The production line based on the VORTEXPROM CMD5 installation and a pre-mixing capacity of 1.3 m3 (the capacity can be of any volume, according to individual order and agreement with the customer) is designed as a turnkey solution for an enterprise with a production capacity of up to 120,000 liters/month when the enterprise works one shift of 8 hours 20 shifts per month and up to 360,000 liters/month when the company operates in three shifts.
One employee is required to work on the line (we are talking about working in one shift), but based on the experience of our clients, it is more convenient and practical when two people work. One employee is more busy with the production process, the second is engaged in analysis in the laboratory. Both employees can substitute for each other if necessary.
1. Stainless steel pre-mixing tank V=1,3 м3:
- possibility of heating up to 150 degrees Celsius;
- welded jacket;
- three pillars;
- thermal insulation of 100 mm;
- mortgage platform;
- a specialized block of 20 kW/hour stainless steel heaters for heating the coolant (oil);
- load cells sensors;
- gear motor;
- agitator with cones;
- thermal resistance;
- shut-off valves;
- security group;
- flight of stairs;
2. Remote control:
- power shield;
- weighing terminal;
- temperature controller;
- LED fittings, buttons, switches;
- frequency converters for pumps and mixing device;
- automation block for automatic dosing of components.;
- automation block for controlling the mixing time through the reactor of the VORTEXPROM CMD5 installation;
- automatic control block for pneumatic valves (optional);
3. Gear oil pumps - 5 pcs.:
- collectors;
- racks, mortgages;
- shut-off valves;
- intakes;
- security group;
4. Installing VORTEXPROM CMD5:
- reactor of the VORTEXPROM CMD5 installation;
- VORTEXPROM CMD5 reactor control/cooling unit;
- replaceable cartridge for the VORTEXPROM CMD5 reactor;
5. Final product filtration system:
- filter rack;
- filters assembled with filter elements;
- collector;
- shut-off valves;
6. Low-profile weighing platform for packing into barrels and eurocubes of the final product, 2000 kg NIP, 0.5 kg measurement discretion, dimensions 1200 x 1200 mm.
- The maximum consumption of the line can reach 39 kW/hour
- Average line consumption of 14 kW/hour
- The minimum loading of the produced batch is 200 liters (with the volume of the pre-mixing tank of 1,3 m3)
- Average production cycle time with a minimum load of 25 minutes
- The maximum load of the produced batch is 1000 liters (with the volume of the pre-mixing tank 1,3m3)
- Average production cycle time with a maximum load of 75 minutes
- AC power supply
- AC frequency 50-60 Hz
- Voltage: 380+- 20 V
- The required area for line placement is 25 m2
- Recommended total production area of 300 m2 (including the storage park of base oils, storage of additives, bottling and storage of finished products)
- The main advantage is the reduction of the production cycle time by at least 4 times, and at most by 10 times in comparison with the classic blending of lubricating oils. The consequence of this is that on a relatively small production area in comparison with classical blending, it is possible to produce sufficiently large volumes of finished products. It is also possible to produce six different types of oils in one working shift of eight hours, if compared with the classic blending, then this would require six containers with heating and strapping;
- The second advantage is the energy efficiency and environmental friendliness of the mixing process. Let's compare it with classic blending, in which it is necessary to maintain the temperature for mixing the components from 60 to 80 degrees Celsius for 6-12 hours. To heat 1 m3 of oil from 15 to 65 degrees C, about 20 kW / hour of electricity is needed and then it is necessary to maintain this temperature for a long time. On average, 40 kW / hour of electricity is consumed per 1 m3 of finished product (when heated by electric heating elements). Blending companies are trying to save energy resources, and they have to heat the tanks with gas or steam, but this is not always possible, and the savings are about 30-60%. When streaming "cold" blending, it is necessary to heat the mixed composition to the minimum input temperature of the components, which is indicated by the manufacturer of these components. Most often, this temperature does not exceed 40 degrees Celsius. To heat 1 m3 of oil from 15 to 40 degrees C, about 9 kW /hour of electricity is needed. Next, it is necessary to pass the entire composition through the working area of the reactor of the VORTEXPROM CMD5 installation on a closed cycle. If we take the minimum capacity of 5 m3/hour and the average consumption of the installation is 7 kW/hour, then we will spend no more than 1.5 kW/hour of electricity per 1 m3 of the mixed composition. The energy savings are at least 75% if the heating was carried out by electric heating elements; - The line is easy to operate and does not require highly qualified working personnel, care and accuracy are more necessary than complex technical manipulations. On-line staff training usually lasts no more than one day; - The low cost of equipment in comparison with its usefulness at the enterprise will pleasantly surprise business owners. After all, the company will have an advantage only from saving on energy resources; - Support at all stages of the opening of the direction for the production of lubricating oils. Consultations and assistance in the selection of premises, staff selection and so on. Together with the equipment, we transfer our knowledge base of lubricating oil formulations and component suppliers. If necessary, we can develop exclusive products of any complexity. We draw up documentation and help to register your technical conditions or organization standards. We train your employees to perform basic tests on laboratory equipment.VORTEXPROM in social networks:
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