powder coating pharmaceuticals. The parallel, segmented compounder

Transcription

1

2 The Concept The continuous compounding of polymers, technical ceramics and foodstuffs whilst miing in various additives at specific points along the etruder barrel is an established technique used in the production process in many branches of industry. HAAKE manufactures laboratory-scale compounders with conical and parallel screw design which are able to simulate this process. Used in combination with the PolyLab System, rheological and substance-specific characteristics can be eamined and new formulations can be proofed and tested. The measuring compounders determine the usage of the PolyLab System for your application. Every measuring sensor contains the necessary measuring, control and monitoring technology for the respective application. Rheome controls the data administration as well as the communication with the master unit via the data highway. All measuring etruders are coded so that the master unit automatically detects which unit is connected. The measuring sensor automatically informs the base unit and thus the operator of the configuration i.e. the number and position of the temperature control zones and measuring ports, unitspecific limit values as well as the possible sensor options. The connected pressure sensors are once again independently coded. A new concept simplifies handling in the laboratory and enables secure operation. This is characterized by: mobile measuring sensors avoid the necessity of handling of heavy and hot parts integrated heating and cooling circuits reduce the number of plug connections and thus the danger of incorrect connections several peripheral units such as feeding and postetrusion units are computer controllable meaning better reproducibility and documentation. The Application Because of its conical design the Twin Screw Compounder Rheome CTW100p realizes very short dwell times and avoids dead volume. This leads to its strength in the following typical applications: processing of thermal critical compounds development of new PVC compounds miing in of processing additives the blending of polymers with greatly different viscosity. Screws with different geometries foresee an application oriented setup for: testing standard polymer melts with regard to plasticizing and compounding standard screws special homogenization applications under high shear miing screws venting of critical compounds venting screws. standard miing venting The parallel mini-compounder Rheome PTW16p with its unique design is an ideal addition to the HAAKE twin screw family for running labscaled compounding and blending tests. Only very small sample volume enables the R&D to run process like tests in a very early stage of formulation development. The split-barrel design with top half lifting upwards enables the inspection of the filled screws for studying: melting behavior incorporation of additives color dispersion The screw design again is variable and with slip on elements for conveying, miing and kneading the screws can be adapted to the process tasks like: compounding of polymers masterbatch production compounding of epensive, low sample volume material (e.g. PEEK + graphite) powder coating pharmaceuticals. The compounder Rheome PTW25p with its modular barrel design enables an optimal adaption to the application. Because of this versatile fleibility R&D work can be carried out in the lab with low sample volume as well as pilot plant applications with high throughput rates. Barrel segments of the following design are available: open barrels for the feeding, venting and injection zones closed barrels segments for conveying, shearing, miing and pressure build-up tasks split feed barrel for horizontal feeding with atmospheric venting measuring elements for supervising the process along the barrel. The screw geometry with conveying elements of different length and design miing elements kneading blocks will be setup on a polygon mandrel according to the processing task. Cont. on page net to the last

3 General Description Specifications Rheome CTW100p In contrast with the discontinuous compounding such as in internal miers of a fied batch size the Rheome CTW100p enables a pilot plant continuous compounding. This etruder can be used for a wide range of tasks in laboratories and pilot plants when used together with specially designed screws of differing geometries. The twin-screw etruder with intermeshing counter-rotating screws provides a positive material displacement from the hopper to the die and thus high levels of pressure. The throughput time is very short and can be well defined to facilitate processing of thermally critical polymers such as PVC. Barrel: Design conical Length (effective) 300 mm Diameter 31.8 / 20 mm (rear / front) Segmentation Material Plasma nitrated, abrasion resistant Measuring ports (standard) 6 Venting ports Feed section temperature controllable (air or liquid) Integrated Heating-, Cooling zones / Cooling medium 3 / air Collector plate (front end) interchangeable Screws: Design conical Alignment intermeshing, counter-rotating D o /D i ratio Function: Heating zones (for dies, melt pump, etc.) up to 4 Coding Overload protection Maimum torque 200 Nm Maimum operating temperature 400 C Maimum operating pressure 700 bar Feeding hopper / volumetric feeder Back pressure sensor optional Heating capacity / zone 1000 W Trough put rate up to 10 kg/h Maimum speed 200 rpm Dimensions: Weight (net) appro. 95 kg Length / Width / Height mm Mains connection via PolyLab drive unit

