Re-Compounding Recycling and Compounding with Tandem Extrusion technology

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1 Re-Compounding Recycling and Compounding with Tandem Extrusion technology Achim Richter, KraussMaffei Berstorff GmbH, Hannover, Germany VDMA Indo-German International Seminar, 08./ , New Delhi

2 2 Agenda KraussMaffei Group, KraussMaffei Berstorff Recycling and Compounding Systems Edelweiss compounding (CEP = cascade extrusion processes) Examples and Conclusion

3 3 Agenda KraussMaffei Group, KraussMaffei Berstorff Recycling and Compounding Systems Edelweiss compounding (single & cascade extrusion processes) Examples and Conclusion

4 4 Introduction to the KraussMaffei Group KM - World market leader in machinery for plastics processing IMM Injection Moulding Machinery 3 series (clamping force: t) IMM Injection Moulding RPM Machinery Reaction Process Machinery 4 series (polyurethane resins) (clamping force: t) EXT Extruders and Extrusion Systems for processing plastics and rubber

5 5 Company Profile of KraussMaffei Berstorff Plastic Extrusion Rubber Extrusion Service Single-screw Extruders Twin-screw Extruders / Compounding systems Plant Engineering Pipe and Profile Extrusion systems Film, Sheet and Foam Extrusion systems Tire Extrusion / Multiplex lines Extrusion lines for profiles, hoses and sealings continuous vulcanizing lines Rubber calendars, V-belt machines, flooring extrusion Global Service for KraussMaffei Berstorff Spare & wear parts with local stocks Full-time service engineers, also local

6 6 Agenda KraussMaffei Group, KraussMaffei Berstorff Recycling and Compounding Systems Edelweiss compounding (single & cascade extrusion processes) Examples and Conclusion

7 Compounding Definition Compounding is the finishing process of plastics (resin / raw polymers) through the incorporation of additives (such as fillers, reinforcing materials, colors, additives, etc.

) The process essentially comprises the process steps of feeding, conveying / transport, melting, dispersive mixing, distributive mixing, degassing and pressure build-up.

7 7 Compounding Definition Compounding is the finishing process of plastics (resin / raw polymers) through the incorporation of additives (such as fillers, reinforcing materials, colors, additives, etc. and / or other plastics and elastomers) in a melt viscous phase to create specific and optimized properties (such as optical, tactile, physical, mechanical and chemical, etc.) The process essentially comprises the process steps of feeding, conveying / transport, melting, dispersive mixing, distributive mixing, degassing and pressure build-up. Mainly thermoplastics and elastomers are compounded, thermosets are rare. In most cases the process is conducted continuously on co-rotating twinscrew extruders. In a broader sense this process also includes reactive processes, degassing and all continuous possible viscous mixing tasks.

8 8 KMB Compounding expertise Polymer spectrum Standard Thermoplastics Low-density polyethylene (LDPE) Linear low-density polyethylene (LLDPE) High-density polyethylene (HDPE) Polypropylene (PP) Polystyrene (PS) Polyvinylchloride (PVC) Polyethyleneterephtalate (PET) High-Performance Polymers Polyetheretherketone (PEEK) Polyphenylenoxide (PPO) Polysulfone (PSU) Fluorpolymers Polyimide (PI) Liquid crystal polymers (LCP) Engineering Plastics Styrene Acrylonitrile (SAN) Acrylonitrile-Butadiene-Styrene (ABS) Polyamide (PA 6, PA6.6, PA 12) Polybutyleneterephtalate (PBT) Polycarbonate (PC) Polymethyl methacrylate (PMMA) Polyoxymethylene (POM) Other Materials Thermoplastic elastomers (TPE,- S, -V, -U) Elastomers, e.g. SBR, EPDM, silicon rubber Thermosets, curable moulding compounds Flooring compounds Powder coatings, photocopy powders Ceramics and catalyst compounds Pharmaceuticals and foodstuffs

9 9 KMB Compounding expertise Additives spectrum Additives Reinforcements (abrasive) Glass Fibres Graphite Fibres Carbon Fibres Boron Fibres Whiskers Basal Fibres Titanium Fibres Synthetic Fibres Glass Beads Polymeric Hollow Beads Reactive Additives (abrasive+corrosive) Antioxidants Heat / UV Stabilizers Plasticizer Process Aids Color Pigments Static Inhibitors Microbicidal Additives Blowing Agents Primer Peroxide / Silane Flame Retardants (halogenes & halogene-free) Acids Fillers (abrasive) Calciumcarbonate Kaolin Wood Flour Wollastonite Barium Sulphate Silica Carbon Black Mica Talcum Metallic oxide/ metallic powder

10 KMB Co-rotating Twin-screw Extrusion / Compounding ZE series Lab

Compounding- Extruders ZE 42-80 BP 500 5.

