INFRARED DRUM IRDDrying, crystallising and heating in minutesrather than hours

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KREYENBORG GROUP

BEST TECHNOLOGY INSIDE!

The KREYENBORG GROUP is comprised of the

following companies: KREYENBORG GmbH, BKG

Bruckmann & Kreyenborg Granuliertechnik GmbH,

Bruckmann Steuerungstechnik GmbH (BSG) and

KREYENBORG PLANT TECHNOLOGY GmbH & Co. KG

(KPT).

As family owned and operated companies, the

members of the KREYENBORG GROUP have been

recognized for more than 50 years as a byword

symbolizing quality components and machines

for the extrusion and polymerization industries.

Customers around the world know and trust the

equipment and systems of the KREYENBORG

GROUP. This has allowed us to become a global

partner for the plastics industry.

We have realized that providing a complete system

with each of the various components designed to be

compatible as a unit, offers the optimal solution and

ensures an efficient utilization of the equipment. All

of our systems are manufactured in-house; combining

automation technology together with screen changers,

melt pumps, pelletizers and bulk material handling

equipment. All of the components are from a single

source. Therefore, problems with interfacing between

the various components are completely eliminated.

The family run KREYENBORG GROUP has over 300

employees worldwide, all of whom share a common

corporate philosophy – to support our customers in

achieving their goals through continuous improvements

and constant self-monitoring. Quick decision-making,

a focus on long-term business strategy and the close

relationship between the owners and their companies

and employees play a crucial role. Customer satisfaction

is at the centre of our daily routine.

Our engineering can provide the smooth integration of

all components into existing systems while maintaining

a minimum of process interfaces and ensuring the

synergy of the overall project. Due to significant vertical

integration, a high proportion of the components for our

machines are manufactured in-house. Components may

also be custom designed to suit the requirements of

individual customers. The member companies of

the KREYENBORG GROUP support our customers

individually and flexibly.

As a special service we offer customers the opportunity

to perform trials of their materials in our own, modern,

test laboratory. Here it is possible for the customer to

view their own material being processed under real

production conditions using the different equipment

items produced by the KREYENBORG GROUP.

We are focused on the production location remaining

in Germany. Because of this we are able to offer the

advantages of “Made in Germany” to our customers.

For our customers this means:

Reliable and precise manufacturing

Complete, in-house, quality control

A high level of innovation demonstrated by many

patents

Quality certified, “Made in Germany”

Because of our own sales and service branches in China

and the USA; together with our industrial representatives

world-wide; the KREYENBORG GROUP is able to assure

a high level of customer service.

www.kreyenborg-pt.cominfrared technology | mixers | special silos | extruder feeding systems

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www.bkg.deunderwater pelletizing | centrifugal dryers

www.kreyenborg.comfiltration systems | pump technology | polymer valves

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Minimal process timesThe KREYENBORG infrared rotating

drum IRD takes just minutes, instead of

hours, to dry material, offering a great

advantage in comparison to conventional

methods.

High fl exibilityThe short dwell drying, in the completely

continuous infrared rotating drum IRD,

means far less material in the drying cycle

at any one time.

Low energy consumptionIn comparison to conventional dry-air

systems, the infrared rotating drum IRD

operates extraordinarily effi ciently by

direct heat irradiation.

Energy consumption during produc-

tion can be reduced signifi cantly – the

KREYENBORG infrared rotating drum

IRD is the ideal alternative in the face.

BASICS OF INFRAREDTECHNOLOGY

FUNCTION OF THE IRDINFRARED RADIATOR

CONTROLMAINTENANCE

AREAS OF APPLICATIONPLANT DESIGNS

IRD MODELScontinuous

IR-BATCH 70/90discontinuous

QUOTATION FORM

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5

6

7–8

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CONTENTS

KREYENBORG INFRARED DRUM

Certifi ed fi rst class quality according to DIN EN ISO 9001

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In contrast to conventional techniques the heat is

applied directly to the material by short-wave infra-

red radiation. The radiation is not absorbed by the

air, but heats the material directly from inside. A

heat fl ow is generated that carries the evaporating

moisture out of the pellets.

