Carter Day Petrochemical Products Brochure

SPINAWAY DRYER SYSTEMSAUDU 2800 3200 3400 4000DRYERS12 Series 32 Series 50 SeriesSCALPERATORWORLDWIDE CARTER DAY INTERNATIONAL500 73rd Ave. N.E. Minneapolis, Minnesota 55432carterday.com Tel: (763) 571-1000 Fax: (763) 571-3012AG99-4/2013CARTER DAY AUDU & 12/32/50 DRYER DIMENSIONSAUDU 3200/3400/4000 AUDU 2800/200A50 SERIES DRYERS32 SERIES DRYERS CARTER DAY PLASTIC EPS Beads EPS Beads Technical Grade / Cup Block and Shape Grade SIZE Microns 250 to 500 600 to 1,200SLURRY TEMP 40 C or higher 40 C or higher Slurry Ratio 40 / 60 - 50 / 50 - 60 /40 40 / 60 - 50 / 50 - 60 /40 BEAD TEMP 40 C or higher 40 C or higher AMBIENT TEMP 0 to 30 C 0 to 30 CINCOMING AIR TEMP/DEW point 0 to 30 C 0 to 30 C Heated air required No heat needed No heat neededADDITIVES TCP less than 1% TCP less than 1%SCREEN SIZE 127 micron nominal 250 micron nominal FINES less than 1% less than 1% OUTGOING MOISTURE 0.1% or less 0.1% or less AGGLOMERATES Less than 0.5 % per hour Less than 0.5 % per hour AGGLOMERATE SIZE None over 13 mm allowed None over 13 mm allowed Motor kW Speed 50hz/60hz Exhaust Air Capacity by Model Capacity by ModelMODEL m3/Static mm (CFM / Inches AG SP) Bead Rate - kg/hr. Bead Rate - kg/hr.D 532 15KW 1000 / 1200 6500 / 75 (3800 / 3) 2,500 3,000 D 550 22KW 1500 / 1800 10100 / 75 (6000 /3) 3,600 4,250 D 650 30KW 1500 / 1800 12100 / 75 (7200 / 3) 4,400 5,000 D 850 30KW 1500 / 1800 16200 / 75 (9600 / 3) 5,900 6,500 D 1050 37KW 1500 / 1800 20300 / 75 (12000 / 3) 7,400 8,000 CARTER DAY DRYER CAPACITIESCARTER DAY INTERNATIONALCARTER DAY PRINCIPLES OF THE DRYING SYSTEMCARTER DAY SCALPERATOR STREAMERS AND FINES REMOVALCARTER DAY INTERNATIONALThe Stainless Steel Scalperator features scalping and aspirationin a single machine which provides a high capacity method forremoving streamers, agglomerates, and fines in a single pass,surpassing the capabilites of traditional Elutriators . Incoming pellets pass through a rotating perforated scalping reeleliminating streamers and other oversized material. The highvolume aspiration then removes fines from the pellet stream.A molded urethane feed roll accurately controls theprocess feed rate and provides a positive shut-off. Theurethane feed roll has high wear resistance and itssmooth surface resists build-up of product and contam-ination. The agglomerate plate ensures high capacity scalp-ing performance and minimizes agglomerates andother particulate buildup behind the scalping reel.Performance-engineered aspiration chamber andflow-modulated air lock valve provides high efficiencycleaning of the product.DRYER WATER DISCHARGEAGGLOMERATEANDDEWATERING 4000AIR INLETCarter Day has been manufacturing quality processing equipmentfor over 100 years. We continue this tradition with our line of Stainless SteelDewatering, Drying and ?Cleaning Equipment for the Plastics Industry. TheSpinAway Dryer separates pelletized products from water slurries in a contin-uous operation. Products can be discharged from the SpinAway dry enoughto go directly to packaging or storage with surface moisture as low as 0.05%. The Pellet Drying Process takes place in four stages.(1) Agglomerate Removal prevents agglomerates greater than 1/2" (12.7mm) from entering the SpinAway dryer and damaging the rotor blades andscreens. (2) Dewatering removes 85 % to 95% of the water which reducesdryer load and increases rates. (3) SpinAway Dryer removes remainingwater from pellets or recycled plastics. (4) Forced air removes surface moisture as dry air counter-flowsthrough the pellets as they pass through the top half of the dryerNo other manufacturer matches the Carter Day SPINAWAY Drying System for superior agglomerateremoval, dewatering and drying of pellets, such as: LDPE, LLDPE, HDPE, PP,NYLON, EPS and RECYCLE.SLURRY INLETDEWATER WATER DISCHARGEPELLET DISCHARGE1050DRYERAIROUTLETRotating Scalping Reel is constructed of a stainless steel perforat-ed screen roound hole screen. The perforated screen design elimi-nates blinding of the scalping reel.The HTD Drive provides increased reliability and decreased down-time with minimal adjustment and maintenance. Simplified design