Co-Rotating Twin-Screw Extruders

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1 Klemens Kohlgrüber Co-Rotating Twin-Screw Extruders Fundamentals, Technology, and Applications With contributions by Bayer Technology Services GmbH, Leverkusen, Germany Dr.-lng. Michael Bierdel Dr.-lng. Jens Hepperle Dr.-lng. Jörg Kirchhoff Dr.-lng. Thomas König Dr.-lng. Klemens Kohlgrüber Dipl.-lng. Ulrich Liesenfelder Dr.-lng. Reiner Rudolf Dipl.-lng. Martin Ullrich Coperion Werner & Pfleiderer GmbH & Co. KG, Stuttgart, Germany Dipl.-lng. Herbert Christ, Dipl.-lng. Ralf Davids Dr.-lng. Peter Heidemeyer, Dipl-lng. Frank Lechner Dipl.-lng. Hans-Joachim Sämann Dipl.-lng. Ulrich Weller Dr.-lng. Werner Wiedmann Dipl.-lng. Reinhard Wuttke HANSER Carl Hanser Publishers, Munich «Hanser Gardner Publications, Cincinnati

2 Contents 1 Introduction 1 2 Historical Development of the Co-Rotating Twin Screw Introduction Early Developments Basic Geometry Basic Patents Basic Patent of the Threaded Screw Basic Patent for Kneading Discs, DBP [16], USP [17], DBP [20] Basic Patent for Modular Design Pioneering Period Machine Development Use in Chemical Processes Licensing Recognition for R. Erdmenger New High Viscosity Technology with Co-Rotating Extruders Screw Machines in Process Engineering Similarity Theory for Screw Machinery Versatile High Viscosity Processes Special Developments from Bayer-Hochviskostechnik (High Viscosity Technology Group) Extended Kinematics, Profile Geometries Clearance Strategies Developments after Licensing Developments after Expiration of the Primary Patents 32 3 Rheological Properties of Polymer Melts Introduction and Motivation Classification of Rheological Behavior of Solids and Fluids Comparison of Viscous and Viscoelastic Fluids Viscous Fluids Viscoelastic Fluids 42

3 VIII Contents 3.4 Temperature Dependence of Shear Viscosity Temperature Dependence for Semi-Crystalline Polymers Temperature Dependence for Amorphous Polymers Influence of Molecular Parameters on Rheological Properties of Polymer Melts Shear Flows Flow Profiles of Pressure-Driven Pipe Flow Flow Profiles of the Simple Drag Flow Extensional Flows 52 4 General Overview of the Compounding Process: Tasks, Selected Applications, and Process Zones Compounding Tasks and Requirements Tasks and Design of the Processing Zones of a Compounding Extruder Intake Zone Plastification Zone Melt Conveying Zone Distributive Mixing Zone Dispersive Mixing Zone Devolatilization Zone Pressure Build-Up Zone Characteristic Process Parameters Specific Energy Input Residence Time Characteristics Process Examples Incorporation of Glass Fibers Incorporation of Fillers Production of Masterbatches Premix Process Split Feed Process Color Matching Coloring Technical Trends in Compounding Gear Element Ring Extruder TPE Production ZSK-NT Technology Injection Molding Compounder Symbols and Abbreviations 87 5 Geometry of the Co-Rotating Extruders: Conveying, and ICneading Elements Introduction The Fully Wiped Profile from Arcs Geometric Design of Closely Intermeshing Profiles Dimensions of Screw Elements with Clearances Transition between Different Numbers of Threads 98

4 Contents IX 5.6 Calculation of a Screw Profile for Production According to Longitudinal Offset Conveying Characteristics of Different Geometries Kneading Elements Modeling: Possibilities and Limitations The Motivation for Modeling Screw Design Modeling Approaches Model Dimensions Extruder: 0-Dimensional Whole Extruder Pumping Efficiency Extruder Section Extruder: 2-Dimensional Extruder: 1-Dimensional Extruder: 1-Dimensional, Extruder Section Extruder: 1-Dimensional, Whole Extruder Extruder: 3-Dimensional Model Depths and Results Extruder: 3-Dimensional, Fields Extruder: 3-Dimensional, Scalar Values Simulation: Possibilities and Limitations Pressure Generation and Energy Input in the Melt Operating States of Conveying Screw Elements Dimensionless Representation with Descriptive Impact Calculation of the Back-Pressure Length Efficiency during Pressure Generation Example for the Design of a Pressure Build-Up Zone Feed Behavior with Shear Thinning Computational Fluid Dynamics Why Computational Fluid Dynamics? Workflow of a Computational Fluid Dynamics Process Pre-Processing Flow Computation and Post-Processing Computational Examples Example Example Conclusion and Outlook Mixing and Dispersing: Principles Introduction Distributive Mixing Mixing in Laminar Flow 160

