ZSK Compounding manual

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ZSK 101

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ZSK 101

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ZSK 101

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COURSE OUTLINE

ZSK TWIN SCREW EXTRUSION COMPOUNDING SYSTEMDAY 1:

I. INTRODUCTION

II. ZSK DESIGN CHARACTERISTICS A. Historical Background

1. WP Batch Mixer2. Applications of Twin Screw Technology3. Different ZSK Generations

B. Definitions1. Outer & Inner Diameter2. Torque3. Shear Rate4. Free Volume

C. Basic Machine Components1. Screw Bushings2. Kneading Blocks3. Special Elements

a. SK/SFb. Distributive Mixingc. 3-lobe KB

4. Barrels5. Vents

D. Pelletizer Options

III. FEEDERS AND FEED HANDLING SYSTEMS

IV. UNIT OPERATIONS Part 1 A. Feed Handling/PreparationB. Feeding

1. Upstream Feeding2. Downstream Feeding

a) Solidsb) Liquids

C. Plastification1 Conductive/Convective



DAY 2:

V. UNIT OPERATIONS Part 2D. MixingE. Devolatilization/DegassingF. Metering/Pressure GenerationG. Discharge

1. Pelletizing Train2. Direct Extrusion

VI. PROCESS CONTROLS & INTERLOCKS A. System ScopeB. DesignC. Safety Interlock System

VII. TROUBLESHOOTING THE PROCESS

VIII. EXAMPLES OF PROCESS SYSTEMS A. Compounding - Ed Beecher

1. Dispersive2. Distributive

B. Devolitalization - Faivus Brauer

IX. LABORATORY PRACTICUM, ASSEMBLY & OPERATION

DAY 3:

X. SCALE-UP FACTORS FOR ZSK MACHINES A. Machine Series Geometry DifferenceB. Basis for Scale-up Method SelectionB. Volumetric Scale-up - Degree of Fill

1. Extruders of Similar Geometry2. Extruders of Dissimilar Geometry

C. Alternate Method to Scale Throughput:Specific Mechanical Energy

D. Scaling Shear Rate for ZSK ExtrudersE. Scale-up for Heat Transfer

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ZSK 101: Design I Jan 2009 I Page 1

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ZSK Design Characteristics

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Process Technology

ProcessEngineering

Laboratory

ProcessApplications

(Field PE)

ProcessDevelopment

(PE & Modeling)

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Werner & Pfleiderer History

● 1873 Patent for Universal Mixer to Paul Freyburger ● 1878 Paul Pfleiderer and Herman Werner

Purchase Patent from Freyburger ● 1879 Production begins

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ZSK 101

UK-A universal mixing and kneading machine

Sigma

Masticator

Hub design

Double-hub design

Shredder

Rotors

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ZSK 101


1913 Rubber Mixer

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ZSK 101

1913 Rubber Mixer

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● 1953 License agreement for Twin Screw Extruder ● 1958 ZSK exhibited● 1959 Werner & Pfleiderer Corporation● 1986 Krupp purchases interest in WP● 2001 Krupp sells WP: Buss, Waechle & WP merge

to form Coperion● 2004 Coperion purchases Keya● 2006 Coperion divests Buss● 2007 Coperion purchases Hartman

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Founded in 1900Founded in 1879 Founded in 1993 Founded in 1885

Coperion – More than 370 Years of Experience.

Global Presence:Compounding systems installed more than 9,000

Bulk materials plants installed more than 6,000

Employees more than 2,000

Customer Service engineers and technicians more than 120

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Coperion Corporation - Ramsey, New Jersey

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Field ServiceField Service

Refurbishing &UpgradesRefurbishing &

Upgrades

ManufacturingManufacturing

ReplacementPartsReplacement

Parts

Design EngineeringDesign Engineering

Process LaboratoryProcess Laboratory

Process EngineeringProcess Engineering

Complete TurnkeySystems

Complete TurnkeySystems

Coperion Corp: Complete Solutions Provider

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Production Compounding Converting

Polymerization

Polycondensation

Polyaddition

Mixing,

Filling, reinforcing

Alloying

Coloring

Devolatilizing

Pelletizing

Extrusion

Injection molding

Blow molding

Compressionmolding

Calendering, etc.

Coperion Process Technology

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Compact unitfor snacks

Cereals

Pet food

More complex units for cereals,

pet food, starches

Food Technology

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Pharmaceutical Technology: Melt Extrusion

1 Lifting advice2 Emptying device3 Loss-in-weight Feeder Premix4 Main Drive and Gearbox

5 Process Section6 Vacuum unit7 Calander 8 Centric Pelletizer(alternatively)

1 2

3

4

5

6

7

8

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In-line Compounding Tech: Compression and IM

PP with Glass or Cellulose Rovings

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Biomass Technology: Solids ProcessingGrinder turns the wood pulp into a mash that

can be broken down further into glucoses.

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Ceramics Technology:Extremely temperature sensitivebinders & high viscosity

1 Pre-conditioner 2 Premix-feeding3 Piston-pump4 Liquid-storage

5 Crammer-feeder 6 Twin-screw vent port7 Vacuum devolatilizing8 Main-drive and gear-box

9 ZSK process section10 Screen-pack-changer 11 Die-plate-changer 12 Air-bed conveyer

13 Honeycomb ceramic

3

1

4

5

7

6

2

8 9 1011

12

13

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Polyolefins 790Engineering Plastics 2,430Masterbatch 610Long fiber reinforced plastics 30Temperature and shear sensitive materials (PVC, cable, TPE, Bio-mat‘l) 1,045

Powder coating, toner 560Direct extrusion / Calender 310Chemical reaction / pharmaceutical technology 525Food Compounding 260

Others (Adhesives & Sealants, Ceramics, Detergents, Printing Ink, 660

Total 7,220

Installed compounding and extrusion systems

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Extruder Systems

+ + + + + +++

+ +

+

Single screwextruders

Multiple screwextrudersTwin screw extruders

Co-rotating Counter-rotating

IntermeshingNon

intermeshing

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Single screwExtruder

Twin-screw extruder Counter-rotating Co-rotating

Axial open system Axial open systemAxial closed system

Closed chamber in the intermeshing area of

the screws."Single screw conveying" in the other parts of the screw.

Good conveyingGood pressure build-upReduced longitudinal mixing

Open intermeshing area of the screws.

"Single screw conveying in the other partsof the screw.

Extruder Systems: Conveying Mechanism

Product conveying depends

on the difference of friction ofthe polymer to the screw andpolymer to the barrel wall.• Low friction to the screw

(chrome plating)• High friction to the barrel

wall (grooved inner surface)

Melt conveying by drag flow.

Good conveyingGood pressure build-upReduced longitudinal mixing

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Twin-Screw Extruder Geometry

● Co-Rotating – Parallel Screw Shafts – Fully Intermeshing

● Counter-Rotating – Parallel Screw Shafts – Fully Intermeshing

●

Counter-Rotating – Conical Screw Shafts – Fully Intermeshing

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The conveying mechanism of an extruder is determined by the ratio of the frictionbetween product to the barrel wall and the rpodcut to the screw element.

Low friction at the screw, high friction at the barrel wall (bolt / nut effect)

No transportation if productsticks to the screw element.

Good product transportation if product sticks to the barrel wall.

Conveying Mechanism

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OD

P i t c h ( m m

)

P i t c h ( m m

)

π OD

Conveying Elements

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Conveying direction of the element

direction of product flow in the extruder

contrary tosame as

Conveying Elements

Right Handed Elements Left Handed Elements

direction of product flow in the extruder

Conveying direction of the element

Extruder

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ZSK - 83/1100

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ZSK-120/1500

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ZSK 70 MEGA Compounder

Small and Medium-size Machines

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ZSK 320 Process Section

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ZSK Building Block System for Screw & Barrel

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ZSK Series: Screw Diameters from 18 to 380 mm

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Diameter ratio:Do /Di

Specific torque:Md / a 3

Do = Outer screw diameter

Di = Inner screw diameter

a = Center distance

2-flighted profile

Do

Di

a

Characteristic Dimensions: Co-rotating Twin-screws

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O D

ID

O D

ID

A

= 2

= 1 . 2 5

O D

I D

Do to D i Ratio

Do = ODDi = ID

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Eff f D /D & RPM h




Effect of D o/D i & RPM on average shear rate

h1 h2

barrel

h3 h4

Do / Di = 1.25 1.44 1.55 1.80barrel wall

γ 31 > γ 2 > γ 4>

2-flighted(High torque)

2-flighted3-flighted 2-flighted(High volume)

Shear rate γ ~[circumferential velocity (v)][channel depth (h)]

Higher screw speeds compensate for lower average shear ratesof filled channels at the same total shear and temperature stress.

0

50

100

150

200

250

300

350

400

450

500

0 100 200 300 400 500 600

Screw speed [rpm]

A v e r a g e

S h e a r

R a t e [ s e c ^ - 1 ]

.

Do /D i = 1.25

Do /D i = 1.44

Do /D i = 1.55

Do /D i = 1.80

ZSK 101

ZSK G S i




ZSK StandardDo / D i = 1.25

ZSK-VariableDo / D i = 1.44

CONTINUADo / D i = 1.71

MEGAvolumeDo /D i = 1.8

ZSK Super Compounder ZSK MEGAcompounder ZSK MEGAcompounder +

Do / D i = 1.55Do /D i

Free volume and permissibletorque as a function D o /D i

Balanced ratioof free volumeand torque

Free volume Torque

ZSK Geometry Series

ZSK 101

ZSK E l ti f T d V l




ZSK Mc (1995)Do / D i = 1.55, 1200 rpmMd / a 3 = 11.3 Nm/cm 3

Increasedfree volume (100%)and specific torque

ZSK SC (1985)Do / D i = 1.55, 600 rpmMd / a 3 = 8.7 Nm/cm 3

ZSK Standard (1955)Do / D i = 1.22, 150 rpmMd / a 3 = 5.0 Nm/cm 3

ZSK-variable (1970)

Do / D i = 1.44, 300 rpmMd / a 3 = 5.0 Nm/cm 3

Constant CenterlineDistance

ZSK Mv (2004)Do / D i = 1.80

1800 rpmMd / a 3 = 8.7

ZSK Mv Plus(2007)

Do / D i = 1.801800 rpmMd / a 3 = 11.3

Increased free volume(additional 40%)

Do / D i = Outer / Inner diameter

Md / a3

= Specific torque

Increasedtorque

ZSK Mc PLUS (2004)Do / D i = 1.55, 1200 rpmMd / a 3 = 13.5 Nm/cm 3

Constant CenterlineDistance

Increasedtorque

ZSK – Evolution of Torque and Volume

Torque

Flight depth

Free volume and permissible torque

Free volume

Balanced ratiobetween free volume

and torque

Balanced ratiobetween free volume

and torque

ZSK 101

ZSK Generations




= outer screw diameter = inner screw diameter = center distance [ cm ]= torque per shaft [ Nm ]= number of flights= specific torque

ODID

Md

Md/a³

a

z

OD

IDa

Volumefactor

Torquefactor

1st ZSK generation: ZSK Standard

2nd ZSK generation: ZSK Variable

3rd ZSK generation: ZSK Variable

4th ZSK generation: ZSK High torque5th ZSK generation: ZSK Super Compounder

6th ZSK generation: ZSK MEGAcompounder

4.7-5.5

3.7-3.9Md/a³

4.7-5.5

7.3-8.08.7

11.3

Z

2

3

3

2

2

2

OD / ID

1.44

1.25

1.25

1.44

1.55

1.55

177

100

100

177

204

204

146

70

100

100

160

210

ZSK Generations

7th ZSK generation: ZSK MEGAcompounder Plus 13.62 1.55 204 253

ZSK MEGAvolume / MEGAvolume Plus 8.7/11.32 1.8 285 160/210

ZSK 101

Basic Data Comparison: D /D = 1 55




Basic Data Comparison: D o/D i = 1.55

40 325 600 41 425 53 510 123

50 815 106 980 123

58 960 600 120 1250 160 1500 188

70 1750 600 217 2274 281 2730 34392 3850 600 477 5000 638 6000

119 12400

133 11600 500 1206

32 245 31

754

1558

ZSKTORQUE/SHAFT

RPMmin^-1

POWERKW

TORQUE/SHAFT

KW @600 RPM

KW @600 RPM

SUPERcompounder SERIES MEGAcompounder MEGA +

TORQUE/SHAFT

15100 1897 18100 2274

26 106 13

25 82 10

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Basic Data Comparison: D /D = 1 80




Basic Data Comparison: D o/D i = 1.80

ZSKMc/Mv

TORQUE/SHAFT

RPM

min^-1

POWER

KWTORQUE/SHAFT

KW @600 RPM

KW @1200 RPM

KW @1800 RPM

40 /43 325 600 41 420 53 106 158

50/54 815 102 205 307

58 /62 960 600 120 1250 157 314 417

70 /76 1750 600 217 2275 286 572 858

92 /98 3850 600 477 5000 628 1257119/125 10300 1294 2588

MEGAvolume SERIES MEGAvolume Plus SERIES

32/34 205 26 52 77

1571*3236*

156

625

8000

600

600

20

600 1005

79

Red indicates new size ZSK *1500 rpm max

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Important Definitions




Important Definitions

Specific Mechanical Energy (Sme): Kwh/Kg

% Torque: Machine Constant(C) x Power(Kw)rpm

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Power Interlocks: Gearbox or Motor




ZSK-92 MC

0200400

600800

1000

1200

0 2 0 0 4 0 0 6 0 0 8 0 0 1 0 0 0

Speed (RPM)

P o w e r

( K W )

Gear Box100% T

1500 HpMotor

1250 HpMotor

Power Interlocks: Gearbox or Motor

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Segmented Screw




Segmented Screw

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Screw Cross Section




ZSK 90

Two Keys

ZSK 92

Involute Spline 24 Teeth

ZSK 90 6 Key

Six Straight Sided Splines

Screw Cross Section Screw Cross Section Screw Cross Section

Screw Cross Section

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Stress distribution in a involute tooth




Stress distribution in a involute toothconnection

Boundary Conditions:•3 D Calculation - realistic•Full Torque on 0,5 D piece –

worst case calculation

•Even load transfer over connecting areaonly for soft metals (e.g. WP 00, WP 15)

Stress peaks (not visible in 2 D)

Inner wall ofscrew element

Shafttooth

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ZSK screw and kneading elements




g(click image to play video)

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Material Flow




(click image to play video)

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Conveying element flow channels




five parallelscrew channels

axial conveyinglength *)

L = 1.67 x pitch

L

5 143213-flighted elements

L

11 2 3

2-flighted elements

12

5

3

4

1

3

2

three parallelscrew channels

axial conveyinglength *)

L = 1.5 x pitch

*) = valid for one turn andconveying efficiency = 1

y g

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Material Flow Pattern




3-flighted profile 2-flighted profile

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Identification of screw elements




Screw d iameter

Length Pi tch Material of construction

00 Nitrided steel

05 Cr-steel15 PM soft core

39 PM through hard

Number of flights

1 1-flighted, right2 2-flighted, right3 3-flighted, right4 1-flighted, left5 2-flighted, left6 3-flighted, left9 Special profile

Screw profile

1 self wiping screw profile2 no self wiping screw profile

Connection

00, 01, 02 Key ( 0 )66, 67, 68 6-key12, 24, 25 splines (SC)34, 48 splines (MC)

18040 00 060 242 060. - / --

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Screw Bushing Variations




Right HandedLarge Pitch1.5 - 2.0 D

Distribution Dispersion Conveying

Right HandedSmall Pitch

< 1.0 D

Left Handed~1.0 D Seal

Fast

Slow

BackPressure

Component

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Pitch vs. Degree of Fill




Large Pitch(Feeding / Venting)

Medium Pitch(Conveyance)

Narrow Pitch(PressurizationHeat Transfer)

(Click image to play video)

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Kneading Blocks




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Working principles of kneading blocks




Positive conveying effect

Back flow ( leakage ) in theupstream screw channel.

