High Pressure Equipment Socrates Intensive Course Budapest Professor Dr.-Ing. E. Schlücker Lehrstuhl Prozessmaschinen und Anlagentechnik Cauerstraße 4

PAT

High Pressure Equipment

Socrates Intensive Course Budapest

Professor Dr.-Ing. E. SchlückerLehrstuhl Prozessmaschinen und

AnlagentechnikCauerstraße 4

Universität Erlangen-Nürnberg

PAT

From High Blood Pressure to Diamonds

A Survey about HP applications

130 - 80 Torr (0,17 - 0,1 bar)

350 000 bar

Professor Dr.-Ing. E. SchlückerLehrstuhl Prozessmaschinen und

AnlagentechnikCauerstraße 4

Universität Erlangen-Nürnberg

3

PAT

Hocdrucktechnik 18.04.23

What is High Pressure... A question of the point of view ... !

High Blood Pressure is only harmful if it acts to long. Short HBP-Episodes are mostly quite healthy.

Exercises! But long lasting HBP lead to heart diseases =

system gets overloaded.

The Meaning of High Pressure therefore is directly related to the system!

Flow

p

Pump and system damage

Pressure loss increases

Pump has to work harder

4

PAT


11000 t on 5 cm²

2 200 000 bar

What is Pressure?

Which pressure is acting when two

elephants are standing on a 10 cent coin ? Which pressure is acting when the

Eifelturm stand upside down m.

4000 bar on a 10 cent coin!

On top of the highest mountain: 0,25 bar,

at the deepest point of the ocean 1000 bar

5

PAT


History of High Pressure Technology?

Ktesebios – first double piston pump (Archimedes times) Romans: Pumps for water supplyment Agricola: wooden high pressure pump James Watt 1785: Steam engine Middle ages: Gun barrels Haber Bosch 1918 Nobel Prize Since mid of 20th century

>120000 bar for Diamond

production

6

PAT


The Path to the High Pressure Summit

Mount Everest 8848m

The higher, the more important is the equipment

868 bar

Maximal Pressure

0 bar

7

PAT


Extraction und Micronisation

Extraction

Maximal Pressure Arome‘s Frangrances

Decaffeination

Up to 700 bar

Micronisation changes liquid into powder

at

300 – 800 bar

Micronisation

8

PAT


ExtractionExtraktionsprozesse

Z.B. star-anis at about 200 bar

Maximum:

Saw teeth palm seed oil at 700 bar

Functional Food !!

9

PAT


ExtractionExtraction processes

Product basket of a

Extraction plant.

10

PAT


MicronisationFrom Liquid to powder

Advantages when used!

Rum-Arome as a powder?

Adhesives (glue) as a powder?

Weidner et. al.

11

PAT


Micronisation

22% curcuma on corn starch

59% Strawberry flavor on silicic

acid

79% celery extract on silicic acid

Weidner et. al.

12

PAT


High Pressure TechnologyBasic rules for high pressure applications

Optimum Low number of bores, steps in cross section area , notches

and steps in the pressure chamber ! Small pressure loaded areas ! Small number of sealings ! Small enclosed volume ! Smooth surface

? !

p p? !

13

PAT


High Pressure TechnologyHigh pressure machines

Bionic application of the „heart“ At high pressure only efficient machines Small pressure loaded surfaces Smooth surfaces No cross section area steps and notches

FLUIDR

Öl VL

Schritt 2

VS

000991 0106b

Diaphragm pumps up to 3000 bar

D

FLUID

R

Schritt 1

VL

VS

000991 0106a

Plunger pumps up to 20 000 bar

14

PAT


Liposom-Manufacturing , Homogenisation

Extraction

Maximal Pressure

Micronisation Liposoms

For your health

Food treatment

800 – 1500 bar

15

PAT


Liposom-MnaufacturingSmallest particles due dispergation

Liposomold greek

Lipos = grease

Soma = body

grease body

Nach Mayhew, et. al., 1985

1200

800

600

400

200

0

nm

0 200 400 600 800bar

Differenzdruck

mitt

lere

Par

tikel

größ

e

001226 0111 Pressure Difference

Mea

n pa

rtic

le s

ize

16

PAT


Heat exchanger

Product

Interaction

chamber

filter

pump

Back flow

Product feed

Liposomen-HerstellungSmallest particles due dispergation

Process

17

PAT


Homogenisation of MilkPhysical stability

Shear forces cut drops into

pieces (dispergation)

Test

UHTProd.feed

HEHEHEHEUHTHOMO Vent.

H (septic) V.

H (aseptic)

FV.

001200e 0111

UHTProd.feed

HEHEHEHEUHTHOMO Vent.