provides for easy clean out and routine mainte-nance. Windows allow the operator to monitor cleaning perfor-mance.Pellet Size/Pellet/Reel Perforation 24x28/CFM 24x56/CFM 24x84/CFM 24x112/CFM3x4.5 mm (PP, HDPE,LDPE) With Slip, 1/2 R 20/2500 40/5000 60/7500 80/100003x4.5 mm (PP, HDPE,LDPE) No Slip,1/2 R 17/2500 34/5000 51/7500 68/100003.2x3 mm (PP, HDPE,LDPE) Slip,1/2 R 25/2500 50/5000 75/7500 100/10000Capacity Notes: CFM based on 6” of Static Pressure, 0% Moisuture Levels, Incoming / Outgoing Fines,Agglomerates and Streamer TBD, Additives TBD. Slip and Non Slip Pellets Defined Above.The first step in the SPINAWAY drying system is theCarter Day AUDU Dewatering System which com-bines the unequalled agglomerate removal and origi-nators of vertical dewatering capabilities. The AUDUis the industry-leading agglomerate and dewateringmachine with capacities matched for our 32 and 50Series dryers. Start-up conditions within extruders and pellet cutterscan produce agglomerate chunks of pellets which, ifgreater than 1/2 inch (12.7 mm), may cause damageto internal dryer screens and rotor. The extra wideagglomerate grid offers more surface area for difficultproducts. For the second step after agglomerateremoval the slurry flows through a highly efficient ver-tical dewatering tower before going to the dryer. Thisdesign has no moving parts therefore greatly simplify-ing maintenance and operation. CARTER DAY INTERNATIONALCARTER DAY INTERNATIONALCARTER DAYPRINCIPLES OF AUDU DEWATERING3200 3400 4000CARTER DAY MICRO DRYERThe MICRO 2001 Dryer presents a unique concept in the art of drying compounded plastic pel-lets. The main design advantages for compound processing are the ability to tilt the dryerhousing back to facilitate the cleaning of the rotor and screen cartridge between productionruns and elimination of the lower bearing and seals to reduce maintenance.The Carter Day Micro 2001 Dryer is designed to accommodate underwater, water ring andstrand pelletizing systems, with a capacity range of 50 to 2,000 lbs/hr (20 to 900 kg/hr) andwater rates up to 80 GPM (18m3/hr).MICRO 2001 PRODUCT FLOW DESIGNThe product slurry enters the dryer at the bottom of the rotor. Theslurry is pulled into the rotor and then radially discharged into thescreen cartridge. Most of the water is removed at initial contact tothe screen. The product is then lifted inside the cartridge and againoutward to the screen. This radial processing continues the fulllength of the cartridge until the product is finally discharged at the topof the dryer substantially free ofmoisture. All of this happens inabout 10 or 12 seconds from inletto outlet.MICRO 2001 DRIVE SYSTEMThe simple drive system requires minimal maintenance. A C-faceddrive motor is quill-coupled directly to the rotor shaft which elimi-nates belts and couplings. The motor can be detached by remov-ing the four mounting screws.MICRO 2001 SCREEN CARTRIDGEThe screen cartridge consists of a perforated screenrolled and welded to form a cylinder. This cartridge design hasseveral advantages over "wrap-around" screen technology:Removal and replacement is very simple since conven-tional latch mechanisms are no longer needed. A simple"twist" of the cartridge retainer releases the screen for easyremoval, cleaning, or replacement.With the absence of latch mechanisms, more screen openarea is available for a given screen size. This means betterdrying performance. The one piece cartridge virtually eliminates the possibili-ty of incorrect screen installations which will eliminate productleakage and screen fatigue.PELLET AND SLURRY FLOWOVER THE AGGLOMERATE GRIDDEWATERING CONEDOOR ACCESS VERTICAL DEWATERINGAgglomerate Remover andPellet DewateringWashdownPortDry PelletsSlurry EntranceCARTER DAY INTERNATIONALCARTER DAYPRINCIPLES OF DRYING12 SERIESCARTER DAY INTERNATIONALCARTER DAY PRINCIPLES OF AUDU DEWATERING3200 3400 4000The capacity and design of our patented AU/DU agglomerate remover and dewatering unit minimizesthe need for individual AU/DU units. The AU/DU provides you with bottom slurry feed and dischargeconnections minimizing pipe runs. The expanding slurry feed chamber reduces the slurry