After the moisture is driven out it is carried away

quickly by natural heat convection. Thus circulat ing

air does not need to be heated and dried as with

conventional drying. The direct input of heat makes

the procedure extra – ordinarily energy effi cient and

accelerates the drying of the material enormously.

ADVANTAGESOF INFRARED TECHNOLOGY

Low energy consumption

Minimum residence time

in the drying process

Production can be started shortly

after the start of the system

High level of effi ciency

Gentle material handling

Easy to clean

BASICS OF INFRARED TECHNOLOGYMODES OF OPERATION OF INFRARED RADIATION

IR technology: Heating from inside

130,0

131,0

132,0

133,0

134,0

10:33:00 10:46:20 10:59:40 11:13:00 11:26:20

Energy consumption of an infrared dryer in a PET crystallising process at a temperature of 165 °C – measurement over 60 min.

Radia

tion inte

nsity

10 2 3 4 5

Wave lengths of infrared radiation Wave length [μm]

Halogen

Short wave

Fast medium wave

Carbon

Medium wave

En

erg

y co

nsu

mp

tio

n W

/kg

/h

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DESIGN AND FUNCTIONOF THE CONTINUOUS INFRARED ROTATING DRUM IRD

The most important components of the continuous

infrared rotating drum IRD are the radiator modules

within a horizontal rotating drum, which has an inte-

gral, welded, conveyor screw.

The material to be processed is fed continuously, by

a volumetric metering unit, into the integral screw

of the rotating drum, distributing it evenly through

the dryer. The dwell time depends on the rotational

speed of the drum and is adapted precisely to the

operational parameters.

At the end of the rotating drum the material falls

into the output hopper and can be transferred di-

rectly to the next process step.

RELIABLE RADIATOR MODULE

The radiator modules, built into the infrared rotating

drum, are the result of KREYENBORG’s intensive

development that has led to thermal optimisation.

Coating the air-cooled modules with a special func-

tional ceramic ensures effective shielding against

short-wave infrared radiation.

The radiator module itself is cooled by a continuous

airstream preventing dust particles effecting them

while quickly exhausting moisture from the dried

material.

As a rule the warm, humid air is extracted and di-

scharged from the rotating drum through an ex-

haust pipe.

Air circulation within the machine

Cut-away view of a continuous infrared rotating drum IRD

Thermal image of the infrared module in operation

CONTROL – MAINTENANCE

FULLY AUTOMATIC CONTROL CONCEPT

Our partner BSG (Bruckmann Steuerungstechnik

GmbH), a well-established control system manu-

facturer, has brought state of the art control to the

IRD, based on many years of experience in process

engineering and machine technology.

In addition to exact programming of all values rele-

vant to the process, such as dwell time and radiator

output, numerous further functions are available

such as a metering test and controlled running of

the machine (without material).

LOW MAINTENANCE

Thanks to its robust and reliable construction

the infrared rotating drum IRD needs minimal

maintenance.

Regular tasks involve just the replacement of the

infrared radiators.

All components of the machine are easily acces sible

through large doors and the separately extract able

radiator unit, which makes it possible to carry out all

necessary maintenance and cleaning tasks quickly.

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Process data, such as material and exhaust tempe-

ratures or fill levels, are continuously monitored by

sensors and pyrometers. In case there are devia-

tions, automatic regulation takes place so that opti-

mal process conditions are maintained at all times.

Stored recipes make it possible to always quickly

fall back on past tried proven settings. Elaborate

adjustments, downtime following a material or pro-

cess change, can there fore be avoided.

