Kingz Compounding

Author: jxw6637

  • Applast Contributes to High-Voltage Torsion-Resistant Cable for Offshore Wind Power

    As the clean energy technology best matching the resource endowment of coastal areas, offshore wind power has received strong support from these regions. Offshore wind power plans and supportive policies have been successively introduced, leading to the launch of a large number of offshore wind farm projects, such as the Fujian Fuqing Xinghua Bay Phase II Offshore Wind Farm.

    This wind farm innovatively utilized China’s first 10-megawatt (MW) offshore wind turbine generator, which at the time ranked second in the world and first in the Asia-Pacific region in terms of single-unit capacity, setting a new record for China’s offshore wind power. As a major piece of equipment independently developed by China, the turbine employed multiple advanced technologies with independent intellectual property rights for the first time, including electric double-drive pitch control technology, permanent magnet direct-drive generator technology, and full-power converter technology. Far East Smarter Energy Co., Ltd. (abbreviation: Far East Co., Ltd., stock code: 600869) participated in the turbine’s construction through its subsidiary Far East Cable Co., Ltd., providing extra-large offshore wind power high-voltage torsion-resistant cables for the wind turbine towers. With timely and极致 (ultimate/premium) products and services, they fully ensured the safe and stable operation of the turbines.

    The hub height of the 10MW offshore wind turbine is approximately 126 meters above sea level, equivalent to the height of a 40-story residential building. The rotor diameter is 185 meters, equivalent to the width of three Boeing 747 aircraft placed side by side. The swept area of the rotor is equivalent to 3.7 standard football fields.

    After commissioning, under wind speed conditions of 10 meters per second, a single turbine can generate 40 million kilowatt-hours of clean electricity annually. This can reduce coal consumption by 12,800 tons and carbon dioxide emissions by 33,500 tons, sufficient to meet the normal electricity demand of 20,000 three-person households.

    The enormous blades place extremely high demands on the tower strength and the drive装置 (devices/system) of the pitch system. Simultaneously, high power意味着 (implies/means) greater power transmission pressure. Through dedicated R&D, Far East Cable launched the extra-large offshore wind power high-voltage torsion-resistant cable. From drafting, design, testing to pilot production, mass production, supporting, and installation, they have been authorized multiple relevant invention patents, holding a far-leading position in this field and meeting the stringent requirements of turbine operation.

    To solve the challenges of torsion resistance and high voltage resistance for offshore high-voltage cables, Far East Cable developed ultra-clean continuous production technology for insulating materials. This ensures cable strength while extending the service life under harsh operating conditions. They also designed a new intelligent extrusion process, further reducing process losses and significantly improving product quality.

    The extra-large offshore wind power high-voltage torsion-resistant cable was developed over three years and successfully passed the technical appraisal of an expert team led by Academician Qiu Aici. Its technical level has reached international leadership. The successful development and application of this product mark Far East Cable’s strong technical advantages in the offshore wind power supply chain and lay a solid foundation for the comprehensive布局 (layout/development) of marine cables.

    Through the verification of indicators such as the torsion-resistant cable’s structural design, insulation material development, and tolerance to harsh working conditions, Far East Cable has established a complete set of standard systems and is fully capable of providing engineering support for extra-large offshore wind turbines.

  • 重磅：爱普助力海上风电新产品助建“大国重器”

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    作为最能匹配沿海地区资源禀赋的清洁能源技术，海上风电得到了沿海地区的大力支持，海上风电规划及支持政策陆续出台，一大批海上风电场项目先后落地，如福建福清兴化湾二期海上风电场。

    该风电场创新性地使用了我国首台10兆瓦海上风力发电机组，在当时位居单机容量世界第二、亚太地区第一，刷新了我国海上风电单机容量新纪录。作为中国自主开发的”大国重器”，机组首次应用了多项具备自主知识产权的先进技术，包括电动双驱变桨技术、永磁直驱发电机技术、全功率变流器技术等。远东智慧能源股份有限公司（简称：远东股份 股票代码：600869）旗下远东电缆有限公司参与到机组建设中，为风电塔筒提供了超大型海上风电高压耐扭电缆，以及时极致的产品和服务，全力保障机组安全稳定运行。

    10兆瓦海上风力发电机组轮毂中心高度距海平面约126米，相当于40层居民楼的高度；风机叶轮直径185米，相当于3台波音747并排的宽度；风轮扫风面积相当于3.7个标准足球场。

    机组投入使用后，在风速10米/秒的条件下，单台机组每年可以输送出4000万度清洁电能，可以减少燃煤消耗12800吨，二氧化碳排放33500吨，可满足20000个三口之家的家庭正常用电需求。

    庞大的叶片对塔筒强度、变桨系统的驱动装置提出了极高要求。同时，高功率也意味着更大的电力输送压力。远东电缆经过匠心研发，推出了超大型海上风电高压耐扭电缆，从起草、设计、测试到中试、生产、配套、敷设，被授权多项相关发明专利，在该领域处于遥遥领先水平，满足了机组运行的严苛要求。

