Compounding Plants for the Cable Industry A Company of the TROESTER Group
Continuous Cable Compound Processing The cable industry requires more and more consistency, reproducibility and consistent product cleanliness towards the use of continuous compounding systems. Since founding, X-Compound manufactured and continuously developed suitable compounding plants for the processing of any kind of wire & cable materials. Due to a high expertise X-Compound advanced to a market leader. X-Compound supplied complete compounding plants to important cable manufacturers. The major demands are Accurate dosing Perfect dispersion and homogeneity Energy-saving process Versatility The design and versatility of the process relevant parts allows a smooth and intensive kneading and mixing as well as the accurate control of the required process temperature profi les. 2
HFFR 3 Halogen-free Flame Retardant Compounds (HFFR) Flame retardant cable compounds are designed to have reduced flammability in order to protect the operation of the cable. HFFR halogen-free cable compounds are the optimum solution for a broad range of cables meeting IEC fi re test standards. Used for both insulation and jacketing, HFFR halogen-free cable compounds maximize value by providing superior process effi ciency. Its innovative low-density formulation increases yield, lends to minimizing waste and processes under lower extruder motor load. Applications Low price cables for buildings, ultrathin wires for automobile up to military/aerospace cables Advantages of the X-Compound Kneader Technology Work in of high filler content up to 80% by a split feed system Special degassing system related to the kneader and the product inlet zones to allow optimal filler-intake Injection of coupling agent liquids into the melt Accurate process temperature control to prevent degradation of the fillers. (e.g. ATH < 185 C) High flexibility for the processing of a large variety of compounds with a unique screw profile HFFR Line = I F EH= JE I O I JA ),, 16 18-5. 1-4 5 ) 6 0 ) 6 0-8 ) - 8 ) 2-2 ; - 4 L =? K K F K F I? HA A? D = C A H L =? K K $! @ EI? D = HC A $ # $ " : + 2 7, - ), - 4 + + 0, # &, 13 7 1, 5? K I J A HI * EC = C? J= E M A EC D E C E E E E E M = JA H M = JA H K @ A HM = JA H F A A JE A H 0 A = JE C? E C K EJI
PVC Cable Compounds A signifi cant role in the cable industry is the use of PVC insulation material. The market share is worldwide more than 70% of the cable sector. PVC cables are mainly used in the low voltage segment in applications as: Telecommunications Installations Machinery and equipment Automotive industry Household Communication- and control cables Semi conductive PVC cables ) + 0 6 6 7 4 * 1: - 4 PVC cable compounds are divided into the categories Insulation Sheathing Bedding For PVC compounding combined with the pelletizing system X-Compound use the established cascade kneader design. Requirements, such as homogeneous gelifi cation by controlling of product temperature and/as well as dispersive distribution of the fi llers and additives will implement superbly in the X-Compound Kneader. Furthermore a large operation window can be covered with a single screw confi guration, which is decisive for frequently formulation changeovers. Advantages of this two stage process are easily handling, fast recipe changeovers and excellent self cleaning behavior. + 1 / 1: - 4 ) + X-Compound offers PVC Line Turn key projects Hybrid (PVC/HFFR) compounder 1 6-4 -, 1) 6-5 1, 4 ; * -, # : + 2 7, - ), - 4 + 1+, # L =? K K I? HA A? D = C A H L =? K K F K F M = JA H M = JA H E E E F A A JJH= I F HJ? E C @ HO A H 0 A = JE C? E C K EJI. 1 ) 2 4, 7 + 6 4 PVC
Cross-linkable PE Compounds (XLPE) Peroxide cross-linkable XLPE (PEX-A) The X-Compound inline process is designed as follows: The peroxide cross-linkable XLPE compounds are applicable for medium and high voltage cables. The peroxide cross-linkable XLPE compounds have to fulfi ll ex ceptional demands in cleanliness and quality to reach high physical requirements on dielectric strength and lifetime. In the first step the polymer with the additives (except peroxide) have to be mixed to a homogeneous well dispersed compound and fed through a high performance filter system to assure the highest possible purity degree. The second step contains the inline transport of the pure polymer pellet into a specially designed mixing tumbling machine which incorporates the peroxide mist over a controlled time period. The process as described allows the production of super clean material on high throughput rates. 5
Cross-linkable PE Compounds (XLPE) Silane cross-linkable XLPE (PEX-B) Silane grafted (Sioplas) cross-linkable Polyethylene (XLPE) compounds are suitable for the use in the manufacture of low voltage as well as medium voltage cables up to 33 kv. The X-Compound kneader technology is perfectly capable to process any kind of grafted polymer compounds. The crosslinking process is worldwide established. Independent steps: 1. Preparation of the grafted polymer 2. Cable extrusion with addition of catalyst masterbatch (~5%). The process to produce grafted polymers can be implemented on a relatively short process length maintaining optimal mixing (dispersion) and grafting results. The same proven technique is also suitable to process fl ame retardant compounds. Both compounds are produced on the X-Compound Kneader. Due to economic reasons it is recommendable to buy the catalyst masterbatch from specialised manufacturing companies. Silane XLPE Line LV, MV ) ) 2 ; - 4 ) Advantages of the X-Compound Kneader Direct injection of silane into the polymer melt Minimum material deposits inside the process area due to the self cleaning kneader principle Perfect mixing behavior allows reduction of silane quantity Reproducible grafting reaction ),, 16 18-5 " A J= @ A JA? J H ) L =? K K A J F K F K @ A HM = JA H F A A JE A H : + 2 7, - ), - 4 + 2, # I? HA A? D = C A H 5 1 ) - 1 - + 6 1 0 A = JE C? E C K EJI L =? K K F K F 6 XLPE Insulation
