Technobell Technology - CFW4000

Congratulations to our Technobell team for another successful completion of a CFW production line.

The giant CFW4000 machine capable of producing GRP pipes up to 4m in diameter and the auxiliary machines were designed, constructed and packed in record time and are now on their way to the new owner.

As usual we built-in all the experience and knowledge accumulated so far to deliver a product that is easy and safe to use, has unparalleled production capacity and will serve its purpose for decades to come.

We look forward to the first GRP pipe to be manufactured with the most advanced CFW4000 production line available on the market.

 

Technobell' Phthalic Anhydride - Double Salt Zone Reactor

Following the successful market introduction of our Maleic Anhydride Double Salt Zone Reactor (DSZR) with its superior performance compared to Single Zone Reactors, we developed the patented DSZR applicable for the production of Phthalic Anhydride (PA).

The development of a new reactor derives from the needs of catalyst manufacturers facing the challenges of the PA catalyst life cycle due to the multi-layer type of catalyst bed, where catalyst layers require different operating temperatures for their optimal performance.

The existing multi-layer PA catalyst operates with the Start-Of-Run salt temperature of about 340 ° C, while the reaction yield can reach up to 115 wt.%. During catalyst operation, the salt temperature must be constantly increased to maintain a high conversion rate and thus a yield.

However, after app. 3.5 years of catalyst in operation, salt temperature exceeds 350 ° C, where a significant negative effect, in terms of performance reduction, is visible mainly on the last catalyst layer, resulting in non-economical production leading to the catalyst change.

Technobell’s Phthalic Anhydride Double Salt Zone Reactor offers a complete solution where the main reaction zone temperature increases over time according to the reaction performance with the aim of maintaining the highest reaction yield, and the bottom reactor zone temperature is maintained at the optimal level for the last catalyst layer, which is only possible in DSZR due to its unique ability of separately controlled salt temperatures in the two zones.

The positive effect is shown in the guaranteed significant catalyst lifecycle extension, as the last catalyst layer performance reduction is much slower, resulting in a reduction of reactor OPEX.

 

Technobell - Camplate for CFW4000 machine

Update on CFW4000 project – 2.

A suitably shaped cam plate is an important part of a Continuous Filament Winding machine. This cam plate for the CFW4000 machine with a diameter of 4.3 meters and weighing approx. 4 tons was annealed for 30 hours, in order to remove internal stresses and to strengthen it. Afterwards the surface was treated with a triaxial drilling milling machine.

 

 

 

Technobell CFW4000 basic construction- frame and mandrel casing

Update on CFW4000 project – 1.

It took us four working days to assemble the basic construction of the CFW4000 machine: the frame and the mandrel casing. When assembled, only the CFW4000 machine will be 7.6 meters high, 10.5 meters wide and 31 meters long. Due to the machine dimensions our partners built a special bridge crane which extends to only a few inches below the roof of the production hall.

 

 

Technobell - CFW production line components

Technobell has just started assembling a new CFW production line for the manufacturing of GRP pipes. It will be a giant amongst CFW’s production lines made from more than 300 tons of steel and other various components. To assemble it, we will need an impressive 4 cubic meters of bolts and nuts. The longest piece is 11 meters long, the largest piece is  4.5 meters in diameter, and the heaviest piece weighs 24 tons.

Due to its exceptional dimensions and weight, the CFW production line represents a challenge in terms of manufacturing and logistics – a challenge we are all proud of.

 

Technobell - CFW production line components

 

Technobell - New type of UPR solution for fiberglass boat industry

Technobell has developed a new type of Unsaturated Polyester Resin (UPR) for the fiberglass boat industry. The new UPR is formulated to minimize friction between surfaces in order to obtain faster water flow due to the so called lotus effect. In addition to its extremely high UV-resistance characteristics, excellent resistance to atmospheric impacts and a high level of self-cleaning, the new solution also helps reduce fuel consumption and prevents material deposition on boat structures.

 

Technobell - New type of UPR solution for fiberglass boat industry
Technobell's Modular CFW 300-1200 machine

Extreme engineering put into practice. The Technobell modular CFW 300-1200 machine for GRP pipes production divided into easy to assemble modules perfectly fits into standard marine containers with obvious but precious benefits for the end-user:

  • machine installation and start-up time reduced almost to zero,
  • possibility to relocate the machine near project sites without any hassle.

 

Technobell Modular CFW1200

We just finished testing the new modular CFW1200 machine and started disassembling it for imminent relocation, an operation that will be completed in less than 5 days. In order to assure reliable and responsive controls, considering that pipe production output can reach 60 m/h, the modular CFW machine had to be fitted with an advanced Programmable Logic Controller (PLC). The PLC features also remote connection which allows real-time monitoring and troubleshooting by Technobell engineers.

 

 

Technobell Polyester Resin Plant

The crude oil price is in decline and large petrochemical companies are heavily investing in Oil & Gas downstream processes, including the Unsaturated Polyester Resin (UPR) production technology because the UPR market has been constantly growing for the past two decades.

#technobelltechnology has a long-time experience in UPR production technology and is constantly investing in R&D in order to provide state-of-the-art solutions for our clients. With advanced technological solutions and deep understanding of the process we can propose optimization and combination of existing production lines allowing simultaneous production of Orthophthalic, Isophthalic, DCPD and Vinyl ester resins as well setting up new production lines with unmatchable performances.

Technobell’s licensed UPR technology enables production with low glycol excess (its concentration in waste reaction is max 3 wt.%) and increased production yield (by using DCPD) which overall significantly reduces the production costs and environmental impact.

 

 

 

Technobell Mandrel Casing Construction

Making big CFW machines for GRP pipes production starts with engineering and continues with manufacturing. Usually is not a problem, but when the part that needs fine machining is bigger than your car… then you need the tools and the knowledge on how to do it.

Technobell team is composed of highly skilled engineers with extensive experience in mechanical, automation and chemical engineering, managed by professionals with long term experience in large and complex projects.