Negative conveying effect

Pressure flow pushes product forward.More leakage flow that conveying KB

No conveying effect

Product flow

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Identification of kneading blocks




Staggering Angle

3 30 o

4 45 o

6 60 o

9 90

Numberof Discs

68040 00 405 242 060. - / --

Profile6 KB same disc width

7 KB different width

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Kneading Block Geometry: Disc Width(Cli k i l id )





Conveying

WideDiscs

MediumDiscs

SmallDiscs

Distributive DispersiveMixing Mixing

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Kneading Block Geometry: Disc Orientation(Cli k i l id )




Conveying

BackPressureComponent

Neutral

Righthanded

Lefthanded

(Click image to play video)Distributive Dispersive

Mixing Mixing

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Action of restriction elements(Cli k i t l id )




With restriction ( left-handed ) elements,it is possible to form an individual

pressure section within the process partof an extruder.

With these elements, a kneading

section can be filled ordifferent vacuum zones be separated.

Pressure

Product flow

Pressure

Product flow


Melt Seal

Mixing & Seal

P1

P1 P 2

P2

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Action of restriction elements




Type of element Back-up effect

right-handed

small-pitchscrew element

neutralkneading block

left-handedkneading block

left-handedscrew element

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Residence Time Distribution




024

68

1012

141618

0 50 100 150

Residence Time (sec)

% T r a c e r

Screw 1 Screw 2 Screw 3



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Special Function Elements




● SK - Undercut● SF – Single Flight● 3L KB – 3 lobe Kneading Block● SAM – Low Shear Kneading Block● TKB/BKB – Tapered Kneading Block● IGEL – Knife Mixing Element● SME – Screw Mixing Element● ZME – Tooth Mixing Element● TME – Turbine Mixing Element

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Comparison of standard vs. undercut (SK) elements




UndercutStandardMaterial

Flow

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Comparison of undercut (SK) vs. standard elements




SK end view Normal Profileend view

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SF: Single Flight Element




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Working principle of SF elements(Click image to play video)




SINGLE-FLIGHTED ELEMENT PAIR NORMAL FLIGHTED ELEMENT PAIR


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Transition between different profiles




Profile A Profile B Profile A Profile B

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Three Lobe KB




Two Lobe Three Lobe

Unequal width, 2 lobe to 3 lobe transition

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Three lobed elements




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SAM Kneading Disc




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SAM Kneading Blocks




Narrow Disc30 Degree Stagger Angle Wide Disc45 Degree Stagger Angle

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Tapered Kneading Block




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Igel Element




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SME: Screw Mixing Element




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Comparison of gear type mixing elements




ZME Element TME Element

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Two piece screw tips




Left-hand Thread Left-hand Thread

Cap

Threaded Bolt

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Mixing screw tips




Cone-shaped screw tip Mixing screw tip (MSSP)

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Standard screw tip




Color distribution in melt strandat the measuring point

Temperature difference inside/outside

approximately 60°C

Flow condition in 8-0adapter piece

Black PE melt Measuring point

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Mixing screw tip




Color distribution in melt strandat the measuring point

Flow condition in 8-0adapter piece

Black PE melt Measuring point

Temperature difference inside / outside

approximately 20 °C

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Barrels: rectangular vs round opening




1

1

2

3 1

1

2

3

1Lor

4D

1Lor 3D

ZSK 101

Vent port adapter design




Form C

Form BForm A

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Twin screw vent port stuffer




Previous design:DSE principle

New design:ZS-EG principle

Vertical arrangement over the ZSK Horizontal arrangement on ZSK side

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ZS-EG General layout




Sight glass

Vacuum port

Devolatilization barrel

Collecting container for melt residues

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Barrel Cross Section




Available Volume Screw Elements

Heater Barrel

Heating orCooling Bores

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Water Flow - ZSK 177 and smaller




InletOutlet

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Cooling system for barrels




Bores for barrel cooling are located asclose as possible to process channel.

Minimum pressure drop based onspecial WP design.

This design ensures optimum flow ofcooling water, e.g.:

ZSK 58 barrel maximum flowof cooling water at 7 bar:

~2,800 l/h

ZSK 101

Cooling Manifold




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Strand Pelletizing




1. Extruder Die 2. Water Bath3. Air Knife 4. Pelletizer 5. Pellet Discharge

ZSK 101

Coperion Pelletizer Systems




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Underwater Pelletizer




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Coperion Compounding Systems




From plastics to cerealand everything in between

S l i F d



1

Selecting a F eeder-

Some of the I ssues Presented to the Coperion ZSK101 Workshop

K-Tron Institute

Rev: D



The Technologies of F eeding



3

• The issues surrounding the feeding of bulk solids

begins with a discussion of the Feeding TechnologyTriangle.• The relationships between technology poles are

important.

F eeding Technology Triangle



4

Bulk Solids Engineering

Electronics/Controls Mechanical/Weighing

Electr ical Engineer ing F actors



5

Includes the design and fabrication of:

• Feeder control systems using uP design and software forsophisticated application algorithms.

• Extensive alarm reporting capabilities.

• Motor/conveying controls with integrated alarm reporting.• Data communication capabilities for rapid and flexible

systems integration with customer data systems.• User interfaces developed from human factors

engineering - task or data driven.

M echanical Engineer ing F actors



6


• Gearboxes and motion systems• Weighing systems• Bins, chutes and hoppers• Conveying mechanisms• Installation structures• Up/down-stream process interfaces

– Refill Systems – Process Equipment

Bulk Solids Engineer ing F actors



7


• Bins, chutes, hoppers, feeders and feeding devicesincluding flow aids.

• Solving problems of no, uncontrolled or erratic bulk

material flow in process systems.• Application of appropriate Refill systems

Flow analysis is not “black magic” but many factorsaffect its reliability.

Contributing F actors



8

System failures may occur when you have:

• Inadequate room for servicing or calibration.• Poor upstream or downstream bin/chute design.

• No dust and pressure control.• Inadequate support structure for feeders.• Thermal or other limits exceeded.

• Feeders not appropriate for bulk materials.• No way to validate feeder performance.• Lack of training and support for personnel.

F or Successful F eeding Systems=



9

Each element of the Feeding Technology Triangle must

work together without flaw. If you succeed, yoursystem will work as advertised.

What are we looking for? Simply, we want:

MF = SP

How do we proceed with the selection process?

You Should



10

• Develop a feeder selection strategy.

• Define your needs and process requirements.• Incorporate both quantitative and qualitative factors

and a value/point system to assess all criteria.

One key factor to consider is feeding performance,but what does that mean? This leads us to considerthe criteria of flow performance validation. Othercriteria may also be important.

Performance M easures



11

• Precision (Repeatability) – Variance of multiple, sequential samples. Variables are sample

time, confidence level and number of samples taken• Accuracy

– Deviation in % between mean flow and setpoint• Linearity

– Accuracy deviation over a setpoint range called ‘turn-down’,normally specified at 20:1 from full scale

• Stability – Variance of accuracy over time

• Reliability – MTBF – MTTR

The M ost Diff icult Decision ?



12

• Clearly, the most difficult decision in most any feeder

application is the determination of the optimalmetering device.• As the old adage goes; “You can’t design an

excellent gravimetric feeder without first starting withan excellent volumetric feeder”.

• Gravimetric feeder controls cannot correct for erraticflow from a volumetric feeder so the metering device

selection is critical for optimal feeder performance.

How do you choose?

Choosing a M eter ing Device



13

• Pick what ever you have handy and try it using the “Guess”principle.

• Use a simple, manual test of the bulk material and then choose.• Select feeding equipment from a piece of literature.• Have your vendor tell you what to choose.

– Work with the Test Lab manager and/or – Conduct a material test at the test lab

• Test the bulk material using analytical methods/tools and thendecide.

Some examples of analytical tools are shown next.

Analysis Tools for Selection



14

• JR Johanson Indicizer ® System @ $50,000

– Hang-Up Indicizer – Flow Rate Indicizer – Hopper Indicizer

Analysis Tools for Selection



15

• Hosokawa Powder Tester and Sieve @ $13,000

Bulk M ater ials; the I ssues



16

Before any decision about feeder selection can bemade, we must have an understanding of the flow

properties of the bulk material to be metered.

• Understanding bulk material attributes and properties

are important as they influence feeder selection,chute and bin design and your physical processinterfaces.

• Have you encountered a bin from which no materialwould flow?

• What do these problems cost in downtime and lostproduction?

• Have you seen the following problems in your plant?

Arching at H opper Outlet



17

The bin opening isnot large enough!

Piping Condition



18

The hopper wall is too shallow

Stable pipe

A Good Solution??



19

Let’s examine some bulk material properties now that we know that a

sledge hammer is not the ideal solution to solving a feeding problem.

A F ew Bulk M ater ial Proper ties



20

• Bulk density - (Loose and compacted)

• Particle size - shape - aspect ratio – distribution-surfacecondition• Moisture and temperature sensitivity• Angle of repose• Kinematic angle of surface friction• Gas permeability• Particle friability

• Compressibility – springback

Let’s look at each property now.

Bulk Density



21

• Weight per unit volume – lb/ft 3

Bulk density may change with applied pressure. If pressurechanges affect the bulk density, a potential for flow problemsmay exist.

Particle Size and Shape



22

• Particle size, shape, aspect ratio, surface condition

and size consistency all affect flowability

Round pellets flow better than irregular ones. Larger particles

often flow better than micron sized ones. Long, skinny particles(high aspect ratio) flow more poorly than particles of symetricaldimensions.

M oisture and Temperature



23

• Moisture and temperature may influence flow

A dry powder may flow through a 8” opening. When moist, theopening may need to be > 10 ‘.

M oisture vs Bin Outlet Example



24

Effects of Moistur e on Flow in a

Bin

0

2

4

6

8

10

0 10 20 30

Per cent Moisture

A r c h

i n g

D i m e n s i o n -

f t

Angle of Repose



25

• Angle of Repose

Definition: It is the angle to the horizontal that a bulk solidsmakes as it flows, unconstrained onto a flat, level surface. It is

an indication of the friction exerted between material particles.

Note: Angle of Surcharge = (90 deg – Angle of Repose)

Angle of Repose for Powder



26

α

Kinematic Angle of F r iction



27

• Surface friction between the bin wall and bulk solids

’

Pressure

Gas Permeabili ty



28

• What is the tendency for the bulk solids to fluidize or

“flood”?• Relates to particle size-shape and density.• Pellets have high gas permeability thus don’t easily

“flood”.• Fine fumed silica has poor gas permeability, thus will

“flood” easily as the sub-micron, light weight particles

become entrained in the air stream.

Particle F r iabil i ty



29

• The characteristic of how easily a bulk solid particle

will crush or break.

Compressibility/Springback



30

• If a material can be compressed and does not spring

back after the compressive forces are removed, thenserious flow problems in bins and hopper may resultas the material may plug at the bin outlet.

Can we simplify the material definition process? Let’s

break the flow condition into four categories.

The F our Basic F low Categories



31

We may simply define bulk material flow properties into fourglobal categories as:

Flooding

Easy FlowingDifficult FlowingCohesive, Sticky

Test for F looding Solids



32

To test

Squeeze some material in your hands. If it squirts outbetween your fingers and does not make a ball, it is

probably floodable.

Test for Easy F lowing Solids



33

To test

If you squeeze material in your hand, and it does notsquirt out or make a ball, it is probably easy flowing

bulk material at least under the conditions of theexperiment.

Difficul t F lowing Solids

Vi l



34

Visual test

If the material is stringy and tends to mat together, itis considered difficult flowing.

Test for Sticky, Cohesive Solids

T t t



35

To test

Squeeze the material in your hand. If it makes a ballof product when the pressure is applied and stays

that way when you open your hand, the material iscohesive or sticky. Anticipate material flow problems.

F eeding F loodable Bulk Solids

C id th f ll i g t i g d i



36

Consider the following metering devices:

• Twin Screw Feeder with concave screws• Rotary Valve with 8-12 sealed vanes

These feeders “ restrict the flow ” in a controlled manner since thesolids behave much like liquids and are able to flow by gravity.

Plugging the flow channel prevents feeder leakage.

Twin Screw Volumetr ic F eeder



37

Concave feed

screws

Rotary Valve F eeder



38

F eeding Easy F lowing Solids




39

Consider the following metering devices:• Belt Feeder • Vibratory Feeder • Disk Feeder • Bulk Solids Pump

• Rotating Nozzle Feeder • Screw Feeder - single screw• Rotary Valve- side entry

Choices may depend upon secondary factors.

Not all types are shown.

Weigh Belt F eeder



40

Single Screw Volumetr ic F eeder



41

Auger

Spiral

Disk F eeder



42

Bulk Solids Pump F eeder



43

F eeding Diff icult F lowing Solids




44


• Vibratory Tray Feeder • Twin Screw Feeder with special extraction

devices - and twin augers

The feeder meters matted, high aspect ratio bulk

material and must deliver it in individual particleswithout damage to those particles plus havingconsistent discharge.

Vibratory Tray F eeder



45Trays may be of differing shapes for selected applications.

Twin Screw F eeder



46

Twin auger screws

F eeding Cohesive & Sticky Solids




47

g g

• Twin Screw Feeder with twin augers or twin spiralscrews

• Belt Feeder with special pre-feeder

* Flow aids are required if flow rates are low.

Twin Screw Volumetr ic F eeder

Twin spiral screws



48

Twin spiral screws

Twin auger screws



Volumetr ic Belt F eeder



50

With agitator flow-aid

L ow Rate M icro F eeder



51

F low Aid Devices

Flow aid devices are used to improve flow quality of solids inbins hoppers and feeders They include:



52

bins, hoppers and feeders. They include:

• Agitators, arch breakers• Bin activators/dischargers• Flexible hopper liners• Matcon ® bin discharger • Diamondback® hopper system• Air pads, air injection

• Hopper vibrators• Martin ® air blaster • Magic Mushrooms ™

Some F low Aid Examples

DiamondBack Hopper Magic Mushroom



53

Matcon Discharger

Flexible Hopper Liner

Now Specify the M eter ing Device

• Pick the best method of bulk material classificationd l d d f



54

and validate metering device performance.• Where possible use an analytical approach that

permits analysis over the environmental conditionsexperienced by the process.

• Test over a long enough period to be sure of results.

What’ s Next?

• Once the metering device is selected, choose ai bl l (LWF/WBF)



55

suitable control strategy (LWF/WBF).• Select options that improve system performance.• Define process interfaces.

