Advances in Plastics Processing: Cost Saving Techniques May 2014 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS

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ZSK Estrusore bivite • Storia e sviluppo • Tecnologia di processo

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Evoluzione dell'estrusore bivite corotante ZSK 1954:

Primo estrusore ZSK: modello ZSK 83/500 con un diametro viti di 83 mm ed una lunghezza fissa della parte di processo di 500 mm. Gli alberi portavite erano posizionati uno sopra l'altro.

1958:

ZSK 120/1500 per la lavorazione di HDPE con una portata di circa 500 kg/h.

1962:

Estrusore Lab ZSK 53L con una parte di processo dalla lunghezza variabile e due alberi paralleli.

1963:

ZSK 160 con una sezione di processo di L/D = 3.

1973:

ZSK 280 per la lavorazione di LDPE. Sviluppo del sistema a 2 lobi con gli estrusori ZSK 90, 130, 170.

1976:

ZSK 300 per il compounding di HDPE (12 t/h).

1978:

Sviluppo della ZSK ad alta coppia torcente (riduttore ad alto rendimento e alberi portavite a 6 chiavette).

1980:

Sviluppo della pompa ad ingranaggi per polimeri ad alta viscosità in collaborazione con la MAAG (Svizzera).

1983:

Sviluppo della serie ZSK Supercompounder con la serie ZSK 70.

1986:

Estrusore ZSK 25 da laboratorio.

1995:

Sviluppo della serie ZSK MEGAcompounder a partire dalla ZSK 70.

1996:

Sviluppo della ZSK 250, ZSK 320 Megacompounder per il compounding di poliolefine e per i processi di devolatilizzazione.

1998:

ZSK 380 e UG 1000 per il compounding di poliolefine.

2001:

Introduzione della ZSK MEGAvolume.

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK – evoluzione coppia torcente e volume ZSK Standard Do / Di = 1,22 Md / a3 = 5,0 Nm/cm3 n = 150 min-1 ZSK variable Do / Di = 1,44 Md / a3 = 5,0 Nm/cm3 n = 300 min-1 ZSK Supercompounder Do / Di = 1,55 Md / a3 = 8,7 Nm/cm3 n = 600 min-1 ZSK MEGAcompounder Do / Di = 1,55 Md / a3 = 11,3 Nm/cm3 n = 1200 min-1 ZSK Mc PLUS Do / Di = 1,55 Md / a3 = 13,5 Nm/cm3 n = 1200 min-1

Incremento del volume utile (100%) e della coppia torcente

Incremento del volume utile (ulteriore 40%)

ZSK MEGAvolume Do / Di = 1,80 Md / a3 = 8,7 Nm/cm3 n = 1800 min-1

Incremento della coppia

ZSK MvPLUS Do / Di = 1,80 Md / a3 = 11,3 Nm/cm3 n = 1800 min-1

ZSK Mc18 Do / Di = 1,55 Md / a3 = 18 Nm/cm3 n = 1200 min-1 Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – design e caratteristiche della ZSK Do = diametro esterno Di = diametro interno a = distanza interasse Do / Di = Rappporto diametro esterno/interno determina shear, degasaggio ed alimentazione della polvere

Do

Md / a3 = Coppia determina potenza e grado di riempimento Di a

n = Velocità delle viti Determina shear e mescolazione

Do / Di = 1,5 to 1,6 Md / a3 ≥ 11,0 Nm/cm3 n ≥ 800 min-1

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – un rapporto Do/Di ottimale di 1.55

• Do/Di di 1,55 consente uno scale-up affidabile per tutta la serie Mc18 Balanced ratio between free volume and torque

Free volume Torque

Flight depth Free volume and permissible torque as a function of flight depth

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK – elementi vite in cross-section

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Entalpia specifica lavorazione

energia minima richiesta per la

lo scopo di ogni sviluppo tecnologico è sempre quello di raggiungere l'obiettivo prefisso ottenendo una migliore qualità

.

P=mxh con il minor dispendio energetico e il minor stress del materiale possibile.

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – shear rate

. .

.

massimo 30 medio

.

minimo 0,9 medio

.

Shear rate 

Velocità circonferenziale v Profondità del canale

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – più coppia meno shear Alta alimentazione

Bassa alimentazione Velocità delle viti costante Q2

ca

cassone

Q2

Q1

cassone

Q1

h

screw

vite

SEI [kWh/kg]

Valore medio miscelazione

Valore medio miscelazione

Calcolo energia specifica SEI

Potenza utilizzata [kW] Portata [kg/h]

Rate [kg/h]

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – barrel con liner shrink-fit

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – nuove coperture isolanti •

Nuove coperture isolanti che vanno a rivestire l’intero barrel

•

Per una massima efficienza energetica

„pampered“ insulation, even on the bottom side!

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – nuovo barrel design Risparmio di energia fino al 35% Energy requirement [kJ] 18

% 18

ZSK 70 Mcformer version

ZSK 70Mc new version new heat insulation

ZSK 70Mc new version new heat insulation

Heating up process 55 min

13630

8778

36

Complete heating process after 80 min

15680

9736

38

Stationary phase 10 min

420

160

62

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 PA6 con fibra di vetro

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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PA6 + 30% fibra di vetro Condizioni:

ZSK 45 Mc18

Md ~ 85%

Mc PLUS

Mc18

650

672

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

1089

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PA6 + 30% fibra di vetro Condizioni:

ZSK 45 Mc18

Md ~ 85%!