Intuitive and comprehensible: Touch-screen control of the IRD Quick access: Up to ten recipes with all necessary process

parameters

APPLICATION

FIELDS OF THE IRD

Drying of plastic pellets (e.g. ABS/PC, PC,

LCP, wood-PP compounds)

Crystallisation and drying of PET, PPS,PLA

(reclaim/pellets)

Drying processes with high initial

moistures > 1 %

Heating of pellets and reclaim before

further processing (e.g. PVC, PE)

for example to increase the extruder

throughput

Heating processes for removing residual

oligomeres and volatile components

Drying in the food, feed and

pharmaceutical industries

AREAS OF APPLICATIONWARMING – CRYSTALLISING – DRYING

KREYENBORG infrared rotating drums IRD are em-

ployed in varied applications – conceivable fi elds of

application are virtually unlimited and can be found

both in the plastics and other industries.

Infrared technology is suitable for drying tasks for

any free-fl owing granule, fl ake or granular powder.

The infrared concept does not need a supply of

dry air and is therefore particularly suited to applica-

tions with high initial moisture.

SPECIAL ADVANTAGES WITH PET AND PLA REGRIND

The classic applications for the infrared rota-

ting drum are crystallisation and drying plants for

PET pellets and regrind. Granulated foil stock

from thermo-forming, and post-consumer bottle

reclaim is processed at throughput rates from

150 kg/hr–1500 kg/hr. As an alternative the fl akes

can be mixed with virgin granules – separation does

not take place in the rotating drum.

A signifi cant potential for IRD technology is the

drying of PLA, for virgin, granulated or mixed feed-

stocks.

The continual movement of the material in the

infrared rotating drum is ideal for, particularly,

PLA granulated stock, which tends to easily stick

together in the crystallisation phase at T = 60 °C.

HEATING PROCESSES

In addition to drying, pure heating processes are

also ideal applications, as pellets can be heated, in

the rotating drum (while being agitated), to close

to the melt temperature without agglomerates for-

ming.Infrared rotating drums are also employed in

processes in which volatile components or residual

oligomeres need to be extracted from the product.

Another heating application is the heating of shear

sensitive materials before plasticising in the extru-

der, (especially in cold climates).

ALWAYS ON THE GO

The rotation of the drum constantly mixes the

material being conveyed in the screw. Mixing ele-

ments, in the individual spiral segments, aid optimal

mixing, so uneven radiation and material agglome-

rates can be ruled out.

Moreover, as the drum rotates at a slow speed of

1–5 rpm, the material is not aerated. 7

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PLANT DESIGNSVARIOUS MACHINE VARIANTS

The KREYENBORG infrared rotating drum IRD is of-

fered in three basic models, whose construction is

determined by the throughput required.

INCORPORATION INTO COMPLEX PLANTS

As a rule the infrared rotating drum IRD can be seen

as an individual component in a complete system.

Based on its many years of experience in plant en-

gineering though, KREYENBORG also offers indivi-

dual total solutions that incorporate infrared tech-

nology.

KREYENBORG offers project planning, construc-

tion and ongoing support.

IN COMBINATION

WITH THE IRD, KREYENBORG OFFERS, FOR EXAMPLE, THE FOLLOWING PERIPHERAL SYSTEMS:

Additional dry-air dryers for residual

moisture below 50 ppm

Systems for throughput regulation of the

dryer

Feeding and conveying equipment

Outfeed and buffer containers (also

insulated)

Big-Bag stations

Working platforms

Based on these three basic types the required radi-

ator output is adapted individually and according to

customer specifi cations to the product to be dried.

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INFRARED ROTATING DRUM IRD

TYPES 160/360 (ø 1600 mm/3600 mm)

180/450 (ø 1800 mm/4500 mm)

180/540 (ø 1800 mm/5400 mm)

200/540 (ø 2000 mm/5400 mm)

THROUGHPUT approx. 500–5000 kg/h

RADIATOR OUTPUT max. 540 kW

APPLICATIONS Drying/crystallising of pellets and reclaim in the high throughput range

Drying of bulk goods with low bulk density and high initial moistures

Infrared rotating drum IRD – type C

IRD C

TYPES 120/180 (ø 1200 mm/1800 mm)

140/270 (ø 1400 mm/2700 mm)

180/270 (ø 1800 mm/2700 mm)

THROUGHPUT approx. 70–1200 kg/hr

RADIATOR OUTPUT ca. 18–135 kW

APPLICATIONS Drying/crystallising of pellets and reclaim in the medium throughput range