• Set control and data exchange requirements.• Address refill requirements, if applicable

Sample Control Strategy

Kc



56

MF

Weight signal

Tach signal

SPTime

Power

DriveController

Weigh Belt Advantages

• Low cost for high volumes of flow



57

• Function easy to understand• Compact for high flow rates• Handle large particle size bulk materials

• Low power requirements• Works well in difficult environments, if maintained• Pre-feeder for powders permits low headroom• Massflow precision comparable to LWF

Weigh Belt Deficiencies

• Material is not totally contained



58

• Control is from inferred measurements – density/area and material velocity not directly measured

• Conveying belt limits materials to be fed

• Requires frequent cleaning• Must be calibrated by sample taking• Calibration stability a function of cleaning and

mechanical alignment

L oss-in-Weight Advantages

• Permits use of suitable metering devices



59

• Direct measurement of process variables• Bulk materials are totally contained• Accuracy a function of the weight measure

• Accurate at low flow rates• Easily cleaned• Rapid process changeovers are possible

L oss-in-Weight Deficiencies

• Reactive control system - must lose weight tocompute the actual flow rate



60

compute the actual flow rate• Discontinuous control, volumetric for refill• Cost increases as flow rates increase

• Large headroom requirements• Algorithm more sophisticated than other applications• Performance may be affected by environment

What F eeder Options?

• Do you have a way to sample the flow to validatemachine performance?



61

• Can you shut off the product flow to the machine toenhance servicing?

• Select model to meet Plastics, Food, Pharma?

• Is dust control a problem?• Are you dealing with vacuum or pressurization at the

feeder?

• Are you dealing with explosion hazards? ATEX,NFPA?

Process I nterfaces

• Add hopper venting as required.



62

• Pressure/vacuum control at discharge must bedesigned in from the beginning.• Flexible connections for all process connections to

the scale are critical. No duct tape please!• Does feeder require refill?

Process I nterfaces



63

Process I nterfaces



64

Process I nterfaces

• Add hopper venting as required.• Pressure/vacuum control at discharge must be



65

Pressure/vacuum control at discharge must bedesigned in from the beginning.

• Flexible connections for all process connections tothe scale are critical. No duct tape please!

• Does feeder require refill?• Bulk material flow connections must be aligned to

prevent material build-up.

• Electrical grounding is critical for operational integrity.• No signal and power wiring in the same conduit.

Data Exchange

• Is feeder data needed by upstream processes?



66

• What data types are required? – Floating point, integer, binary, strings

• If required, what is the format and method oftransmission? – Ethernet, Profibus DP, DeviceNet, ModbusTCP, etc.

• Will you use physical I/O to control the feed system?

• Have you designed for emergency conditions?

Putting i t al l Together

• With the metering device, control strategy, process



67

W t t e ete g dev ce, co t o st ategy, p ocesslinks and machine options selected, put it all togetherand validate performance with the bulk solids to beused in the process.

• Consider individual feeders as well as the entire feedsystem.

Wrap Up

• Bulk material flow is affected by the environment.• Same material, different vendors, differing flow



68

, , gproperties may occur.

• Product shipping and storage can influence flow.• Environment can affect feeder performance.• Your process can adversely affect feeder

performance.• Adequate service space is a must.

• Provide methods to validate performance.

Wrap Up

• Operational methods can adversely affect feederperformance.



69

p• Train your people to operate and maintain the

equipment.• Fully test your process prior to production to validate

satisfactory operation.• Know your feeder vendor’s service and test lab

managers. They can help you when you need it most.• Care in total system design and installation will reap

rewards for many years to come.

ZSK 101

Unit Operations: Part I



ZSK 101: Unit Ops 1 I Jan 2009 I Page 1

ZSK 101

Raw Material Silos

Weigh System

Discontinuous Mixer

Feeding System e e

d i n g

S y s

t e m

Compounding Line Unit Operation




Continuous Mixer

Extruder

Pelletizing

Pellet Drying

Pellet Silos

Bagging Unit

P e

l l e t H a n

d l i n g

E x

t r u s

i o n

F

ZSK 101

Typical Unit Operations

Main feed Downstream feed




1 2 3 4 5 6 7Pre-heat &

ConveyMelting Additive

Intro.AdditiveMixing

Devol. &Metering

DieForm

ZSK 101

Torque Pressure Melting Feeding Degassing Prod quality

100 % torque 100 % torque

x . p r e s s u r e

100 % torque

u c e d m e l t i n g

100 % torque

.100 % torque

.

Qualitya

b

Limitations Of Throughput Rate




m a

max. rate max. rate

r e d

max. rate

max. rate

Rate

F e e d

r a t e

Extruder rate

Time

max. rate

High viscosity materials Low viscositymaterials All types of materials

Screenpressure

max. rate

max. rate

Quality

max. rate

ZSK 101

Feed Preparation & Handling




ZSK 101

PremixMaterials A + B Material A Material B

Feed Sequencing Configurations




Similar Physical form, Melt Point & Viscosity

Material A Material B

Diff Physical form, Same Melt point & Viscosity

Diff Melt point or Viscosity

Material BMaterial BMaterial A

IM (10-20%) in Polymer Matrix

ZSK 101

Warm Mix

WaxPolymer Pigment

Impact of Feed SequencingMasterbatch Production

Warm Premix Feed




Cool Mix

1 2 3 4 5 6 7 8 9 10ZSK

VacuumFeeder

ZSK 101

Masterbatch ProductionSingle Feed Location

Wax

2 or 3 GravimetricFeeders

Impact of Feed Sequencing




ZSK

Vacuum

Polymer Pigment

1 2 3 4 5 6 7 8 9 10

Pelletizing

ZSK 101

Masterbatch ProductionDownstream Pigment Addition

3 Gravimetric Feeders

P l

Pigment





1 2 3 4 5 6 7 8 9 10ZSK

Vacuum

Pelletizing

WaxPolymer

ZSB

ZSK 101

1

23Pressure P (bar)

120

100r

Impact of Feed SequencingPressure Filter Test




4

5

6

Masterbatch + Polymer (Pigment Concentration 4%)

Melting

Gear PumpBypass

Screen Pack

Pressure Transducer

1

2

34

5

6

P F = P F 100

t K G

101 bar 5,73 cm 100

Pressure as a function of

time in filter test (examplewith high P value)

80

60

40

20

07 6 5 4 3 2 1 Time t (min)0

5,5 min 4 105 g/min= = 25 bar cm /g

= 5,5 min

P

= 1 0 1 b a r

22

F



ZSK 101

Peroxide PP-powder Peroxide

PP-powder

PP-powder P id

Impact of Feed SequencingFeeding Mechanisms For Peroxide Addition




Improvement of peroxide dispersion in the PP powder

PP-powder

Peroxide

Extruder Extruder Extruder

Peroxide

Extruder

PP-powder

Peroxide + N 2

Cont. mixer

ZSK 101


Relative X-Sectional Area: ZSK 58 vs. ZSK 320




ZSK 101

Compounding of pharma tablets

P ff d B kf t C l

Typical Feed Zone Layout for Various Applications




Compounding of filledand reinforced materials

Puffed Breakfast Cereal

Compounding of powder coatings



ZSK 101

Filled hopper

Single screw extruder Twin screw extruder

Feeding system

M

Comparison of SSE & TSE Mechanisms Feeding




Product intake from full hopper No feeder necessaryScrew channels are filledOutput rate = f (screw speed)

Product flow is controlled by a feedingsystemScrew channels are partly filledOutput rate is independent of the screwspeed

ZSK 101

Fill factor Conveying

efficiency

Pitch

Screwspeed

Throughput rate

G = F * H * n * ε * η * γ

Conveying Capacity of an Extruder




Free cross

yProductDensity

section

speed

1. Currently it is not possible to calculate fill factor or conveying efficiency based onfeed stock characteristics.

2. Additionally feed stock bulk density at the moment when the powder enters the rotatingscrews is not measurable.3. Therefore only calculations which compare different extruder sizes are possible, since in

this case the unknown parameters drop out of the equation.

1. Currently it is not possible to calculate fill factor or conveying efficiency based onfeed stock characteristics.

2. Additionally feed stock bulk density at the moment when the powder enters the rotatingscrews is not measurable.

3. Therefore only calculations which compare different extruder sizes are possible, since inthis case the unknown parameters drop out of the equation.

ZSK 101

Feed Hopper VentingFeed Limitation




Wrong Correct

ZSK 101

Filter

Feeder

Filter sack

Density35 lb/cf

Incorrect Correct

Feedstock Aeration




Extruder

Feeder

Filter sack

Filter sack

Extruder

Filter sack

Density15 lb/cf

ZSK 101

Feeder Feeder

Central Aspiration

Feeder

Filter sack

Incorrect Correct

Inefficient Venting in Feed System




Extruder Extruder Extruder

Filter sack

Gas escaping from

extruder impedespolymer intake

ZSK 101

Comparison of SSE & TSE Mechanisms

Feed

Volatiles

Devol Pressure Build-upPlastificationFeed Zone

Product Fedon LIW Basis




Feed

Feed Zone PlastificationZone

DevolZone

Pressure Build-upwith Mix Zone

Product Fedon Volume Basis Volatiles

Zonep

with Mix ZoneZone

ZSK 101

FeedingArea

"Compression Ratio"

for TSE Pitch vs. Degree of Fill

Solids Conveying - Compression




Large Pitch(Feeding/Venting)

Medium Pitch(Conveying)

Narrow Pitch(PressurizationHeat Transfer)

ZSK 101

Feedstock Material Form

●

Pellets● Powder ● Low Bulk Density Powder ● Liquid




q

ZSK 101

Material Handling OptionsLow Bulk Density or Difficult to Feed Materials

● 2L vs. 1L Feed Barrel● SK Profile Elements● SF Profile Elements




● SF Profile Elements● 2 X D Pitch Elements

ZSK 101

1

1

2 1Lor

(non-Super and Mega Compounder Systems)

Feed Barrel Options




1

2

3 1

3

2L

or 6L/D

or 3L/D

ZSK 101

1

2

1

2

31Lor

Rectangular vs. Round Opening

Feed Opening Optimization




1

3 1

3

1Lor

4L/D

or 3L/D

Easier, less obstructed feed intakewith rectangular opening. The fullscrew channel depth is exposedalong the entire length of the feedopening, not just in the center as isthe situation with the round opening.

ZSK 101

Pocketed Feed Barrel




ZSK 101

STANDARD PROFILE ELEMENT SK PROFILE ELEMENT

Review of SK & SF Elements




SINGLE-FLIGHTED ELEMENT PAIR NORMAL FLIGHTED ELEMENT PAIR

ZSK 101

ZSK

2540SC/MC

PITCH

4875/79

LENGTH

2437.5/39.5

Increased Feeding VolumeLower Degree of Fill

Safer Devolatilization

2 x D High Pitch Screw Bushings




40SC/MC

587092133SC/MC177

5075/79

110135180240/270320

9937.5/39.5

5567.590120/135160

49.5

ZSK 101

PPHDPEr a t e [ k g

/ h ]

1,1001,200

1,3001,4001,5001,600

1,7001,800

ZSK 90

180 2-lobe

120 2-lobe

120 SF

80 SF

Effect of Pitch on Powder Feed




increase of the pitchby 50%

increase of the outputrate by approx. 15%

PPHDPE

Screw speed [ rpm ]

O u

t p u

t r

50 100 150 200 250 300 350 400400500600700800

900

1,000

180 pitch

120 pitch

ZSK 101

LHLL

Impact on feeding of distance between feed openingand melting section




LH

L

Particle size, bulk density

ZSK 101

A left-handed element fillsthe kneading blocks andmakes them melt thepolymer completely. Thegas (air or nitogen) goes

back out of the feed hopperand might restrict the feed.

Air Powder

+ air

Layout of the Melting Zone




Powder

+ air

Air Right-handed kneadingblocks are not fully filled.The polymer will not meltcompletely. The gas (air ornitogen) can pass through

the melting zone anddoesn’t influence the feed. Itis vented downstream

ZSK 101

Increasescrew speed

Venting of thefeed hopper

Wrong

100 150 200 250 300

100

90

80

70

Screw speed [ rpm ] R a t e

/ s c r e w s p e e

d [ % ]

Modify screw

FHn

...

...

...

...

......

free cross-sectionpitchscrew speedfill factor

conveying efficiencyproduct density

G = F x H x n x x x

G ... Conveying capacity

Feed Limitation




All values are for information only. They have to be checked individually for each case.

Single flightedelements

Undercutelements

Large pitchelements

Reduction of compressionCorrect

Product is forcedstraight forward.

15 % less freevolume.

Undercutprofile

Increase of free volume3-lobe system: + 40%2-lobe system: + 15%

Not self cleaning

Pitch = 1,3 x D

Pitch = 2 x DStandardprofile

P i t c h + 5 0 %

R a

t e + 1 5 -

2 0 %

ZSK 101

Downstream Feeding




ZSK 101

Product Quality vs. Feed Location




DF = 0,9 DF = 0,17Upstream Filler Feed: Agglomerated

Downstream Filler Feed:Well Dispersed

ZSK 101

1 2 3 4 5 6 7 8

Vacuum

Side Location for Feeding Filler orReinforcing Agent via ZSB

Polymer

1 2 3 4 5 6

Polymer Filler and/or Reinforcing Agent Vacuum

Product Quality vs. Machine Wear




Melting andMixing Zone

Wear

Dispersion

Fiber Length

Wear

Dispersion

Fiber Length

Melting Zone Mixing Zone

ZSK 101

ZS-B Twin-Screw Side Feeder




ZSK 101

ZS-B Twin-Screw Side Feeders

ZS-B 25 40 58 70 92 120

Screw Diameter (mm)Channel Depth (mm)

256

409 5

5814

7017 5

9222

12029




Channel Depth (mm) 6 9.5 14 17.5 22 29

Suitable for ZSK Sizes 25, 30 40, 53 50, 58 70, 8283, 90

92120, 130133, 160

170

ZSK 101

Side Feeder Capacity Chart

Speed Set/RPM 1/55 rpm 5/140 rpm 9+/339 rpm Bulk Density

(lb/ft*3)HDPE Powder 984/29.8 2304/69.8 4536/137 33.0

TiO2

(DuPont R-960)

918/21.3 2472/57.5 3888/90.4 43.0

Lime 1044/34.8 2585/83.4 4068/131 31.0

ZSB-70




Starch N/A 3295/85 5904/151 39.0

Fumed Silica(Cabosil M-7)

N/A 305/67.7 576/128 4.5

TheoreticalVolumetric Rate

29.8 81.3 170 N/A

(WPC ZSB-70 #1)Rate in lb. Per hour/cubic feet per hour These rates were taken with flooded hopper and do not reflect standard side feeder operation

ZSK 101

15

17

19

21

a t e p e r

R P M

Max Rate vs. RPMZSB 70 Side Feeder




11

13

50 100 150 200 250 300

RPM

R a

HDPE Powder TiO2 LIME

ZSK 101

Down Stream Feeding - Solids




2 x

6 0 / 6 0

3 x

9 0 / 9 0

2 x

6 0 / 6 0

ZSK 101





2 x

6 0 / 6 0

4 x

6 0 / 6 0

3 x

9 0 / 9 0

ZSK 101





2 x

6 0 / 6 0

3 x

9 0 / 9 0

2 x

6 0 / 6 0

ZSK 101

Down Stream Feeding - Liquids




6 0 / 3 0 L H

6 0 / 3 0 L H

5 x

T M E 2 2

. 5 / 2 0

5 x

T M E 2 2

. 5 / 2 0

ZSK 101

Plastification(Melting)




ZSK 101

I II III

Filler Feed & Mix CompressionFeeding andPreheat

Plastification Devol

Typical Pressure Profile (radial & axial) &Temperature Profile Along the ZSK




Liquid Feed& DischargePreheat

ZSK 101

Extrusion Energy Input

100

1000

[ K W ]

Viscous Dissipation vs. Heat Transfer As a Function of Machine Size




10

0 50 100 150

Machine Diameter (mm)Installed Drive Power

Heater Shell Power

10 Barrel MC, 300 RPM

ZSK 101

Thermal Energy Input




ZSK 101

Heating for a ZSK 70

Heater Design KW / ClosedBarrel Watts / Sq. In.

