Advances in Plastics Processing: Cost Saving Techniques Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS

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1 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 1

2 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Dr. Oliver Eitel Business Segment Manager Engineering Plastics, Coperion GmbH, Stuttgart Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 2

3 Product range ZSK series STS series CTE / CKY series Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 3

4 ZSK Mc 18 machine technology - new power density of 18 Nm/cm³ Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 4

5 ZSK Mc 18 design criteria of the ZSK D o = Outer diameter D i = Inner diameter a = Centerline distance D o D o / D i = Diameter ratio determines shear, degassing and powder intake M d / a 3 = Specific torque determines power density and filling degree D i a n = Screw speed determines shear and mixing D o / D i = 1,5 to 1,6 M d / a 3 11,0 Nm/cm 3 n 800 min -1 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 5

6 ZSK evolution of torque and volume ZSK Standard D o / D i = 1,22 M d / a 3 = 5,0 Nm/cm 3 n = 150 min-1 ZSK variable D o / D i = 1,44 M d / a 3 = 5,0 Nm/cm 3 n = 300 min-1 ZSK Supercompounder D o / D i = 1,55 M d / a 3 = 8,7 Nm/cm 3 n = 600 min-1 ZSK MEGAcompounder D o / D i = 1,55 M d / a 3 = 11,3 Nm/cm 3 n = 1200 min-1 ZSK Mc PLUS D o / D i = 1,55 M d / a 3 = 13,5 Nm/cm 3 n = 1200 min-1 ZSK Mc 18 D o / D i = 1,55 M d / a 3 = 18 Nm/cm 3 n = 1200 min-1 Increase of free volume (100%) and of specific torque Increase of free volume (additional 40%) Increase of torque ZSK MEGAvolume D o / D i = 1,80 M d / a 3 = 8,7 Nm/cm 3 n = 1800 min-1 ZSK MvPLUS D o / D i = 1,80 M d / a 3 = 11,3 Nm/cm 3 n = 1800 min-1 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 6

7 ZSK Mc 18 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, Mc ,200** Mc , Mc , Mc , Mc , Mc ,200 1, Mc ,000 1, Mc ,000 2, Mc ,000 3, Mc PLUS ,6 1,000 3, * Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version. Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 7

8 Technical Features of STS Mc 11 Optimized die head with breaker plate Multi-key screw shafts European Coperion gear box Bibbygard safety clutch (UK) AC/DC Motor Profile steel baseframe (Engineered in Germany) Wear and/or corrosion protection for barrels and screw elements STS side-feeder SS hose with flexible connection TOUCHmaster control panel (option) for easy operation Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 8

9 STS torque level STS D o / D i = 1,55 M d / a 3 = 8,7 Nm/cm 3 n = 600 min-1 STS Advanced D o / D i = 1,55 M d / a 3 = 10,0 Nm/cm 3 n = 800 min-1 STS Mc 11 D o / D i = 1,55 M d / a 3 = 11,3 Nm/cm 3 n = 900 min-1 ZSK Supercompounder D o / D i = 1,55 M d / a 3 = 8,7 Nm/cm 3 n = 600 min-1 ZSK MEGAcompounder D o / D i = 1,55 M d / a 3 = 11,3 Nm/cm 3 n = 1200 min-1 ZSK Mc PLUS D o / D i = 1,55 M d / a 3 = 13,5 Nm/cm 3 n = 1200 min-1 ZSK Mc 18 D o / D i = 1,55 M d / a 3 = 18 Nm/cm 3 n = 1200 min-1 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 9

10 Technical Data of STS Mc 11 STS35 Mc 11 STS50 Mc 11 STS65 Mc 11 STS75 Mc 11 STS96 Mc 11 Screw diameter (mm) Specific torque (Nm/cm³) Torque per shaft (Nm) ,590 2,440 5,350 Max. Screw Speed (rpm) Max. Motor Power (kw) Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 10

11 ZSK Mc 18 Review Introduced into the market in 2010 (K fair) More than 250 ZSK Mc 18 sold, including new sizes ZSK45Mc 18 & ZSK82Mc 18 Reliable and extreme robust machine technology Several ZSK Mc 18 for testing in the test labs in Stuttgart and Ramsey ZSK92Mc 18 reference: 5000 kg/h for Polyamid + Glassfibres (ZSK Mc / McPlus: kg/h) Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 11

12 ZSK Mc 18 technical highlights Heat insulation Shrinked liners Coolable Combi-Block barrels New cooling manifold New quick-release features Optimized die head for polymer flow Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 12

13 ZSK Mc 18 reduced shear rate with higher available torque Low feed rate Constant screw speed barrel Q 2 Q 1 h Q 2 Higher feed rate barrel Q 1 screw screw Average value of Shear rate Average value of Shear rate SEI [kwh/kg] Rate [kg/h] Specific Energyinput SEI = Consumed power [kw] Throughput rate [kg/h] Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 13

