BUSS KNEADER TECHNOLOGY BUSS quantec G3 Kneader series High-end compounding technology for PVC pelletizing
quantec G3 SERIES 02 The quantec G3 series sets new benchmarks in high-grade PVC compounding The innovative BUSS quantec G3 series, afurther development of the successful quantec EV, sets new benchmarks for cost-effectiveness and product quality. Applying free-form three-dimensional surface geometry to optimize the well-proven four-flight technology enables new mixing and shear modes that were not possible before.
CUSTOMER BENEFITS 03 PVC pellets, medical grade In course of ongoing innovation, BUSS has intensively reworked the quantec Kneader, taking account thereby of own findings as well as the operating experience of users. The quantec G3, third generation of the high-performance BUSS quantec Kneader, has alarger process window and higher throughput capacity and also costs less. Compact and all-inclusive Based on the well-proven two-stage quantec concept, the upstream and downstream systems including material feed, heating, discharge extruder and line control are built into the quantec G3 mainframe for additional compactness. The machine is delivered fully assembled, wired and works tested to minimize installation and coissioning time. More user-friendly The quantec G3 has also been ergonomically optimized, with all controls conveniently arranged at the front side. The swing-out feeder enables easy calibration, and the quantec G3 barrel housing opens still wider for easier maintenance or product changeover access. Better product quality Much higher throughput Further perfection of the well-proven four-flight technology, optimization of the feed and intake zone, and amodified screw diameter /stroke ratio have increased throughput by 60% ormore without any speed increase or significant temperature rise. This improvement is largely attributable to more consistent transport by the screw elements, whose four flights overlap in individual zones. More cost-effective overall Investment cost per throughput is lower thanks to greater capacity. Since asmaller size quantec G3 than previous machines can be used for the same throughput, operating and maintenance costs are also lower. And thanks to more intensive mixing due to the optimized quantec G3 process section geometries, 15% less energy input is required. The quantec G3 barrel capacity is much greater because of the larger outside-to-inside screw diameter ratio D o /D i.together with the longer process section ( L/D) and optimized geometry, this intensifies mixing so that the additives are distributed more evenly. The result is asignificant improvement in product characteristics and strength, also at high throughputs.
LINE CONCEPT 04 quantec G3 volumetric feeder in the calibration position Screw flights with free-form three-dimensional surface geometry During the course of quantec G3 development, all systems were thoroughly analysed and optimized for efficiency, cost-effectiveness and user-friendliness. Raw materials feed The quantec G3 includes avolumetric feed system optimally adapted to the kneader characteristics. This feeder can easily be swung out for throughput calibration and to empty the line prior to shutdown. It is positioned directly on the kneader, minimizing feed height so much that there is no risk of premix separation or any dust development. The feed opening to the process section is 20% larger than previously, and the well-tried eccentric intake shape has been further optimized with feed pockets. This not only increases throughput, but also improves feed behaviour, particularly with hard-to-metre raw materials. Process section The standard barrel length /diameter ratio of the quantec G3 has been increased to L/D, contributing to amuch wider processing window. The outside-to-core diameter ratio D o /D i of the mixing/ kneading screw has been increased to 1.62. This provides additional processing space in the barrel. The intake-to-barrel diameter ratio is 20% larger than before, and smooth transition from the larger intake diameter to the smaller mixing/kneading zone diameter is facilitated by two tapered halfshell liners, which can be freely positioned along the processing zone. The quantec G3 includes water heating for the barrel, and an electrically heated discharge extruder. This ensures efficient temperature control and greater operational safety. Partitioning of screw elements and barrel liners has been completely revised. With standard components that can be positioned according to need, fewer different elements and half-shells are required. This reduces stock-keeping and maintenance outlay for customers. Patented processing geometry Based on positive experience with the MX Kneader series, the well-proven quantec four-flight technology has been significantly improved. In particular, free-form three-dimensional surfacing of the screw elements now enables new mixing and shear modes that were not possible before. Discharge extruder with pelletizer Integrated in the quantec G3 mainframe is asingleshaft discharge extruder, with adownstream pelletizer that can be swung completely open for cleaning purposes.