NORMAL 7 0 30




NORMAL 7.0 30

HIGH WATTDENSITY 10.5 45

ZSK 101

Mechanical Energy Input




ZSK 101

Powder Melt

re

Time

Powder

Incorrect Melting Process




T e m p e r

a t u r e

Inhomogeneous melt

with powder clusters

Melting sectionMelting of the powder without immediatemxing of the melt with the remaining

powder or mixing of the high and lowviscous particles results in aninhomogeneous melt .

ZSK 101

Pressure Pressure

Incorrect Layout of the Melting Zone




Small pitch element is 100% filled.Compressed powder starts to melt attho hot barrel surface.

Left-handed elements are backing-upthe product into the powder conveyingsection. The compressed powder

starts to melt at the hot barrel surface.

ZSK 101

PressurePowder compressionIn the first kneading disk.No melt film is yet existing.

Layout of the Melting Zone




Without any compression of Powder or pellets, no uncontrolledPremelting of the product in theconveying elements possible.

The polymer iscompletely molten.The screw is onlypartly filled.

Layout of this zone is basedon thetype of polymer and the processingtask.

Conveying of powder / pellets Kneading and mixing zone Pressure zone Conveyingof melt

ZSK 101

Powder Melt

e

Time

Powder

Correct Melting Process




Melting of the powder and immediatemixing of the melt with the remaining

powder or mixing of the high and lowviscous particles results in a resultsin a homogeneous melt.

Homogeneous melt T e m p e r

a t u r e

Melting section

ZSK 101

Pressure Pressure Pressure

Correct Layout of the Melting Zone




No premelting of the powder upstream of the kneading blocks due to powder compression

ZSK 101

Effect of Screw Configuration on Energy Input




Feed Plastification Mixing Discharge

ZSK 101

Effect of Element Sequence on Energy Input




ZSK 101

As Function of Rate, RPM, & Screw Geometry (70% PP/30% EPDM)

Specific (Drive) Energy in Plastification Zone

# of LHElements

Q = 12 Kg/HrN = 225 RPM

Q = 12 Kg/HrN = 300 RPM

Part CrystallineEPDM 0 0.116 0.129

1 0.165




2 Together 0.160 0.181

2 Separated 0.154 0.177

ZSK 101

As Function of Rate, RPM, & Screw Geometry (70% PP/30% EPDM)

Specific (Drive) Energy in Plastification Zone

# of LHElements

Q = 12 Kg/HrN = 225 RPM

Q = 12 Kg/HrN = 300 RPM

AmorphousEPDM 0 0.112 0.123

1 0.157




2 Together 0.139 0.165

2 Separated 0.145 0.168

ZSK 101

Average EPDM Particle Diameter as Function ofSme in the Plastification Zone

10

15

20

25

P a r t i c

l e D i a m e

t e r

( m i c r o n s

)




0

5

0.11 0.13 0.15 0.17 0.19

Specific Mechanical Energy (Plastifiaction Zone)

A v e .

P

ZSK 101

2 x KB 45°/5/... leftright

Screw design remarks

When the first ZSK 240 for PE-HD compounding was started up, thescrew shaft broke after a relatively short running time at the marked pointThe reason was high local pressures (300 - 600 bar) on the first kneadingdisk. As soon as the powder was molten, the pressures were reduceddramatically.

No screw shaft failures any more. Low specific energy level.The behaviour, which means the melting effect, depends very much on thefill factor the screw speed or the outside heating

No longer installed.

The pressure level was reduced to uncritical values (100 - 250bar).

Melting of Polyethylene Reactor Powder




KB 45°/5/...Kombi KB 45°/5/...rightincreased clearance

right

right 2 x KB 45°/5/...3-lobe profile

left

Good results, when a narrow melt index range is produced and when the

the throughput doesn't change to much.

fill factor, the screw speed or the outside heating.

Only installed for Phillips grades.

Pressure level same as with the combi-element-screw.No screw shaft failures, but a higher specific mechanical energyWith modifications the energy level was reduced and the melting behaviour was optimized (see next page).

3-lobe kneading blocks are today standard for

.

ZSK 101

Screw configuration Spec. energy

Melting of Polyethylene Reactor Powder




3-lobekneading block

2-lobekneading block

Left handed element(kneading block orconveying element )

ZSK 101

Screw design remarks

3 * KB 45°/5/... left

When the first ZSK 240 for PP compounding was started up, the

screw shaft broke after a running time of about 10000h at the marked point.The reason were high local pressures (300 - 600 bar) on the first kneadingdisk. As soon as the powder was molten, the pressures were reduceddramatically.

No stable running condition could be achieved.fill factor, the screw speed or the outside heating.

Not any more installed.

The pressure level was reduced to uncritical values (100 - 250bar).The behaviour, which means the melting effect, depends very much on the

Melting of PP Reactor Powder




KB 45°/5/...Kombi KB 45°/5/...rightincreased clearance

Pressure level same as with the combi-element-screw.No uncontrolled melting behaviour.

Not installed.

Standard profile for PP.

2 * KB 45°/5/... leftKB 45°/5/...increased clearance

ZSK 101

Screw profile Spec. energy level

2 * KB 45°/5/... leftKB 45°/5/...increased clearance

Application

ZSK with low torque designZSK without gear pump

ZSK with high torque designZSK with gear pump

Melting section for PP Reactor Powder




2 * KB 45°/5/... leftKB 45°/5/...

KB 45°/5/...KB 45°/5/...

left

KB 90°/5/... leftleft

Copolymers

increased clearance

increased clearance

ZSK with high torque designZSK with gear pump

ZSK 101

Product specific limit

L e v e

l o

f s p e c .

e n e r g y

" R o o m

" f o r

i n s

t a l l a t i o n

o f m

i x i n g e

l e m e n t s

u m

b e r o

f l e

f t h a n

d e

d s e c

t i o n s Particle size (Pellet) (Powder)

Layout of the melting zone




With increased channel depth, more left handedelements are necessary to fill the kneading block

and to achieve good melting.

N

Z S K 3 - f l i g

h t e d

D o

/ D

i =

1 , 2

2

Z S K 2 - f l i g

h t e d

D o

/ D

i =

1 , 5

5

Z S K f l i g h t e d

D o

/ D

i =

1 , 4

4

Z S K 3 - f l i g

h t e d

D o

/ D

i =

1 , 2

2

Z S K 2 - f l i g

h t e d

D o

/ D

i =

1 , 5

5

Z S K 2 - f l i g

h t e d

D o

/ D

i =

1 , 4

4

With increased channel depth, the energy levelof the extruderos rediced. There is more "room"

available to installmore mixing elements.

ZSK 101

TWO LOBE KB MIX/MELT

Melting Section Comparison




THREE LOBE KB MIX/MELT



ZSK 101

Three Lobe Geometry Development

R i

R o

a n c e

R o M a xOD/ID = 1.37 (3-lobe max)

OD/ID 1 22 (T i l 3 l b )




C e n t e r

l i n e D i s t

a OD/ID = 1.22 (Typical 3 lobe)

OD/ID = 1.55 (Optimum 2 lobe)



ZSK 101

1. ZSK 70 Super Compounder

Melting Acetal: 2 lobe vs. 3 lobe KB

1 2 3 4 5 6

Acetal Vacuum

1140 lb/hr 220 deg C

500 RPM86 kw

Acetal Vacuum2 ZSK 90

4 x KB45/5/60




1250 lb/hr 232 deg C1 2 3 4 5 6 7 8

Acetal Vacuum

250 RPM100 kw

2. ZSK 90

2 x KB45/5/80, KB45/5/30 LH



ZSK 101

Heating of the barrel withsteam, oil or electricity

With increased size ofextruder this heating effect

will be reduced becausethe volume to surface ratiobecomes less and less

FrictionHeating of the barrel

Internal friction of thepowder

Friction and shear stress inthe narrow gaps, e.g. in the

kneading blocks

Shear stress between themolten and the solid parts

Heat Transfer

The polymer melt iswetting the un-moltenparts, which therefore willstart to melt at its surface.

Melting of the polymer




Could be influenced by:Heating of the barrelsInsulation of the barrelsHeating of the screw shaft

Could be influenced by:Screw Profile (kneadingblocks)Screw speedFeed rate

Could be influenced by:Screw Profile (mixing)Residence time (length ofthe extruder)

ZSK 101

Shifting of the melting pointUnmelt

Rate

P r e s s u r e

-Powder in the pellets-Powder at the start-up valve

Increase 8-0 pressure

Close DAV-valveinstall ( finer ) screens

Torque[ Md ]

Pressure[ P ]

Location of the melting point is not fixed.It is moving periodically up and down.

Rate

Spec. energy [ SEI ], melt temp. [ T ]

Location of the melting point is not fixed.It is related to the rate.

Surging of the melting point

Rate

P: downMd: up

Rate

M e

l t t e m p .

P

Spec. energy

Melt

Time

Melting Limitations




Install stronger screw

Increase barrel temperature in themelting area ( less effective with bigmachines )

Increase pitch upstream of the kneadingblock

P: downMd: upP: upMd: down

Stabilize the melting point with left handelement. Replace kombi-element [ rh/lh ].

Melt

Increase 8-0 pressureClose DAV-valveinstall ( finer ) screens

Spec. energy

rpmMelt

Melt

Melt

Melt

Melt

ZSK 101

ZSK 101

Unit Operations: Part II



ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 1



ZSK 101

Do

DispersiveDistributiveMixing Functions




Dt



ZSK 101

0.1

1

10

100

1000

0 000001 0 0001 0 01 1 100 10000

D i s p e r s e

P h a s e

D i a m

e t e r

( r e l a t i v e

)

Influence Of Viscosity Ratio On Mixing




0.000001 0.0001 0.01 1 100 10000

Viscosity Ratio (Disperse Phase/Matrix)

Shear Flow Shear + Extensional Flow

ZSK 101

Distributive Mixing Screw DesignMineral & Particulate Additives




4 x

1 2 0 / 1 2 0

8 0 / 8 0

4

x K B 4 5 / 5 / 4 0

K B 4 5 / 5 / 8 0

K

B 4 5 / 5 / 4 0 L H

8

x K B 4 5 / 5 / 4 0

K

B 4 5 / 5 / 4 0 L H

3 x

6 0 / 6 0

6 0 / 6 0

ZSK 92Distributive Distributive



ZSK 101

Increasing Distributive Mixing Intensity LowViscosity Additives




ZSK 101

ZSK 101

Devolatization




ZSK 101

VACUUM

Devolatilization Section




DEVOLATILIZATION ZONE



ZSK 101

Safety of the vent portVoids in the pellets

ZSK with 5 barrels without vent

Improved venting of the feed hopper

Separation of gas and polymer inthe melting section:

(see feed limitation).

Rate

% o f v o i d s Back-up

length (L)is too short.

Polymer

Increasescrew

speed

Screw speed

L

Optimizescrewpitch E

f f i c i e n c y

Rate factor

Pitch

Un-molten Polymer polymer

stronger screw

Fill factor Polymer

is too high.

Installlarger pitchelements.

Vent Limitation




the melting section:left-handed element at the end-->of the kneading blocks.

Installation of a small vent opening.

Movevent portupstream

Elongate

processsection

Reduce discharge pressure Des ign C V e nt s tuf fer

Des ign BDe s ign A

Vent portnot working

Installother type

of vent port.

good.

ZSK 101

ZSK 101

Metering / Discharge




ZSK 101

220

240

260

280

300

320

Deg CZSK 83

ZSK 70

Note: PC, L/D = 12, ~1.5 D Pitch,

Energy Consumed by Conveying




Axis LocationZSK 83

ZSK 70

120/120

90/90

ZSK 101

Influences on the pressure built-up behavior

Back up length

Pressure

Feed rate

Pressure

Back up length

Screw speed

Pressure

Back up length

Pressure

Back up length

Viscosity

Metering Zone




Back up lengthwill increase withincreased feed rate .

The pressurebuild-up improveswith increasedscrew speed.

Less pressurerequired reducesthe back up length.

The pressure built-up improves withincreased viscosityor reduced melt

temperature.

ZSK 101

rate factor

e f f i c i e n c y

small pitch

large pitch

Back up Length vs. Pitch

pressurepressurepressure




product flowproduct flowproduct flow

ZSK 101

F1

F1F2 F1

Pressure P

F o r c e

( V i s c o s i t y

R e l a t e d

)F1

Wear atScrew Tip

e e l a t e d )

F1

SF Elements for Pressurization




F2 F1Pressure P

F o r c

( V i s c o s i t y R

No Wear atScrew Tip

F2

ZSK 101

Increase screw speed Reduce pressure Reduce spec. energy Increase torque

Torque [ % ]

Screw speed Pressure

SmePower 100%

90%80%

T o r q u e

necessary

a v a i l a b l e

Actual Aim Theoretical

Torque

Standard High torque

100%

~ 65%

drive drive

Increase motor power Reduce mixing and/or kneading

Higher speed gear (two-speed gearbox) See pressure limitation

Torque Limitations




Change screw shaftand elements

(Replace gearbox)(has to be checked)

Install more efficientworking elements

Shortening of theprocessing length

Modify gearbox:change gear ratio

Variable speed motor

Increase motor power Move melting sectionfurther downstream

ZSK 101

ZSK 101

Downstream Handling




ZSK 101

1 2 3 4 5 6 7

Basic Machine Set-up and Definitions

Drive sectionmotor couplinggearbox

Process sectionscrew shafts and elementsbarrel sectionsstart-up / throttle valve (DAV)

Downstream equipmentgear pump (GP)screen pack changer (SWZ)pelletizer (UG)




DAV GP SWZ UG

ZSK 101

Start-up position Operating position

X

Combined Start-up / Throttle Valve (DAV)




X

ZSK 101

150

50

100

Pressure difference

new

OldOld design New design

0°

Butterfly Throttle in DAV




80°0° 45°

50

Throttle position

ZSK 101

o

C ]

DAV UGSWZ

8

ZSK

P r e s s u r e

[ b a r

]

300

200

100

0

max. High Pressure Die

Low Pressure Die

8

DAV GP SWZ UGZSK

300

200

100

0

max .

o

Low Pressure Die

High Pressure Die

r e s s u r e

a r

Pressure and temperature characteristics forhigh molecular weight PE without and with gear pump

Benefits of Gear Pump




T e m p e r a

t u r e

[ ° C 0

300

250

200

150

High Pressure Die

Low Pressure Die

0

300

250

200

150

Low Pressure Die

High pressure die

e m p e r a

u r e

ZSK 101

0.30

0.25

0.20 S p e c . e n e r g y

[ k W h / k g

]

300

200

140 S c r e w e n e r g y

[ r p m

]

Energy in Relation to Pressure and RPM




0.15 50 100 150 200 300

Pressure

[ bar ]

ZSK 101

Gear Pump Operation




ZSK 101

Gear Pump with Drive




ZSK 101

1. Suction Pressure2. Drive Power 3. Speed

4. Throughput Rate

Control System for Gear Pump




ZSK 101

Melt FiltrationConstruction Nomenclature

Mesh Width

Mesh Width Approximate Size Equivalence

Mesh Number Mesh(M/cm ) (M/inch)(um)

Screen Mesh




Fine screen Support screen(Large mesh)

Screenpack

Support plate(Breakerplate)

(M/cm ) (M/inch)

205080

100

200325400

800300180150

754535

64400

1 0001 600

6 40014 40022 500

ZSK 101

Stationary Filter Screen Changers

Discontinuous Operation Continuous Operation

Flat Screen Cylindrical Screen (SWZ)

Small to medium rates.Larger screen diameter Medium to high rates.i i

Spare filter

Screen change possible while extruder operates. Changeover ~ 1-2 sec.

