Advances in Plastics Processing I 2013 I Page 1 - K-Tron

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Advances in Plastics Processing I 2013 I Page 1
Advances in twin screw compounding
Dipl.-Ing. Sabine Schönfeld
Dipl.-Ing. Peter von Hoffmann
BU Engineering Plastics & Special Applications, Coperion GmbH, Stuttgart
Customized solutions are our response to complex
challenges.
Coperion is the worldwide market and technology leader in Compounding & Extrusion,
Materials Handling and Services – as well as being a partner for global corporations and small
and medium-sized enterprises in the plastics, chemical, food and aluminium industries.
Company history
Werner &
Pfleiderer
Waeschle
1879
1957
Foundation
Werner &
Pfleiderer
First ZSK twin
screw extruder
1900
1955
Foundation
Waeschle
Bulk materials
processing in the
plastics industry
2001
2007/2008
Merger to form the
Coperion Group
Realization of the
world´s largest
plants for polyolefin
production
2002
ZSK NT
development
Hartmann
Keya
PELL-TEC
2007
Acquisition and
integration into the
Coperion Group
2004
Acquisition and
integration into the
Coperion Group
2008
Brand
consolidation /
merger to form
Coperion
Successful
launch of ZSK Mc18
series
2012
Majority stake
in PELL-TEC
Majority stake
in Weicom
Hillenbrand, Inc.
acquires Coperion
2010
2012
Weicom
2012
Coperion part of the
Process Equipment
Group
Hillenbrand, Inc.
Process Equipment Group
3 Competence Centers
Clear structures for fast, efficient and reliable solutions – worldwide
compounding & extrusion
materials handling
service
ZSK, STS and CTE – three
letters embody modern processing
machinery and plant design for
compounding technology. Our twinscrew compounders continually
set new standards in the plastics,
chemical and food processing
industries.
Hand in hand – we master all
process steps in the treatment and
handling of bulk materials. Quality is
our benchmark when conveying,
elutriating, homogenizing, storing,
dosing or thermally treating the
products.
Your success is our success –
already during installation and commissioning of a machine or plant a
service team is on-site. Maintenance,
spare parts service, service consulting,
training and modernization – we use
our experience and competence to the
advantage of our customers.
Close cooperation of the 3 Competence Centers
Compounding &
extrusion systems
Bulk materials plants
and components
Global
services
Global presence in the
plastics, chemical, food
and aluminium industries
Coperion worldwide
Headquarters
Stuttgart, Germany
Compounding & Extrusion
Stuttgart, Germany
Materials Handling
Weingarten, Germany
Service
Stuttgart / Weingarten, Germany
Coperion companies and
offices
Agencies
Facts and figures
Key figures of Coperion
Compounding systems installed worldwide, over
10,000
Bulk materials handling systems installed worldwide, over
8,000
Employees worldwide, over
1,900
Network of locations worldwide
29
Product range
ZSK series
STS series
CTE / CKY series
/T
ec
h
ua
lit
y
Q
ZSK Mc18 and Mv Plus
(highest efficiency and
technology)
e
ic
Pr
no
lo
gy
Range of Coperion twin-screw compounders
STS advanced
leading machine for mid tier segment, lower
investment cost / sold worldwide
CTE and CKY machine series made by Coperion (Nanjing), China
(for China + Asia market)
Technology /
Performance
Positioning of Coperion Twin Screws
Torque level 18
Wide variety of
applications
and materials
ZSK
STS
CTE
Torque level 5,6
Robust design,
no CE certificate
Torque level 10
Standard
applications
and materials
Price
Product range
Melt pumps
Screen pack changers
Pelletizers
Modular and turnkey plants
Facts and figures
Compounding & Extrusion
Over 130 years of experience with mixing and kneading processes
Pioneering work and continuous development of the closely
intermeshing, co-rotating twin-screw extruder
Over 10,000 compounding systems installed worldwide
Comprehensive product portfolio: from laboratory extruder
ZSK 18 MEGAlab to largest extruder ZSK 420 MEGAcompounder
Throughput rates from 1 kg/h to 100 t/h
Turnkey compounding systems from raw material feeding to
downstream pelletizing and handling equipment
Scope of supply
Example: Highly filled compounds
Dosing and Extruder
Discharge equipment
Strand Pelletizer
Waterring Pelletizer
Underwater Pelletizer
Compounding and extrusion applications
Polyolefins
Polyolefins
Engineering Plastics
and Masterbatch
Engineering Plastics,
Masterbatch, Wood Composites,
Long Fiber Technology
Special Applications
PVC, Temperature- and Shear-Sensitive Plastics,
Powder Coatings, Toner, General Chemicals,
Reaction Technology,
Food, Pharma
Implemented compounding and extrusion systems
Polyolefins
814
Engineering Plastics
4,350
Masterbatch
1,160
Long Fiber Reinforced Plastics
Temperature- and Shear-Sensitive Plastics
(PVC, Cable, TPE)
36
1,659
Powder Coating, Toner
602
Direct Extrusion / Calender
160
Chemical Reaction Technology
543
Food Extrusion
270
Others
766
Total
10,360
More than 25% of all compounding
and extrusion systems worldwide
were installed by Coperion.