    为解决海上高压电缆耐扭和耐高压的难题，远东电缆开发了绝缘材料超净化连续生产技术，在保证电缆强度的同时，延长了恶劣工况下的使用寿命，并设计了全新的智能挤出工艺，进一步降低了工艺损耗，极大提高了产品品质。

    超大型海上风电高压耐扭电缆历时3年研发，顺利通过了以邱爱慈院士为首的专家团队技术鉴定，技术水平达到国际领先。该产品的成功开发及应用，标志着远东电缆在海上风电配套环节已具备强大的技术优势，也为海洋电缆的全面布局奠定了坚实基础。

    通过对耐扭电缆的结构设计、绝缘料开发、恶劣工况的耐受度等指标验证，远东电缆已建立了全套的标准体系，完全有能力在超大型海上风电机组进行工程配套。

  • JC281FR：Low-Smoke Zero-Halogen (LSZH) Sheathing for GE Wind Power Cables

    JC281FR：Low-Smoke Zero-Halogen (LSZH) Sheathing for GE Wind Power Cables

    This product is primarily used for the sheathing of flexible cables in wind power generation that require halogen-free and low-smoke properties in European markets. It is also applicable to other European-standard rubber-sheathed power cables. The material exhibits torsion resistance, cold resistance, flame retardancy, oil resistance, halogen-free/low-smoke environmental compatibility, and high mechanical physical properties. The development of this product significantly reduces the cost of imported materials while outperforming them in performance. Cables manufactured with this material have been exported to wind power projects in Europe, South America, Africa, and Southeast Asia, playing a critical role in breaking foreign technological monopolies and capturing the international market.

  • JC281FR：低烟无卤护套之GE风电电缆

    JC281FR：低烟无卤护套之GE风电电缆

    该产品主要应用于欧洲国家对无卤低烟提出要求的风力发电用软电缆的护套，也可用于其他符合欧标的橡套电源线，具有耐扭性、耐寒性、阻燃性、耐油性、无卤低烟环保以及较高的机械物理性能，该产品的开发大大降低进口材料的成本，且性能优于进口材料。用该材料生产的电缆已经出口到欧洲、南美洲、非洲及东南亚等风电项目，打破国外技术垄断，抢占国际市场具有重要意义。

  • Kingz embraces compounding capacity with Buss PR 140

    Kingz embraces compounding capacity with Buss PR 140

    With quality and efficiency in the balance, Applast embraces its compounding capacity with sets of 140 mm Buss Ko kneader.

  • Kingz adds filtration system to insulation compound quality

    Kingz adds filtration system to insulation compound quality

    Applast adds self-cleaning filter system to our EPDM Insulation compound line, which features continuous extrusion and filtration. With this add on, our line is claimed to be operating at 24/7 for many weeks without major pressure or flow fluctuations.

  • Building shared, safer and greener life

    Asia’s first 66kV offshore wind torsion cable is in operation. With high-voltage twisted design and diameter of 105mm, it is suitable for offshore wind turbines of 8MW and above. Applast plays an active role in the R&D and supply chain.

  • Applast contributes to the world’s largest blade diameter wind turbine

    On May 9, 2019, Shanghai Electric 6.25-172 offshore wind turbine successfully completed the hoisting of the first wind turbine of Shanghai Lingang Offshore Wind Power Phase I Demonstration Project. This unit is the largest offshore wind turbine in Shanghai and also the world’s hoisted blade diameter. This landmark re-charges the forefront of China’s offshore wind power for six years. On March 20, 2009, China’s first 3MW offshore wind turbine provided by Sinovel Wind Power was successfully hoisted at the Shanghai Donghai Bridge Wind Farm, and it was by then China Offshore Wind Turbine Group broke through 3MW.

    Shanghai Linggang Hoisting Site

    These breakthroughs are substantial in China’s wind power history marked by engineering precision, materials innovation and seamless joint force between companies. The cable kit used in the wind turbines were provided by FE cable company, a wholly-owned subsidiary of Far East Smart Energy Co., Ltd. (abbreviation: Smart Energy Stock Code: 600869). Applast provides tailored insulation and sheath compound by request from FE R&D team, which makes the flex-cable resistant to demanding environment. For more information, please visit http://www.applast.co or email us at info@applast.co

  • Kingz Polymer Behind the Story of Locomotive Overhaul

    Kingz Polymer Behind the Story of Locomotive Overhaul

    Taxes, 2017 Summer. This was the third time FAR EAST Cable team came to the states visiting one of the major locomotive facility in north America.

    Above: Far East Cable (FEC and below) with Managing Director Jing Chen (middle) leading the team, FEC Technician Yilei Wang with facility tech leader. Below: Texas factory scene.

    Behind the scene is the client’s rebuilding factory recently set up in DFW. ”This is an extreme makeover at scale” according to the client, ”Advances in new train technology as well as sensors and software have made the overhaul market extremely attractive to the freight rail industry”.