Infrared rotating drum IRD – type B

IRD B

TYPES 50/90 (ø 500 mm/900 mm)

THROUGHPUT approx. 20–150 kg/hr

RADIATOR OUTPUT 9–15 kW

APPLICATIONS Laboratory dryer for frequent product change

Crystalliser for small quantities up to 100 kg/hr

Infrared rotating drum IRD – type A

IRD A

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HEATING, CRYSTAL LI-ZA TION, DRYING:

APPLICATION FIELDS FOR THE BATCH DRUM IR-BATCH 70/90

drying of plastic pellets

(z.B. ABS/PC, PC, LCP,

wood-PP-compounds)

crystallization and drying of PET, PPS,

PLA (ground stock/pellets)

drying processes with high input

humidities > 1 %

heating of pellets and ground stock

before the subsequent processing

(e.g. PVC, PE) among others for

throughput increase in the extrusion

heating processes for the discharge of

rest oligomers and volatile contents

drying tasks in the foodstuff

and pharmaceutical field

roasting of coffee beans

INFRARED DRUM IR-BATCH 70/90 FOR BATCH APPLICATIONS

The development of a discontinuous version pre-

sents new possibilities. The KREYENBORG batch

drum IR-BATCH 70/90 is the ideal solution for the

thermal treatment of single batches.

The fi lling and discharging of the machine is effect-

ed fully automatically. The real process may be

controlled by a defi ned residence time or a specifi c

required temperature of the material.

1. 2. 3.

1. CHARGING OF THE DRUMThe complete charge (batch) is continuously fi lled

into the drum via a feed hopper.

The input is controlled by a stop valve.

2. THERMAL TREATMENTThe drum rotates with preset speed clockwise. With

this direction of rotation the material overfl ows the

main baffl e mixing elements. An additional mixing

may be achieved by means of further pyramidal

mix ing elements.

The infrared radiators are switched on and heat the

material to the preset temperature. If required, tem-

perature ramps with drying profi les may be adjust-

ed (option control system).

3. DISCHARGE OF THE DRUMThe thermal treatment is completed after a de fi ned

period or after the reaching of a specifi ed required

temperature. For discharge the direction of rotation

of the drum is reversed. Thus the material under-

fl ows the main baffl e mixing elements and is fed

into the outlet funnel.

FUNCTIONALITY OF THE BATCH DRUM IR-BATCH 70/90

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NOTES

4. Drying Process Crystallisation Heating Process

Input moisture % – –

Output moisture % – –

Input temperature °C °C °C

Output temperature °C °C °C

other

2. GRAIN AND RATES

Film flakes weight % bulk density

Ground stock weight % bulk density

Pellets weight % bulk density

Powder weight % bulk density

others weight % bulk density

CONTACT

Company name Contact person

Address

Phone Mobile

Fax email

FURTHER INFORMATION (e.g. Operation, Process ...)

1. INPUT PRODUCT/-S

a)

b)

c)

3. THROUGHPUT

Throughput performance kg/h

KREYENBORG PLANT TECHNOLOGY GmbH & Co. KGBUSINESS UNIT INFRARED TECHNOLOGY AND PLANT ENGINEERING

FAX +49 (0) 25 97 / 9 39 97-60

CONTINUOUS PROCESS DISCONTINUOUS PROCESS

KREYENBORGPLANT TECHNOLOGY GmbH & Co. KGMessingweg 1848308 Senden GermanyPhone: +49 [0] 25 97/9 39 97-0Fax +49 [0] 25 97/9 39 97-60info@kreyenborg-pt.comwww.kreyenborg-pt.com

KREYENBORGPLANT TECHNOLOGY GmbH & Co. KGMessingweg 1848308 Senden GermanyPhone: +49 [0] 25 97/9 39 97-0Fax: +49 [0] 25 97/9 39 97-60info@kreyenborg-pt.comwww.kreyenborg-pt.com

Representative:

11

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www.kreyenborg-group.com

info@kreyenborg-group.com

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