ZSK Mc18
Transcription
ZSK Mc18
| page 1 Twin screw compounder ZSK and STS - perfect performance and economic solution Dipl.-Ing. Roland Elsaesser, Sales Manager Compounding&Extrusion, Coperion GmbH Stuttgart Jakarta 2014 | page 2 Twin screw compounder ZSK and STS - perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 3 Twin screw compounder ZSK and STS - perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 4 Company history Werner & Pfleiderer Waeschle 1879 Foundation Werner & Pfleiderer 1900 Foundation Waeschle 1957 First ZSK twin screw extruder 2001 2007/2008 Merger to form the Coperion Group Realization of the world´s largest plants for polyolefin production 2002 1955 2008 ZSK NT development Bulk materials processing in the plastics industry Hartmann Keya 2007 Acquisition and integration into the Coperion Group 2004 Acquisition and integration into the Coperion Group Brand consolidation / merger to form Coperion 2012 Hillenbrand, Inc. acquires Coperion 2010 Successful launch of ZSK Mc18 series 2012 PELL-TEC Majority stake in PELL-TEC 2012 Majority stake in Weicom Weicom Jakarta 2014 | page 5 Coperion part of the Process Equipment Group Hillenbrand, Inc. Process Equipment Group Jakarta 2014 | page 6 Coperion worldwide Headquarters Stuttgart, Germany Competence Center Compounding & Extrusion Stuttgart, Germany Materials Handling Weingarten, Germany Service Stuttgart / Weingarten, Germany Jakarta 2014 | page 7 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 1,700 Network of locations worldwide Jakarta 2014 | page 8 29 Coperion Twin screw compounders - Portfolio ZSK series STS series Jakarta 2014 | page 9 Mc18: Md/a3 < 18 Nm/cm3 Md/a3 < 10 Nm/cm3 Mv PLUS: Md/a3 < 11.3 Nm/cm3 CTE / CKY series Md/a3 < 5.6 Nm/cm3 Twin screw compounder ZSK and STS - perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 10 General twin screw extruder layout Feed Motor Safety clutch Gear box Drive section Jakarta 2014 | page 11 Shaft coupling Barrels Screws Process section Die head Discharge Self-cleaning screw profile Jakarta 2014 | page 12 Self cleaning intermeshing twin screw Working principle D Jakarta 2014 | page 13 Screw Elements. H1 Conveying elements Kneading elements Mixing elements Left-handed elements Jakarta 2014 | page 14 V > H2 V > H3 V Design criteria of twin screw compounders 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 Jakarta 2014 | page 15 ZSK – evolution of torque and volume 1955: ZSK Standard Do / Di = 1,22 Md / a3 = 5,0 Nm/cm3 1970: ZSK variable Do / Di = 1,44 Md / a3 = 5,0 Nm/cm3 1985: ZSK Supercompounder Do / Di = 1,55 Md / a3 = 8,7 Nm/cm3 Increase of free volume and of specific torque Increase of free volume (additional 40%) 2001: ZSK MEGAvolume Do / Di = 1,80 Md / a3 = 8,7 Nm/cm3 Increase of torque 1995: ZSK MEGAcompounder Do / Di = 1,55 Md / a3 = 11,3 Nm/cm3 2004: ZSK MEGAcompounder PLUS Do / Di = 1,55 Md / a3 = 13,5 Nm/cm3 2010: ZSK Mc18 Do / Di = 1,55 Md / a3 = 18 Nm/cm3 Jakarta 2014 | page 16 2007: ZSK MEGAvolume PLUS Do / Di = 1,80 Md / a3 = 11,3 Nm/cm3 Series of Coperion twin-screw compounders Taylormade ZSK Mc18 Made by Coperion in Germany (for world market) Standard Twin-Screw / Two Stage STS Advanced made by Coperion (Nanjing), China (for world market) CTE and CKY machine series made by Coperion (Nanjing), China (for China + Asia) Jakarta 2014 | page 17 ZSK Mc18 The new dimension in compounding technology Specific torque of 18 Nm/cm3 Do/Di = 1.55 Screw speed 1.200 min-1 Jakarta 2014 | page 18 Why Mc18-torque ? Specific energy / shear: Influence of rate and screw speed Low feed rate High feed rate Low screw speed High screw speed barrel Q2 High feed rate Low screw speed barrel barrel Q2 Q1 Q2 Q1 Q1 h Shear rate Shear rate Average value Average value screw Shear rate screw screw Average value With higher torque, a higher fill grade can be realised. The higher the fill grade, the lower the screw speed, the lower is the shear stress Jakarta 2014 | page 19 ZSK Mc18 Most appropriate applications For all torque limited processes like e.g. • PP + 30 % GF • PA 6.6 + 30 % GF • PBT + 30 % GF • ABS+PC + 20 % GF • undried PET • Higher output: as higher fill grades can be realised, which in parallel allows higher screw speed with same average shear stress. and/or • Better product quality due to lower screw speed / higher filling degree / lower shear stress / lower melt temperature and a lower specific energy consumption Jakarta 2014 | page 20 ZSK McPLUS - Mc18 Increase in throughput Jakarta 2014 | page 21 ZSK Mc - McPLUS - Mc18 Optimised price-performance ratio Jakarta 2014 | page 22 ZSK Mc - McPLUS - Mc18 Reduced energy input with increased throughput Jakarta 2014 | page 23 ZSK Mc18 – Features Wear protection hard cast chromium steel oval liners with high wall thicknes and a solid apex area for sturdiness & long life Jakarta 2014 | page 24 ZSK Mc18 – Features Liners are shrink fit for improved heat conduction Liner Jakarta 2014 | page 25 ZSK Mc18 – Features Direct coated surface directly soldered, hiped or welded wear- or corrosion protection surface Jakarta 2014 | page 26 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 Jakarta 2014 | page 27 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! Jakarta 2014 | page 28 ZSK Mc18 – Features Jakarta 2014 | page 29 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 10,400 17 1,000 2,293 103 119 Mc18 15,300 17 1,000 3,373 118 133 Mc PLUS 18,100 13.6 1,000 3,791 133 * Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version. Jakarta 2014 | page 30 ZSK Mc18 ZSK 106 Max. Throughput (depending on process, raw materials and products) Jakarta 2014 | page 31 Twin screw compounder ZSK and STS - perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 32 ZSK – evolution of torque and volume 1955: ZSK Standard Do / Di = 1,22 Md / a3 = 5,0 Nm/cm3 1970: ZSK variable Do / Di = 1,44 Md / a3 = 5,0 Nm/cm3 1985: ZSK Supercompounder Do / Di = 1,55 Md / a3 = 8,7 Nm/cm3 Increase of free volume and of specific torque Increase of free volume (additional 40%) 2001: ZSK MEGAvolume Do / Di = 1,80 Md / a3 = 8,7 Nm/cm3 Increase of torque 1995: ZSK MEGAcompounder Do / Di = 1,55 Md / a3 = 11,3 Nm/cm3 2004: ZSK MEGAcompounder PLUS Do / Di = 1,55 Md / a3 = 13,5 Nm/cm3 2010: ZSK Mc18 Do / Di = 1,55 Md / a3 = 18 Nm/cm3 Jakarta 2014 | page 33 2007: ZSK MEGAvolume PLUS Do / Di = 1,80 Md / a3 = 11,3 Nm/cm3 ZSK MEGAvolume MEGAvolume MEGAcompounder - Do/Di= 1,8 - Do/Di= 1,55 ca. 40 % more free volume for compounding processes with high torque demand - optimised ratio regarding mechanical strength vs. free volume less shear stress due to - deeper channels and - smaller screw crests Do/Di= 1,8 Do/Di= 1,55 Di Do Jakarta 2014 | page 34 ZSK MEGAvolume Deeper screw channels offer advantages - improved intake - higher screw speed applicable - higher throughput - reduced shear - lower stock temperatures - lower product stress - improved product quality - more reliabily venting performance Do/Di = 1.8 v u h max ZSK Mv Shear rate gamma = vu /h Do/Di = 1.55 v u h' max ZSK Mc Jakarta 2014 | page 35 ZSK MEGAvolume Most appropriate applications • for products with low bulk density • for processes with low specific energy input (< 0,15 kWh/kg) Jakarta 2014 | page 36 ZSK MEGAvolume Example: max. throughput Powder Coating production Machine ZSK 27Mv 34Mv 43Mv 54Mv 62Mv 76Mv max. Capacity [kg/h] 160 350 750 1.200 1.600 3.200 max. Speed [rpm] 1.200 1.200 1.200 1.200 1.200 1.200 max. Power [kW] 27 54 112 214 329 600 Jakarta 2014 | page 37 ZSK MEGAvolume PLUS Example: max. throughput Carbon Black - Master Batch LDPE + 40 % RCF 20 nm particle size [kg/h] LDPE + 40 % RCF 30 nm particle size [kg/h] PP + 35 % RCF 20 nm particle size [kg/h] ZSK 34 Mv PLUS 150 165 100 ZSK 43 Mv PLUS 300 330 200 ZSK 54 Mv PLUS 600 650 400 ZSK 62 Mv PLUS 930 1.000 620 ZSK 76 Mv PLUS 1.700 1.800 1.100 ZSK 98 Mv PLUS 3.700 4.000 2.500 ZSK 125 Mv PLUS 7.800 8.400 5.200 Jakarta 2014 | page 38 Twin screw compounder ZSK and STS - perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 39 Series of Coperion twin-screw compounders Taylormade ZSK Mc18 Made by Coperion in Germany (for world market) Standard Twin-Screw / Two Stage STS Advanced made by Coperion (Nanjing), China (for world market) CTE machine series made by Coperion (Nanjing), China (for China + Asia) Jakarta 2014 | page 40 Coperion’s Standard compounding machines STS Advanced Standard Twin Screw additional series of co-rotating twin screw compounders - well proven Coperion quality, ZSK MEGAcompounder screw