Dual Vacuum Pump System for Continuous BCF Extrusion
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Solution Overview
Problem
Downtimes in polymer extrusion processes due to cleaning requirements lead to lost revenue and reduced output, particularly when recycling polyethylene terephthalate (PET) into bulked continuous filament (BCF) for carpet production, necessitating a reduction in downtime to maintain production efficiency.
Innovation Solution
A method utilizing a multi-screw extruder with a dual vacuum pump system that maintains pressure between 0 and 5 millibars within the MRS Section, allowing continuous operation during vacuum pump cleaning by alternating the vacuum pumps' usage, ensuring uninterrupted production of BCF.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single vacuum pump is used in the extrusion process, then the device complexity is reduced, but the productivity decreases due to downtime required for cleaning the vacuum pump
Solution Approach 1:
The vacuum pump system is segmented into multiple independent vacuum pumps (at least two) that operate in parallel. Each vacuum pump can be cleaned independently while the other continues to maintain vacuum in the extruder, eliminating production downtime. This segmentation of the vacuum system allows maintenance without stopping the extrusion process.
Solution Approach 2:
The patent implements a system where one vacuum pump is discarded from service for cleaning while the other vacuum pump continues to operate and recover by maintaining the vacuum environment. This allows the cleaning function to be performed on one pump without affecting overall system operation, and the cleaned pump is quickly recovered and reintegrated into the system.
2Manufacturing precision
If the vacuum pump is cleaned frequently to maintain process quality, then the manufacturing precision is improved, but the loss of time increases due to repeated shutdowns
Solution Approach 1:
The vacuum system is divided into multiple independent vacuum pumps, each capable of maintaining the required vacuum level independently. This allows one pump to be cleaned without affecting the other, which continues to maintain vacuum for quality production, thereby eliminating time loss.
Solution Approach 2:
The dual vacuum pump system ensures continuous useful action by maintaining vacuum throughout the extrusion process without interruption. While one pump is cleaned, the other continues to perform the useful function of maintaining vacuum, ensuring continuous production and eliminating downtime.
3Ease of operation
If the extrusion process is interrupted for vacuum pump maintenance, then the ease of operation is improved, but the productivity decreases
Solution Approach 1:
The vacuum pump system is segmented into multiple independently accessible units. Each vacuum pump can be maintained separately while the extrusion process continues uninterrupted by the other pump(s), making maintenance easier without sacrificing productivity.
Solution Approach 2:
One vacuum pump is temporarily discarded from active service to be easily accessed and maintained, while the other pump continues operating. The maintained pump is quickly recovered and brought back into service, ensuring ease of maintenance without productivity loss.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces downtime and increases throughput, enabling the production of high-quality BCF from 100% recycled PET content with minimal interruptions, thereby enhancing production efficiency and reducing the frequency of vacuum pump cleaning.
Implementation Method 1
a first vacuum pump configured to independently maintain a pressure within the MRS Section between about 0 millibars and about 40 millibars
Implementation Method 2
using the first vacuum pump and the second vacuum pump to maintain the pressure within the MRS Section to between about 0 millibars and about 5 millibars
Data Source
AI summary
In particular embodiments, a process for producing bulked continuous carpet filament from recycled polymer utilizes two vacuum pumps (140A, 140B) in combination with a single extruder (100). In various embodiments, the dual vacuum arrangement (e.g., at least two vacuum pumps (140A, 140B)) operably coupled to the single extruder (e.g., MRS extruder (100)) may be configured to remove one or more impurities from recycled polymer as the recycled polymer passes through the extruder.