Extrusion Specific Energy (SEC)
Calculate the extrusion specific energy consumption (SEC), SEC = power ÷ mass throughput, from the screw motor power (kW) and the mass throughput (kg/h). The result, in kWh/kg, is the energy to process each kilogram of polymer, and the main ENERGY-EFFICIENCY indicator of an extruder. Since extrusion melts and pumps plastic largely by VISCOUS heating (screw mechanical energy converted to heat by shear), specific consumption directly reflects how well the screw is doing its job. Typical values are 0.1-0.4 kWh/kg, varying with polymer (each has a melting enthalpy), screw geometry, speed and temperature. An abnormally HIGH SEC signals problems — wrong screw, excessive shear (which can degrade the material), poor temperature setting — and energy waste (the largest part of an extruder's operating cost). A very low SEC may indicate incomplete melting. Monitoring SEC is central to efficiency, quality and cutting cost and emissions in plastics processing. Enter the power consumed and the mass throughput.
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Energia específica de extrusão (SEC)
A energia específica de extrusão (SEC — Specific Energy Consumption) é SEC = potência ÷ vazão mássica, a partir da potência consumida pelo motor da rosca (kW) e da vazão mássica de produção (kg/h). O resultado, em kWh/kg, é a energia gasta para processar cada quilograma de polímero — o principal indicador de eficiência energética de uma extrusora. Como a extrusão funde e bombeia o plástico em grande parte por aquecimento viscoso (a energia mecânica da rosca convertida em calor pelo cisalhamento), o consumo específico reflete diretamente o quão bem a rosca está fazendo seu trabalho. Valores típicos ficam entre 0,1 e 0,4 kWh/kg, variando com o polímero (cada um tem sua entalpia de fusão), a geometria da rosca, a rotação e a temperatura. Um SEC anormalmente alto indica problemas — rosca inadequada, cisalhamento excessivo (que pode degradar o material), temperatura mal ajustada — e desperdício de energia (a maior componente do custo operacional). Um SEC muito baixo pode indicar fusão incompleta. Monitorar o SEC é central para a eficiência, a qualidade e a redução de custos e de emissões na indústria de transformação de plásticos. Informe a potência consumida e a vazão mássica.
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Energy per Elevator Trip
Calculate the potential energy spent to raise a load, E = m·g·h, from the unbalanced mass m (net load after the counterweight, kg), gravity g and the lift height h (m). The result, in joules, is the minimum theoretical energy to hoist the load — a basis for estimating the elevator's electrical consumption and the energy-regeneration potential. Modern elevators with regenerative drives recover part of this energy on descent (when the counterweight descends with a light car), feeding it back to the grid. Actual consumption is higher, divided by the efficiency. Enter the unbalanced mass and the lift height.
Screw Degree of Fill
Calculate an extrusion screw's degree of fill, η = (actual flow ÷ drag flow) · 100, from the actual production flow and the screw's theoretical drag flow. Degree of fill measures how much of the screw's theoretical pumping capacity (the drag flow, which would occur with no back-pressure) is actually delivered as real flow — the difference is 'lost' to pressure flow (backflow from die resistance). It is thus a measure of the extruder's volumetric EFFICIENCY and operating point on the characteristic curve: a high fill (near 100%) means little back-pressure (open die, simple product); a low fill means strong back-pressure (restrictive die), with much internal backflow. In gravity-fed (flood-fed) extruders the screw runs full, and degree of fill reflects the drag-pressure balance; in metered-feed (starve-fed, common in twin-screw) extruders, degree of fill is deliberately controlled by the feed rate, decoupling flow from speed and giving independent control of residence time and shear. Knowing the degree of fill helps diagnose the process and optimize productivity. Enter the actual flow and the drag flow.
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