4 Rheome PTW16p Rheome PTW25p The Rheome PTW16p is a versatile mini-compounder, specially designed for compounding applications in the laboratory. Only very small sample volume is needed to work out first compounding or blending eperience with newly developed recepees. The horizontally split barrel with top half fitting upwards enables an easy inspection of the melting and miing behavior. For an optimization of this behavior the screws are individually configurable. In combination with a special cooling system, this etruder is also a proofed technology in powder coating applications. Parallel, segmented twin screw etruders are used for continuous compounding applications, in which additives are required to be mied in and volatile components removed under vacuum during the etrusion process. The Rheome PTW25p is specially designed to carry out these applications in the laboratory or pilot plant with a cylinder layout and screw geometries taken directly from the production process. The individually configurable cylinder and screws allow the adaptation of the barrel to changing requirements in compound development and processing optimization. parallel, horizontally split 15D / 25D 16D to 48D 16 mm 25 mm elements with L=4D and 6D Heat treated, abrasion resistant Stainless steel, ionitrated 3 T M / 1 2 in metering zone 3 secondary ports for venting or feeding according to application temperature controllable temperature controllable up to 4 / up to 8 / water injection (Enthalpy), optional: air intermeshing, co-rotating intermeshing, co-rotating 1.44 up to Nm/screw 300 C (optional 400 C) 400 C (optional 450 C) 100 bar 300 bar (150 bar) volumetric / gravimetric feeder with hopper volumetric / gravimetric feeder with hopper 1.2 / 1.8 / 1.8 / 1.8 KW depending on barrel segment: KW up to 15 kg/h up to 35 kg/h 500 rpm 400 rpm appro. 120 kg appro. 250 kg (16 D) 500 kg (46 D) mm mm via PolyLab drive unit 3 400/230 V, 50/60 Hz, N PE, 10 A/Phase

5 The Application (cont.) Combined with the measuring capabilities of the PolyLab System a wide field of applications can be offered like: standard compounding and compound development recycling and masterbatch production rheology reactive etrusion polymerization. Compounding & Rheology HAAKE offers unique technology to combine the twin screw etruders with special sensors to study the rheological properties of the polymer melt during processing. This results in informations about the: viscosity, flow behavior compound formulation blend ratio etrusion and injection molding processability morphology recycling capabilities influence of the screw design on the viscosity. The Accessories... and HAAKE support The main concept of the Rheome Twin screw family is application-orientated. Further support is available from the HAAKE eperts in the form of: design and optimization of the cylinder construction and screw geometry data base in which known applications are documented SIGMA, i.e. computersupported processing simulation for advance estimates of pressure, filling level, melting and temperature data along the length of the barrel for defined screw element screw design program to document the recommended screw design. Ring nut with heating element and control thermocouple avoids cold spots during transfer to dies. Sensors for measuring the melt temperature and pressure. The pressure sensors are coded so that the system automatically sets the measuring range and calibration routines. Dies for testing the flow characteristics (rheological dies) and for producing profiles like flat films, blown films, rod and multi strands, wires, filaments as well as screen life tests. Poste for taking off the etrudate directly from the die under controlled conditions. Feeding devices Funnel type hoppers for free-flowing powders or pellets with compressed air driven vibrator avoid bridge formation in the hopper. Single screw feeder with echangeable barrel for the precise feeding of powdery test substances and pellets. Twin screw feeder with echangeable feeder screws. Force feeder for materials which do not ehibit uniform flow. Single-, twin screw- and force feeder can be either manual or computer controlled. Computer controlled feeding devices Application eamples Application CTW100p PTW25p PTW16p Compounding, venting, homogenizing, color matching PVC compounding Thermal critical compounds Masterbatch production Low sample volume (e.g. 1 kg) Blending and Rheology Reinforcing of glass fibres + + Incorporation of fillers Shear sensitive material Reactive etrusion + + Powder coating Food etrusion Processing ceramic compounds Pharmaceuticals Biodegradable Polymers