I N S P I R E D I N N O V AT I O N
Integrated Carbon Fiber Lines
Installation and optimization of complete
carbon fiber production lines for peak performance
Value
differentiated
technology for
next generation
performance.
Single Source Provider
Integrated Carbon Fiber Production Lines
Value differentiated technology, service and performance
Along with the world’s
leading oxidation technology,
Despatch is a single-source
provider of the complete line
of equipment sub-systems
including: LT and HT
furnaces, surface treatment,
sizing, drying (both contact
and non-contact), material
handling equipment and
integrated control systems.
Despatch Industries is a reputable, single-source
provider of integrated carbon fiber production lines.
Our technology is scalable, from small-volume
research-scale to full production scale, which allows
our customers to prove process ability and achieve
consistent, repeatable processing results.
We provide the full line of equipment and a complete
service package that includes line installation,
commissioning and optimization. Despatch has
the capability and experience of working with
the customer to coordinate facility design and
construction, creating a partnership between the
equipment and facility components of installing
an integrated production line. Our integrated line
solutions enable customers to achieve their specific
process parameters and production goals.
Despatch’s complete line solution is brought to life by
its integrated process control software system that is
vital to the performance of the line. Our sophisticated
PLC-based software system can replace a traditional,
cumbersome distributed control system (DCS), and
allows operators unmatched process control of every
aspect of the line and comprehensive data logging and
reporting capabilities.
The world’s leading carbon fiber oxidation technology
Reinventing oxidation technology for next generation performance
Despatch oxidation ovens have been the top choice
of carbon fiber manufacturer’s for more than 30
years. We recently took our oxidation oven through a
reinvention process where we addressed opportunities
for improvement in the current technology and
design. We are implementing and testing these new,
enhanced features that will essentially reinvent oxidation
technology and performance for the next generation of
operation.
The next generation in Despatch oxidation technology
includes: improved airflow uniformity and mapping,
air-tight sealed process chambers, hybrid heating and
lower temperature variance. Improving the integrity
of the process chamber creates better temperature
uniformity and airflow balance. Uniformity and
balance in the chamber leads to lower temperature
variances and a more uniform oxidation process.
Improving the stability of the air in the oxidation oven
allows for more flexibility in oven operation, increased
fiber throughput and reduced operating costs.
The addition of hybrid heating technology allows
operators to instantly switch between a gas and electric
heat source. All of the oxidation oven’s new technology
enhancements focus on improving airflow, saving
energy, and allowing customers to produce the highest
quality fiber at the lowest operating cost.
Despatch uses a new airflow
mapping metrology tool to
confirm airflow uniformity
and balance.
High Performance LT and HT Furnaces
Provided by industry partner, Furnace Engineering
Following oxidation, precursor material undergoes
several stages of pyrolysis to achieve a fiber with the
desired properties. These critical stages of pyrolysis
take place in the low temperature pre-carbonization
(LT), and high temperature carbonization (HT)
furnaces.
The LT and HT furnaces in Despatch’s integrated
lines are manufactured by long-time industry partner,
Furnace Engineering out of Melbourne, Australia.
Furnace Engineering’s fresh approach to the LT and
HT furnaces offer innovative and efficient designs that
are new to the LT/HT platform and the industry.
Furnace Engineering’s unique furnace designs feature a
robust, airtight casing with adjustable end-seal systems
that effectively exclude air, with reduced nitrogen
consumption. The insulation and heating designs make
the furnaces more efficient and energy conscious.
Losses to cooling water are minimized, yet the fiber
emerges cool from the process. Zone temperatures in
each furnace are precisely controlled and monitored by
the Despatch PLC control system.
Surface Treatment, Sizing and Drying
Critical final steps of carbon fiber production
During surface treatment, the surfaces of the fiber
filaments are chemically etched through an electrolysis
process. Despatch’s surface treatment equipment
provides consistent, uniform etching across all fiber
filaments and is designed to ensure that, post-etching,
all electrolyte solution is efficiently and effectively
removed from the fiber prior to drying.
