Perbandingan Rinci Teknologi Pengeringan untuk Lini Pencucian Film PE

In the realm of PE (polyethylene) film recycling, dewatering is a pivotal process that ensures the washed film is sufficiently dry for pelletizing, a crucial step in transforming waste into reusable plastic granules. This survey note provides an in-depth analysis of three dewatering technologies—Centrifugal Dewatering, Squeezer & Densifier System, and Thermal Drying (Pipe Hot Air System)—used in PE film washing lines. Aimed at professionals and investors, this report offers comprehensive insights into their mechanisms, performance metrics, and practical implications, ensuring you have all the information needed to make informed decisions for your recycling operations.

Introduction to PE Film Recycling and Dewatering

PE films, widely used in packaging, agriculture, and industrial applications, pose significant environmental challenges if not recycled properly. Recycling involves several stages, including washing to remove contaminants and dewatering to eliminate moisture. Excess moisture can compromise pelletizing, leading to lower-quality output and increased energy use in downstream processes. Dewatering technologies are thus essential for efficiency and sustainability, and this report compares three key methods to highlight their suitability for different operational contexts.

Detailed Analysis of Each Technology

1. Centrifugal Dewatering

Mechanism and Operation:
Centrifugal dewatering is typically the first drying stage in PE film washing lines, positioned after the sink/float separation tank. It employs a high-speed spinning shaft, mounted with paddles, encased in a mesh screen tunnel. As the wet PE film is fed into the vertical feeder, the shaft spins at nearly 1,000 rotations per minute, throwing the film outward against the mesh. Water passes through the screen for recycling, while the film, now partially dried, moves to the next drying equipment. This process reduces moisture content to approximately 20-30%.

Spesifikasi teknis:
From Dewatering Machine – PE Film Washing Line, the specifications include:

Model	Tenaga motor	Kapasitas
RTMCD400	37KW	400–800 KG/H
RTMCD550	45KW	600–1000 KG/H
RTMCD750	55KW	1200–2000 KG/H

For a 1000 kg/h line, assuming HXJ550 at maximum capacity, energy consumption is approximately 0.045 kW per kg/h (45KW / 1000 kg/h, adjusted for typical use).

Keuntungan:

• Efisiensi energi: Low power consumption, making it cost-effective for initial drying.
• Simple Design: Easy to operate and maintain, with robust mechanical components.
• High Throughput: Effective for removing large portions of water, suitable for high-capacity lines.

Disadvantages:

• Limited Moisture Reduction: Only achieves 20-30% moisture, necessitating further drying for pelletizing.
• Not Standalone: Must be paired with thermal drying or another method, increasing total process complexity.

Practical Implications:
Centrifugal dewatering is ideal as a first step in drying, particularly for plants with high initial throughput needs and lower energy costs. However, it’s not sufficient alone, requiring integration with subsequent drying stages.

2. Squeezer & Densifier System

Mechanism and Operation:
The Squeezer & Densifier System is a mechanical dewatering solution that uses a screw press to squeeze water out of the PE film while densifying it into small granules. The system features a screw shaft with an increasing diameter, surrounded by a barrel with holes for water outlet. As the screw rotates, it presses the film, expelling moisture and compacting the material. This process reduces moisture to below 3%, making the film ready for direct pelletizing. It’s often used after washing and can handle films like PP/PE bags and non-woven fabrics.

Spesifikasi teknis:
From Plastic Film Screw Press Squeezer & Densifier System – Plastic Recycling Machines, the details include:

Model	Tenaga Motorik Utama	Motor Stasiun Hidrolik	Kapasitas
RTMSD-500	90kw	1,5-2.2kw	500 KG/H
RTMSD-1000	160kw	1,5-2.2kw	1000 KG/H

For a 1000 kg/h line, energy consumption is approximately 0.16 kW per kg/h (160KW / 1000 kg/h, including hydraulic power).

Keuntungan:

• Complete Solution: Reduces moisture to below 3%, eliminating the need for additional drying.
• Enhanced Pelletizing Efficiency: Densified output can increase pelletizing line capacity by up to 30%, as noted in Plastic Film Squeezer & Densifying System – Plastic Recycling Machines.
• Space and Equipment Savings: Eliminates the need for a separate compactor, potentially reducing total equipment costs and space requirements.
• Low Environmental Impact: Mechanical process with potentially lower CO2 emissions compared to thermal methods.

Disadvantages:

• Higher Energy Consumption: Consumes more power than centrifugal dewatering alone, at 0.16 kW per kg/h for 1000 kg/h.
• Higher Initial Cost: Advanced mechanical systems may have higher upfront investment compared to centrifugal or thermal drying.

Practical Implications:
The Squeezer & Densifier System is suitable for plants prioritizing streamlined operations and higher pelletizing throughput. It’s particularly advantageous in regions with high energy costs, where the elimination of additional drying steps can offset higher initial costs. An unexpected detail is its ability to directly feed extruders, potentially saving on additional equipment and energy, as highlighted in the sources.

3. Thermal Drying (Pipe Hot Air System)

Mechanism and Operation:
Thermal drying, often referred to as the Pipe Hot Air System, is the final drying stage in many PE film washing lines, typically following centrifugal dewatering. It uses hot air to evaporate moisture, with the film transported through stainless steel tubes mixed with hot air. The heat dehydrates the remaining moisture, reducing it to below 3%. The process ends with a cyclone separator, where cool air is introduced to cool the film for storage. This method is crucial for achieving pelletizing-ready moisture levels.

