Ingtec Technik AG Company Presentation EnMat EN Feb 2016
Ingtec Technik AG Ingtec Technik in a nutshell Ingtec Technik AG is an innovative Swiss engineering company, operating globally in the field of specialised construction, covering a wide scope. Our main focus is on batch and continuous mixing and compounding technology for ambitious tasks like high viscosity products or energetic materials. We are a powerful team of experienced engineers, which excels in inventing genius and construction of heavy machinery. New technologies, applications and solutions are driving us forward Every day. Page: 2
Ingtec Technik AG Ingtec Technik Project Network Client Ingtec Technik AG Plant Layout Engineering Software Design Project Management Sourcing Quality Control After Sales Service One shop stop solution for our clients Total Customer Orientation Maximum Flexibility Small, High-Performance Organisation Long-Term Partnerships Excellence in Manufacturing State of the art Production Facilities & Technologies Mechanical Manufacturing Partners Page: 3
Ingtec Technik AG Ingtec Technik in a nutshell Starting out with more than 30 years of experience in mixing and agitation technology, Ingtec Technik developed into its present focus application: Compounding of high viscosity products. Our top quality machines and plants are employed in sensitive industries like the automotive and aerospace industry. Also the defence industry relies on our products in the manufacturing of state of the art systems. Ingtec Technik AG is proud to be among the chosen few world-class suppliers in energetic materials. We also offer our services as general contractor in planning, design and assembly of entire plants. Our services include the construction of the machines, process automation, raw material handling and post processing steps. We can cover greenfield development and we can implement our equipment solutions into existing infrastructure. With our swiss-made technology you achieve superior quality for your products. Do not hesitate to challenge our performance and contact us with your special construction application. One of our recent projects: 1000 L Vertical kneader including solid and liquid dosage systems plus discharge press. Page: 4
Fields of Activity Fluid Handling Bulk Material Handling Control Systems Mixing and Dispersion Technology Mixing and Storage Vessels Filling and Dosage Technology Turn-Key Plants Storage Silos Pneumatic Conveyor Systems Mechanic Conveyor Systems Weighing and Dosage Systems Dust containment & Removal Programmable Logic Controller Parameter Trending and Recording Process Visualisation Formulation Management Integration into superior Control Systems (SCADA, MES, ERP) Process Control Systems (PCS) We are active in several industries: Construction Materials Paints & Coatings Food & Feed and more Mineral Products Chemical Industrie Adhesives & Sealants Instrumentation and control engineering Page: 5
Process Technology Batch-wise or continuous Processing? Mixing and compounding are among the most widespread technological processes. Whenever planning equipment for a mixing process, the first decision for the user to take is which processing principle should apply: Batch-wise or continuous processing. Traditionally, the starting point is batch processing. But especially mixing tasks are often designed as continuous processes. Ingtec Technik offers solutions for both categories, also for special applications like energetic materials. Some basic criteria, which may help to decide which technology is suited best for a given task: PROCESS Batch-wise Continuous Process Flexibility ++ Excellent Multi-Purpose Plant - Dedicated Equipment Product Quality - Fluctuating + More Constant Raw Material Supply + Simple - Complex Large Scale Production - More difficult with scale ++ Excellent Slow Processes + Suitable - Difficult (short residence time) Set-up Time - For each batch + Only once per run Processed Volume - = Batch Size + Small Application of Energy - Low + High Investment + Low - High Manpower - High + Low Process Automation + Low Level feasible - High Level mandatory Start-Up/Shut-Down Procedure + Short - Complex Maintenance + Relatively simple - Complex Process Safety - More difficult with scale + Excellent Page: 6
Process Technology Fluid Handling Typical coaxial combination of fast and slow moving agitators Mixing & Compounding The basic Process Low and Middle Viscosity Agitators and Mixing Vessels High Viscosity Slow moving Past mix (semi-continuous) Fast moving Vertical Planetary Kneader PKV (batch) Atextruder (open, continuous) Twin Screw Extruder (closed, continuous) Page: 7
Fluid Handling Mixing & Compounding The basic Process Low and Middle Viscosity Agitators and Mixing Vessels Slow moving Fast moving Slow Fast 5000 L Mixing Vessel for the Production of Emulsion Paint & Plaster Production, Bosshard AG, Switzerland Page: 8
Fluid Handling 3500 L Mixing Vessel for the Production of Emulsion Plaster Production, Austria Page: 9
Fluid Handling 3500 L Mixing Vessels on previous slide are part of: Production Plant for Emulsion Plasters, incl. Bulk Material Handling, Saint-Gobain AG, Switzerland Page: 10
Fluid Handling Slow Fast 3000 L Conical Shaped Co-axial Mixer KDA for Emulsion Paints and Plasters, Greutol AG, Switzerland Page: 11
Fluid Handling Production Plant for Emulsion Paints and Plasters, Switzerland Page: 12
Fluid Handling 6 x 7000 L Agitated Maturing & Storage Tanks for Emulsion Paints, Switzerland Page: 13
Fluid Handling Mixing & Compounding The basic Process Low and Middle Viscosity Agitators and Mixing Vessels Slow moving Past mix (semi-continuous) Fast moving High Viscosity Vertical Planetary Kneader PKV (batch) Atextruder (open, continuous) Extruder (closed, continuous) Special Equipment for RTV Sealants PAST mix 1000L for RTV Sealant Manufacturing, Sika AG, Germany Page: 14
Fluid Handling Vertical Planetary Mixer 1000 L for Automotive Adhesives, Dow, Germany Page: 15
Fluid Handling PKV 1000 Plant, Energetic Materials, incl. Bulk Material Handling and Discharge Press Discharge Press for Automotive Sealants, Dow, Germany Page: 16
Fluid Handling Typical PI Diagram of Mixing Plants (red: solids, black: liquid raw materials) Page: 17
