Advances in Plastics Processing: Cost Saving - Coperion K-Tron

Transcription

Advances in Plastics Processing: Cost Saving Techniques
October 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS
Page 1
Compounding of Filled Polymers with the
Co-rotating Twin Screw Extruder ZSK and STS
Sr. Carles Solà
Managing Director, Coperion SL, Barcelona
Page 2
Machines as platform for other PEG products
LSTK
MTS
Coperion K-Tron
extended scope
Coperion K-Tron
feeders
ZSK/STS machines
CPT
(strand
peletizers)
Packaging Systems
Rotex
screeners
Page 3
Product range
ZSK series
STS series
CTE / CKY series
Page 4
History of kneading and compounding
1879
Paul Pfleiderer founded the company in Stuttgart and Hermann Werner started the
production of Universal Kneaders UK.
1953
License from Bayer (Erdmenger) was taken for the continuous
Twin Screw Kneader ZSK.
 2010
Constant increase of volume and torque
Page 5
Development of the ZSK-Compounder.
History
- Low volume
- Low torque
- Low screw speed
ZSK
- Large volume
- High torque
- High screw speed
ZDS-K
ZSK
Mc+
ZSK-V
ZSK
G ZDSKG
ZSK
H
ZSK
SC
ZSK
MV
ZSK
Mc
ZSK
MV+
Page 6
ZSK
Mc18
ZSK Mc18 – machine technology - new power density of 18 Nm/cm³
Page 7
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
Page 8
ZSK – evolution of torque and volume
ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
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
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
Increase of
free volume (100%)
and of specific torque
Increase of free volume
(additional 40%)
ZSK MEGAvolume
Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3
Increase of torque
ZSK MEGAvolume
PLUS
Do / Di = 1,80
Md / a3 = 11,3 Nm/cm3
Increase of torque
Page 9
ZSK Mc18 – technical data
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 Mc18
140
15
1,200**
37
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
ZSK
* Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version.
Page 10
Technical Features of STS Mc11
Optimized die head
with breaker plate
Multi-key screw
shafts
Profile steel baseframe
(Engineered in Germany)
European Coperion
gear box
STS side-feeder
Bibbygard safety
clutch (UK)
SS hose with flexible
connection
TOUCHmaster control panel
(option) for easy operation
Wear and/or corrosion protection
for barrels and screw elements
AC/DC Motor
Page 11
STS – torque level
STS
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
n = 600 min-1
ZSK Supercompounder
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
n = 600 min-1
STS Advanced
Do / Di = 1,55
Md / a3 = 10,0 Nm/cm3
n = 800 min-1
STS Mc11
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
n = 900 min-1
ZSK MEGAcompounder
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
n = 1200 min-1
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
Page 12
Technical Data of STS Mc11
STS35 Mc11
STS50 Mc11
STS65 Mc11
STS75 Mc11
STS96 Mc11
36
51
62
71
94
Specific torque (Nm/cm³)
11.3
11.3
11.3
11.3
11.3
Torque per shaft (Nm)
305
835
1,590
2,440
5,350
Max. Screw Speed (rpm)
900
900
900
900
600
Max. Motor Power (kW)
60
165
315
483
706
Screw diameter (mm)
Page 13
ZSK Mc18 – machine technology - new power density of 18 Nm/cm³
Page 14
ZSK Mc18 – Review
 Introduced into the market in 2010 (K fair)
 More than 250 ZSK Mc18 sold,
including new sizes ZSK45Mc18 & ZSK82Mc18
 Reliable and extreme robust machine technology
 Several ZSK Mc18 for testing in the test labs in Stuttgart and Ramsey
 ZSK92Mc18 reference: 5000 kg/h for Polyamid + Glassfibres
(ZSK Mc / McPlus: 3600 – 4200 kg/h)
Page 15
ZSK Mc18 – technical highlights
Heat insulation
Shrinked liners
Coolable Combi-Block
barrels
New cooling manifold
New quick-release features
Optimized die head for
polymer flow
Page 16
ZSK Mc18 – new barrel heating and cooling design
Energy savings for the heating up process up to 35%
Energy requirement [kJ]
Energy savings [%]
ZSK 70 Mcformer version
ZSK 70Mc 18 new version
ZSK 70Mc 18 new version
new heat
insulation
ZSK 70Mc 18 - ZSK 70Mc 18 new version new version
new heat
insulation
Heating up process 55 min
13630
8932
8778
35
36
Complete heating process after 80 min
15680
10582
9736
33
38
Stationary phase 10 min
420
293
160
30
62
Page 17
ZSK Mc18 – shear rate for ZSK
.