H (septic) V.

H (aseptic)

FV.

001200e 0111

UHTProd.

feed

HEHE

HE

HE

UHTHOMO Vent.

H (septic)V.

H (aseptic)

FV.

001200e 0111

Nach Mayhew, et. al., 1985

1200

800

600

400

200

0

nm

0 200 400 600 800bar

Differenzdruck

mitt

lere

Par

tikel

größ

e

001226 0111

18

PAT


Methanol-Injection

Maximal Pressure

ExtractionMicronisation LiposomsMethanolinjection

Against Icing of the injection nozzle at 700

up to 1200 bar

19

PAT


Methanol-InjectionOil-/natural gas conveying

From the oil platform to the drilling location i.e. oil platform Gyrfalcon: Oil from a depth of 3000 m Crude oil as a emulsion of oil and water, hydro carbons and

sand At the discharge the mixture expands from 830 to 730 bar Result: hard cooling at a environmental temperature of 4 °C Danger of icing !!! measure: injection of methanol ! Pump for 1000 bar at 400 l/h

20

PAT


Methanol-InjectionMethanol Pumps

Diaphragm pumps required – lubrication problems! As small as possible – 1 m2 oil platform für 125 000 €URO ! Classical diaphragm techology to big an not save enough Goal: Plastic diaphragms

001224 0111

21

PAT


Methanol-InjectionSimulation of the stress situation

FEM-net of a diaphragm pump head

22

PAT


Methanol-InjektionCalcuation results

Pressure

loaded surface

23

PAT


Methanol-Injektion

F F

24

PAT


Water Jet cutting, Jet Cleaning, Hydroform.

Maximaler Druck

ExtraktionMikronisation LiposomenMethanolinjektion

Water jet cutting

Clean cut beginning at

1500 – 4000 bar

Jet cleaning at 2500 bar

Hydroforming at 1000 – 4000 bar

25

PAT


Water Jet cutting, Jet Cleaning, HydroformA great variety of applications

Metall, Stone, Paper, Cake ... Extreme shapes possible No thermal influence

example: steel platen 30 mm, clean cut with 10 mm/min

Stainless Steel

Working Pressure400 / 600 / 800 MPaOrifice0.1 mmFocus0.6 mm / L=50 mmCutting Speed100 mm/min

0

5

10

15

0

5

10

15

mmmm

0

5

10

15

20

25

mm

0

5

10

15

20

25

30

35

mm

0

5

mm

0

5

10

mm

0

5

10

15

mm

View CAluminium

26

PAT


Water Jet cutting, Jet Cleaning, HydroformNozzle technique

Water jet is able to wash out steel Jet wear

Additional particles = a liquid saw Main problem: wear

Goal: Avoiding of high wear by increasing pressure up to 4000 bar and more, leaving out particles

27

PAT


Water Jet cutting, Jet Cleaning, HydroformHydroforming process for metal deformation

- 4000 bar Special tube based

shapes Large curved parts

3

1

4 4

2

2

4

3

4

A

B

001219 0111

With such a pressure: doing a correct design is not enough!

28

PAT


Water Jet cutting, Jet Cleaning, HydroformAutofrettage for increase of the ability for loading

Plastical deformation of the materialp Volumenänderung

p

r

Stresssituation

r

p

t

t

ErhöhteStresssituation

p

t

t

r

p

unbelastet

druckbelastet

t

unloaded

under pressure

29

PAT


High pressure polymerisation of Polyethylen

Extraction

Maximal pressure

Micronisation LiposomsMethanol-injection

Water jet cuttingPE-Polymerisation

High value plastics

at about

3000 bar

30

PAT


High pressure polymerisation of PolyethylenLD-Polyethylen (branched molekule structure)

System A: storage B, C: Compressors D: Stirred Vessel

Reactor F: H-Exchange G: Separation H: H-Exchange J: Separation K: Gas Recycling

Modifier Comonomerem

Äthylen

PeroxidProdukt (PE)

300 bar

250

0 b

ar

a

c

d

e

f

g

h

i

j

k

l

b 2500 bar

001197e 0111

31

PAT


High pressure polymerisation of PolyethylenLD-Polyethylen (branched molekule structure)

Reaction:

Reaction in tube reaktor: up to 3500 m long, pieces 10 m long. Reciprocating positve displacement pump Resistant materials

CH2 + CH2 + .... = CnH2n+2

plus additional chemicals! D

FLUID

R

Schritt 1

VL

VS

000991 0106a

32

PAT


High pressure polymerisation of PolyethylenOptimal Materials

Fatigue testing with pulsating internal pressure

1000

800

600

400

200

0

Ver

glei

chss

pann

ung

v

106105 107 108

N / mm2

N

Lastwechselzahl

Spindelöl

Salpetersäure Automatic Autofrettage !!