Risparmio energetico di 0,034 kWh/kg con portate costanti! Mc PLUS

Mc18

0,201

Average value of Shear rate

0,167

672

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

1089

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Energia specifica – confronto Mega+ con Mc18 PA6 + 30% fibra di vetro 7000

ZSK 82 Md/a3 18,0 3500 kg/h @ 600 rpm Md = 85% SEI = 0,172 kWh/kg

6000

Throughput [kg/h]

ZSK 70 Md/a3 = 13,6 ZSK 82 Md/a3 = 13,6

5000

ZSK 82 Md/a3 = 18,0

4000 3000 2000

ZSK 70 Md/a3 13,6 2560 kg/h @ 1100 rpm Md = 85% SEI = 0,203 kWh/kg

ZSK 82 Md/a3 13,6 2560 kg/h @ 600 rpm Md = 85% SEI = 0,180 kWh/kg

1000 0 0

200

400

600

800

1.000

1.200

1.400

Screw speed [rpm] Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – Feed Enhancement Technology FET

Cariche

Additivi

Polimero

FET ZS-B

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – Brevetto per FET - Feed Enhancement Technology Con la FET (brevettata), l’alimentazione del prodotto può essere ottimizzata in maniera tale che una maggiore potenza del motore della ZSK Mc18 viene trasferita al compound – anche quando si stanno lavorando materiali con bassa densità.

• • • •

Incremento delle portate fino al 300 % Massima produttività Massima sicurezza operativa Aumentata flessibilità del sistema di processo

*Brevetto europeo Richiesta di brevetto in USA. Richiesta di brevetto in Giappone Richiesta di brevetto in Cina

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Installazione della FET e suo funzionamento

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Esperienze con FET- ZSB (prove)

+ 55 %

Throughput [kg/h]

+ 250 %

Prove su ZSK 40: PA 6 + carica, Carica nel barrel 4 tramite ZSB Talco Luzenac Steamic OOS: 0,25 g/cm3

+ 200 %

Ritardanti di fiamma: 0,20 g/cm3 Grafite: 0,08 g/cm3

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Esperienze con FET- ZSB (prove)

Prove su ZSK 50: + 200 % + 140 %

PP + Talco + 170 %

Talco nel barrel 4 tramite side feeder (ZSB) Talco Luzenac A3: 0,21 g/cm3, d50: 1,1 µm Talco Luzenac A7: 0,22 g/cm3, d50: 2,3 µm Talco Luzenac A20: 0,28 g/cm3, d50: 3,7 µm

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – Feed Enhancement Technology FET

Energia specifica può essere ridotta: • incrementando la portata alla stessa velocità delle viti • riducendo la velocità delle viti con la stessa portata

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – degasaggio laterale bivite (ZS-EG)

•

Viti gemelle corotanti per mantenere il prodotto entro la zona di processo ed assicurare una devolatilizzazione sicura e costante

•

Ampia sezione trasversale libera del canale di flusso assicura una bassa velocità del gas

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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ZSK Mc18 – degasaggio laterale (ZS-EG)

• due separatori • pulizia senza fermare la linea vuoto

manometro

separatore

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Gamma di prodotti

Estrusori serie ZSK

Estrusori serie STS

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Questo è quello per cui Coperion Machinery Co. Ltd. si differenzia

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Caratteristiche tecniche degli estrusori STS

Testa filiera ottimizzata con breaker plate

Alberi portavite millerighe

Riduttore

Giunto di sicurezza Bibbygard (UK)

Motore ac/dc

Basamento in acciaio Protezione all‘usura e/o corrosione per Alimentatore laterale i barrel e gli elementi a vite

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

Tubazione con raccordi flessibili

Pannello di controllo TOUCHmaster (opzionale) facile da utilizzare

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Barrel STS

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Elementi vite STS

Capsula in HIP

Materiale in polvere metallurgica

Cuore morbido

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Coperion Estrusore standard STS Advanced 800 giri/minuto Estrusore bivite standard Standard Twin Screw per la compoundizzazione di - Tecnopolimeri - Masterbatch - Recycling

Standard Twin Screw STS Advanced tipo diametro vite in mm. Md/a³ potenza motore in kW velocità della vite 1/min portata prevista in kg/h

35 35,6 10 55 80-800 80-230

50 50,5 10 132 80-800 300-690

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

65 62,4 10 250 80-800 500-1.150

75 71 10 400 80-800 800-1.840

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96 93,6 10 900 80-800 1.200-3.800

Recycling and Compounding in un solo passaggio COREMA apre a nuove soluzioni nel riciclo

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Tecnologia

Advantages Advances in in Plastics PlasticProcessing: Processing:Cost CostSaving SavingTechniques Techniques May 2014 March 2015 Compounding Compounding of with Filled the Polymers Co-rotating withTwin the Co-rotating Screw Extruder Twin Screw ZSK and Extruder STS ZSK and STS

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Grazie per la vostra attenzione

Advances in Plastics Processing: Cost Saving Techniques May 2014 Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK and STS

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