.
.
gmaximum = 30 gaverage
.
gminimum = 0,9 gaverage
.
Shear rate g =
circumferential speed v
channel depth
Page 18
ZSK Mc18 – reduced shear rate with higher available torque
Higher
feedrate
rate
High
feed
Low feed rate
Constant screw speed
barrel
barrel
Q2
Q2
Q1
Q1
h
screw
screw
SEI [kWh/kg]
Average value
of Shear rate
Average value
of Shear rate
Specific Energyinput SEI
=
Consumed power [kW]
Throughput rate [kg/h]
Rate [kg/h]
Page 19
Factors limiting capacity
Torque
Volume
- Engineering plastics
- Masterbatch
- PET
High torque
extruder
- Do/Di
= 1.55
- Md/a3 = 18
MEGAcompounder / Mc18
- Low bulk density products
- Shear sensitive products
High volume
extruder
- Do/Di = 1.8
- 37% more volume
Residence
time
MEGAvolume
2-stage
extruder
- Bimodal HDPE
- Polyolefins
- 600 rpm / 80 rpm
- longer residence time
- independent melt-/
homogenization zone
(177 – 420 mm)
Others: Quality, temperature, fluidization, degassing, heat transfer, discharge and downstream
equipment, …
Page 20
Specific Enthalpy
min. required energy for processing
The difference in enthalpy
multiplied with the
throughput rate results in
the required power input
P=m. h
Page 21
Specific Energy Input - areas of application of the ZSK
Page 22
Example 1: ZSK Mc18 for reinforcing with glass fiber
1
1
2
3
3
4
4
5
6
7
8
9
10
11
2
7
7
10
8
6
Polymer A + polymer B + additives
(premix, alternative separate feeders)
Chopped glass fibers
Chopped glass fibers (alternative to 2) or
fillers
Alternative: glass or carbon fiber rovings
ZS-B twin screw side feeder
ZSK Mc18
Devolatilization
Strand die head
Water bath
Air knife unit
Pelletizer
11
9
Page 23
Example 1: Fiber reinforcement – PA6 + 30% GF
Conditions:
ZSK 45 Mc18
Md ~ 85%
Throughput increase: up to 50%
Mc PLUS
Mc18
650
672
1089
Page 24
Example : Fiber reinforcement – PA6 + 30% GF
ZSK 45 Mc18
Conditions:
Md ~ 85%
Energy savings of 0,034 kWh/kg at constant rates!
Mc PLUS
Mc18
0,201
Average value
of Shear rate
0,167
672
1089
Page 25
Energy input – comparison of machine sizes
Fiber reinforced PA6 + 30% GF
7000
ZSK 70 Md/a3 = 13,6
ZSK 82
18,0
3500 kg/h @ 600 rpm
Md = 85%
SEI
= 0,172 kWh/kg
6000
Throughput [kg/h]
ZSK 82 Md/a3 = 13,6
Md/a3
5000
ZSK 82 Md/a3 = 18,0
4000
3000
2000
ZSK 70 Md/a3 13,6
2560 kg/h @ 1100 rpm
Md = 85%
SEI = 0,203 kWh/kg
ZSK 82 Md/a3 13,6
2560 kg/h @ 600 rpm
Md = 85%
SEI = 0,180 kWh/kg
1000
0
0
200
400
600
800
1.000
1.200
1.400
Screw speed [rpm]
Page 26
ZSK Mc18 –
Patented Equipment for Feed Enhancement Technology FET
With the patented FET equipment, the product feed can be optimized so that drive power of the
ZSK Mc18 is fully transferred into the process section – even when processing powder bulk
materials.
