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Aerosol production line

  • Система автоматизации и контроля
  • Система контроля линии аэрозольной продукции
THE RANGE OF SERVICES

THE RANGE OF SERVICES

Design, installation, construction, starting-up and commissioning of the equipment for aerosol production

OBJECTIVE

OBJECTIVE

Storage, filling cylinders and cans with dimethyl ether and aerosol

CERTIFICATION

CERTIFICATION

SP 62.13330.2011
ТР ТС 032/2013
ISO 9001:2015

Aerosol production plants are widely applied at the enterprises of chemical, construction engineering and paint-and-varnish industries and serve for gas and propellant supply to aerosol cans.

The aerosol production line allows to provide technological processes with a two-phase aerosol which consists of gas vapors and propellants - substances capable to convert the operating environment into foam, spray or powder under pressure. The most common propellants are a group of liquefied petroleum gases (LPG), such as propane, butane and propane-butane mixture, as well as dimethyl ether (DME).

The weight content of propellant is determined depending on the type of aerosol and affects the structure of the sprayed product: fine substances, poly-disperse mixtures, etc.

Application Aerosol type The weight content of propellant
Household cleaning products Antistatics, air freshener, planishing (buffing, polishing substances), etc. 60-80%
Bacteriological decontamination, exterminating and disinsectant substances, etc. 70-90% 
Paint-and-varnish industry Paints, varnishes and lacquers, enamels 20-60%
Industrial application Aerosol mastics, corrosion preventatives 20-50%
Construction foam 20-30%

The core functionality of aerosol product line is as follow:

  • LPG and dimethyl ether unloading by pumps;
  • dimethyl ether and LPG storage in tanks up to 25 m3;
  • filling cylinders and gasification systems with dimethyl ether and liquefied petroleum gas.

The competent implementation of the aerosol production line project allows for the uninterrupted supply under pressure of a limited amount of liquefied gas and propellant of required quantity. In case of allowable gas concentration excess or an emergency, the supply of LPG and DME can be stopped manually, remotely automatically by means of electromagnetic valves with the possibility of pipelines opening and closing. Valve response time depends on the pipeline diameter and is at least 30 MS.

AEROSOL PRODUCTION LINE CONFIGURATION

LPG storage tanks
Gas transmission system and spill line
Pumping units

Aerosol production line includes a technical liquids and propellants storage warehouse, aerosol cylinders filling equipment, control room or desk and a quality control equipment. The typical layout is as follow:

  • single- or double-walled gasholders for propane-butane mixture;
  • single- or double-walled gasholders for dimethyl ether;
  • compressor and pump units for gas evacuation, liquid phase of propane and butane supply to the cylinder filling line;
  • gas piping and spill line;
  • he nitrogen block for pipeline purging;
  • relief and shut-off valves ensuring safe operation;
  • metering unit and the additional process facilities at the Customer's request.

Storage tanks can be installed both above and uderground. The choice of the location mode is determined by free space at site, the allowable distance between the tanks, climatic service conditions, etc.

The number of LPG and DME tanks depends on daily and annual output rate, as well as the requirements to a number of stand-by tanks. Tank manufacturing is carried out by the Plant SARZ in accordance with Quality management system ISO 9001-2015 and the requirements of Russian state and industry standards.

The exact equipment configuration and its characteristics are selected taking into account the optimal compliance with the technical design specification and Customer's requirements. All the supplied equipment is delivered fully shop-assembled. It reduces construction and installation period and gears up commissioning.

OPERATING PRINCIPLE OF AEROSOL PRODUCTION LINE

The gasholder is designed for underground or above ground dimethyl ether or liquefied petroleum gas storage and is filled up to 85%. Dimethyl ether acts as a solvent, liquefied gas is used as a foaming agent.

The processing medium flows from gas pipeline to the pumping unit. The type of pumping unit (with metering equipment, self-priming, side-channel) depends on either above- or underground tanks as well as required output rate. Due to the pump circular fluid motion is achieved under pressure of about 10-12 kg/cm2. Flow control is carried out by a solenoid valve which can also be used for cylinders filling.

Technological processes control is held up by control equipment, which transmit data to the control cabinet (pressure, temperature, filling level etc). The standard list of equipment includes electric-contact or visual pressure gage, thermometer, ultra-audible level alarm, magnetic displacer level transmitter, sensors, differential level sensor, etc.

The processing medium is discharged from the gasholders by means of a compressor unit, which removes the dimethyl ether and liquefied petroleum gas through the draining station into the tank truck at a speed of up to 220 l/min.

STAGES PERFORMED

Aerosol production line design
Aerosol production line design
Equipment for aerosol production line selection
Equipment for aerosol production line selection
Equipment manufacturing
Equipment manufacturing
EQUIPMENT DELIVERY AT PLACE
EQUIPMENT DELIVERY AT PLACE
EQUIPMENT ASSEMBLY WITHIN CONTRACTUAL TERM
EQUIPMENT ASSEMBLY WITHIN CONTRACTUAL TERM
Equipment starting-up and adjustment
Equipment starting-up and adjustment
RTN CERTIFICATION
RTN CERTIFICATION
Equipment for aerosol production line commissioning
Equipment for aerosol production line commissioning

Construction and installation works require site preparation. The work area should correspond to the general layout and have approach drive and clearing construction site for heavy construction vehicles moving.

The scope of dirt works may vary depending on the type of tanks (above- or underground).

Work item Aboveground tanks Underground tanks
Site stripping + +
Ground survey + +
Clearing and grubbing + if applicable
Foundation installing + +
Ditch for foundation - +
Tank burial - +

Regardless of the tank type the tank foundation is essential. The foundation is reinforced-concrete assembly or site concrete foot. The foundation diameter should be more than the tank diameter. Pole or saddle is placed upon the foundation so that the pressure-tight seam is externally inspectable. At the point of tank shell and tank rack contact waterproofing covering is coated, which provides biological impact and chemical attack resistance.

REGULATIONS GOVERNING AEROSOL PRODUCTION LINE INSTALLATION

Aerosol production lines are manufactured by SINTEK and meet the requirements of Federal norms and regulations, as well as industry standards. While designing, construction, starting-up and adjustment the specialists of design engineering department are guided by:

  • SP 62.13330.2011 "Gas-distribution system. The revised edition of SNiP 42-01-2002";
  • Safety rules for facilities using liquefied hydrocarbon gases;
  • Regulations of industrial safety for hazardous facilities using equipment working under excess pressure.

Compliance with the requirements specified in the documents listed above ensures long-term service and decrease of emergences due to the equipment high quality.

PRICING AND PERFORMANCE TIME

Specialists of OOO Neftegazengineering carry out cost and time calculation depending on the required output rate, equipment configuration (the number of tanks, spill lines, storage capacity, gas pipe length), as well as the range of construction and installation works.