velocity,delivering it gently onto the large agglomerate removable grid system. This design eliminates thehigh velocity impact onto the screen, the associated jamming of agglomerates and splashing of hot -water. The retained agglomerates flow freely to an unobstructed agglomerate chute. Carter Day has been manufacturing quality processing equipment for over 100 years. We continuethis tradition with our line 12 Series Dryer Equipment for the Plastics Industry. The Stainless SteelSpinAway Dryer separates pelletized products from water slurries in a continuous operation.Products can be discharged from the SpinAway dry enough to go directly to packaging or storagewith surface moisture as low as 0.05%. The 12 Series Dryer is our smaller size dryer with many of the features of our large 32 and 50 SeriesDryer Designs. The 12 Series dryers are capable of Polyolefin pellets drying in the range of 3000 lbsto 16,000 lbs per hour. PATENTED INLET SLURRY DIVIDERPrior attempts to split an inlet slurrystream to ultimately deliver it to two sepa-rate dryers have failed - until now. OurPatented inlet slurry divider offers thisusing one slurry inlet.Reliable performance isassured with proven CarterDay design features of theAU/DU: Reduces grid clogging,reduces splashing, andimproves dewatering efficiency.Low velocity feed from theexpansion column avoidshigh velocity impact andhelps eliminate clogging.Wide agglomerate removalgrid with easy access and nomoving parts for simplifiedmaintenance on our curtaindesign.Photo Eye With Gate agglom-erate discharge for troublefree operation.High Capacity PatentedVertical Screen / ConeDewateringPLASTIC Polyethelene/Polypropolene(PP, HDPE, LDPE & LLDPE)SIZE MM 2.5 x 3mm to 4x4 mmWATER TEMP 60C and abovePELLET TEMP 60C and aboveAMBIENT TEMP 20-45 C INCOMING AIR TEMP/DEW point 20-40 C / 80-95% HumidityADDITIVES NoneADDITIVE Slip & Non SlipMELT INDEX 4 to 10SCREEN SIZE .077 RoundFINES > 0.5% per hr.OUTGOING MOISTURE NAAGGLOMERATES Less than 0.02% per hrAGGLOMERATE SIZE 13 mm or lessSTRINGERS Less than 0.01% per hr. AUDU Water Removal 90 to 95%AU/DU CapacityModel Configuration Pellet kg/hr / Water M3/hr2800 3/4" Grid 20,000 / 200 to 300 2800 3/4" Grid 25,000 / 250 to 375 2800 3/4" Grid 45,000 / 450 to 700 3200 3/4" Grid 27,500 / 275 to 450 2800 AX 3/4" Grid 55,000 / 550 to 780 3400 3/4" Grid 44,000 / 440 to 660 3400 3/4" Grid 60,000 / 660 to 780 4000 3/4" Grid 75,000 / 660 to 975 4000 3/4" Grid 100,000 / 720 to 1,300 CARTER DAY AUDU CAPACITIES12 SERIES DRYERSCARTER DAY INTERNATIONALCARTER DAYPRINCIPLES OF DRYING32 AND 50 SERIESCARTER DAY INTERNATIONALCARTER DAY 2800 AU & 2800 DU DEWATERING The third step in high capacity pellet drying is the 32 and 50 Series Spinaway Dryer. For more thanfive decades serving the polyolefin industry. Carter Day’s Centrifugal Dryers have a proven record ofperformance dating from the 1960's. We still service and support dryers built in that era. CarterDay's new 50 Series SPINAWAY Drying System delivers unsurpassed dewatering and drying effi-ciency for pelletized plastics. The D1050 can dry plastics pellets 100,000 kg/hr and beyond.The Carter Day SPINAWAY Drying System protects against product contamination, reduces mainte-nance intervals, and maximizes dryer output. Longer service life, reduced downtime, large panelaccess doors, accessible top and bottom bearing assemblies isolated from hot, moist air streams,and industry exclusive modular housings all contribute to easier servicing and lower expenditures.2800 AGGLOMERATE UNITStart-up conditions within extruders and pellet cutters can produceagglomerated chunks of pellets which, if greater than 1/2 inch (12.7 mm),may cause damage to internal dryer screens and rotor. The extrawide agglomerate grid offers more surface area for difficult prod-ucts such as polypropylene.Carter Day's exclusive DRAW BRIDGE GATE opens automati-cally or on demand to release agglomerate build up. The gate isopen during start-up of underwater pelletizers and closed duringnormal operations to prevent the loss of pellets and water. 