CUSTOM
BELLOWS
MULTILAYER RECTANGULAR BELLOWS VS SINGLE LAYER WELDED CORNERS BELLOWS – CO2 EMISSIONS
Rectangular expansion joints in service study clearly indicates, that besides welding and material emissions, fatigue life performance of bellows has significant impact on Co2 emissions as well. Due to manufacturing improvements in bellows forming and improved fatigue life, CUBE bellows is considered to be low Co2 emissions product. Based on this study, the average Co2 emissions improvement with use of Multilayer Rectangular Rounded Corner Bellows produced by CUBE may be considered as app. 1929 % compared with Single Layer Welded Corners. Presented below Co2 emissions values were made with use of generic input and should be considered as informative only, however If needed, more thorough analysis may be performed upon request.
Due to importance of Co2 emissions reduction, it is becoming crucial to reduce production energy consumption and increase cyclic life time of components made of stainless steel, which growth in the use has been highest of any material in the world.
In this document we will show the improvement in Co2 emissions of multilayer rounded corners rectangular expansion bellows compared to the welded 90 degrees single layer expansion bellows.
This case study is based on different approaches to rectangular bellows manufacturing and factor of average amount of Co2 generated in Stainless Steel production. Below table contains 4 sizes of bellows made with use of CUBE technology compared to equivalent in size (however not equivalent in fatigue life) old fashioned welded corners bellows. Methodology of the comparison is based on kg of stainless steel used for production of bellows together with welding time needed for welding of bellows material and consideration of needed filler metal deposit. Additionally to that, CUBE fatigue improvement factor will be used for accounting of welded corners bellows replacements during operation. Due to complexity of the calculations, the effect of the start ups and shut downs together with not scheduled maintenance related to old fashion bellows production will not be taken into account, however it should be considered as conservative approach.
| Dimension [mm] |
800 x 600 |
1200 x 800 |
2000 x 1000 |
3000 x 1500 |
|---|---|---|---|---|
| Movements [mm] |
Ax: 10, Lat: 5 |
Ax: 10, Lat: 5 |
Ax: 10, Lat: 5 |
Ax: 10, Lat: 5 |
| Single Bellows Length [mm] |
160 |
160 |
240 |
240 |
| Square Welded Corners Stainless Steel Co2 consumption [kg] |
4.9 |
4.9 |
13.9 |
20.2 |
| Rounded Multilayer Corners Stainless Steel Co2 consumption [kg] |
3.9 |
3.9 |
10.8 |
17.8 |
| Square Welded Corners manual welding Co2 consumption [kg] |
0,27 |
0,27 |
0.615 |
1.23 |
| Rounded Multilayer Corners automatic welding Co2 consumption [kg] |
0.043 |
0.043 |
0.05 |
0.11 |
| Fatigue Improvement [factor] |
10.07 |
8.43 |
16.9 |
25.35 |
| Square Welded Corners total in service Co2 consumption [kg] |
52.06 |
43.58 |
245.3 |
543.25 |
| Rounded Multilayer Corners total in service Co2 consumption [kg] |
3.94 |
3.94 |
10.85 |
17.91 |
| CUBE Co2 emissions improvement [%] |
1320.36 |
1105.33 |
2260.86 |
3033.22 |
UL. TRANSPORTOWA 1
70-715 SZCZECIN
CUSTOM BELLOWS SP. Z O.O.