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如今,机械上安全,坚固且可靠的搅拌器或设备设计对于经济且无故障的运行必不可少。 对设备机械设计的需求已大大增加,这不仅是因为工厂单位规模的稳步增长。 我们在EKATO正面临着这些挑战!

近几十年来,流程工业出现了制造更大的工厂单元和高档设备以实现“规模经济”的巨大趋势。 追求“规模经济”方法会带来成本优势。 随着设备尺寸的增加,单位产量的生产成本降低。 这通常与生产线的减少和工艺增长密切相关,即更高的生产力和产量。 这在石化、塑料和聚合物行业、湿法冶金或生物技术中使用的工业发酵罐中尤其明显。 在其中一些行业中,自 1990 年代以来,反应器体积增加了 10 倍。

EKATO 正与其客户密切合作开发下一代工业设备,并与他们一起开发合适的搅拌器技术解决方案,包括搅拌器和相应的反应器设计。

最大的挑战在于从中试规模到体积通常大 100 - 1,000 倍的世界规模工厂的设计转移。 根据测试结果,我们的专家不仅在工艺技术方面而且在机械方面进行了可靠、安全的放大。 这通常得到相应 CFD 分析的支持。 此类设备的搅拌器和反应器设计必须能够承受最高负载,以确保我们的客户获得最大的运行可靠性。 为此,在施工前对各种组件以及搅拌器和反应器的整个系统进行有限元计算,以确保设备的最长使用寿命。

根据其重要性,有限元方法 (FEM) 现在已进入几乎所有可以想象的物理学科。 EKATO 可以执行的混合技术领域中最重要的方法是:

  • 结构力学计算(运行稳定性、变形)
  • 用于评估共振危害的模态/振动分析
  • 热计算
  • 流固耦合(激励频率、固有频率、容器中流体的阻尼)


驱动功率高达 4,000 kW、搅拌桨叶直径超过 6 m 或轴直径超过 500 mm 的搅拌器对于 EKATO 来说并不罕见。 这种搅拌器的总重量往往超过100吨。 这些尺寸导致巨大的静态和动态负载。 这需要对作用在整个容器、其内部构件和支撑结构上的力进行更加精确和可靠的计算。 EKATO 可以借鉴该领域数十年的经验,其中计算方法不断得到进一步发展。

One challenge in the design of stirred reactors is the coordination of the interfaces between the agitator, vessel and its associated internals necessary for the process. Often, these individual components are supplied by different manufacturers, which can easily lead to coordination and information problems. For reasons of productivity and economy, it makes sense not only to adapt the agitator to a predefined vessel, but also to work out an optimum overall concept together with the plant operator and equipment manufacturer.

EKATO offers an extended engineering services and scope of supply, in order to guarantee the customers an efficient and smoot progress in the project with as few interfaces as possible. In addition to the agitators, we also take care of the associated process technology, such as heat exchangers, baffles, optimum positions of the feed and discharge pipes as well as vessel engineering – all from a single source.

Our project engineers coordinate the interfaces throughout the project, from manufacturing and pre-assembly to delivery, commissioning support and training.

The construction and design of complete process plants requires perfect interaction between the disciplines of process technology, automation and engineering. Based on key figures and process variables determined in feasibility studies and tests, plant components are designed using scientifically based scaling methods (scale-up), requirements are identified and combined to form a completely functional plant. The design of the plant or the components themselves also includes methods such as CFD analyses and FEM calculations in order to ensure plant functionality and safety. Automation plays a central role in the optimal interaction of the process plants. This combines the actuators and sensors of the plants according to the process requirements and customer needs. The degree of automation ranges from semi-automatic operation to fully automatic processes with recipe control, data recording and the documentation of the Batch (BatchRecord). Integrated plants are built for processes in the fields of SOLIDMIX and UNIMIX. SOLIDMIX covers the processes of solids drying and solids mixing, while UNIMIX offers solutions to produce suspension- or emulsion-based products in the low to high viscosity range. The range of process plants varies from pre-engineered solutions (short delivery times) for specific products of our customers to engineered solutions in which specific process and customer requirements are implemented.

In the Process Plants division, EKATO offers a comprehensive service and equipment package as a development and engineering partner for process plants based on stirred processes. With practical special knowledge and innovative methods from process and apparatus engineering, EKATO offers concept design, basic engineering, execution, procurement, and delivery as well as construction and commissioning of the system.

In the concept phase of the engineering, EKATO defines the essential process steps in the context of process analyses as well as mass and energy balances. If necessary, EKATO performs tests in its own highly corrosion-resistant laboratory and pilot apparatuses in which operating conditions up to 100 bar and 300°C are possible. The required scale-up to the operating scale is based on 80 years of expertise. The process concepts developed in this way are examined by our specialists regarding to feasibility, and an initial rough cost estimate is provided.

In the basic engineering phase, EKATO then technically and mechanically interprets the main apparatuses in interdisciplinary project teams and defines the utilities as well as the control and monitoring concept. An HAZOP is carried out together with the customer. Accompanied by further risk analysis, the P&ID and system layout will be gradually developed. With completion of the basic engineering, the system is then cost-assessed within a few percentage points.

In the detailing phase, the EKATO project team then specifies the equipment, fittings, and instruments in detail and clarifies their interfaces. On request, these will also be supplied by EKATO. In this case, EKATO takes over the entire order processing with technical, quality, and delivery schedule expediting at the component suppliers and manufacturers.

EKATO carries out the mechanical, hydraulic and electrical pre-assembly of the plant, skid or system components as well as the necessary test runs and functional tests (FAT). The final assembly on site and the piping are planned and organized by experienced practitioners and implemented by internal or external personnel depending on the place of installation and the scope. Our commissioning engineers supervise the system until proof of the required process results.

With this comprehensive range of services and equipment, EKATO offers partial or complete solutions from the idea to a technically and economically sound solution. By means of piloting and many years of experience in the scale-up of process engineering equipment, EKATO offers the customer process guarantees and provides high-quality production plants.