2800 DEWATERING UNIT Carter Day Dewatering Units feature impact dewatering to provide higherdewatering rates. The cylindrical screen and baffle design removes 90% to95% of the slurry water prior to entering the SpinAway dryer. With no movingparts they are virtually maintenance-free, leak-free and easy to access forcleaning. The 2800 AUDU and SPINAWAY Dryer is the Carter DayDewatering and Drying System which combines agglomerateremoval, vertical dewatering and Spinaway Dryer. We typi-cally use this AUDU system when rates are between 450GPM to 3000GPM.Just like our AUDU 3000/4000 system we separate pel-letized products from water slurries in a continuous opera-tion. Products can be discharged from the SpinAway Dryerdry enough to go directly to packaging or storage with sur-face moisture as low as 0.05%.All electric devices are pre-wired to local junction boxes, making for quick fieldinstallation and rapid start-up. Our standard brand of electronics and controldevices meet most applications. We do our best to accommodate your brandof electronic devices. Final drying is accomplished by spinning off the mois-ture through the centrifugal action of the vertical rotorlocated in the center of the dryer. The rotor consistsof impeller blades extending from the bottom to thetop of the SPINAWAY Dryer. As the water is removed,pellets are carried to the top by the rotating blades.Our tubular solid rotor design and solid casing(screen) selection allows us to control the counter- current air flow through the pellets with none of itpassing into the rotor (path of least resistance) andbypassing the pellets. This allows for improved pelletdryness. In this example we have provided additionalsolid casings to increase the air contact time. Theproduct is then discharged at the top.CARTER DAY 50 SERIES DRYER FEATURESCARTER DAY INTERNATIONALCARTER DAY FEATURES AND ADVANTAGESCARTER DAY INTERNATIONALComplete laboratory service is at your disposal. Carter Day facili-ty enables us to test your unique product sample in a controlledlaboratory environment to aid in determining the right model foryour application. A free performance verification trial of yourproduct assures that Carter Day’s SPINAWAY dryers are yourbest solution prior to purchase. We invite you to participate intests conducted at our facility in Minneapolis, Minnesota, USA.Carter Day has the ability to ship your dryer viatruck for container loading or export packing any-where in the world.Carter Day uses a special assembly practice on ourD850 and D1050 dryers allowing us to assemble themachines lying down. We then use our internallydesigned lifting carriage to vertically orientate thedryer for testing running prior to shipment.Carter Day works with many engineering housesand extruder manufacturers to provide dewateringand drying systems.CAD rendition courtesy of Simon Carves,LTD., UKAll welded construction of the bot-tom module allowing for excellentvertical support and housing forthe rotor bottom bearing.All welded construction of the topmodule pellet discharge.Screen arrangements and stacking modulesfound in the 50 and 32 series.CARTER DAY DRYER CAPACITIESPLASTIC Polyethelene/Polypropolene(PE, HDPE, LDPE & LLDPE)SIZE MM 2.5 x 3mm to 4x4 mmWATER TEMP 60C and abovePELLET TEMP 60C and aboveAMBIENT TEMP 20-45 C INCOMING AIR TEMP/DEW 20-40 C / 80-95% HumidityADDITIVES NoneADDITIVE Slip & Non SlipMELT INDEX 4 to 10SCREEN SIZE .077 RoundFINES > 0.5% per hr.OUTGOING MOISTURE 0.05%AGGLOMERATES Less than 0.02% per hrAGGLOMERATE SIZE 13 mm or lessSTRINGERS Less than 0.01% per hr. Motor Rpm 50hz/60hz Exhaust Air Capacity by ModelMODEL m3/Static mm (CFM / SP) Pellet (kg/hr) / Water (m3/hr)D 212 1.5kw 1,500 / 1,800rpm 1,300 / 75 (750 / 3) 1,400 / 5 D 312 1.5kw 1,500/1,800rpm 1,900 / 3 (1,100 / 3) 4,00 / 10 D 412 1.5kw 1,500/ 1,800rpm 2,000 / 75 (1,200 / 3) 6,000 / 15 D 512 1.5kw 1,500 / 1,800rpm 2,200 / 75 (1,300 / 3) 7,200 / 20 D 332 7.5kw 1,000 / 1,200rpm 4,900 / 75 (2,800 /3) 13,000 / 25 D432 7.5kW 1,000 / 1,200rpm 6,400 /75 (3,800 / 3) 20,000 / 40 D 532 7.5kW 1,000 / 1,200rpm 8,100 75 (4,800 / 3) 25000 - 30000 /50-63D 550 22 kW 1,500 / 1800rpm 12,700 / 75 (7,500 / 3) 30000 - 43200 /60-75D 650 37 kW 1,500 / 1800rpm 15,300 / 75 (9,000 / 3) 