: +44 (0) Fax: +44 (0) Catalogue PDE2614SLUK Your local authorized Parker distributor
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