Not used extensivelysince extruder must bestopped to make ascreen change.

Melt Filters




Larger screen diameter required for higher throughputSurface area 100 cm

No restriction on screensurface. Rate: 500 to800 kg/h polymer for every 100 cm surface.Surface area 100 cm1 1

, 3 c m

2 , 8 c m

2

2

2

ZSK 101

SWZ 4500

SWZ 9000 / 14000

Screen Changer SWZ




Number of screen elements 7 12 19 27 12 19 28 38

Filter area [ cm² ] 798 1369 2167 3079 2922 4626 9252 14608

Output rate [ t / h ] 2...7 4...12 4...18 12...27 12...32 13...40 26...60

SWZ 700 1200 1900 2700 2800 4500 9000 14000

35...80



ZSK 101

SWZ > 2800

Screen Cartridges for SWZ




SWZ 700 up to SWZ 2700

ZSK 101

1.000

2.000

3.000

SWZ 700

SWZ 1900

SWZ 2700

SWZ 1200

S c r e e n

S u r f a c e

( c m

² )

Candle vs. Flat Plate Screen Surface




0 100 200 300 400

0

SWZ 300

Diameter of the Breakerplate (mm)

Flatplate Screenchanger

ZSK 101

ZSK 101

Pelletization




ZSK 101

Hot CutPelletization of polymer melt directly on dieplate.

Polymer solidifies in final pellet form.

Cold CutPelletization after

polymer isalready solidified.

Pelletsconveyed

and cooledin air.

Pelletizing in Air Pelletizingunder water

EccentricPelletizing

(EG)

Rotating knifePelletizing

(MWG)

WateringPelletizing

(WRG)

UnderwaterPelletizing

(UG)

Pellets are conveyed and cooled in water

StrandPelletizing

Slab-Granulation

(Dicing)

Pelletization




Non-tackyproducts, mostly

used for PVC.

Throughputs upTo 10,000 kg/hr.

Tackyproducts and

especiallyPolyolefin.

Throughput50-75,000 kg/h

Filled, reinforced and low tackproducts.

Engineering plastics, PE

Throughput50-800 kg/h

Throughput50-12,000 kg/h

Nearly impossiblefor brittle products.

Max. throughputlimited by ability to

handle strands.(>3,000 kg/hr)

ZSK 101

Strand Pelletizing Train




ZSK 101

Pelletizerhood

Knife arm

Dieplate

Motor

Eccentric Knife Pelletizer




ZSK 101

PneumaticControl

Strand Cutter MWGStrand and Knife Rotor Pelletizing




ZSK 101

1 Polymer melt 2 Water inlet3 Water ring 4 Pellets in water stream

Water Ring Pelletizer (functional diagram)




ZSK 101

Without Transition With Transition

Optimized geometry determinedby polymer and rate

Dieplate

Transition Dieplate

DieplateTransition

Pelletizer Barrel

EG MWG, Strand pelletizing WRG, UG

Dieplate Design




Dieplate - Hole Geometry

Feed bore, pocket Land

BoreDiameter

ZSK 101

C u t t i n gF a c e-W

ar m

C u t t i n gF

a c e-

C ol d

C u t t i n gF

a c e

- C old

WRG UG

Insulated Dieplate Low Pressure Dieplate

Bore Geometry




l d Heating Channel

Heating Channel Heating ChannelInsulationLandlength = 1-2 x D Landlength = 6-8 x D Landlength = 4-6 x D

(Melt filled)

ZSK 101

Melt Plug of a Die Plate Pocket




ZSK 101

Die Plate Surface




ZSK 101

Die Channel / Die Surface

- Nib design wear protection withapprox. 60% cover factor

- Tungsten carbide material with1300HV

- 2, 3 and 4 rows of die holesper slot

- Coathanger profile in the transitionslot/die hole for PP-applications




ZSK 101

Die Channel / Die Surface

- Caterpillar design wear protectionwith approximately 70% coverfactor (patented)

- Tungsten carbide material with1300HV

- single row of die holes per slotbut same no. Of die holes like2-row design

- approx. 100% more heat

transfer surface compared tostandard design




- Individual approach holes perdie hole

ZSK 101

tungsten carbide nibs70% surface areaapprox. 80 HRC(patent pend.)

titanium carbide segments100% surface area

60...62 HRC

cutting surface

Wear Protection Die Plate




ZSK 101

Super intensively heated: Single row designUG525




ZSK 101

Pelletizer Hub & Knives




ZSK 101

Knife Orientation to Cutting Surface




ZSK 101

Underwater Pelletizer System UG 500




ZSK 101

Dryer Classifier

DAV1 2 3 4 5

GP SWZ UG

Additives

Polymer

MasterbatchMasterbatch

Color Change - Natural to Black




Water circulationsystem

time for self cleaning

< 1 hour < 30 min More hrs > 1 day

ZSK 101

Open throttle valve(DAV)

Modify screens Modify die plate Install gear pump

Pressure

Open Closed0 9060

Valve

w i t h o u t s c r e e n

2 0 m e s h

5 0 m e s h

w i t h o u t

s c r e e n

5 0 m e s h

2 0 0 m e s h

Pressure [ bar ]

30

130

200

1050

120

p=f { }(flow per hole )

(diameter of hole )

die length1/m

x

1+3/m

Reduction of die length:not possible because of mech. stability of the die plate

Increase of number of holes:+10% holes --> -5% pressureIncrease of hole diameter:+10% diam. --> -30 % pressure

Installation of low pressure die--> - 40 to 50 % pressure

ZSK D SWZ UG

Pressure [ bar ]

120

220250

Pressure [ bar ]

120

220

Without gear pump

With gear pump

Highviscosity

Lowviscosity

Die

Pressure Limitation




Low pressure die

Insulating gap D SWZ UG Die

120

40

GP

20

All pressure values are for information only. They have to be calculated individually for each case.

ZSK

ZSK 101

Total Line




ZSK 101

ZSK 101

Direct Extrusion




ZSK 101

Direct Extrusion

Extrusion Injection M. ExtrusionBlow molding Calendering Comp. M. Special

Foam

Thermoform

Rotationalmolding

Semi-solidforming

Polymer Finishing

Flat film

Sheet

Containers

Bottles

Profile

Pipe

Sheet

Flat film




FilmCoating

Film Caping

Blown film

Monofila-ment



ZSK 101

● Throughput● Screw Speed● Barrel Temperature● Discharge Pressure● Screw Configuration● Throttle Position● Recipe

Operating Parameters




ZSK 101

Individual productProduct range

Rate Spec. energy

T o r q u e

P r e

s s u r e

Q u a l i t y

M e l t i n g

P e l l e

t i z i n g Operating window

T o r q u e a t

h i g h s p e e d

T o r q u e a t l o w s p e e d

Q u a l i t y

p e l l e t i z i n g

Operatingwindow

P r e s s u r e

f e e d

i n t a k e m e l t i n g

Operating Window




Melt index Rate

y

ZSK 101

%

kg/h

kWH/KG

kg/h

°C

kg/h

bar

kg/h

%

kg/h

kg/h

RPM

%

RPM

kWh/kg

RPM

°C

RPM

bar

RPM

%

RPM

kg/h

°C

%

°C

kWh/kg

°C

°C

°C

bar

°C

%

°C

kg/h

bar

%

bar

kWh/kg

bar

°C

bar

%

bar

kg/h % kWh/kg °C bar %

THROUGHPUT TORQUE SPECIFIC ENERGY MELT TEMP. 8-0 PRESSURE MI-CHANGE(kg/h) (%) (kWh/kg) (°C) (bar) (%)

PROCESS VARIABLES

T HR

O U GHP

UT

( k g / h )

S C RE W

S P E E D

( U pm )

B A R.T E MP .

( ° C )

8 - 0 P RE

S S

( b ar )

T HR

OT T

OP E RA T I N

GP A RA ME T E R

S OF T HE

E X T R

UDE

Design and Operating Parameters




CLOSED

kg/h

STRONG

% °C bar %

OPEN

WEAK

CLOSED

STRONG

OPEN

WEAK

CLOSEDOPEN CLOSED

STRONG

OPEN

WEAK

kWh/kg

STRONGWEAK

CLOSED

STRONG

OPEN

WEAK

CLOSED

STRONG

OPEN

WEAK

T L E E R

S C R

E W C ONF I G.

ZSK 101

Controls and Interlocks



Controls 2009 I 11/2/2009 I Page 1

ZSK 101

Interlocks

● To prevent initiation of new operations until current operations arecompleted.

● Interlocks could be electrical, mechanical or both.




ZSK 101

Interlocks

Engine Start Interlocks Gear interlocksIgnition Key on

Starter Button DepressedBike not in Gear or Clutch depressed and Kickstand in up Position

Handlebar Kill Switch in Run Position

Kickstand in Up Position




ZSK 101

MEGAcompounder




ZSK 101

Extruder Start-up Permissive Interlocks

Extruder ZoneTemperature

Heat upTimer

1 to 4hours

Heat SaturationPeriod Complete

Thermocouple NotBroken

Extruder Lube OilPump Running

Extruder Speed Pot At Zero Set Point

Cooling Water Pump Running

0 RPM

A

N

D

PermitExtruder

Drive Start

By-PassHeat Up

Feeder Interlock

OR




Feeder InterlockNot Bypassed

No ExtruderImmediate or Timed

Shutdown

ZSK 101

Immediate Trip Interlocks

Bank Angle Sensor




ZSK 101

Extruder Immediate Trip InterlocksExtruder Motor

Torque <High-High(<110%)

Extruder DischargePressure <High-High

Extruder Thrust BearingStrain <High-High

Extruder Motor Temperature <High

Extruder Motor Cooling Air flow Above Low

A

ND

Permit

Extruder DriveRun

Extruder CouplingGuard in Place

Extruder CouplingNot Disengaged(Torque <115%)

d

NOT ALARM

NOT ALARM

NOT ALARM

NOT ALARM

NOT ALARM

NOT ALARM

NOT ALARM




Extruder Drive NoMalfunction

No Timed Shutdown

NOT ALARM

ZSK 101

Extruder Timed Trip Interlocks

OR

Extruder Motor Torque >20%

Extruder Speed <10%

Lube Oil PumpRunning

Lube Oil Pressure Above Low

Extruder Motor Torque <105%

A

N

D

Permit

Extruder DriveRun

Lube Oil Temperature

NOT ALARM

NOT ALARM

OFFDELAY2 MIN.

OFFDELAY4 MIN.

A

N

D

NOT ALARM

OFFDELAY5 SEC.

OFFDELAY2 MIN.

A

ND

NOT ALARM




pBelow High

NOT ALARM

ZSK 101

Feeder Interlocks

OR

Extruder Running

Extruder Speed <10%

Lube Oil PumpRunning

Lube Oil Pressure Above Low

Extruder Motor Torque <105%

A

N

D

PermitFeeders

ToRun

Lube Oil TemperatureBelow High

A

N

D

OFFDELAY5 SEC.

A

N

D

A

N

DNOT

Sid S I l k d

NOT ALARM

NOT ALARM

NOT ALARM

NOT ALARM




Side Screw Interlocked

Feeder InterlockIs Bypassed

ZSK 101

Process Control

Process Control

D u t y C y c l e

P I D R e s e tC y c l e T i m e

P r o po r t io nal O n

- O f f

E R R

O R

O f f s e t

R a t e A u t o T u ne

L A G

4 - 2 0

m A

GAIN

P B




t n e

ZSK 101

Cruise Control

Set Point Entry

Controller

Throttle




Speed Sensor

ZSK 101

Cruise Control

Cruise Control Unit

Set Point

Speed Set Point

Actual Speed Speed Sensor

Throttle Output Throttle

Permissive

Motorcycle Running

Motorcycle > 30 MPHMotorcycle < 80 MPH

Break not Depressed




Actual Speed Speed Sensor Clutch not Depressed

ZSK 101

Temperature Control

S

ControlPanel

Machine Area

SP Input

Actual Input

CoolOutput

TEi.e..Thermocouple,

RTD, Etc.

Barrel

Heater

HeatOutput

PowerDemand

Load CurrentFuse FailureHeater OpenBroken Wire

ETC

PDSIO

Pulse densitySignaling

Input/Output

TemperatureController

(PID)

Power Controller

SCR or SSR

Power DemandConventional Power

Demand

(4-20ma or timeproportioning)

Set Point




Solenoid

ZSK 101

Dual Output with Single Set Point Control

Output

100% On

50% On

0% On

HeatingOutput

CoolingOutput

HeatingPB

CoolingPB

Temperature




Set Point

ZSK 101

Melt Pressure and Axial Strain Gauge

Process Section

Screw shafts

Clutch

Main motor

CONTROL PANELOPERATOR STATION

DH, MB RTU, E-NetCommunication Cable

Communication

Communication

PE

PITP ressure IndicatingTransmitter

Strain Gauge

P ressure E lement

PIT

P ressure IndicatingTransmitter

Axial

Gearbox

AutoZero Span Reset

Alarm Filter Peak

On Off

0 % 100

1800

1 ALARM 2

Bridge

Pressure Indicating

Transmitter

(PIT)




ZSK 101

Torque Interlocks ZSK

max. power [ kW ] =

max. allowed torqueat screw shafts =

Screw shafts

Process sectionClutch

Gearbox100 %

100 %

exit gear box

=screw shafts

exit motor

=input gear box

< 105 %

105 %

< 100 %

100 %

Continuous operation

Alarm

Power supply[ % of kW ]

Mode of operation

max. continuous power

[ kW ] = 105 %

Motor




110 %

115 %

105 %

110 %

Shut-off main motor

Clutch slips

ZSK 101

Power/Torque Characteristic

Base Speed Max. Speed Speed

Torque

H o r s e

p o w e

r

100%Continuous

Torque




Torque (lbs/ft) = Horsepower x 5250RPM Horsepower = Torque (lbs/ft) x RPM5250

ZSK 101

Control of an Adjustable Speed Drive

Screw shafts

Process sectionClutch

Gearbox

Main motor

MAIN DRIVE

Motor Leads

Tach or EncoderFeedback

CONTROL PANEL

Speed SP

Speed PV

% Torque

Speed SP

Speed PV

% Torque

Analog Signal4-20ma or 0-10Vdc

OPERATOR STATION

DH, MB RTU, E-NetCommunication Cable

Communication

Communication




ZSK 101

Disengagement Coupling

● Manufacturer - Brunel● Small size & low weight● Large range of torque adjustment

available● Simple resetting method● Ability to service and disassemble without

removing the motor ● Labyrinth seals for containing grease




ZSK 101

Zero Speed Interlock - Brunel Coupling

Gearbox

Speed Sensor

Motor




ZSK 101

Coupling (Autoguard) Spring Chart

8,000

7,000

6,000

5,000

4,000

3,000

20 25 30 35 40

T o r q u e

( l b s

/ i n )




.20 .25 .30 .35 .40

Nut Gap Dimension (inches)

ZSK 101

COPERION: Moving to meet your needs



ZSK 101

What Is Troubleshooting?