XLPE Semicon 7 Semi Conductive Compounds One of the key components in power cables are semi conductive compounds. The main task on the manufacturing of semi conductive compounds is the perfect incorporation of high structure carbon black into the polymer matrix. In order to keep the required conductivity it is of importance to prevent any damage of the carbon black structure. The X-Compound Kneader is well adapted to requirements as homogenizing and dispersing (break up of agglomerates), wetting and distributing of pigments, additives and fi llers into the polymer matrix. Advantages of the X-Compound Kneader Technology Uniform mixing and distribution of high structure carbon black Split feeding of conductive carbon black which permits high level of filler loading and minimize the critical formation of agglomerates Precise temperature control to prevent degradation of the heat sensitive polymers Smooth mixing process to avoid damage of the filler chain structure Semicon Line. 1-4 5? = H =?? = H =? - 8 ) - 8 ) 2-2 ; - 4 ),, 16 18-5 = I F EH= JE I O I JA L =? K K F K F L =? K K A J F K F K @ A HM = JA H F A A JE A H : + 2 7, - ), - 4 + 2, #, I? HA A? D = C A H 13 7 1, 5? K I J A HI * EC = C? J= E M A EC D E C E E E E E M = JA H M = JA H 0 A = JE C? E C K EJI
Special Applications Speciality grades, and value added compounds are designated to make use of the specifi c features of the X-Compound Kneader technology. The controlled shear effect of the X-Compound Kneader is the key to produce any kind of speciality compounds. Following Specialty Compounds Requiring the X-Compound Kneader Technology EPDM/EPR elastomer cable compounds Irradiated, cross-linked compounds Thermal resistant Silicone cable compounds Tailor-made blends and alloys for specific mechanical and chemical resistance Additive blends used in the cable compounds Cable compounds with grafted chemistry 8 FURTHER APPLICATIONS
Control Systems & Service Control Systems Service X-Compound designs and builds complete control systems with visual displays for Turn key plants as well as for replacements or supplements to existing plants. On request we also manufacture less sophisticated control systems. The application of existing peripheral plant components as well as their incorporation via Profi bus network is also part of our standard programme. Basically our control systems are designed as follows: A PC based Windows system which performs plant monitoring and controlling together with a programmable logic controller (PLC). The process and the plant are visualised using a series of on-screen pages and allowing interactive display and modifi cation of current setpoint values and alarms. X-Compound is your reliable partner for the supply of spare parts covering oscillating single screw compounders of nominal size up to 600 mm. X-Compound offers High quality, durable, and corrosion resistant - kneading elements - barrel liners - kneading teeth All spare parts, e.g. - screw shafts - worm shafts - lubrication pumps - process chamber sealing systems - die plates - pelletizing knife arms Interchangeable kneader barrels completely refurbished and guaranteed Any individual part for gear boxes or complete interchangeable gear boxes, all guaranteed Our spare part service is well-known for High quality Low prices Short delivery times CONTROL SYSTEMS & SERVICE 9
Technical Data X-Compound Kneader Discharge Unit Technical Data Type Screw diameter mm Process length L/D Speed max. rpm Max. drive power kw Screw diameter mm Process length L/D Max. drive power kw CK 45 45 8-24 500 30 55 6 15 CK 90 98 8-24 500 250 140/150 6 75 CK 120 120 8-24 500 350 160 6 80 CK 150 150 8-24 500 650 200 6 150 CK 200 200 8-24 500 1200 250 6 300 Process Data HFFR Semicon XLPE Silane XLPE peroxide Black Jacketing PVC Insulation/ sheathing/ bedding Process length [L/D] 16-22 18-24 12-16 12 12 12 Spec. energy [kwh/kg] 0,07-0,12 0,15-0,25 0,2-0,3 0,12-0,16 0,15-0,25 0,06-0,08 CK 45 20-40 40-70 40-80 40-60 40-80 70-110 CK 90 300-600 350-700 500-800 500-800 500-800 700-1400 CK 120 450-800 500-900 600-1000 800-1200 600-1000 1000-1800 CK 150 800-1500 900-1600 1000-1500 1400-1900 900-1600 2500-3500 CK 200 1500-2800 1800-3000 1700-2200 2000-2800 1800-3000 3500-5500 Subject to change without notice. 10 Technical Data
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X-Compound GmbH Hardmatt 932 CH -5082 Kaisten, Switzerland Phone +41-62-869 10 30 Fax +41-62-874 32 08 E-mail info@x-compound.com www.x-compound.com TROESTER Machinery (Shanghai) Co., Ltd. Workshop No. 1, Area C No. 6999 Chuan sha Road, Pudong Shanghai 201202, PR CHINA Phone +86-21-58598308 Fax +86-21-58598310 E-mail info@troester.cn www.troester.cn TROESTER Machinery, Ltd. 300 Loomis Avenue Cuyahoga Falls, Ohio 44221, USA Phone +1-330-928-7790 Fax +1-330-928-7239 E-mail info@troester-usa.com www.troester-usa.com TROESTER Moscow Representation Office 2nd Sinichkina St. 9A, Bldg 3 Moscow, 111020, RUSSIA Phone +79169280672 E-mail troester-soloshenko@mail.ru TROESTER GmbH & Co. KG Am Brabrinke 1-4 30519 Hannover, GERMANY Phone +49-511-87040 Fax +49-511-864028 E-mail innovations@troester.de www.troester.de X-COMPOUND 2013/10 500 E (U) TROESTER GmbH & Co. KG 2013. Only the contract between the customer and X-COMPOUND is binding for any guarantees and commitments. The particulars given herein do not represent promises of any special characteristics. They serve purely for general information pur poses and may differ in individual cases. No claims of any nature may be derived herefrom. The observation of commercial trade marks or patents shall in every instance be the responsibility of the customer.