Production and assembly locations
Coperion, Ramsey (USA)
Coperion, Wytheville (USA)
Coperion, Stuttgart (D)
Coperion, Nanjing (CN)
Research & development
The most comprehensive test labs in the industry: in Stuttgart (D),
Ramsey (USA) and Nanjing (CN)
30 compounding systems worldwide permanently available for testing
Experience from 5,000 compounding tests and 40,000 product
analyses in our own laboratories
Simulation programs to calculate flow processes, optimize existing
processes and the design of individual components
140 patents and patents pending
Services of Coperion’s process engineering
Customer Support
Conception and dimensioning of extruders and
plants
Process
Development
Development of new processes and required
components
Process Optimization
Improvement of process stability, efficiency
and product quality
De-Bottlenecking
Extension of production capacity of plants
through optimization
Product Analysis
Evaluation of product properties in laboratory
Training
Training at Coperion’s training facilities or on
customer site
Rental Equipment
Long term product development and process
optimization on customer site
PELL-TEC Pelletizing Technology GmbH
Since January 2012 a Coperion company as a further consistent step
in strengthening Coperion‘s competence as a systems supplier
Specialized in pelletizing technology for plastics processing and
recycling
Technical solutions for entire pelletizing process from melt discharge
through to the ready-to-use pellets
Throughput rates of up to 6,000 kg/hr, for small and medium-size
extrusion systems
From planning and commissioning through to the after-sales supply
of spare parts
Packaging & palletizing technologies for plastic compounds
Plastics manufacturing
Plastics compounding
 The complete process chain from one single source
The twin screw extruder ZSK Mc18
– Experiences with Highest torque
ZSK Mc18– Overview and history
Self cleaning intermeshing twin screw
Working principle
Company Presentation I 2013 I Page 25
ZSK Mc18
Identical screw elements as former Mc/McPLUS
ZSK Mc18 – Design criteria of the ZSK
Do = Outer diameter
Di = Inner diameter
a = Centerline distance
Do / Di = Diameter ratio
determines shear, degassing and powder intake
Do
Md / a3 = Specific torque
determines power density and filling degree
Di
a
n = Screw speed
determines shear and mixing
Do / Di = 1,5 to 1,6
Md / a3 ≥ 11,0 Nm/cm3
n ≥ 800 min-1
ZSK – Evolution of torque and volume
ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
n = 150 min-1
ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
n = 300 min-1
ZSK Supercompounder
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
n = 600 min-1
ZSK MEGAcompounder
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
n = 1200 min-1
Increase of
free volume (100%)
and of specific torque
Increase of free volume
(additional 40%)
ZSK Mc PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
n = 1200 min-1
ZSK Mc18
Do / Di = 1,55
Md / a3 = 18 Nm/cm3
n = 1200 min-1
Increase of torque
ZSK MEGAvolume
Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3
n = 1800 min-1
ZSK Mv PLUS
Do / Di = 1,80
Md / a3 = 11,3 Nm/cm3
n = 1800 min-1
ZSK Mc18 – Machine technology - new power density of 18 Nm/cm³
ZSK Mc18 – Fully protected electrical manifold
•
Assembly optimized parts groups
•
Fully closed cable trays in IP54 or IP65
•
Cable entry from bottom  no cable glands
•
New heater cartridges „4-in-1“ with junction
box
•
Heater cartridge can easily be replaced as
single part
=> Coperion‘s new way for electrical installation
ZSK Mc18
Heating with heater cartridges
ZSK Mc18 – New cooling manifold
•
New solenoid valves even for aggressive, polluted fluids, highly resistant against pollution and
baking. Reinforced diaphragm resp. directly operated (depending on machine size)
•
New square-shaped cooling tubes with flexible hose connections, positioned below barrels
•
Mounted at the barrels support pillars
Free accessibly machine bed surface for
cleaning
ZSK Mc18 – New insulation covers
•
New, user-friendly, segmented barrel insulation covers around the whole barrel!
•
For optimum energy efficiency
„pampered“ insulation, even on the
bottom side!
ZSK Mc18 – Shrink-fit barrel liners for improved heat transfer
• Modified base barrels
- Shrink fit liners
- Radial cooling bores for reduced thermal
deforming
- No welding  reduced failure rate in
manufacturing
- Complete heat insulation
• Compatible for existing machines
Optimum heat transfer from barrel body
and liner to the melt
ZSK Mc18 – Die head (example SK70)
•
The die head for ZSK
systems features
optimum flow geometry
•
It ensures maximum
throughputs with gentle
product handling
•
The quick-release device
enables fast, easy
assembly and
disassembly
• Homogeneous
temperature distribution
• No local overheating
• No freezing of polymer
ZSK Mc18 – Wear protected die plate
Base material (standard material)
Wear protected border
Hard metal inserts (carbide)
ZSK Mc18 – Wear protected die plate
Highest shear rate
Polymerflow
Lifetime extension by factor 100 for glass filled
polymers (GF > 30%wt).