10 10 KMB Co-rotating Twin-screw Extrusion / Compounding ZE series Lab Extruders ZE 25 A/R UTXi ZE 28 BP kg/h High Performance Compounding- Extruders ZE BP kg/h Large Extruders ZE A/R UTi 2 12 t/h Standard Extruder ZE BASIC kg/h main applications for EP, PO, PET, MB, cable compounds, reactives, adhesives, degassing, polymerisation, re- and upcycling, specialities, etc.

11 11 KMB Compounding Scope of Supply Maschine, Lines and plants Plant Extrusion Line Extruder

12 12 Process Applications of Recycling Conventional Way of Recycling of thermoplastic waste Conventional: Division of Recycling and Compounding Thermoplastic waste Recycling Cutter/ Compactor Single-screw Extruder with Degassing Filtering Pelletizing Recycled Pellets Recycled Pellets Virgin Pellets Additives Filler Reinforcements Additives Compounding Twin-screw Extruder Pelletizing Customized Compounds (Pellets)

13 Process Applications of Recycling New Way of Recycling: Edelweiss process KMB Solution: Integration of Recycling and Compounding in one step Washed and sorted Thermoplastic waste Integration:

13 13 Process Applications of Recycling New Way of Recycling: Edelweiss process KMB Solution: Integration of Recycling and Compounding in one step Washed and sorted Thermoplastic waste Integration: Cutter / Compactor / Drying Single-screw Extruder with Degassing Filtration Melt Pump Recycling + Compounding = value adding over the entire process! Filler Reinforcements Additives Twin-screw Extruder Pelletizing Customized Compounds (Pellets)

14 KMB solution for Recycling + Compounding Compounding ReCompounding (Cascade Extrusion Process) Recycling Co-rotating Twin-screw Extrusion Single-screw + Twin-screw (Edelweiss) Twin-screw + Twin-screw (Edelweiss) Single-screw Extrusion Twin-screw Extrusion Applications / Advantages: Low density and fluffy material / film with Cutter Compacttor Shredded Recyclate, Granules, Agglomerate, etc. Re-Pelletizing Re-Pelletizing plus light Compounding - Melting and Alloying of Polymers - Filling and Reinforcing - Production of Masterbatch - Incorporation of Additives - Polymerization - Stabilizing - Colouring - Reactive Extrusion - Degassing - etc. Advantages: - Complete Recycling and Compounding in one step - max. reduction of thermal stress - Energy and time saving production - Added value to the supply-chain - Large range of applications / max. flexibility Advantages vs. Single-screw: - Better degassing - Highest melt homogenity - Better melt filtration ability - No throughput limitation - Moderate shear and pressure stress

15 15 Agenda KraussMaffei Group, KraussMaffei Berstorff Recycling and Compounding Systems Edelweiss compounding (single & cascade extrusion processes) Examples and Conclusion

16 16 Process Applications of KMB Recycling and Edelweiss Recycling of thermoplastic waste: in-house recycling In-house Recycling / Re-use Recycling of pre-consumer material (cut-off material, internal waste) Recycled material is sorted, clean, pre-cut (shredder) No intensive filtration required (contamination < 1 %) Compounding and Pelletizing with Twin-screw Extrusion lines Post-consumer Recycling, Municipal & Industrial Recycling Recycling of post-consumer thermoplastic waste Recycled material must be sorted and washed Recycled material is contaminated, intensive filtration is required (>> 1-2%) Recycling / Filtration with Single-screw Extrusion line Compounding and Pelletizing with Twinscrew Extrusion line

17 17 Process Applications of KMB Recycling and Edelweiss Recycling of thermoplastic waste: in-house recycling Challenge: feedin properties of recycled meterial (low density and fluffy material)

18 18 Process Applications of KMB Recycling and Edelweiss Recycling of thermoplastic waste: post-consumer recycling In-house Recycling / Re-use Recycling of pre-consumer material (cut-off material, internal waste) Recycled material is sorted, clean, pre-cut (shredder) No intensive filtration required (contamination < 1 %) Compounding and Pelletizing with Twin-screw Extrusion lines Post-consumer Recycling, Municipal & Industrial Recycling Recycling of post-consumer thermoplastic waste Recycled material must be sorted and washed Recycled material is contaminated, intensive filtration is required (>> 1-2%) Recycling / Filtration with Single-screw Extrusion line Compounding and Pelletizing with Twinscrew Extrusion line

21 Process Applications of KMB Recycling

(film + flakes) or 300 kg/h LDPE, HDPE clean

Diverter valve 300 kg/h recycled pellets or

21 21 Process Applications of KMB Recycling (Edelweiss) Combi-Line film to pellet or compound (500 kg/h) I Hot die face pelletizing system 300 kg/h LDPE, HDPE waste (film + flakes) or 300 kg/h LDPE, HDPE clean waste or virgin (pellets) Filter Melt pump Diverter valve 300 kg/h recycled pellets or 500 kg/h customized compound pellets Twin-screw Extruder ZE50R

22 22 Process Applications of KMB Recycling ZE / ZE combinations for shredded recyclate, high volume e.g.: 100 % PE or PP DSD-recycle-shredder with mineral filler (CaCO3, Talc, TiO2) for filler MB or direct use compound (extrusion, injection moulding, > 5 t/h).