    Applast supplies FEC both electric compounds for power and control wire and cable, in size vaires from 1 to 24 AWG. They are consistent by various OEM and Tier 1 approvals. With ease of extrution these compounds are well suited for high speed thin-layered extrution.

    Above: Thin layer extrusion at FEC facility and wire and cable harnessing facility.

    Extremely heat and frost resistant, flexibly adapted to installation, Applast® IR201FR and Applast® IR202FR are robust designed to withstand engine oil, scratches, hot edged pressure, moisture, fire or even environmental concern, as you name it.

    Being cut into certain lengths these wire and cable are ready to integrate into “the suite of digital solutions intended to enable a digital freight rail ecosystem”.

    ”Yes, and we are glad our polymer mixer played a role in these rejuvenation process”. Says Dr. Wu, Applast managing director.

    In fact, these refurbishment involves dissembling cabs, trucks, engine and other parts. Overhaul crews sands off the old paint and cleans out the engine cylinders, upgrades to digital system with wiring sensors. “This will allow the railroad to remotely monitor and troubleshoot the truck, “according to the workshop manager.

    Some of these locomotives are 25 years old and they’ve done their job well. They come for an extreme makeover and when they leave, they will be ready to roll for a couple more decades with all new gears.

  • Applast Tells The Wind Story

    Did you know one third of the wind turbine cables are protected by Appren® rubber compounds? Here comes one show case of how it is done with combined science, engineering and field cooperations.

    Pic 1. Field shots in Korea

    This project involves medium voltage 15 KV cables delivered in site Korea. Cables are fixed in the tower and hooked up after which contractor runs the final haul. “There is no such place as offshore Korea”, says Far-East Cable engineer. But the team leaned into it, adapted to it. Under harsh field conditions plus extorted daily facility charges, the contract itself lays bit on easy installations.

    Pic 2. “Working life in wind tower” – Field Engineer at Far-East Cable

    With elaborate configuration of (1*50 plus shields, FR foils, and more, Pic 2) the cable is heavy and bulk in size. By choosing Appren® IC 1035 EP compound, FAR-EAST CABLE managed to shrink the insulation thickness – without sacrificing physical and electrical performance.

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    At Applast, our chemists designed the insulation formula with balanced consideration and we are sharing it with our community:

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    Technically, Translink grade clay is strictly selected ore vein from Montana, USA, which has the best purity and least content of iron. After grinding, calcination, and coating, it is branded by BASF targeting wire & cable industry. However, one can always fortify hydrophobicity of clay by adding 1 PHR of vinyl silane in situ or separately. This step will ensure the insulation to withstand stringent agency test regarding “power factor” or “change of Delta” as described in UL 62 or IEC to the equal.

    Chart 1 Keith 6517 Polarity Sweep & Wet Electrical Trail

    Another key to a good insulation is the extrusion. To minimize the area electric discharge a smooth tension between either layer junctions should be obtained – joint with outer semicon, inner surface with inner semicon – to be smooth. Traditional formulations involve high ethylene polymer gum to fit the physical and electrical strength. However, the process window shuts down and the extrusion often results uneven surface.

    Haake.png    Pic 4. Surface comparison @ Haake®Polylab

    To address the above problem, medium molecular weight distribution EP grade is selected here. Ziegler-Natter electrical grade is superior to newer metallocene grade due to less metallic residue and wider extrusion window. Nonetheless in Appren® IC1035, by further adding Fatty-Zr/Titanate2 Coated CaCO3 in association with the above effort plays a functional role in the whole. This combination lowered the crystallinity of the compound by 20 Celsius upon observation. Trials are performed in Haake® Polylab system (557-9300) with set up of SSE (557-2804), Melt pump (557-2480) and rod die (557-3235).

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    Chart 2. Comparison of Process window (Appren® grade vs “Equal Market grade”)

    The final compounding involves “One Step Compounding” process using TSE published By Coperion years ago (http://www.coperion.com). We will not recite the whole again in this paper. Nonetheless, detailed work flow will be provided here for reference, and roughly 400kg / hr throughput is obtained. Final products are pelletized, dried and stored in octabin for usage. Further request upon process and machinery information, you can contact us at info@applast.co.

    Actual cable is extruded in Trioster® trifle extrusion system with Sikora® Xray auto alignment. All three layers, inner semicon (Appren®SCN101), insulation (Appren®IC1035) and outer semicon (Appren®SCW101) are extruded at once along with the foiled conductor and vulcanized in the steam.

    Pic 5. Extrusion Field at Far-East Cable

    This process is well known in cabling industry. Further process involves winding up, electrical and physical test, braiding, and final extrusion with the sheathing (Appren® JC45LT). “Between -45 to 105 celsus, the final cable is expected of 25 yrs of service life upon installation” – FarEast Cable.

    Pic 6.“Sustainable makes it better by Acciona”

    “The challenges we face in the immediate future, the new trends in services, products and technologies, all form an important part of sustainable development”, says Acciona. Indeed, these endeavors are minute part of our effort in supporting sustainable societies, really. Here at Applast, material innovations are happening each day. This is the least we can do to help our community.