Contact drying takes place after surface treatment
to reduce the moisture content on the fiber. Contact
drying involves weaving the fiber through a single
series of stainless steel, heated rollers that apply
direct, uniform heat to the filaments for quick and
efficient drying. Fiber exits the dryer with less than 1%
moisture content.
Sizing is the final finishing process where fiber is
passed through a liquid sizing solution that coats
individual fiber filaments and enables handling of the
fiber without incurring filament damage. Despatch’s
sizing equipment is capable of processing various
types of size fluid as required by the customer, and
the equipment provides an even distribution of size
on the fiber. Recipes and fluid levels are conveniently
controlled through the PLC. Size fluid is continuously
circulated via a pumped filtration system.
Non-contact drying takes place after sizing and is
performed with a recirculation air dryer for complete
drying through uniform, low velocity airflow. This
drying method maintains uniform amounts of size
on the fiber throughout the drying process. The
temperature and airflow levels of the dryer are PLC
controlled and the dryer features a filtration system to
capture debris.
Despatch offers
its own surface
treatment, sizing
and drying
equipment to
perform the final
process steps
in carbon fiber
production.
Material Handling System
Precise fiber transport through the process line
Despatch’s material handling equipment includes
creels, winders, drive inverters and rollers. Our winder
and creel equipment pieces are sourced through
qualified and highly regarded industry vendors.
As PAN moves through each of the manufacturing
processes to convert to carbon fiber, the control of
tension and speed throughout the complete process is
critical.
Our integrated material handling system is engineered
for safe operation and peak performance. Our lines
feature clear visibility and easy accessibility to the rolls
for clearing any wraps quickly and efficiently.
Line speeds and tensions are set in accordance with
process specifications and are closely monitored and
controlled through the PLC.
Integrated Carbon Fiber Line Software Control System
Industry specific PLC control system for precise control
and flexibility of production lines
Despatch’s integrated process control software
system offers differentiated technology and control
functionality not available from any other carbon fiber
equipment provider. Despatch’s integrated PLC control
system software is written by industry experts with
more than fifteen years of experience writing code
for systems specifically designed to run carbon fiber
production lines. Applying this knowledge and insight
to create the control software allows Despatch to offer
a carbon fiber specific integrated system that is tightly
tied to the critical needs of the customer.
Features of the integrated control system include:
 Individual
HMI consoles at key locations
for convenient access
 Full
system diagnostics to aid troubleshooting
 Comprehensive
alarm system
 Data
logging of all real time process parameters
and variables
 Clear
and intuitive HMI display screens
 Reporting
 User
and data logging capabilities
access control for operational security
The control system is capable of isolating each equipment
subsystem in the line to precisely monitor and control
temperature, speed, ramp rates, liquid solution levels, and
many more specific performance metrics.
CFR - Carbon Fiber Research
A complete carbon fiber line in a
research-scale package
The Despatch CFR Series is a complete carbon fiber
production line in a research-scale package. The CFR
Series allows users to run trials to study and test fibers and
processes with the same quality of a full-scale production
line. The flexibility, functionality and size of the CFR
make it an ideal solution for universities, laboratories,
new market entrants and existing manufacturers.
The CFR is available as a complete continuous production
line or as independent subsystems, complete with
material handling and integrated or individual equipment
control systems.
SERVICE AND TECHNICAL SUPPORT
GLOBAL HEADQUARTERS
www.despatch.com
service parts: 1-800-473-7373
international service/main: 1-952-469-8230
service fax: 1-952-469-8193
main phone: 1-800-762-0110
international/main: 1-952-469-5424
sales: 1-800-762-0550
international/sales: 1-952-469-8240
8860 207th Street West
Minneapolis, MN 55044 USA
[email protected]
[email protected]
[email protected]
© 2014 Despatch Industries. All rights reserved. Despatch is a registered trademark of Despatch Industries in the U.S. and other countries. CFIL 2-14