!!

0 10 20 30 40%

Dehnung

0

200

400

600

800

1000

N / mm2

Spa

nnun

g

1.4462

001222 0111

1.4462

RP 0,2

Rm

Notch factor ca. 2,8

Spindloil

Nitric acid

Load cyclesstrain

Van

Mis

es S

tres

s

33

PAT


High pressure sterilisation

Extraction

Maximal Pressure

Micronisation LiposomsMethanol-Injektion

WasserstrahlschneidenPE-Polymerisation Water Jet CuttingPE-Polymerisation

HP-Sterilisation

Alternative to hot sterilisation ?

Up to 8000 bar

34

PAT


High pressure sterilisationCreatures under high pressure

35

PAT


High pressure sterilisationcareful alternative to hot sterilisation

1914: Nobel price winner Bridgeman – egg white coagulates at 7000 bar similar to > 50°C

At 5000 – 6000 bar lethality of all life forms

At pressure > 6000 bar it is possible to sterilize

Advantage: - Vitamins and proteins don‘t get destroyed- Aroma stays - Allergens are not added

Disadvantage: - high technical effort, long pressure load time- 2 - 3 more expensive than hot sterlized products

36

PAT


High pressure sterilisationAlternative to hot sterilisation

High product safety

Problem: ecconomic !

Food varmints

Kill at 8000 bar

55 KJ/Kg

125,4 KJ/Kg from 20 up to 50°C (water)

Especially sucessful in Japan

Here Autofrettage sometimes is not enough!

37

PAT


D+X

High pressure sterilisationShrinking

Shrinking generates at the inside of a cylinder compression stress

D

unbelastet

druckbelastet

t

unloaded

under pressure

38

PAT



Flüssiges Lebensmittel

K. Hori et al., Mitsubishi Heavy Ind., Hiroshima 1992

1

23

45

Trinkwasser1

Niederdruckpumpe2

Hochdruckpumpe (4000 bar)3

Kolben4

Hochdruckbehälter5

(Fruchtsaft)

150598_3.dsfPlant – quasi continual

39

PAT



Sucessful applications for a lot of food Increase of the stability from 4 days up to 4 weeks

careful alternative to hot sterilsation

40

PAT


High Pressure Cristallisation

Extraction

Maximum Pressure


Water Jet CuttingPE-Polymerisation

High Pressure Cristallisation High Pressure Steril.

Galliumnitrit-crystals

in highest quality up to

15000 bar

Autofrettage up to 13000 bar

41

PAT


High Pressure CristallisationWhy?

Optimal Pressure (> 10 kbar) - reactands homogen in stoichiometric ratio

Pressure gerates optimal growing conditions Growing velocitiy is increasing

with pressure

15000 bar

1500 °C

N2

GaN2

Ga

42

PAT


High Pressure CristallisationHigh Pressure – to high for common steel

Hard metal segments as stress reducer (pressure transformer) Seal made out of metal – self sealing principle

Stahl

Weich-Metall

Kunststoff

O-Ring

Kunststoff

Weich-Metall

Stahl

Anti-Rutsch-Ring

Weichmetall oderKunststoff

Anti-Rutsch-Ring

Stahl

a)

b)

alternativ

pR1

R2

1

2

=

R2

R1

p

R3

1

2

R4

43

PAT


Diamond-Manufacturing

Extraction

Artificial Diamonds with

more than

100 000 bar


WasserstrahlschneidenPE-Polymerisation

Maximum Pressure Diamond Manufacturing

Water Jet CuttingPE-Polymerisation

High Pressure Kristallisation High Pressure Steril.

44

PAT


Diamond-ManufacturingTools / Process

No Fluid! Compression of powder

Tetrahedral Press

bis 120 000 bar!

Opposed Anvil Apparatus

bis 350 000 bar!

GraphiteNickel

Maximum Size:

1 Carat

(0,2 Gramm)

45

PAT


Cheers - We reached the Maximum!

Welcome to the Pressure Summit!

46

PAT


Maximum Pressure

Minimum Pressure

?Pressure influences:

Density/Molekule Distance

Diffusion Behavior

Energy Density

etc...

Future?

47

PAT


Future?

Pressure as a modelling

parameter

Modelling functional boundary layers

Generation of Functional Particle Systems

Nano Particle Behavior in Gases

Diffusion of Gas into Metals

Idea

Documents

High Pressure Equipment Socrates Intensive Course Budapest Professor Dr.-Ing. E. Schlücker Lehrstuhl Prozessmaschinen und Anlagentechnik Cauerstraße 4