(Criteria: Diameter increase from 4.5 mm to
4.8 mm / compared with Coperion hardened material
of construction 1.2379 with HRC ~52)
ZSK Mc18 – All advantages at a glance
Increase in torque of 30%
Increase in throughput of up to 30%
Improved compounding quality by gentle processing
with a higher filling degree
Maximum flexibility due to broader operating window
Reduced melt temperature at higher output
Increased energy efficiency by reduced specific
energy input
Significantly improved productivity
Proven high ZSK safety enabled by new designs and
developments
ZSK Mc18 – Technical data
ZSK
Max. torque per
shaft [Nm]
Specific torque
Md/a³ [Nm/cm³]
Max. screw
speed [min-1]
Max. drive
power N [kW]
Screw diameter
[mm]
18 MEGAlab*
38
11.3
1,200
10
18
26 Mc*
106
11.3
1,200**
28
25
32 Mc18
315
18
1,200
83
32
45 Mc18
930
18
1,200
246
45
58 Mc18
2,000
18
1,200
529
58
70 Mc18
3,500
18
1,200
926
70
82 Mc18
5,700
18
1,200
1,508
83
92 Mc18
7,500
17
1,000
1,654
92
106 Mc18
11,900
18
1,000
2,617
106
119 Mc18
15,300
17
1,000
3,373
118
133 Mc PLUS
18,100
13.6
1,000
3,980
133
* Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version.
STS – Standard Twin Screw
This is what people typically associate with “Chinese machine manufacturing”!!
This is Coperion (Nanjing) Machinery Co. Ltd.
Manufacturing / Assembly hall
lity
a
man
rion
e
p
Co
by rmany
Ge
Qua gement
More
than 450 machines
per year
Coperion Nanjing Manufacturing
Screw element manufacturing
Quality control center for screw elements
Wear Protection Liner grinding shop
Computer controlled base frame manufacturing
Assembly floor for control panels
Machine assembly floor
Typical machine assembly at Coperion (Nanjing) Machinery
Absolutely clean and well arranged assembly floor for each STS close to
MADE IN GERMANY!
Factory acceptance test (fat) with polymer allows for fast and
troublefree installation and start-up on customer‘s site
Factory acceptance test with product
CE certification
professional over-sea crating
Final top-quality products by Coperion
(Nanjing) Machinery
Coperion‘s Highest Priority
Quality control
Quality control
Quality control
Quality control
1. Quality Control Incoming Goods
1.1 Chemical elements test to ensure the raw material 100% qualified
Chemical elements test report
Test Equipment
1. Quality Control Incoming Goods
1.2 Material Crack Detection
Ultrasonic scanning, magnetic inspection and permeation detection on key parts
shaft, gear and elements roughcast - no crack.
Ultrasonic scanning
Magnetic inspection
Permeation detection
2. Production Quality Control
2.1 Hardness test
Surface hardness and interior hardness grads test to ensure heat treatment quality
Hardness test system
2. Production Quality Control
2.2 3D Measuring System to Ensure Precise Dimension
Strictly control manufacturing precision on Barrels, gearbox houses and screw
couplings by 3D Measuring System FARO
3. Assembling Quality Control
Concentricity Control
The coaxiality (concentricity ) along gearbox out-shaft, screw shaft and barrel 8 holes to be
controlled in less than 0.1mm, to ensure smooth running of screw shaft, and reduce
abnormal abrasion and prolong using life of barrels and screws.
STS commitments
• STS is built acc. to Coperion‘s worldwide quality philosophy
• Coperion is granting for ZSK and STS 12 months warranty*
• Coperion is offering a full After-Sales Service for STS as for all
Coperion products
• Coperion is keeping a large spare parts stock for STS
* 12 months after start-up , but no longer than 18 months after delivery EXW
Turnkey Systems
ZSK
Modular and Turnkey plants
Content
•
•
•
•
•
•
•
•
Company information
ZSK Mc18 – technology, design, key figures
FET – Feed enhancement technology
ZS-EG – Twin screw side degassing
Example: High filled CaCO3 compounds
Modular- and Turnkey Compounding Lines
Service
Summary
Example Modular line with ZSK 82 and K-Tron feeders
Modular and Turnkey Compounding Lines
Assembly and I/O check in Stuttgart – ready for operation
Modular and Turnkey Compounding Lines
Installation of 4 lines in China
Thank you very much for your attention.

Advances in Plastics Processing I 2013 I Page 1 - K-Tron

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