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Compressed air and nitrogen supply for the research autoclave

In a centre for lightweight production technology, methods are being researched to produce super-light carbon fibre componets in a time-saving, mass-produced and fully automated way. With heavy equipment. KAESER Kompressoren SE is supporting this project with expertise and know-how

Energy efficiency is increasingly demanding lightweight construction, whether in aircraft, cars or bicycles. CFRP “carbon fibre reinforced plastic” is the material of the future.

Challenge

The customer of KAESER Kompressoren is researching ways to make the production of high-quality CFRP-components more profitable and thus also attractive for other applications and industries. Production amounts to 100,000 units per year. Expertise and know-how of the customer are used here to investigate effects on the material or on the plant in original size. Applications are fully simulated. This is done in a research autoclave.

Materials form a bond with each other at high temperature and under pressure. This happens in an oven – the so-called autoclave. This works like a pressure cooker. Here, for example, aircraft fuselage components, wings or vertical stablisiers can be completely produced and analysed. The autoclave has an external length of 27 m and an external diameter of 6.50 m, a weight of 181 t and is an imposing appearance as a heavy tube.

Solution statement

  • The research autoclave is operated at a temperature of 420 °C. At these temperatures, there is a risk that the research objects inside will ignite. Therefore, nitrogen is used, which acts as a protective gas and prevents the components from buring.
  • KAESER makes an important contribution to this: compressed air is broken down into its components and oxygen in a KAESER nitrogen generator.
  • An KAESER adsorption dryer type DC 169 dehumidifies the air before a post-compressor compresses it to 35 bar.
  • Two additional KAESER refrigeration dryers type THP 142-45 and two KAESER microfilter activated carbon adsorber combinations ensure that only dry and high-purity KAESER compressed air flows into the nitrogen generator.
  • The second stage of the compressed air system consists of two KAESER CSD 125 SFC series of screw compressors (75kW, speed-controlled), which feed a 9.5 bar compressed air network or three piston after-compressors in alternating operation. The nitrogen is stored at around 30 bar pressure in two pressure tanks, each with a capacity of 200 cubic metres.

Customer value

  • The 9.5 bar compressed air dried in an energy-saving KAESER refrigeration dryer (TF 251) and cleaned by a microfilter-activated carbon adsorber combination is used to operate air cushion transport vehicles that can carry payloads of up to 70 tonnes.
  • Efficiency is a top priority here.

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