● Troubleshooting implies that the process or the equipment once ranCORRECTLY.

● Troubleshooting is identification of the problem in a process or piece ofequipment.

● Troubleshooting is finding the best way to eliminate the problem.

● Troubleshooting is not process development.

– R&D

– Scale up



ZSK 101: Troubleshooting I Jan 2009 I Page 2

ZSK 101

Goals of Troubleshooting

Repair it properlyRepair it quickly

Repair it cost-efficiently

Repair it safely




ZSK 101

Safety

Always use the correct safety procedures.

Keep ALL personnel informed about changes.




ZSK 101

The successful troubleshooteruses a combination of :

● Experience

– I remember one time when… – Don’t just remember - keep a record for future reference

– Build a decision tree




ZSK 101

Build a decision tree

● Vent Flow

– Symptoms – Increased die pressure (underwater pelletizer)

– Increased pellet size

– Die holes plugged / blocked

– Symptoms

– Die pressure OK – Product in vent appears slightly undermixed

– Pull screw, check for wear in mixing zone




ZSK 101


● Experience

– I remember one time when….. – Don’t just remember - keep a record for future reference


● Product, Process, & Equipment Knowledge




ZSK 101

%

kg/h

kWH/KG

kg/h

°C

kg/h

bar

kg/h

%

kg/h

kg/h

RPM

%

RPM

kWh/kg

RPM

°C

RPM

bar

RPM

%

RPM

kg/h

°C

%

°C

kWh/kg

°C

°C

°C

bar

°C

%

°C

THROUGHPUT TORQUE SPECIFIC ENERGY MELT TEMP. 8-0 PRESSURE MI-CHANGE(kg/h) (%) (kWh/kg) (°C) (bar) (%)

T HR

O U GHP UT

( k g / h )

S C RE W

S P E E D

( U pm )

B A R.T E MP .

( ° C )

Process Variables

Design and operating parameters




ZSK 101


● Experience

– I remember one time when…..

– Don’t just remember - keep a record for future reference


● Product, Process, & Equipment Knowledge

● Good Troubleshooting Technique




ZSK 101

Define the problem

● Observe and record the problem (symptoms)




ZSK 101

Identify the type of symptoms

● Machine

– Barrel temperature not controlled at set point● Process

– Surging

– Specific mechanical energy too high

– Feed intake limitations

●

Material – Discharge temperature too high

– Mechanical properties not in spec




– Black specks

ZSK 101

Example

Symptom: Extruder temp zone 2 (Melting) does not maintain setpoint. It is

25 degrees too low. Product quality appears unaffected – Equipment issue




ZSK 101

Define the Problem

● Observe and record the problem (symptoms).

● Can the problem be reproduced?

● Can you make it disappear and reappear?




ZSK 101

Example

Symptom: Extruder temp zone 2 (melting) does not maintain setpoint. It is

25 degrees too low. Product quality appears unaffected – Equipment issue

Reproducibility: Happens immediately after start up and remains.



ZSK 101

Example

Symptom: Extruder temp zone 2 (melting) does not maintain setpoint. It is25 degrees too low. Product quality appears unaffected

– Equipment issue


Experience: This happened once before. – Then: Check valve leaked allowing return line water to flow back into

barrel. Replaced check valve.

– Now: Check valve OK.




ZSK 101

Cooling Manifold




ZSK 101

Define the Problem

● Observe and record the problem (symptoms).

● Can the problem be reproduced?

● Can you make it disappear and reappear?

● Did this happen before?

● When did it start?

● What happened at the time it first appeared?

● What has changed since the process ran well and the problem appeared?




ZSK 101

Example

Symptom: Extruder temp zone 2 (melting) does not maintain setpoint.It is25 degrees too low. Product quality appears unaffected

– Equipment issue


Experience: This happened once before.

– Then: Check valve leaked allowing return line water to flow back intobarrel. Replaced check valve.

– Now: Check valve OK.

When/What: Started a week ago / switched from pellet to powder resin.Have run powder often. Never seen problem.

When/What: Last ran powder 3 month ago / Annual PM.




ZSK 101

Example - continued

● What was done during PM?

– Worn barrels and elements replaced (but not in zone 2)

– New feeder installed

– Pelletizer bed knife replaced




ZSK 101

Problem is defined, now what: First Steps

● Identify the section of the equipment/process that probably contains theproblem.

– Probably not feeder or bed knife

– Look at barrel cooling and screw configuration

● List possible causes for the problem.

– Solenoid malfunctioning

– PLC malfunctioning

– Screw configuration incorrect

● Try quick fixes first.




ZSK 101

Example - continued

● What was done during PM?

– Worn barrels and elements replaced (but not in zone 2) – New feeder installed

– Pelletizer bed knife replaced

● Actions – Switch PLC, replace solenoid - Problem still there

– Pull the screw - may be assembled incorrectly

– Melting kneading block configuration OK

– Something is different

– Moved melt section downstream 1/2 barrel because didn’t have correct

i b hi i k Did ’ i f d li Sh ld ’




conveying bushing in stock. Didn’t want to wait for delivery. Shouldn’tmake a difference.

ZSK 101

Steel Temperature - Contact Measurement

Melt Temperature - Immersion Measurement

The Thermocouple Measures ItsOwn Temperature

The Thermocouple Measures ItsOwn Temperature

Temperature measurement




ZSK 101

Thermocouple types

FLOW




ZSK 101

Example solution




ZSK 101

What to do if the “First Steps” don’t work:Wade in Deeper

● List who has knowledge in the problem area and where to get help

– In house specialist – Machine manufacturer

– Raw material supplier

– Consultants

– www.info.apple.com/te/troubleshooting

● Assemble related historical data

● Establish a detailed written time line

● Get flow sheets and layout drawings

● Prioritize




Prioritize

ZSK 101

Dec Feb April

A l PM

Start up

Time Line

T C t l P bl

Powder Resin




Annual PM Temp Control Problem

ZSK 101

Final Thoughts

Speak with everyone involved, but takeeverything you are told with a grain of salt.

Maintain a sense of humor.Don’t take yourself too seriously.

Speak with everyone involved, but takeeverything you are told with a grain of salt.

Maintain a sense of humor.Don’t take yourself too seriously.




ZSK 101

Compounding Systems

Mixing Materials Using aTwin-Screw Extruder



Compounding I 11/2/2009 I Page 1

ZSK 101

Compounding

● The mixing of two or more ingredients to make a new material that has certainpredefined properties, i.e.: – color – cost – physical attributes – improved processibility – etc.




ZSK 101

Typical Compounds

● Mineral filled polyolefins

● Mineral and/or glass reinforced engineering resins

● Impact modified resins

● Color concentrates

● Filled masterbatches




ZSK 101

Filled Compounds

● Talc, Calcium Carbonate, Clay, or Mica for cost reduction or physical properties

● TiO2 for opacity

● Inorganic or Organic pigments for color concentrates

● Carbon Black for conductivity, physical properties, or color

● Masterbatches of hard to handle materials




ZSK 101

Filled Compounds

● PROCESS TASK: – Compound 20% Talc into PP for automotive applications

– Determine configuration which enables max rate.

● MATERIALS: – PP 8 MFR – Talc 20 lbs/ft3

● CRITERIA: – Dispersion for aesthetics – Dispersion for impact strength – Rate – Final MFR




ZSK 101

Process for Compounding 20% Talc Filled PP

Filled Compounds




ZSK 101

Screw Design for 20% Talc Filled PPBack Venting of Side Feeder

Polymer Feed

ATMVent

TalcFeed

Filled Compounds




ZSK 101

Filled Compounds

● PROCESS TASK: – Compound a carbon black filled specialty resin in one pass for semi-conductive

applications.

● CRITERIA: – Volume resistivity – Process robustness

● PRIOR TECHNOLOGY: – Two pass compounding with constant adjustment of carbon black




ZSK 101

Process for Compounding Semi-Conductive Material

Filled Compounds




ZSK 101

Distributive Mixing Screw forSemi-Conductive Compounds

Polymer feed

CarbonBlack

Filled Compounds




ZSK 101

Fiber Reinforced Compounds

● Predominantly fiberglass filled for reinforcement

● Process task is to mix fiber for maximum property development:

– wet out surface – minimize fiber breakage




ZSK 101

Machine Set-up for Fiberglass Compounding

Fiber Filled Compounds

VACTYPE

45°DIE

POLYMER

ZSB

1 2 3 4 5 6 7 8

FIBERGLASS




ZSK 101

High Viscosity Polymer

Low Viscosity Polymer





ZSK 101

Fiberglass Compounding Using ZME’s





ZSK 101

Liquid - Liquid Mixing

● Reactive processing

● Masterbatches of liquid additives – Lubricants – Process aids – Anti-stats

● Solvation of polymers – Adhesives – Gum Base




ZSK 101


● PROCESS TASK: – Compound an elastomer based pressure sensitive adhesive for coating

applications on the ZSK-58

● MATERIALS: – Elastomer/Thermoplastic Blend – Tackifier Resins (liquids)

– Antioxidants – Process oil

● CRITERIA: – Rate 800 pphr

– Turndown Ratio 5:1 – Maximum stock temperature 175 oC – Gel Free – Bubble Free




ZSK 101

Process for Compounding Pressure Sensitive Adhesive

To Transfer Pump


POLYMER

LIQUID INJECTION

VACTYPE A




ZSK 101

Max Rate: 600pphr

Rate Limitation : Gels

Max Rate: 800pphr

Rate Limitation : Gels




ZSK 101

Test Machine Set-up





ZSK 101

0

5

10

15

20

25

% A n t i -

S t a t

Percent Anti-Stat as a Function of MixingConfiguration

Mixing Configuration





ZSK 101

ZME vs. TMEZME TME

% Additive 10 10

Rate, pphr 428 378

S mech , kw-hr/kg 0.229 0.226

Polymer - Liquid Additive




ZSK 101

Lab Operations



ZSK 101: Lab Operations I Jan 2009 I Page 1

ZSK 101

The most comprehensive Twin-screw

development and customer service lab in North America

Lines for demonstrating:

ZSK 26MC to ZSK 62MVRates from 4 to 4000 pphProcesses ranging from:

Filled and reinforced polymers toBreakfast cereal and candy




ZSK 101

Coperion Process Lab: Experience

● General Polymer Compounding

● Highly Filled and Reinforced Material

● Heat and Shear Sensitive Products● Toner and Powder Coating

● Nanocomposites & Natural Fiber Composites

●

Reactive Processes● Devolatization

● Food/Candy & Chemicals

● Direct Extrusion

● Polyolefin Processing

● New Process Development

Application of the FutureDevelopment Steps

1) Careful Feed Preparation




ZSK 101

Coperion Process Lab: Material Feeding

Dry Feeders:

●

Loss in Weight (95%) & Volumetric● Acrison and Ktron Control Systems

● Rates from ~1 lb/hr to > 4000 lb/hr

Pumps:

● Metering Piston and Gearpumps

● Liquid Viscosity ranges of 1 to 6,000,000 cps

● Rates 1-600 pphr & Mass Flow Meters


2) Precision Metering




ZSK 101

Coperion Process Lab: Discharge Equipment

Stranding Dies Followed by Strand Cutter

Single Screw Discharge Extruders

(100 & 150 mm)Underwater Pelletizer (Gala M6)

Miscellaneous:

MWG (hot face, strand cut),

Food Pelletizer (hot face, centric hub),

EGR w/air conveying

(hot face, eccentric knife hub),

Sheet dies and roll stack

Chilled Belt

Water slurry cooling

Pneumatic conveying


3) Painstaking Sample Collection




ZSK 101

Coperion Process Lab: Special Features

Analytical Lab:Melt Index, GC, Microscopy, Dispersion Analysis,Moisture Level & Sieve Analysis

Ash analysis3/4” Single ScrewBench top space and Hood for Customer Use

Privacy:Test Bays are partitionedMeeting rooms are situated above most test bays.

Maintenance:Electronic and Mechanical TroubleshootingParts CleaningQuick Mechanical Fabrication


4) Quality ControlComparison Testing




ZSK 101

Throughput Range (pounds/hr)10-150 500-4000 100-1200

Bay 2ZSK 26

Bay 3ZSK

58MC62MV

Bay 6Special

ExtendedTesting

Bay 5ZSK

40MC43MV

Bay 4ZSK

58SC62MVSpecial

ExtendedTesting

Coperion Process Lab: Extrusion Lines and Floor Plan




ZSK 101

1 2 3 4 5 6 7 8 9

Troubleshooting 1

● Polyolefin + 60+% TiO 2

●

ZSK 70 - 9 barrels

– Polymer + 1/3 TiO 2 fed at Barrel 1

– Balance of TiO 2 at Barrel 4 with ZSB 70

● Normal Rate 1800 lbs/hr

● Current Rate 1400 lbs/hr

– Limited by feed throat back up

Troubleshooting Homework



ZSK 101: Homework I Jan 2009 I Page 1

ZSK 101

Troubleshooting Homework

● Symptom: Feed rate limitation

– Material/Process

● Reproducibility: Happens whenever rate is above 1400 lbs/hr

● Experience: Never happened before

● When/What: Started a week ago / switched from Talc to TiO2

– Have run same level of Talc and CaCO3 successfully

● When/What: 3 months ago / Annual PM

– Changed out worn barrels and elements

– Screw configuration is correct.




