PRODUCTS & PROCESSES
A turbine exchange increases productivity and lowers energy consumption
A major reason for such short payback periods is the unrivaled Rösler portfolio of state-of-the-art turbines ranging from single or twin disk wheel designs to the high performance Gamma turbines . All turbine components are available in different materials like cast steel , tool steel and carbide steel or combinations of these materials . This unmatched variety allows the creation of turbine packages that are individually tailored to the application at hand and that are fulfilling all customer requirements regarding throughput , operating costs , energy consumption and maintenance . Michael Motschenbacher explains : „ Most customers choose Gamma turbines , because they offer significant cost advantages and exceptionally high productivity ”.
Key for the outstanding performance of the Gamma turbines are their curved throwing blades in “ Y ” design with a precisely calculated curvature angle . Compared to conventional turbines , the Gamma design allows extremely fast throwing speeds and a precisely bundled blasting stream resulting in a drastically higher blasting efficiency . This increases the overall performance and significantly reduces processing times . „ The installation of Gamma turbines into their existing shot blasting machines allowed numerous customers to eliminate a complete shift , increase their overall throughput and considerably improve the quality of their shot blasting results ”, comments Manfred Kohmann .
Another significant feature of the Gamma turbines with “ Y ” shaped throwing blades is their energy-efficient media acceleration and delivery . They produce energy savings of up to 25 %. Michael Motschenbacher elaborates : “ The potential for energy savings is also very attractive for relatively new shot blasting machines , because it allows the operators to obtain or renew a certification according to DIN EN ISO 50001 “. It might even be possible to partially finance equipment modernization projects through a grant from an energy efficiency aid program .
The special “ Y ” design of the throwing blades also allows the use of both blade sides . Compared to a conventional turbine , this already leads to a double life time of the blades .
By selecting the ideal wear material , the service life can even be raised up to 16 times . This increases the overall equipment availability and , thus , helps reduce the maintenance costs . Rösler is so sure of the superiority of the Gamma turbines
If the media contains large amounts of sand , for example in foundries producing sand castings , the turbines and other equipment components are exposed to a high and costly wear rate . In such cases the shot blasting machine can be retrofitted with a magnetic separator that reduces the amount of sand in the media to 0.01 percent .
that TuneUp offers its customers to test them in their shot blasting machine cost-neutral for a certain time period without having to make a firm commitment .
Systematic solutions for all kinds of retrofit challenges
For the various equipment modernization tasks TuneUp offers a broad spectrum of different solutions . Manfred Kohmann explains : “ If , for example , the main task consists of achieving repeatable shot blasting results , this can frequently be achieved by adding an automatic media replenishment system ”.
Shot blasting machines are generally exposed to a certain amount of wear . The wear rate is significantly higher in foundries using a sand casting process , where the media might be contaminated with a certain amount of core and mold sand . In such cases the installation of a magnetic separator can extend the service life of the wear parts of turbines and the machine considerably . A magnetic separator from Rösler reduces the sand content in the media to 0.01 percent .
Modernization of the material handling and work piece transport – for example , the steel belt in a tumble belt machine – improves productivity and reduces the scrap rate .
Since 2017 the 42 . federal emission protection regulation ( BImSchV ) in Germany demands regular , rather expensive , tests for legionella contamination in wet dust collectors . As alternative to these time consuming and costly tests Rösler offers an automatic dosing system for injecting a specially developed additive that prevents legionella contamination . „ This retrofit solution , available as stand-alone unit , maintains a constant pH value on a high alkaline level in the wet dust collector and ,
thus , prevents the formation of legionella . The pH value is constantly monitored and documented ”, explains Manfred Kohmann . From a health-related point of view , this system may also be of interest to operators who place a high value on sustainability , even if there are no local regulations governing its use .
The range of retrofit solutions also extends to material handling and work piece transport . Manfred Kohmann remembers a project : “ The owner of a tumble belt machine made by another manufacturer had the problem that work pieces were regularly caught between the bars of the steel belt . This produced a significant amount of scrap . We solved the problem by completely redesigning the belt .
The examples described above clearly show that the modernization of an existing shot blasting machine is frequently a more cost effective alternative to the purchase of a new machine . Because of the current economic situation shot blasting equipment is frequently under-utilized . Therefore , this is a good time for the owners of shot blasting machinery to inform themselves about the modernization possibilities for their equipment . Of course , free-of-charge and without any financial obligation .
Visit : www . rosler . com read online : www . surfaceworld . com JANUARY 2021
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