Polyurethane Pipe for Monocrystalline Silicon Production
Client introduction
Our project client is a prominent and highly respected domestic manufacturer specializing in the production of monocrystalline silicon materials. These materials are crucial components in the rapidly growing photovoltaic new energy sector, which focuses on harnessing solar power to generate clean and sustainable electricity.
The challenge
Producing monocrystalline silicon requires a high-temperature and ultra-clean environment. Thus, using iron and PVC pipes in the production line have long faced the following issues:
- Frequent damage: Pipes are prone to breaking as a result of friction and fluctuations in temperature, necessitating replacement approximately every three months. This leads to significant costs due to the associated downtime.
- Noise pollution: Vibrations from metal pipes generate high-frequency noise, which can disrupt the work environment and pose health risks to employees.
- Inefficient transport: Traditional pipes possess rough inner surfaces that can capture silicon powder, thereby diminishing the effectiveness of raw material transportation.
The primary technical challenges involved the intricate design of their molds and the compatibility of materials. It was essential to accommodate various pipe specifications to achieve seamless connections. Additionally, the protective cover needed to exhibit flexibility for effective shock absorption and possess wear resistance to prevent damage from silicon powder.
Our solution
We engineered a modular mold design that incorporates split structures, allowing for adaptation to various pipe diameters. Additionally, we integrated a corrugated buffer layer to effectively minimize vibrations.
Our polyurethane protective sleeve was specifically designed to absorb shocks from silicon and reduce noise levels, while the inner layer, coated with PTFE, was implemented to decrease the adhesion of silicon powder.
Furthermore, during the assembly process, we utilized a snap-on sealing joint, which significantly enhanced production efficiency by 60%.
Results
By changing from PVC to polyurethane, the service life of our client’s pipes was extended from 3 months to 2 years, and the annual maintenance cost was reduced by 85%.
We achieved a breakthrough in this project by designing our own mold despite the complexity as the cost was only 30% of a previous imported solution.