The results:
• Increases in throughput rate up to 300 %
• Maximum productivity
• Maximum operating safety
• Increased flexibility of the processing system
*European Patent
U.S. Patent Application
Japanese Patent Application
Chinese Patent Application
Page 27
Installation possibilities for FET and working principle
Page 28
Example 3: Filled Polymers
Experience with Feed Enhancement Technology FET
Trials on ZSK 50:
+ 200 %
+ 140 %
PP + Talcum
+ 170 %
talcum in barrel 4 by side
feeder (ZSB)
Talcum Luzenac A3:
0,21 g/cm3, d50: 1,1 µm
Talcum Luzenac A7:
0,22 g/cm3, d50: 2,3 µm
Talcum Luzenac A20:
0,28 g/cm3, d50: 3,7 µm
Page 29
Experience with FET-ZSB (trials)
200
+ 250 %
+ 55 %
without FET
with FET-ZSB
160
Throughput [kg/h]
[kg/h]
Throughput
Trials on ZSK 40:
PA 6 + filler,
filler in barrel 4
by side feeder (ZSB)
120
Talcum Luzenac
Steamic OOS:
0,25 g/cm3
+ 200 %
80
Flame retardant :
0,20 g/cm3
40
Graphite:
0,08 g/cm3
0
60 % Talcum
43 % Flame
Retardant
50 % Graphite
Page 30
ZSK Mc18 – Feed Enhancement Technology FET
SEI can be reduced by:
• Increasing capacity at same screw speed
• Reducing screw speed at same capacity
Page 31
ZSK Mc18 – twin screw side devolatilization unit (ZS-EG)
ZS-EG – Zweiwellige Seitenentgasung
•
Co-rotating twin screws to keep the product within
the processing zone and ensure a safe and constant
devolatilization
•
Large free cross-sectional area of the flow channel
ensures low gas velocity
Page 32
ZSK Mc18 – twin screw side devolatilization unit (ZS-EG)
Field configuration
• Redundant separators
• Cleaning without shut down
Vacuum connection
Manometer
Separator
Page 33
Highly filled polymers – Keywords
• Recipe (physical limitation polymer matrix / filler)
•
Viscosity of the polymer
•
Particle Size d50 and particle size distribution of CaCO3
•
Coated / uncoated CaCO3 and additives
•
Moisture content of fillers
• Feeders accuracy (short time, dropping of fillers)
• Feed intake into ZSK (ZSK, ZSB, Bridging, Gas streams, conveying)
• Dispersion / Mixing
• Pressure built-up
• Pelletizing
Page 34
Filling degree of Compounds
80 – 85 % wt CaCO3
Percentage volume in melt [%]
80
PA 6.6 / GF
70
PE / ATH
60
LDPE / CB
50
PE-BaSO4
PP / Talc
40
PP / Timber
30
PBT / GF
20
POM-Keram
10
LCP-C-Faser
PA-Keram
0
0
10
20
30
40
50
60
70
80
90
100
PA-Ferrit
PA-Hollow GM
Weight percentage (%)
PP-CaCO3
Page 35
Characterization of bulk material
Fibres
GlassBeads
Form of particles
Talc
CaCO3
Aspect ratio
5 - 100
approx. 1
> 10
1
very cohesive
cohesive
good flow
very good flow
Flow factors
0
2
4
Bulk density (kg/m³)
Talc :
CaCO3:
GF fibres:
Hollow glass beads:
Moisture (%)
Representative: 0,1 - 2 %
Wood
Mohs-Hardness
>10
170-500
600-800
100-300
80-150
CaCO3
1
TiO2
Diamond
5
>10
Page 36
Feeder layout CaCO3
CaCO3 is sticky and has a high tendency to
bridge:
•
Agitators / Vibrators are used
•
Special geometry of the hopper
Page 37
Highly filled CaCO3 Compounds
PP + 70%CaCO3
LDPE + 85%CaCO3
LLDPE + 75%CaCO3
LDPE + 84%CaCO3
LLDPE + 80%CaCO3
Page 38
How to prepare a cake mixture (discontinuous)
-
1st loading - mixing
2nd loading - mixing
3rd loading - mixing
....
How to prepare a Highly filled polymer compound (continuous)
Polymer +
Filler
Melting and Mixing
Mixing
....
Filler
Filler
Page 39
Process section for Compounding of Filled Polymers
Main hopper:
- Polymer
- (Additives)
- (Fillers)
Atmospheric
Degassing
Vacuum
devolitilization
Side feeder:
- Fillers
Main feeding
and preheating
Melting
Feeding
of fillers
Mixing Degassing
Mixing
Page 40
Degassing
Pressure
build-up
General layout for Compounding of Filled Polymers
Feeders and Extruder
Discharge equipment
Strand Pelletizer
Waterring Pelletizer
Underwater Pelletizer
Page 41
Processing sections and gas streams inside the ZSK
Polymer
Filler
Filler
1
2
Feed intake
3
Plastification
4
side feeder
ZSB
5
6
Wetting/Dispersion
7
Atm.
Deairation
8
Homogenising
Air/Gas streams entering the twin screw extruder
Backflowing air/gas streams
Page 42
9
10
Vacuum
Pressure
build up
Highly filled polymers: Set-up 2
L/D = 52
ZSK 92 Mc18:
nZSK = 300 – 600 rpm
up to 2.500 kg/h for 83% CaCO3
Page 43
Highly filled polymers: Set-up 1
L/D = 52
ZSK 92 Mc18:
nZSK = 300 – 600 rpm
up to 3.600 kg/h for 83% CaCO3
Page 44
General layout for Compounding of Highly Filled Polymers.