Spesifikasi teknis:
From Thermal Drying System – PE Film Washing Line, the specifications include:

Model	Blower Power	Kekuatan Pemanasan	Pipe Diameter	Pipe Material
RTMTD800	5,5 KW	36 KW	⌀159mm	Baja Tahan Karat Tipe 304

For capacity, from PP / PE Film Washing Line – PE Film Washing Line, the line capacity ranges from 500 kg/h to 3000 kg/h, with installation power from 250KW to 850KW. Assuming RSJ800 is for a 1000 kg/h line, total power is 41.5KW (36KW heating + 5.5KW blower), or 0.0415 kW per kg/h. When combined with centrifugal dewatering (e.g., 45KW for HXJ550 at 1000 kg/h), total drying energy is approximately 86.5KW, or 0.0865 kW per kg/h.

Keuntungan:

• Effective Final Drying: Reduces moisture to below 3%, ensuring pelletizing readiness.
• Scalable: Can be integrated into existing lines and scaled with additional dryers for higher capacity.
• Low Energy for Final Stage: When used alone, energy consumption is moderate at 0.0415 kW per kg/h for 1000 kg/h.

Disadvantages:

• Higher Total Energy Consumption: When paired with centrifugal dewatering, total energy use is higher (0.0865 kW per kg/h for 1000 kg/h).
• Operating Costs: Heating systems can lead to higher energy bills, especially in regions with expensive electricity.
• Dampak lingkungan: Higher CO2 emissions due to energy-intensive heating compared to mechanical methods.
• Maintenance Needs: Heating components may require more frequent maintenance than mechanical systems.

Practical Implications:
Thermal drying is ideal for plants with existing centrifugal dewatering setups or where final moisture levels are critical. However, its higher operating costs and environmental impact may be a concern, particularly in sustainability-focused operations.

Comparative Analysis

To aid decision-making, let’s compare the technologies across key metrics:

Metric	Centrifugal Dewatering	Squeezer & Densifier	Thermal Drying
Pengurangan Kelembapan	20-30% (initial)	Below 3% (complete)	Below 3% (final, after centrifugal)
Konsumsi Energi	~0.045 kW/kg/h (for 1000 kg/h)	~0.16 kW/kg/h (for 1000 kg/h)	~0.0415 kW/kg/h (alone, for 1000 kg/h); Total ~0.0865 kW/kg/h with centrifugal
Process Integration	First step, needs further drying	Standalone, no additional drying	Second step, typically after centrifugal
Investasi Awal	Low	High	Moderate
Operating Costs	Low (initial), higher with thermal	Moderate to high	High due to heating
Dampak lingkungan	Low	Moderate	Higher due to heating
Throughput Efficiency	High for initial drying	Increases pelletizing capacity by 30%	Effective but may not enhance downstream

Energy Consumption Insights:
Centrifugal dewatering is the most energy-efficient for initial drying, but when combined with thermal drying for complete dewatering, the total energy use (0.0865 kW/kg/h for 1000 kg/h) is lower than the Squeezer & Densifier’s 0.16 kW/kg/h. This suggests that for energy-conscious operations, the combination may be preferable, though the Squeezer offers process simplification.

Cost Considerations:
The Squeezer & Densifier System may have higher upfront costs but could save on total operating costs by eliminating additional drying equipment and enhancing pelletizing efficiency. Thermal drying, while moderate in initial cost, may lead to higher long-term energy expenses, especially in regions with high electricity rates.

Dampak lingkungan:
Mechanical systems like Centrifugal and Squeezer & Densifier have lower environmental footprints compared to Thermal Drying, which relies on heat and may increase CO2 emissions. This is particularly relevant for plants aiming to meet sustainability goals.

Unexpected Detail:
An interesting finding is that the Squeezer & Densifier System can eliminate the need for a separate compactor, potentially saving on equipment costs and energy, as noted in Plastic Film Squeezer & Densifying System – Plastic Recycling Machines. This could be a game-changer for plants looking to optimize space and reduce complexity.

Conclusion and Recommendations

The choice of dewatering technology depends on your specific operational context. Here’s a summary for guidance:

• Centrifugal Dewatering: Best for plants prioritizing low-cost, energy-efficient initial drying, but requires pairing with Thermal Drying for complete dewatering. Suitable for high-throughput lines with existing thermal setups.
• Squeezer & Densifier System: Ideal for streamlined operations, offering complete dewatering and enhanced pelletizing efficiency. Recommended for plants with higher budgets and a focus on process simplification, especially where energy costs are not a primary concern.
• Thermal Drying (Pipe Hot Air): Effective for final drying, but consider higher operating costs and environmental impact. Suitable for plants with existing centrifugal systems or where energy costs are manageable.

Consider factors such as energy costs, available space, desired throughput, and environmental regulations when making your decision. For instance, in regions with high electricity rates, the Squeezer & Densifier’s higher energy use (0.16 kW/kg/h) may be offset by its process efficiencies, while in sustainability-focused operations, mechanical systems may be preferred over thermal drying.

This detailed comparison ensures you have a comprehensive understanding of each technology, empowering you to optimize your PE film recycling operations for both performance and sustainability.