geometry, Do/Di = ca. 1,55 - specific torque: 10 Nm/cm³ for standard compounding tasks: - Engineering Plastics - Masterbatch - Recycling - certified Jakarta 2014 | page 41 Coperion (Nanjing) Machinery Co. Ltd. Jakarta 2014 | page 42 Coperion (Nanjing) Machinery Co. Ltd. Assembly hall Production capacity more than 450 machines per year (STS and CTE) Jakarta 2014 | page 43 Coperion Nanjing Manufacturing Machine assembly Jakarta 2014 | page 44 Assembly floor for control panels Quality Control Incoming Goods Chemical elements test for monitoring the raw materials quality Test Equipment for Chemical elements analysis Jakarta 2014 | page 45 Production Quality Control 3D Measuring System to Ensure Precise Dimensions Strict control of manufacturing precision on barrels, gearbox houses and screw couplings by 3D Measuring System Jakarta 2014 | page 46 Factory acceptance test (FAT) with polymer allows for fast and troublefree installation and start-up on customer‘s site Factory acceptance test with product Jakarta 2014 | page 47 CE certification proper over-sea crating Coperion Standard machine STS Advanced - Torque 10 STS Advanced type screw diameter [mm] Md/a³ motor power [kW] screw speed [1/min] expected capacity [kg/h] Jakarta 2014 | page 48 35 35,6 10 55 80-800 80-230 Standard Twin Screw 50 65 75 96 50,5 62,4 71 93,6 10 10 10 10 132 250 400 900 80-800 80-800 80-800 80-800 300-690 500-1.150 800-1.840 1.200-3.800 Number of STS Sold by Region America 19% Europe/Middle East 17% almost 500 STS machines sold 2004 - 2014 Jakarta 2014 | page 49 Asia 64% Applications Wood Plastic Comp 5% TPE 5% Recycling 2% Others 17% Masterbatch 20% Engineering Plastics 51% total ≈ 500 STS Jakarta 2014 | page 50 Twin screw compounder ZSK and STS – perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 51 Service Coperion’s three promises given with its service structure Global operation Confidence Customers‘ benefit Jakarta 2014 | page 52 Innovation Spare parts service With over 48,000 parts managed Coperion‘s warehouse is one of the largest in the industry. It includes both original Coperion spare parts and parts from suppliers. Spare parts produced to the highest production standards Short delivery times and 24-hour express delivery service for stock parts Provision of substitute types for parts which are no longer available Gearbox and barrel replacement service Emergency stock for the quick replacement of core components Screw and kneading elements Jakarta 2014 | page 53 Twin screw compounder ZSK and STS – perfect performance and economic solution Content • • • • • • Company information ZSK Mc18 – technology, key figures, design ZSK MEGAvolume PLUS STS Advanced Service Summary Jakarta 2014 | page 54 Summary Coperion is the worldwide market and technology leader in Compounding & Extrusion, Materials Handling and Services. We are a partner for global corporations as well as for small and medium-sized enterprises in the plastics, chemical, food and aluminium industries. Coperion has over 130 years of experience with mixing and kneading processes. Pioneering work and continuous development of the closely intermeshing, co-rotating twinscrew extruder. Our twin-screw compounders continually set new standards in the plastics, chemical and food processing industries. Over 10,000 compounding systems are installed worldwide. 30 compounding systems worldwide for testing. More than 25 process specialists, high skilled technical support for our customers Global service and suport. Coperion – confidence through partnership Jakarta 2014 | page 55 Your Contact in Indonesia WAHANA MITRA ABADI Mr. Bernadus Slamet Jl. Telesonic Komp. Pergudangan Surya Kadu Blok I No. 10 Jatake - Tangerang Phone: +62 21 2943 8030 +62 811 849706 +62 21 2943 8031 +62 817 0066675 Fax: +62 21 2943 8059 Email: [email protected] Jakarta 2014 | page 56 This document and all contributions and illustrations contained there in are protected by copyright. Any use there of beyond the scope of the copyright without editor’s prior written consent is illegal and will be prosecuted. This shall in particular apply to translations, reproductions, micro filming and processing in electronic systems. | page 57
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