43200 - 52800 /70-88D 850 55 kW 1,500 / 1800rpm 20,000 / 75 (12,000 / 3) 52800 - 75,000 / 95-119D 1050 75 kW 1,500 / 1800rpm 24,700 / 75 (15,000 / 3) 75,000 - 100,000 / 115-144CARTER DAY 12/32/50 SERIES OPTIONSCARTER DAY 32 SERIES MODULAR DIFFERENCESCARTER DAY INTERNATIONALCARTER DAY INTERNATIONALREPLACEABLE ALL WELDED CONSTRUCTIONOF THE PELLET DISCHARGE SCROLL32 SERIES MODULAR DRYER DIFFERENCE:Integrated scraper blades on rotor.Hard-faced rotors include hard-faced scraper blades.Low cost discharge pan is 100% removable / Replaceable.Hoop ring supports have been redesigned to reduce "ledges"where fines can buildup.Spray system utilizes Spiral-Jet nozzles for better screen & inte-rior sidewall coverage with lower water supply requirements. Bottom bearing, top bearing,screens and disruptor bars are all100% interchangeable with existing D32 & D50 dryer productline.Carter Day also offers sound package enclosures to meetyour particular sound reduction needs.Carter Day offers their product in many stainless types suchas 304L or 316L. We also provide special finish grinding ofthe stainless steel if your application requires.We also offer screen spray down systems for certainapplications requiring fines cleaning from the screens.The Carter Day Diverter Valve is used to purge the system during extruderstart ups. The Diverter Valve is typically mounted directly to pellet outlet ofthe dryer and is constructed of stainless steel. The hinged gate is posi-tioned by a pneumatic actuator and may be remotely activated. All electric devices are pre-wired to local junction boxes, making for quickfield installation and rapid start-up. Our standard brand of electronics andcontrol devices meet most area classes and zones. We do our best toaccommodate your brand of electronic devices Carter Days standard is to provide doorlocks or locking systems with each of ourdryers. CARTER DAY SPINAWAY DRYER ROTOR AND SCREEN DESIGNSCARTER DAY 32 AND 50 SERIES DRIVE PACKAGECARTER DAY INTERNATIONALCARTER DAY INTERNATIONALCarter Day’s drive design uses a no-thru shaft design, instead offering replaceable stub shafts forease of maintenance. Bearings and shafts can be replaced with rotor assembled in dryer. The SpinAway Dryer includes a totally enclosed pellet-free rotor with double-welded rotor blades with top and bottom stub shaft. This design adds strength,reduces maintenance and eliminates cross contamination of pellet, while improv-ing counter current air flow. The SpinAway rotor is dynamically balanced andcan be shipped any place in the world and will not require rebalancing at thejob site. For special applications we offer hardfaced rotor blades to meet your needs.Carter Day offers a range of screens including Perforated Screenrecommended for pelletized plastics and recycled plastics, Tri BarScreen recommended for expandable polystyrene beads or smalldiameter pellets, and Laser Burned Screen recommended forexpandable polystyrene beads and micro-sized pellets.The SpinAway Screen ring design allows for proper and secureinstallation of segmented screens.The Patented SpinAway Flow Disrupter Bar System nearly eliminatesplastic pellet banding and motor load surging. The rugged FlowDisrupter Bars randomly distribute the product in the annular areabetween rotor and screen. This allows the maximum amount of thruput. Rugged and absolutely tight screen closure for maximum perfor-mance.The 32/50 Dryer drive system is located on the top of the dryer to enhance service-ability and to protect the belt from water often encountered in the drain area.The drive consists of a motor, HTD belt and driver and driven sheaves. The HTDbelt maintains constant rotor speed at all times. Our Patented thrust bearing design is isolated in a sealed cavity of the bolt on stub shaft assembly. Shouldthe V-ring water seal fail water will be discharged through drain slots without coming in contact with thebearing. This design provides the below operational benefits.• Increased reliability• Bearing and stub shaft can be exchanged with rotor in place• Interchangeable with previous stub shaft designs• Similiar bearing design is used in our 12 Series Dryer