Feeders and Extruder for Filler content between 75 and 85 %
Important questions:
• Feeders / feeder layout / refilling of feeders
• Screen changer (Yes / No – if Yes – mesh size?)
• Gear pump (Yes / No)
• Pelletizing:
- Underwater
- Waterring
- water treatment system (remark: fines)
• Which product range will be produced?
- PP, LDPE, LLDPE, (which MFR values?)
- Filler content 60 % to 75% => Standard ZSK machine set-up
- Filler content 75 % to 85% => Optimized ZSK machine set-up
Additives
CaCO3
20% - 30%
PP, PE
15% - 30%
CaCO3
30% - 60%
Atm.
ZSB
ZSB
ZSEG
M
M
M
Vac
M
M
M
P1
1
5
3
4
5
5
7
8
5
9
10
11
12
P2
SW AV
Page 45
UG
Side-feeder ZSB
ZS-B 133
ZS-B 92
Sight glass to monitor process stability
Page 46
Significant influence of screw configuration (Rate & Quality)
LLDPE (MI 1) + 80% CaCO3
screw no 1
screw no 2
screw no 3
Output [kg/h]
350
300
250
200
150
100
300
400
500
screw speed [rpm]
Page 47
600
700
0,14
160
0,12
140
120
0,1
100
0,08
80
0,06
60
0,04
40
0,02
Discharge Pressure [bar]
Specific Energy Input [kWh/kg]
Specific energy / discharge pressure versus CaCO3 content
20
0
0
74
76
78
80
82
84
CaCO3 [wt%]
Page 48
SEI
Pressure
ZSK 92 Mc18 - Output for 78 - 85% CaCO3
2500 – 3650 kg/h
2000 – 3000 kg/h
1500 – 2500 kg/h
d50,
rBulk
MFR
Page 49
Process layout – key words
•
•
•
•
Feeders / feeder layout / refilling of feeders
Screen changer (Yes / No – if Yes – mesh size?)
Gear pump (Yes / No)
Pelletizing:
• UG
• WRG
• Water treatment system (remark: fines)
• Which product range will be produced?
• PP, LDPE, LLDPE, (which MFR values?)
• Filler content 60% to 75%  Standard machine set-up
• Filler content 75% to 85%  Optimized machine set-up
Page 50
LDPE / LLDPE + 80 – 85% CaCO3*
MFI 2,16/190°C dg/min
1190°C dg/min
ZSK 32
ZSK 40
ZSK 45
ZSK 50
ZSK 58
ZSK 70
ZSK 82
ZSK 92
SK 103
SK 119
SK 133
ZSK 50
32
ZSK100
40
ZSK140
45
ZSK200
50
ZSK300
58
ZSK540
70
ZSK860
82
ZSK1200
92
ZSK1700
103
ZSK2600
119
ZSK3600
133
5
kg/h
-
10050
200
100
280
140
400
200
600
300
1100
540
1700
860
2400
1200
3400
1700
5200
2600
7300
3600
1-5
kg/h
-
100
200
280
400
600
1100
1700
2400
3400
5200
7300
5 - 100
5 - 100
kg/h
kg/h
80
15080
150
150
300
150
300
220
450
220
450
300
600
300
600
450
900
450
900
800
- 1600
800
- 1600
1300 - 2600
1300 - 2600
1850 - 3650
1850 - 3650
2600 - 5200
2600 - 5200
3950 - 7900
3950 - 7900
5500 - 11000
5500 - 11000
* Throughput depends on raw materials and formulation
Page 51
• Filling Degree > 80 % requests a very good processing Know-How together
with a suitable formulation for highest throughput.
• Feeder layout & arrangement, screw configuration, temperature profile and processing
parameters are essential.
• Coperion started to focus on these formulations many years ago and initiated internal
trials (also with customers). In the meantime machines specifically configured for
these highly filled polymers are successfully in operation
Page 52
Key references lines (CaCO3: > 80%):
ZSK
92 Mc
ZSK
70 Mc
ZSK
98 Mv
ZSK
70 Mc
STS
50
STS
50
STS
65
STS
75
STS
96
ZSK
70 Mc
ZSK
92 Mc
ZSK 125 Mv
ZSK
70 Mc
ZSK
98 Mv
South America
South America
South America
South America
South America
South America
South America
South America
South America
Europe
Europe
Europe
Europe
Europe
Page 53
Thank you very much for your attention.
Page 54

Advances in Plastics Processing: Cost Saving - Coperion K-Tron

Transcription

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