5 X Contents Axial Mixing and Residence Time Distribution Dispersive Mixing Dispersion of Solid Particles Dispersion of Melts, Liquid Droplets, and Gas Bubbles Types of Loads and Frequency of Loads in an Extruder Determining the Mixing Quality Parameters Experimental Methods for Determining Mixing Quality and Residence Time Distribution Degassing Polymer Melts with Co-Rotating Twin Screw Extruders Requirements for Degassing Function-Specific Design Flash Vaporization Multi-Stage Vacuum Residual Degassing and Use of Stripping Agents Process Set-Up and Design of Degassing Zones Process Limits Scale-Up Process Examples Devolatilization of Solvents from LLDPE Melt Solutions Degassing Solvents from Synthetic Rubber (Styrene-Butadiene Compounds) Degassing Vinyl Acetate from LDPE/EVA Copolymer Degassing POM Degassing PC Degassing PES and PSU Degassing ABS Degassing Un-Dried PET Conclusion Simulation or Scale-Up - Alternatives for Extruder Layout? Process Sections of the Compounding Extruder Feed and Solid Conveying Section Plastification and Homogenizing Sections Devolatization and Discharge Sections Computation Possibilities in the Melt Phase Computation Possibilities for Discharge Parts Scale-Up Screw Elements for Co-Rotating, Closely Intermeshing, Twin-Screw Extruders Design of the Screw Element Combining Screw Elements Screw Elements and How They Work Conveying Elements Kneading Elements 225

6 Contents XI Backward-Pumping Elements Mixing Elements Special Elements Overview of Patented Screw Elements DE , US A DE A1, EP Bl, WO Al US A DE B4, EP Al, US Al DE В, US А US A, DE Al DE Al, EP Bl, US А US A DE Al, US А DE B, US А US А US А EP 2131 Al B2, JP AA, US А DE Al, EP Al, US А DE Al DE A, US А EP Al, US А US Bl, WO A DE B4, US B2, WO Al DE Al, EP Bl, US А DE Al, EP A2, US Bl DE Al, EP Bl, US А DE Al WO Al, US A, EP Al WO Al, EP Al US A, EP Al, WO Al DE Ul US Bl, WO Al DE Al, EP Al, US B DE C2, US A, WO Al DE Al, EP Al, US А DE Al, US А WO Al, US A, EP Al DE Al DE Al, EP Bl The ZSK Series and Applications in the Chemical Industry and for Renewable Raw Materials Development of High Torques, Volumes and Screw Speeds Torque-Limited and Volume-Limited Throughputs Process-Dependent Energy Requirement 268

7 XII Contents Throughput-Energy Diagram High Torque for Glass Fiber Reinforcement of Plastics High Torque for Film Extrusion of Non-Dried PET or PLA Applications of Low Torques and High Volume Requirement Chemical and Pharmaceutical Applications Silicone Sealants Pressure-Sensitive Adhesives Ceramic Catalyst Carriers Insulating Films Battery Separator Films Metal and Ceramic Mixtures Pharmaceutical Mixtures Applications for Renewable Raw Materials in the Plastic and Food Sectors Composite Materials Made from Wood Fibers in Polyolefins Biodegradable Materials Made from Thermoplastic Starch and Polylactic Acid Extrusion Cooking of Cereals for Foodstuffs and Animal Feed Applications in the Confectionery Industry ZSK-NT the New Two-Stage Processing System for High Throughputs Current Requirements for the Processing of Polyolefins Two-stage Large-Scale Plants for the Processing of Bimodal Polyethylene Quality Assessments for Bimodal Pipes ZSK-NT Compared with the Standard Technology Design of Pressure Build-Up Zones Outlook Notation Material Selection for Twin Screw Extruder Components in Contact with Resin Introduction What is Wear? Wear in Operating Experience Choice of Materials for Extruder Barrel and Screw Elements Materials for Extruder Barrel Barrel Designs Material Variations Materials for Screw Elements Designs Material Variants Drive Units for Co-Rotating Twin-Screw Extruders Introduction Drive Units for Small- to Medium-Size Co-Rotating Twin-Screw Extruders 315

8 Contents XIII Electric Motors Drive Configuration DC Drives Power Converters DC Motors Asynchronous Drives Frequency Converters Asynchronous Motors Network Feedback and EMC Motor Monitoring Torque Measurement Torque Measurement for Extruder Protection Torque Measurement for Scale-Up Bearing Currents Bearing Currents Caused by Asymmetry Bearing Currents Caused by Common Mode Voltage Bearing Currents Caused by Circular Flux Avoidable Sources of Error Corrective Measures Drive Units for Large Co-Rotating Extruders Drive Types Medium Voltage Asynchronous Motor Medium Voltage Synchronous Motors Fixed-Speed Drives Starting Aids Direct on-line Starting Variable Speed Drives Frequency Converters Converter-Transformers Emergency Running Properties Safety Clutches Slip Clutches Mechanically Disengaging Clutches Gearbox Design Gear Teeth Bearing Lubrication 346

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