Objetivo del cliente
Cool 2,000 kg/h of hot PP pellets from 85°C–90°C down to ≤ 40°C prior to packaging, eliminate pellet caking in 1,000 kg bulk bags, reduce fines (< 1.5 mm) below 0.05%, and reclaim over 20 meters of workshop floor space.
- Etapa verificada
- In Operation
- Fecha del proyecto
- 2024-04
- Aplicación principal
- Continuous Polyolefin (PE / PP) Extrusion Pelletizing and Spiral Cooling Line
- Identidad del cliente
- Anonymized
- Ubicación del proyecto
- East China Petrochemical Park
The situation
Where this project started
A project is read from the conditions it began with — the profile, the background and the constraints are the customer's, and the result only means something beside them.
Perfil del cliente
A major polyolefin extrusion pelletizing enterprise in East China operating six continuous single- and twin-screw extrusion lines with an annual pelletizing volume exceeding 60,000 tons of virgin and compounded PP/PE resins.
Antecedentes del proyecto
Polyolefin resins (PP/PE) exhibit semi-crystalline solidification behavior. If pellets are packaged before core temperature drops below 40°C–45°C, residual latent heat induces post-crystallization creep, fusing pellets into stubborn lumps inside bulk shipping containers and destroying customer process automation.
Condiciones iniciales
The client operated an open 24-meter horizontal vibrating cooling bed. Hot PP pellets (88°C) arrived at the bagging station at over 65°C, softening and fusing under compressive stack pressure inside 1-ton bulk bags. In hot summer weather, relative humidity exceeded 80%, causing pellet moisture re-absorption and generating mold flash complaints.
Limitaciones clave
Total allocated floor footprint could not exceed 2.0 m x 2.0 m, while elevating material 5.5 meters to reach the overhead bagging surge bin.
Delivery
What was delivered, and why it was chosen
The scope below is what this project actually received; the configuration snapshot is the one agreed for this delivery, not a current product sheet.
Por qué esta selección
A Vibrating Spiral Elevator was selected over pneumatic cooling dilute-phase systems or long water flumes because it combines 5.5-meter vertical elevation with 120 seconds of gentle, non-degrading air cooling within a Ø1.4 m footprint, consuming 75% less electrical power than pneumatic conveying blowers.
Personalización específica del proyecto
Equipped with dual counter-rotating vibratory motors with adjustable eccentric weights and heavy-duty polyurethane elastomeric isolators, achieving 97.5% vibration absorption to prevent dynamic resonance transmission to the mezzanine structure.
Alcance entregado
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Equipment Vibrating Spiral Elevator Cooling Tower VSE-1455: Tower diameter 1,400 mm, lift height 5.5 m, SUS304 spiral flighting, dual 3.7 kW vibratory motors, 2,000 kg/h capacity1 set
Lifts pellets vertically while providing 120 seconds of convective air cooling over a 48-meter developed spiral path.
Configured with air-knife plenum covers and reinforced base dampening springs.
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Equipment Linear Vibrating Screen Classifier LVS-1225: Dual-deck linear vibrating screen (4.5 mm top deck, 1.8 mm bottom deck), SUS304 mesh, quick-release clamps1 set
Scalps agglomerates and removes micro-dust fines directly beneath the spiral elevator discharge.
Equipped with dust aspiration hood.
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System Refrigerated Air Dehumidification & Chiller Skid AC-20HP: Closed-loop industrial air chiller supplying 15°C dehumidified cooling air at 4,500 m³/h1 set
Blows high-velocity chilled dry air across spiral flights to accelerate conductive and convective cooling.
Equipped with washable G4 pre-filter and F8 secondary air filter.
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Service Turnkey Demolition, Rigging & Commissioning Service Complete removal of legacy horizontal conveyors, rigging, electrical integration, and thermal imaging sign-off1 service
Full turnkey installation executed in 4 days during plant annual maintenance turnaround.
Included 12-month preventive vibration monitoring checkups.
Verification
How far the project is verified
A stage is written down only when there is evidence for it; a project that is running says so, and a project still in the factory does not claim more.
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Factory Tested
Resonant vibration frequency and amplitude mapped at 1.8 mm stroke; motor phase synchronization verified; all SUS304 spiral welds dye-penetrant tested to ensure zero micro-cracks under cyclic vibratory loading.
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Shipped
Shipped in two open-top transport cradles with vibratory drive motors secured with transport locking brackets.
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Installed
Installed over a 4-day scheduled annual maintenance shutdown. Legacy horizontal cooling conveyor dismantled; new spiral elevator anchored to heavy inertia foundation pad; ductwork connected to chiller skid.
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Commissioned
Commissioned over 48 hours of uninterrupted extrusion of homopolymer PP (MFI 3.0 g/10 min) at 2,050 kg/h throughput. Thermal imaging cameras recorded continuous pellet temperatures along each tier of the 5.5-meter spiral tower, and inline sieving tests confirmed zero blinding on the dedusting screen.
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In Operation Verified
In continuous operation for over 15 months on a 24/7/365 production schedule, handling over 22,000 tons of polyolefin pellets with zero vibration spring fatigue failures or downtime.
Results
What changed, and what backs it
Every result names its evidence. A number without the method and conditions behind it would not be a result worth quoting.
Final Pellet Packaging Core Temperature
66.8 37.5
°C
Final pellet packaging temperature was reduced from 66.8°C down to 37.5°C under continuous 2,050 kg/h throughput, completely eliminating post-packaging pellet fusion and bulk bag caking.
Evidencia Commissioning Record
Pellet Fines & Dust Content (< 1.5 mm)
0.18 0.015
%
Pellet fines and dust content entering bulk packaging dropped from 0.18% to 0.015%, meeting high-end optical film and medical molding virgin resin cleanliness specifications.
Evidencia Factory Test Record
Floor Footprint Occupied by Cooling Equipment
28.5 3.2
m²
Floor footprint occupied by the cooling system shrank from 28.5 m² to 3.2 m², liberating over 25 m² of prime factory floor space for forklift maneuvering and warehousing.
Evidencia Internal Project Record
Evidence
Pictures, videos and records
Only material the customer has cleared for publication is shown here.
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Placeholder · 1200 × 900 px (4:3)（占位图） Replace with an approved photo of the installed section at the plant at this size.（按此尺寸替换为正式图片。） -
Placeholder · 1200 × 900 px (4:3)（占位图） Replace with an approved photo from the factory test or the installation at this size.（按此尺寸替换为正式图片。）
Details
Further details
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