ZSK 101

Rate in lb. per hour/cubic feet per hour These rates were taken with flooded hopper and do not reflect standard side feeder operation

Speed Set/RPM 1/55 rpm 5/140 rpm 9+/339 rpm Bulk Density(lb/ft*3)

HDPE Powder 984/29.8 2304/69.8 4536/137 33.0

TiO2(DuPont R-960)

918/21.3 2472/57.5 3888/90.4 43.0

Lime 1044/34.8 2585/83.4 4068/131 31.0

Starch N/A 3295/85 5904/151 39.0

Fumed Silica

(Cabosil M-7)N/A 305/67.7 576/128 4.5

TheoreticalVolumetric Rate

29.8 81.3 170 N/A

Side Feeder Capacity Chart: ZSB-70




ZSK 101

Maintenance



ZSK 101: Maintenance I Jan 2009 I Page 1

ZSK 101

Types of Maintenance

● PREVENTIVE ($)

● PREDICTIVE ($$)

●

CRASH ($$$$$$$$$$$$)




ZSK 101 M i t I J 2009 I P 3

ZSK 101

Maintenance Areas

Grease motor bearings

Grease and inspect clutchChange oil; check oil filters

Keep couplings protected and

packing gland greased

Verify water quality

Monitor screw &barrel wear





ZSK 101

Screw Shaft

Coupling





ZSK 101

Installation and Removal of Screw Shafts

3 32 24 51

item 1: clutch sleeve item 4: pinion shaftitem 2: split rings item 5: screw shaftitem 3: threaded rings

item 1: clutch sleeve item 4: pinion shaftitem 2: split rings item 5: screw shaftitem 3: threaded rings

Gearbox side:right hand thread

process section side :left hand thread

Keep Protected with Never-Seize





ZSK 101

Position of the Gear shaft and the screw shaft

Left screw shaft

Right screw shaft

Installation of screw shaft

Do not install screw with these missing !!!





ZSK 101

Installation of the machine

screw barrel

gland sealing

screw shaftgear lantern

Screw shaft sealing

Torque toSpecification



g


ZSK 101

Gearbox Process section

Woodex Seal – For Gas tight Processing Needs




ZSK 101

Woodex assembled




ZSK 101

Woodex Dismantled




ZSK 101

Installation and Removal of the Screw Shaft

Hole for liftingdeviceScrew shaft

Screw shaft

Barrel

Extraction device to the screw shafts

Left hand bolts




ZSK 101

Technical Data

Tightening torques for screw connections (Discharge )

size of screw

M 6M 8M 10M 12

Tightening torque(Nm)

10244784 At a temperature of

approx.. 250°CM 16M 20M 24M 30M 36

M 42

200400720

13602340

3000

All bolts to be coated with high temperature paste, like Molykote P 37 fittingpaste at thread and contact surfaces.




ZSK 101

Installation

of theMachine




ZSK 101

ZSK- Installation Space




ZSK 101

Installation of Leveling Element

Loosen the counter nut on each leveling elements.

Align the machine in longitudinal and transversedirection by means of the screws on the 4 outerleveling elements.

A good floor contact of all leveling elements mustbe ensured.

Place the spirit level on the screw barrels and check the alignment inlongitudinal and transverse direction.

Turn the screw on the two middle leveling elements up to the base frame.Lock the screws of the 4 outer leveling elements with the counter nut.




ZSK 101

Installation

Leveling shoe

Bolt for adjusting the heightof the leveling shoe

+/- 5 mm




ZSK 101

Screw Shaft Installation

Timing block for installationof the screw shafts

Clamping device (pos.1 and 2) fortransport and and installation of thescrew shafts




ZSK 101

Installation and Removal of the Screw Shaft

Screw shaft Screw shaft

hole for lifting device


http://slidepdf.com/reader/full/zsk-compounding-manual 399/506ZSK 101: Maintenance I Jan 2009 I Page 21

ZSK 101

Technical Data

Barrel CoolingShaft Cooling

Melt Pump Cooling

Watering-Pelletizer

Underwater-Pelletizer

Cooling Waterfrom Cooling

Tower

Pressure (bar) 3 - 7 3 - 7 4 - 7

Temperature ( oC) 10 - 80 10 - 55 Max. 28Max Temperature ( oC)Increase 10 - 20 10 - 20 10

Permissible (bar)Pressure Drop - - 0.7 - 3.5

Water Specification




ZSK 101

Water Specification for Cooling Manifolds

1 2 3pH-value (-)* 8 – 9.5 8 – 9.5 7.5 – 9Conductivity (µS/cm)

(mg/l)(mg/l)(mg/l)(mg/l)(mg/l)(mg/l)(mg/l)(mg/l)

(CFU/ml)

( d ° )

< 0.2 - < 1,500

O 2 -content< 0.02

- -Cl -content < 5 < 50 < 200SO 4 -content < 5 < 50 < 300Cu (total) < 0.003 - -Fe (total) < 0.02 - -Mineral acid < 0.02 - -Suspended matter < 1 < 2 < 2Oil < 1 < 1 < 1Colony forming unitsContent

< 1,000 < 1000 <10,000

Total hardness - < 4 < 18*The pH-value is allowed to be adjusted only with volatile alkalizing agents, e.g. ammonia




ZSK 101

Alignment of the

Machine

ZSK 101




ZSK 101

Machine alignment

Motor is aligned to gearbox

Primary reference

Key alignment point

Keep support position

if barrels are moved

Clutch wear if misalignment

Element wear if

misalignment

ZSK 101




ZSK 101

Alignment of the Machine

Adjustment values – clutch slip(at operating temperature of gear and motor)

Maximum permissible radial run out: 0.05 mm

Maximum permissible axial run out: 0.1 mm

Values ascertained ( in 1/100mm)

ZSK 101




ZSK 101

Alignment of the Machine

Value ascertainedin 1/100mm

Parallelism of the pinion shaftsMaximum offset of the pinion shaft front faces,

with the thrust bearing assembly installed: 0.03mm.

Compensation washers- Do not discard!

ZSK 101




ZSK 101

Hose clamp

Blocks of wood bolted together to hold shaftsin place while backlash is removed from the

gearboxLeft screw shaft Right screw shaft

MachinistSquare

<0.002” gap

Machinist Pins

Gearbox Timing Check

ZSK 101




ZSK 101

Quickie check for timing & shaft twist problems

Gap MUST be symmetrical !!!

ZSK 101




ZSK 101

Interlocks& Shutdowns

ZSK 101




ZSK 101

Interlock Diagram

Control Voltage

Thrust

Thrust

Torque > 100 %

Torque > 105 %

Coupling slipped at 110 %

Torque 20-40 % adjusted duringCommissioning

Thrust

Torque

Idle Running

C o u p

l i n g

V e n

t e d Main Drive

OFFFeed

System

Control VoltageOFF All Equipment OFF

Emergency Shut Down

Measured by Load Cell

PSHH

PSH

XSH

XSHH

XSL

PAH

XAH

XALMax.6 min 3 0 S e c .

2 m

i n

i m m e d i a t e l y

Pressure is usually measured at machine discharge(gearbox strain gauges are optional equipment)

ZSK 101




ZSK 101

Shutdown Interlocks

Standard Shutdown(Machine mechanical limit)

Interlocks based onspecific operation

Pressure ~ 2500 psig 1000 psig

High TorqueFeeder Shutdown

105 % (or 100 % for 2minutes

80 % for additiveconcentrates

High TorqueMotor Shutdown

110 % Usually keep high to clearout stalled machines

Clutch

Disengagement

115 % Motor limit,

not gearbox limit 1

Undertorque 2 minutes <20 % torque < 5 % torque for very lowviscosity material 2

1 For setups that are motor limited, not gearbox limited2 Gearbox oil & temperature may be change if always at low torque

ZSK 101




Machine Shutdown Options

ZSK 101




Clutches

ZSK 101




To protect the extruder against damage,it will disengage in the following cases:

1. Gearbox power 110 %, the clutch slips (power on main drive >115%)

2. Air pressure at overpressure switch of the clutch controller > 130%

3. Gearbox power 105% ( on main drive 110 % on motor)

4. Thrust pressure by product is too high.5. Failure or fault fault of the underwater pelletizer.

6. Clutch slip is more than 4 revolutions within 2 minutes.

7. Fault in the EKW clutch supervision device ( self-supervision)

8. Emergency-off is actuated

In general, these couplings are used in ZSK-177+ machines in NAFTA

Desch Clutch (pneumatic)

ZSK 101




Brunel Clutch

Maintenance

1. Grease into greasefittings every 2-3 months

2. Safety elements shouldbe disassembled andinspected every 3 years.

3. Bearings should be re-greased every 3 months

4. Keep spare buffers asthese do wear out every6 months to 2 years.

(Item # 13)

ZSK 101




Autogard-Clutch

ZSK 101




Maintenance of theMachine

ZSK 101




Checklist

● Grease motor bearings every 2-6 months (depends on environment)

● Grease packing gland

●

Measure or photographs screw elements when pulled out – At least every 1500 hours of operation (unless >ZSK-133)

● Whenever oil is changed, check oil filter

● Do oil analysis at least once every 6 months

– Check with lubricant supply house

● Do not let water get in oil

– Rust

– Reduces lubricant’s efficiency

ZSK 101




Spare Parts Quote Recommended list



ZSK 101




3

- Three measurementsin each bore

- Every 5 mm in the length

The maximum value from the 3 measurement points gives an exact wear status for thatspecific position.

0

1

2

3

4

5

67

8

9

10

0 1 2 3 4 5

E v e r y 5 m m

- Barrel or Liner

- Measuring mouse

GBM Barrel Measuring Device

ZSK 101




0,00

0,50

1,00

1,50

2,00

2,50

3,00

3,50

4,00

4,50

5,00

5,50

6,00

Links Rechts

Sensor

Black boxLaptop

Graphicleft right

Data Transfer to the Laptop

ZSK 101




0,00

0,50

1,00

1,50

2,00

2,50

3,00

3,50

4,00

4,50

5,00

5,50

6,00

Links Rechts

1 2 3 4 5 6 7 8 9 10

1,20 mm

X X XX

X Wear = to high, barrels should be replaced A.S.A.P. Wear alarm: Spare to be ordered !

Left Right

Wear Picture from a ZSK Process Section

ZSK 101




Torque Transmission through a twin screw extruder

1 2 3 4 5 6 7 8 9

99-3123.008

Lockup point

ZSK 101




Total Power Transmission Path

1 2 3 4 5 6 7 8 9

99-3123.008

Clutch

Gear

box

ZSK 101




Top Ten Things not to Do with Twin screw extruders

10. Do not force screws into couplings

9. Do not change PLC logic without careful documentation

Should provide copy of change to Coperion

8. Do not use city water or any water that is prone to plugging of barrels or solenoids.

7. Do not run extruder without working pressure interlock.

6. Do not let screws and barrels get so worn that they vibrate and possibly wrapthemselves up rolling over each other.

ZSK 101




Top Ten Things not to Do with Twin screw extruders Pg 2

5. If using water to clean area, make sure that the screw shafts, screw couplings andclutch are kept well greased/lubricated.

4. Do not flood feeder extruder, especially during purging

3. Do not use steel tools on screw elements and barrels.

Use brass, wood, or plastic implements

2. If the machine over torques, do NOT continually try to restart with screws frozen

Strain in drive and motor cooling

Screws can be fatigued if constantly twisted under high loads

Clutch is designed to operate at normal speeds, not zero speed.

ZSK 101




Do not use a screwdriver on the “Touch” screen!

ZSK 101




Thanks for your attention !!

● Steven Jackson Manager Coperion Technical Services

– Process

– Electrical – Mechanical

● 1 888 Coperion 24-7 Access

ZSK 101



ZSK 101: Scale up I Jan 2009 I Page 1

Twin Screw Process Scale-up

… Or how to take a process commercial with fewerheadaches

ZSK 101




Key Items in Making a Scaleup Work

● Have a solid understanding of what controls the process

– Torque /Power - Nylon + glass fiber

– Volume (feeding) – PP + 40 % talc – Heat transfer - crystallization

● Have “decent” experimental data as a basis for calculations

● Scale up expected pilot rate data to a target machine if time and $$$ permit

ZSK 101




What is Going On Inside a Twin-Screw Extruder?

● Mechanical power transmission

(RPM x Torque)

● Heat transfer

(heating & cooling)

● Devolatilization

ZSK 101




Heating

Cooling

+100%

-100%

Visualization of the Inside of an Extruder

ZSK 101




Critical Parameters to Match for a Scaleup

● Screw design (and machine L/D ratio)

● “Average” shear rate

●

Relative degree of fill (i.e. rate for a machine size at a certain screw speed)● Verify that adequate power is available

ZSK 101




1 2 3 4 5 6

1 6 / 1 6

6 x

3 6 / 3 6

2 4 / 2 4

3 x

K B 4 5 / 5 / 2 4

K B 9 0 / 5 / 2 4

2 x

K B 4 5 / 5 / 2 4

2 x

K B 4 5 / 5 / 1 2

K B 4 5 / 5 / 1 2 L H

3 x

3 6 / 3 6

3 x

2 4 / 2 4

Company ScrewID Mach ID Product S.L (-16) B.Length Name Date

Drawing Nr. Revision Process Spec Nr. Shaft Length

PROPRIETARY NOTICE Description App/Rel

Hopefully not yours 001 ZSK26MC Anything 600 600 Sep 14, 2005

Not Defined

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF Coperion Corporation, Inc.. IT IS TRANSMITTED TO YOU IN CONFIDENCE AND TRUST A ND IS TO BE RETURNED UPONREQUEST. IT MAY NOT BE REPRODUCED NOR ITS CONTENTS DISCLOSED IN WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSES FOR WHICH TRANSMITTE DWITHOUT THE PRIOR WRITTEN PERMISSION OF Coperion Corporation, Inc.. USER AGREES THAT BY ACCEPTING THIS DRAWING THEY AGREE TO COMPLY WITH THE ABOVE TERMS.

COPERION US EXCO32 Ver 3.26/pessj

1 2 3 4 5 6 7 8

2 5 0 / 2 5 0

1 3 x

5 0 0 / 2 5 0

3 8 0 / 3 8 0

3 x

K B 4 5 / 5 / 3 8 0

K B 9 0 / 5 / 3 8 0

2 x

K B 4 5 / 5 / 3 8 0

2 x

K B 4 5 / 5 / 1 9 0

K B 4 5 / 5 / 1 9 0 L H

5 x

5 0 0 / 2 5 0

4 x

3 8 0 / 3 8 0




Hopefully Not Yours 002 ZSK380 Anything 9120 9117.5 PESSJ Sep 14, 2005

Not Defined

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF Coperion Corporation, Inc.. IT IS TRANSMITTED TO YOU IN CONFIDENCE AND TRUST AND IS TO BE RETURNED UPONREQUEST. IT MAY NOT BE REPRODUCED NOR ITS CONTENTS DISCLOSED IN WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSES FOR WHICH TRANSMITTEDWITHOUT THE PRIOR WRITTEN PERMISSION OF Coperion Corpo ration, Inc.. USER AGREES THAT BY ACCEPTING THIS DRAWING THEY AGREE TO COMPLY WITH THE ABOVE TERMS.


ZSK 101




1 2 3 4 5 6

1 6 / 1 6

6 x

3 6 / 3 6

2 4 / 2 4

3 x

K B 4 5 / 5 / 2 4

K B 9 0 / 5 / 2 4

2 x

K B 4 5 / 5 / 2 4

2 x

K B 4 5 / 5 / 1 2

K B 4 5 / 5 / 1 2 L H

3 x

3 6 / 3 6

3 x

2 4 / 2 4




Hopefully not yours 001 ZSK26MC Anything 600 600 Sep 14, 2005

Not Defined

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF Coperion Corporation, Inc.. IT IS TRANSMITTED TO YOU IN CONFIDENCE AND TRUST A ND IS TO BE RETURNED UPONREQUEST. IT MAY NOT BE REPRODUCED NOR ITS CONTENTS DISCLOSED IN WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSES FOR WHICH TRANSMITTE DWITHOUT THE PRIOR WRITTEN PERMISSION OF Coperion Corporation, Inc.. USER AGREES THAT BY ACCEPTING THIS DRAWING THEY AGREE TO COMPLY WITH THE ABOVE TERMS.