23 23 Machine equipment: Single Screw Recycling Extruder incl.: conveyor belt cutter-compactor single screw extruder with degassing

24 24 Machine equipment: Melt filtration I Process, Volume and Pressure constant, continuous filter Example: continuous rotary drum filter here: Ettlinger design, ERF 250

25 25 Machine equipment: Melt filtration II Process, Volume and Pressure constant, continuous filter Example: continuous rotary disc filter here: MAS design, CDF 500-D also possible: - Erema design - Gneuss design

Example: quasi-continuous multi piston filter

26 26 Machine equipment: Melt filtration III Process, Volume and Pressure constant, continuous filter Example: quasi-continuous multi piston filter here: Nordson Kreyenborg design, V-Type back-flush filter

co-rotating twin-screw compounding extruder Depending on compounding

27 27 Machine Equipment: Compounding extruder ZE65x46DBP with two side feeders and vacuum degassing KraussMaffei Berstorff, ZE BP series, co-rotating twin-screw compounding extruder Depending on compounding task, also deep-cut, high volume extruders are available (e.g., for high-filled compounds

(Flexwall with Single Screw Discharge; Belt Discharge,

28 28 Machine equipment: Feeding Equipment Gravimetric Loss-in-Weight Dosing Units Example: Brabender design (Flexwall with Single Screw Discharge; Belt Discharge, or Twin Screw Discharge) also possible: - K-Tron - Colotrtronic

29 29 Machine Equipment: Pelletizing System Underwater pelletizing system Example: Gala design, EAC 6 also possible: - BKG - Econ

30 30 Agenda KraussMaffei Group, KraussMaffei Berstorff Recycling and Compounding Systems Edelweiss compounding (single & cascade extrusion processes) Examples and Conclusion

screw with degassing) Filtration (two piston, continuous) Melt pump (volumetric feeder) Diverter Valve and Adapter (heated) Twin-screw Extruder

31 Process Applications of KMB Edelweiss Recycling ES / ZE combination: Combi-Line film to pellet or compound Task: Recycling of LLDPE film waste and high-filled Compounding with up to 70% CaCO3 Final Throughput: 500 kg/h Scope: Single-screw system (conveyor belt, Cutter compactor, Single screw with degassing) Filtration (two piston, continuous) Melt pump (volumetric feeder) Diverter Valve and Adapter (heated) Twin-screw Extruder ZE50Rx56D UTxmi (2x Side Feeder, Vacuum system) Loss-in-weight feeder system Melt pump Underwater pelletizing system Alt. Waterring pelletizing system

Meltpump Melt pump Underwater pelletizing

32 32 Process Applications of KMB Edelweiss Recycling ZE / ZE combination: high volume for shredded recyclate Polymer Filling material Additive Powder Shredded recyclate Twin-screw extruder with vacuum degassing and twinscrew side feeder Filter Meltpump Melt pump Underwater pelletizing Twin-screw extruder with vacuum degassing e.g.: 100 % PE or PP DSD-recycle-shredder with mineral filler (CaCO3, Talc, TiO2) for filler MB or direct use compound (extrusion, injection moulding), throughput > 5 t/h.

33 33 KMB Edelweiss Recycling Technologies An new innovative way to up-cycle by in-line compounding From waste to value - Focus on high quality compounding out of plastic waste (fibres, film, regrind) - Value adding by up-cycling rather than re-pelletizing High capacities - from 300 kg/h up to kg/h of melting capacity - from 500 kg/h up to kg/h for high-filled, reinforced, blended compounds Proven - in production scale lab tests and sold lines - intelligent combination of proven technologies

34 34 The KMB Edelweiss Recycling Technology Challenges Know-how / Formulations - protected intellectual property, must be supplied by customer or 3rd party High Outputs: - > 3,5 t/h (up to 5 t/h) of melt (> 8 t/h of compound). - bottle-neck is continuous filtration, not (twin screw) extrusion Smell: - Smell of post consumer recycle plastic will not be destroyed by usual process temperatures. Use in automotive or other, consumer and not-industrial applications hardly possible. - improved pre-washing process (hot water with special detergents)? - active extruder degassing by stripping? Water or solvents? Who will take the lead in the industry - Recycler or Compounder?

35 35 Thank you! Achim Richter Senior Manager Business Development Asia/Pacific KraussMaffei Berstorff GmbH An der Breiten Wiese Hannover Germany Phone + 49 (0) Achim.Richter@kraussmaffei.com

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