PROCESS TECHNOLOGY 05 160 Throughput [%] 0 120 100 80 60 40 20 quantec G3 quantec EV Free volume Torque MKS series D o /D i =1.55 D o /stroke =6.67 quantec EV series D o /D i =1.56 D o /stroke =4.77 quantec G3 series D o /D i =1.62 0 0 100 200 300 400 500 600 700 800 Screw speed [rpm] D o /D i D o /stroke =5.15 The quantec G3 process window is much wider Optimal torque-to-volume ratio The quantec G3 owes its decisively better performance and product quality to acomplete redesign of the entire process section. Of key importance thereby is the advanced four-flight technology. Bigger barrel capacity Not only is the quantec G3 screw outer-to-core diameter ratio D o /D i larger, but also the outer diameter-to-axial stroke ratio (see graphic above right). This increases the barrel capacity, thereby optimizing the intake and mixing/kneading efficiencies. The result is higher throughputs at the same screw speeds, awider processing window, and better utilization of available volumes according to torque requirements. Optimized screw geometries Four-flight screw geometry allows much more design and optimization scope than three-flight geometry. Not only do screw flights with long flanks convey the product more efficiently, but also their distributive and dispersive characteristics can be optimized by means of specific flight geometries. Based on positive experience with the MX Kneader series for high-grade cable compounds, BUSS uses optimized screw elements in individual zones of the quantec G3 process section. Their free-form threedimensional surface geometry, adapted to the sinusoidal motion of the screw flight, ensures an absolutely constant shear gap that enables the optimal compounding of extremely shear-sensitive products. Furthermore, the design flexibility of free-form three-dimensional screw flight surface geometry enables new mixing and shear modes that were not possible before, because the shear gap can be precisely adjusted according to application. Optimized zones The quantec G3 has three specific zones: the feed zone, the intake zone and the processing zone. Each of these zones has been analysed and optimized by means of mathematical simulation and trials. Mixing element Kneading element Processing zone Intake zone Feed zone Conveying element
PROCESS TECHNOLOGY 06 7000 6000 110 G3 Throughput [kg/h] 5000 4000 3000 2000 1000 0 46 G3 40 EV (ø44) 50 EV (ø55) 60 G3 75 G3 67 EV (ø72) 85 G3 80 EV (ø86) 96 EV (ø105) Machine size [] 110 EV (ø121) quantec G3 quantec EV Swing-open pelletizer housing Throughput comparison quantec G3 vs. quantec EV Each compounding stage is optimally implemented in the individual processing zones of the quantec G3 Kneader. Larger feed zone Dry-blend enters the feed opening, now 20% larger, directly from the volumetric feeder closely above. The additional space created by eccentrically arranged intake pockets boosts the intake rate to enable higher throughput particularly effective for hard-to-metre materials and ensures dependable dry-blend venting. Freely configurable intake zone The intake-to-process zone diameter ratio is also 20% bigger (105/85 on the quantec 85 G3). Geometric linearity with product compression along the compounding zones (finished product to dryblend density factor 2.5) is thus assured. Smooth transition from the larger intake diameter to the smaller mixing/kneading zone diameter is facilitated by two tapered liners, which can be freely positioned along the quantec G3 processing line. This design solution enables easy adaptation of the transition length between intake and mixing/kneading zones to suit product-specific requirements. Optimized processing zone In the processing zone the polymer is melted almost entirely by shear energy input from the screw elements, which are optimized with free-form threedimensional surface geometry. These also enable the dependable compounding of high-purity products such as for medical applications. Thanks to the extended barrel length ratio of L/D and the additional free capacity, the quantec G3 has asignificantly wider process window than its predecessors (see graphic on page 5). This increases the formulation possibilities per screw shaft configuration, thereby enabling faster changeovers and less production outage time. All in all, the quantec G3 benefits our customers with much greater freedom of screw shaft configuration for current and future product formulations.
TECHNICAL DATA 07 H2 H1 L W TECHNICAL DATA BUSS Kneader Discharge extruder Barrel diameter Intake diameter Barrel length L/D Max. speed rpm Max. drive power kw Screw diameter Barrel length L/D Max. drive power kw quantec 46G3 quantec 60G3 quantec 75 G3 quantec 85G3 quantec 110G3 46 60 75 85 110 58 75 94 106 138 55 110 200 315 630 80 130 160 200 280 4 4/6 4/6 4/6 4/6 7.5 18.5 45.0 75.0 132.0 Throughput Dimensions PVC unfilled [kg/h] PVC filled [kg/h] Length L Width W Height H1 Height H2 quantec 46G3 quantec 60G3 quantec 75 G3 quantec 85G3 quantec 110G3 200 400 380 800 1600 1250 2500 2250 4500 250 500 500 1000 1000 2000 1500 3000 3000 6000 3300 4300 5400 6100 8000 950 1200 1500 1700 2200 1100 00 1800 2000 2600 1800 2300 2900 3300 4200
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