14 Specific Energy Input - areas of application of the ZSK Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 14

15 Example 1: ZSK Mc 18 for reinforcing with glass fiber Polymer A + polymer B + additives (premix, alternative separate feeders) 2 Chopped glass fibers 3 Chopped glass fibers (alternative to 2) or fillers 4 Alternative: glass or carbon fiber rovings 5 ZS-B twin screw side feeder 6 ZSK Mc 18 7 Devolatilization 8 Strand die head 9 Water bath 10 Air knife unit 11 Pelletizer Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 15

16 Example 1: Fiber reinforcement PA6 + 30% GF Conditions: ZSK 45 Mc 18 Md ~ 85% Throughput increase: up to 50% Mc PLUS Mc Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 16

17 Example : Fiber reinforcement PA6 + 30% GF Conditions: ZSK 45 Mc 18 Md ~ 85% Energy savings of 0,034 kwh/kg at constant rates! Mc PLUS Mc 18 0,201 Average value of Shear rate 0, Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 17

18 ZSK Mc 18 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 Mc 18 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 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 18

19 Installation possibilities for FET and working principle Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 19

20 Example: Filled Polymers Experience with Feed Enhancement Technology FET Trials on ZSK 50: % % % PP + Talcum talcum in barrel 4 by side feeder (ZSB) Talcum Luzenac A3: 0,21 g/cm 3, d 50 : 1,1 µm Talcum Luzenac A7: 0,22 g/cm 3, d 50 : 2,3 µm Talcum Luzenac A20: 0,28 g/cm 3, d 50 : 3,7 µm Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 20

21 ZSK Mc 18 Feed Enhancement Technology FET SEI can be reduced by: Increasing capacity at same screw speed Reducing screw speed at same capacity Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 21

22 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 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 22

23 Characterization of bulk material Form of particles Talc CaCO 3 Fibres Glass- Beads Aspect ratio approx. 1 > 10 1 very cohesive cohesive good flow very good flow Flow factors >10 Bulk density (kg/m³) Talc : CaCO 3 : GF fibres: Hollow glass beads: Moisture (%) Representative: 0,1-2 % Mohs-Hardness Wood CaCO 3 TiO2 1 5 >10 Diamond Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 23

24 Highly filled CaCO 3 Compounds PP + 70%CaCO3 LLDPE + 75%CaCO3 LDPE + 85%CaCO3 LDPE + 84%CaCO3 LLDPE + 80%CaCO3 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 24

25 General layout for Compounding of Filled Polymers Feeders and Extruder Discharge equipment Strand Pelletizer Waterring Pelletizer Underwater Pelletizer Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 25

26 Processing sections and gas streams inside the ZSK Polymer Filler Filler Feed intake Plastification side feeder ZSB Wetting/Dispersion Atm. Deairation Homogenising Vacuum Pressure build up Air/Gas streams entering the twin screw extruder Backflowing air/gas streams Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 26

27 General layout for Compounding of Highly Filled Polymers. Feeders and Extruder for Filler content between 75 and 85 % PP, PE 15% - 30% Additives CaCO 3 20% - 30% CaCO 3 30% - 60% 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 Atm. ZSB M M ZSB M M ZSEG M M Vac P1 P SW AV UG Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 27

28 Significant influence of screw configuration (Rate & Quality) LLDPE (MI 1) + 80% CaCO3 350 screw no 1 screw no 2 screw no 3 Output [kg/h] screw speed [rpm] Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 28

29 Specific energy / discharge pressure versus CaCO 3 content 0, Specific Energy Input [kwh/kg] 0,12 0,1 0,08 0,06 0, Discharge Pressure [bar] 0, CaCO 3 [wt%] SEI Pressure Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 29

30 ZSK 92 Mc 18 - Output for 78-85% CaCO kg/h kg/h kg/h d 50, Bulk MFR Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 30

31 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 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 31

32 LDPE / LLDPE % CaCO 3 * MFI 2,16/190 C dg/min ZSK 32 ZSK 40 ZSK 45 ZSK 50 ZSK 58 ZSK 70 ZSK 82 ZSK 92 ZSK 103 ZSK 119 ZSK kg/h * Throughput depends on raw materials and formulation kg/h Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 32

33 Highly filled CaCO 3 Compounds 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 Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 33

34 Highly filled CaCO 3 Compounds Key references lines (CaCO3: > 80%): ZSK 92 Mc South America ZSK 70 Mc South America ZSK 98 Mv South America ZSK 70 Mc South America STS 50 South America STS 50 South America STS 65 South America STS 75 South America STS 96 South America ZSK 70 Mc Europe ZSK 92 Mc Europe ZSK 125 Mv Europe ZSK 70 Mc Europe ZSK 98 Mv Europe Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 34

35 Thank you very much for your attention. Sep 2015 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS Page 35