Control Systems Complex mixing and compounding equipment requires sophisticated control systems: Managing of Process Procedures: Weighing, Dosage, Mixing, Thermostatting, Vacuum, Manual Process Steps, etc. Optimising of Plant and Equipment Utilisation Administration of multiple batches in a production line -> Campaign Management User Interface: Process Visualisation, Setting of Parameters, Formula Administration Consistent Data Recording of all Process Parameters Statistical Analysis Production Planning and Monitoring Interface to superior control systems Page: 18
Control Systems Human Interface of PKV 1000 Plant, Process Visualisation Page: 19
Process Technology Fluid Handling Mixing & Compounding The basic Process Low and Middle Viscosity Agitators and Mixing Vessels High Viscosity Slow moving Past mix (semi-continuous) Fast moving Vertical Planetary Kneader PKV (batch) Atextruder (open, continuous) Twin Screw Extruder (closed, continuous) Page: 20
Process Technology Energetic Materials When processing energetic materials, the mechanical sensivity of the material against impact and friction is a critical factor in process design. Typically, compounding of PBX materials is performed batch-wise on vertical kneading machines of the PKV type. Advantages of the PKV: Small but well defined distances of the mixing blades, hard contact of mixing tools or vessel is impossible Product does not get in contact with shaft sealings of the kneader No dead zones The entire useful volume is worked by the mixing blades Amount of shear is well controlled by the torque, applied Vacuum degassing Ingtec Technik exclusively uses hydraulic drives in environments, where explosive atmospheres may occur. Nevertheless, with increasing batch size, perspective may change: The increasing potential risk of large batches needs to be taken into consideration Heat exchange is getting slower with increasing kneading vessel size When processing energetic materials, there is also demand for continuous equipment. Ingtec Technik provides two major technologies for continuous processing of energetics: Atextruder and Twin Screw Extrusion The outstanding advantage of continuous processing is the comparatively low amount of material inside the equipment at a particular time, dramatically reducing the risk potential. The residence time of the product on the machine is very short. Page: 21
Vertical Planetary Kneader PKV PKV 1000 PKV 50 PKV 5 Page: 22
Vertical Planetary Kneader PKV PKV 2000 for Automotive Adhesives PKV 5 for Energetic Materials Page: 23
Vertical Planetary Kneader PKV PKV: Movement of kneading blades For simplicity of illustration, the central blade is shown stationary. PKV 1000: Gap of kneading blades 4.0 6.0 mm Intensive shear is created when the blades intermesh with each other and the wall of the mixing vessel Page: 24
Atextruder ATE Rotation of grooved Rollers (red) and Material Flow (green) Atextruder ATE Roller Gap adjustable between 500-5000 m on both ends individually Increasing Shear Constant Shear Decreasing Shear Page: 25
Atextruder ATE The Atextruder has many special advantages: Very low hazard potential, owing to the open construction (no confinement) and Small amounts of energetic material present on the device during processing Continuous operation, suitable for remote control Flexible process design, not limited by the rigid position of ports, arranged on a fixed barrel Homogenisation of the processed material by shear in the gap of the roller, the rollers never touching Variable but very precise adjustment of the distance of the rollers (roller gap), gradients possible Shear applied to product by rollers, gap small but well defined, hard contact of rollers is impossible Reproducible, constant product quality Page: 26
Atextruder ATE Type ATE 150 approx. Capacity: 3 to 30 L/h Roller Length: 1345 mm Length/Diameter (L/D): 9 Diameter of Rollers: 150 mm Type ATE 250 approx. Capacity: 15 to 150 L/h Type ATE 350 approx. Capacity: 75 to 500 L/h Performance of drives: 11-40 kw. For maximum process safety, for processing energetic materials, we recommend hydraulic drives Material Feeders: No spatial restrictions in positioning Product felt on one of the two rollers Page: 27
Atextruder ATE Temperature Gradient: Cool to HOT Flow Up to 4 temperature zones: Flexibility in temperature control Temperature Gradient: Hot to Cool Feed stream Page: 28
Twin Screw Extruder Co-Rotating For compounding and forming processes In some applications not only the continuous compounding is required, but also a subsequent forming of the product is desired. In this case, conventional extrusion is the method of choice, because it can provide the necessary pressure on the product for forming. Ingtec Technik offers also Twin Screw Extrusion Technology, especially adapted to the requirements of energetic materials. Co-rotating screws to limit shear and friction on the products Folding half barrel design to enable emergency pressure relief The extruder is operated below the maximum technically feasible feed rate of starting materials to reduce the degree of filling and hence mechanical stress on the product. Pressure is only generated towards the output zone of the extruder. If no pressure for forming is required in the process (only compounding), we can offer bearings of the screws on both ends. In this case the product is exposed only to very gentle pressure during processing. Page: 29
Twin Screw Extruder Co-Rotating For compounding and forming processes Drive Safety Clutch Gearbox Shaft Coupling Processing barrel with screws Output Material Feeders omitted, Degassing, Thermostatting Modular Structure of the Process Barrel: Barrel Segments (closed version is illustrated), Serrated Shafts with modular Screw Elements (not in operating set-up) Page: 30
Twin Screw Extruder Material Input Atmospheric Degassing Vacuum Degassing Solid Feeder Material Input Plasticisation Zone Feeding Zone Mixing Zone Degassing Zone Homogenisation Degassing Zone Product Output Typical Extrusion Process Page: 31
Zweiwellenextruder Twin Screw Extruder Twin Screw Extruder suitable for Energetic Materials with folding half barrel design Flow Pattern of the material inside the corotating Twin Screw Extruder Page: 32
Thank You! Page: 33