New hydrocyclone design with DuPont™ Zytel® nylon resin that makes it more strong and durable

Hydrocyclone-341x171

Issue:

Current engineering and industrial is looking at change in materials for applications due to critical factors of optimizing cost, lower weight and improving performance leading to zero defects or repairs.

Gone are the days of any parts being over engineered, today parts are vigorously analysed and re-engineered to optimize price, weight, and performance.

The practical effect of all of this is that many steel parts even in traditional irrigation systems are being put under review to see if there is a better material.

Challenge:

Hydrocyclone is the key part of irrigation system, and uses centrifugal force to separate particulates from irrigation water in order to protect pumps, valves and other irrigation systems from damage and abrasion caused by suspended solids. Traditionally, these are made of metal.

Automat is leading irrigation company and one of the largest manufacturers of irrigation products globally. They had been trying to redesign the part in order to make it stronger and durable, but every time, it was not getting required performance in terms of strength.The ultimate aim of the redesign exercise was to improve the life of the cyclone units and reduce their overall life costs.

The main issue faced by the units fabricated from metal is corrosion, which can eventually cause complete failure. Plastics could certainly address the corrosion issue, but there was always a concern regarding their strength, especially when you consider some of the forces and pressures involved.

Solution

Automat India has been DuPont customer for other advanced polymer material and contacted DuPont. Both the organizations collaborated to create a successful solution using DuPont™ Zytel® nylon resin. This advanced material used in the new hydrocyclone design offered the required performance level, such as dimensional stability, outstandingcombination of stiffness and toughness, tolerance for moist and hard-water environment, coupled to very good flow characteristics, which make it suitable for filling the 2.5kg part and providing it with a good surface finish.

DuPont also helped Automat undertake life testing, which was important for the worldwide warranties they intended to offer.

This has prompted Automat to come forward with innovations to show what is possible when it comes to metal replacement with engineering plastics in parts including filters, parts of sprinklers, valve seats, fastening systems, clamps.

Benefit:

Zytel® nylon was selected to replace metal because it retains rigidity at high temperatures and offers a better resistance to corrosion. With its adoption, the plastic hydrocyclone filter application offers multiple benefits including greater service life, enhanced robustness and lighter overall weight by 8 kgs. The reduction of the overall weight of the unit has resulted in reduced operator installation effort and reduced transportation costs for export sales.

Since their invention by DuPont over 50 years ago, DuPont™ Zytel® Nylon Resins have been the most widely used of all engineering plastics. They are tough, withstand repeated impact, and are highly resistant to abrasion and most chemicals. Molded articles retain their shape at elevated temperatures, are strong in thin sections, and have low coefficients of friction.

“Plastic Hydrocyclone Filter for Micro Irrigation” made with DuPont™ Zytel® Nylon has been selected as 2014 winner for the 4th National Awards for Technology Innovation in the category of Polymers in Agriculture and Water Conservation.

The National Awards for Technology Innovation in Petrochemicals have been institutionalized by the Ministry of Chemical & Fertilizers, Government of India, with a view to incentivizing meritorious innovations and inventions in various fields of petrochemicals and downstream plastics processing Industry.