1 2 3 4 5 6

2 7 / 2 7

6 x

5 4 / 5 4

5 x

K B 4 5 / 5 / 1 8

K B 3 0 / 7 / 3 6 S A M

2 x

K B 9 0 / 3 / 3 0 B K B

K B 4 5 / 5 / 3 6 N - 3

F e

K B 4 5 / 5 / 3 6 3 F e

K B 4 5 / 5 / 3 6 3 F e - N

3 6 / 1 8 L H

3 x

5 4 / 5 4

4 x

3 6 / 3 6

Company ScrewID Mach ID Product S.L (0) B.Length Name Date



Hopefully Not Yours 003 ZSK40MC Anyhitng 969 972 Sep 15, 2005

Not Defined

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION OF Coperion Corporation, Inc.. IT IS TRANSMITTED TO YOU IN CONFIDENCE AND TRUST AND IS TO BE RETURNED UPONREQUEST. IT MAY NOT BE REPRODUCED NOR ITS CONTENTS DISCLOSED IN WHOLE OR IN PART TO OTHERS OR USED FOR OTHER THAN THE PURPOSES FOR WHICH TRANSMITTEDWITHOUT THE PRIOR WRITTEN PERMISSION OF Coperion Corporation, Inc.. USER AGREES THAT BY ACCEPTING THIS DRAWING THEY AGREE TO COMPLY WITH THE ABOVE TERMS.


ZSK 101

Wh M k P S l E




What Makes a Process Scaleup Easy

● Machines with a constant torque/volume ratio (SC/Mega)

● No screw speed correction (SC/Mega)

●

A material with “reasonable” (>5000 cps) viscosity

ZSK 101

Wh t M k P S l Diffi lt




What Makes a Process Scale up Difficult

● Going between different element geometry(particularly 3 to 2 lobe)

● Surface area limited processes

● Scaling data from a machine <40 mm diameter

ZSK 101

S li g B l D ig (P S/C hi )




Scaling up a Barrel Design (Pre S/C machines)

● Match L /D , not # of barrels

● Pre-SC machines have L/D per barrel of2.7-3.4

● Remember to include injection/support plates in overall length calculation

ZSK 101

Scaling up a Screw Design




Scaling up a Screw Design(Within the Same Machine Family)

● Substitute screw elements “one for one”

● Adjust for differences with conveying elements

●

Avoid rounding down to a smaller pitch screw element as the element may beoverfilled

● Watch which elements are near vents (especially machines that are preSuperCompounders)



ZSK 101

ZSK 40 MC Element List




ZSK-40 MC Element List

ZSK 101

Matching Average Shear Rates by




Matching Average Shear Rates by Adjusting Screw Speed

● Not necessary for Super/MEGA Compounders

● Screw speed correction is 10-30% with 3 lobe and 10-20% with older 2 lobemachines

● Highly risky for 3 lobe to 2 lobe scale up

ZSK 101

Method of Calculating Average Shear Rate




K F Nx

y

B

3 lobe

Method of Calculating Average Shear Rate

Shear = rpm / h

h 1

h 2

2 lobe

ZSK 101

Average Shear Rate Vs Screw Speed




0

100200

300

400

500

600

0 200 400 600Screw Speed

Shear rate(sec-1)

Three Lobe

Older Two Lobe

SC/MC/MC +

MV

Average Shear Rate Vs. Screw Speed

ZSK-53/57 not included

ZSK 101

The Effect of Degree of Fill on




The Effect of Degree of Fill on Average Shear Rate

Low Power DesignHigh Power Design

Three lobe geometry

H = pitch of conveying element

Three lobe geometryH = pitch of conveying element

ZSK 101

Example of Screw Speed Adjustment Calculation




Example of Screw Speed Adjustment Calculation

ZSK-57 runs at 350 rpm

Shear rate constant for ZSK-57 = 0.367 sec -1 per rpm

Shear rate = 0.367 x 350 = 128 sec -1

Shear rate constant for ZSK-90 = 0.427 sec -1 per rpm

Required ZSK-90 rpm = 128/0.427 = 300 rpm

{Not needed for SC/MC machines}

Screw speed calculations are simplified by theScrew speed calculations are simplified by the““scale up chartsscale up charts ”” included in the handoutsincluded in the handouts

ZSK 101

Screw Speed Adjustment




p j

ZSK 101

Rate Calculations




● Volumetric Capacity = actual internal volume of theextruder • screw speed

Note: Internal volume is independent of screw design

● Calculate ratio of volumetric capacity between lab and commercial machine

● Rate2= Rate1• (V2•N 2)/ (V1•N 1)

ZSK 101

Rate Calculation Chart for




Super/Mega Compounders

From / To 26 32 40 50 58 70 92 119 133

26 1 1.86 3.64 7.12 11.1 19.5 44.4 95.8 133

32 0.54 1 1.95 3.82 5.95 10.47 23.8 51.4 71.8

40 0.27 0.51 1 1.96 3.0 5.36 12.0 25.7 36.0

50 0.14 0.30 0.51 1 1.56 2.74 6.22 13.5 18.8

58 0.09 0.168 0.33 0.64 1 1.79 4 8.6 12

70 0.052 0.0960 0.187 0.36 0.56 1 2.24 4.79 16

92 0.023 0.042 0.083 0.161 0.24 0.446 1 2.14 3.0

119 0.010 0.019 0.039 0.74 0.116 0.21 0.047 1 1.4

133 0.075 0.013 0.027 0.053 0.086 0.149 0.33 .072 1

ZSK 101

Concerns in Scaling From Machines




g< 40 mm Dia.

● Very large area/volume ratio hides heat transfer problems

● Less power per volume due to mechanical limitations of small extruders

● Low level components may be difficult to meter accurately

● Data is often collected far below rate potential of machine

● Small channel depth can create feeding/ venting problems

– SK (undercut) elements can reduce this problem

ZSK 101

Rate Calculations for




Non-Super/Mega Compounders● Find the machine sizes on the Volumetric Capacity Ratio chart

● Look up Volumetric Capacity ratio between lab and commercial machines

● Multiply Volumetric Capacity ratio times rate of lab machine

ZSK 101

Volumetric Capacity Ratio Chart




ZSK 101

Rate Calculation




● ZSK-57 rate = 300 pphr

● ZSK-90 rate = ZSK-57 rate • 3.030

● ZSK-90 rate = 909 pphr

ZSK 101

Scaling from a ZSK-25 to a ZSK-70




If a ZSK-25 is running at 25 pphr,what is the rate scaling to a ZSK-70??

⇒ 2000 pphr

⇒

1200 pphr

⇒ 660 pphr

ZSK 101

Power Calculations




● S mech should be constant…

Then:

● Calculate required power at target screw speed

● Compare to available power at same screw speed

● kW = RPM • % torque • gearbox rating9550

ZSK 101

Example of Power Calculation: ZSK-57




● Basis 300 pphr @350 rpm at 75% torque

● Gearbox torque rating = 1000 N-m per 2 shafts

● Power={rpm • % torque • gearbox rating}/9550

● kW = {350 • 0.75 • 1000}/9550

● Power consumed = 27.5 kw

● S mech = (27.5/300) • 2.2 = 0.202 kw-hr/kg.

ZSK 101

Power Calculations for ZSK-90




● Basis 909 pphr with S mech = 0.202 kw-hr/kg

● Energy required kW = (909/2.2) • 0.202 kw-hr/kg

= 83.5 kW● % Torque = Power • 9550/(Rpm • Gearbox)

● % Torque = 83.5 • 9550/(300 • 4800 N-m)

● % Torque = 55 % (vs. 75 % fo r ZSK -57)

Note tha t th i s to rque d i spar i ty d oes no t h appen w i th m ach ines w i th same to rquelevel.

ZSK 101

Power Calculations ZSK-92MC+




● Basis S mech = 0.23 kw-hr/kg● Energy available @ different rpm

● Torque rating = 11,500 N-m 2 shafts

● Power @ 600 rpm = kW =

Torque (90%)• Rpm • Gearbox/9550

= (0.90)•(600 • 11,500)/9550

= 650 kW/0.23kw-hr/kg X 2.2 = 6,200 pphr @ 600 rpm

= 867 kW/0.24 kw-hr/kg x 2.2 = 7,950 pphr @ 800 rpm

= 1084 kW/0.25 kw-hr/kg x 2.2 = 9,540 pphr @ 1000 rpm

Note: S mech increases with higher rpm

ZSK 101

Scaling Across Machine Types




● Ideally, S mech and T melt should not change● Screw designs do not scale directly● Three lobe to two lobe process transfer is very “challenging”

Remember that there is a big difference in surface/volume ratio betweenthese two designs.

ZSK 101

Screw Design Across Machine Types




ZSK-101 Scaleup

ZSK-101 Scale90

Scaleup83

OD/ID 1.22{3 lobe}

OD/ID 1.44

{2 lobe)

OD/ID 1.55

{SC/MC}

LH LH

LH LH

LH

ZSK 101

Shortcut Calculation Method




● Volume of cylinder ∝ (Diameter) 3

● Area of cylinder ∝ (Diameter) 2

● Rate 2=Rate 1• (D2/D1) 3 Volume/Torque limited

{Still have to verify available torque}

● Rate 2=Rate 1• (D2/ D1) 2 Area limited

● Rate 2=Rate 1• (D2/D1) 2.3-2.7 Devolatilization

Valid only for same generation of element design

ZSK 101

Effect of Volume on Area/Volume Ratio




0.0001

0.001

0.01

0.1

1

1 10 100 1000 10000

Relative Volume

Area/unitvolume

3 Lobe2 LobeAutoclave

3

2

A

ZSK 101

Effect of Surface Area Limitations on Scaled Rates




● Compounding

– Reduced rates

– Lower degree of fill = higher shear rates

– “Light” seals like 3 lobe KB and neutral KB may not work

● Pelletizing

– Fewer die holes available on larger machines- Track pphr per die hole● Devolatilization

– Significantly reduced rates

ZSK 101

Run Tests to Calculate Exponent-Devol Process




050

100150200250

300350400450

1400 1600 1800 2000 2200 2400 2600

Residual monomer (ppm)

Rate (pphr)

ZSK58

ZSK40

Q 58Q 40

= 2.61 = 2.47= 2.56

Avg.

Q 58Q 40

= 2.55 = D58D40

= 2.52

ZSK 101

Examples of Area LimitationInduced Rate Reductions




Induced Rate Reductions● ZSK-58 test machine rate = 1000 pphr

● ZSK-133 rate based on process limitation

Volume/Torque 12,000 pphr

Devol 2.7 Exponent 9,400 pphr

Devol 2.4 Exponent 7,330 pphr

Area 2.0 Exponent 5,260 pphr

ZSK 101

Scale-up from a ZSK-58 to a ZSK-58




● Feedstocks can change (esp. density)

● Solids handling equipment can alter feed characteristics

● Temperature zones are set up differently

● Production machine may have an undersized motor

● Wear may alter screw performance

ZSK 101

Calculations From ZSK-101 Students ??




ZSK 101



ZSK 101: Materials I Jan 2009 I Page 1

Extruder Wear Materials of Construction

ZSK 101

Types of Wear in Plastics Processing*




* from Reinhard

Unmolten MineralFilled Polymer

Metal

Unmolten Polymer

Mineral

Metal

Abrasive

Molten MineralFilled Polymer

Metal

ZSK 101

Types of Wear in Plastics Processing*




* from Reinhard

Metal

Metal

Metal

Metal

Adhesive

ZSK 101

Schematic of Radial Pressure Profile of the ZSK




Active Side of Apex(Pressure Build up)

Passive Side of Apex(Pressure Release)

ZSK 101

Outward Forces Due to Action of Screw Elements




The material tends to go into the gap between the 2 screws.As this gap becomes very small in the intermeshing area, outward forces are created.These forces are related to the crest width of the screw element as well as on the

material characteristic (viscosity, powder or pellets).Further these forces are influenced by the fill factor of the screw channel.

O u

t w a r d

f o r c e

F 1

Crest width, fill factor

Viscosity

Material

F1

Powder

PelletsF1

ZSK 101

Outward Forces Due to Action of Screw Elements




2-flightedConveying elements

Almost all the product is able to movefrom one screw to the other one.Only very little amount of product issqueezed into the gap between thetwo screws.Low radial outward forces are created.

Single-flightedConveying elements

A large quantity of the product cannotmove from one screw to the other one.It is blocked by the crest of that screwand therefore it is squeezed into the

gap between the two screws.High radial outward forces are created .

Kneading blocksThe quantity of the product "in front of"a kneading disk, which is squeezed into

the gap between the two screws isrelated to the width of the disk. Withthin disks the material can "escape"more easily up- and downstream. Thewider the disk, the higher are theoutward forces.

ZSK 101

Inward Forces Due to Behavior of Polymer Melt




Filled screw length, volume of screw channel

Viscosity or elasticity

F2 F2

I n w a r d

f o r c e

F 2

When the screw channels are fully filled, the material melt forms a kind of continuouslayer, going around both screws. This "rubber band" is causing inward forces.These forces are related to volume of the channel (thick or thin belt) as well as

on the material characteristic (viscosity, elasticity).These forces are further influenced by the filled axial length of the screw channel.

ZSK 101

Wear Pattern ExplanationDisplacement of Screw Shafts

Screw Wear




Outward forces

Inward forces due to theelasticity of the melt

When the diameter of the screwis reduced very much, screwstend to climb up onto each other.

Axial displacementof screw shafts

Twisting ofone screw shafts

ZSK 101

Representative Wear Pattern in Amorphous Material Plastification Zone




-5

-4

-3

-2

-1

0

1

W e a r ( m m

R a d i u s )

ZSK 101

Representative Wear Pattern inCrystalline Material Plastification Zone




-5

-4

-3

-2

-1

0

1

2

W e a r ( m m

R a d i u s )

ZSK 101

Wear Due to Abrasive Materials




P r o

d u c

t f l o w

ZSK 101

Wear Due to Radial Forces at the Screw Tip




ZSK 101

Heat Transfer in LDPE as aFunction of Element/Barrel Gap & RPM




0

200

400600

800

1000

1200

1400

0 50 100 150 200

RPM

m u

( w / c m * 2 ) No Gap

0.25mm Gap0.5mm Gap

ZSK 101

ZSK Extruder Barrel Material Examples




Nitrided

- Standard base material- Nitriding ½ mm thick

Vautid

- Thru-hardened liner - Cast chromium steel- Basic wear & corrosion protection

WPR-29

- High wear protection

- Braze Coating 1 mm thick- Good corrosion resistance

- Highest wear protection- HIP Layer 3 mm thick- Advanced wear and

corrosion resistance

Wear &Corrosion

Resistance

TechnologyImprovements

ZSK 101

ZSK Extruder Barrel Materials:Barrel or Liner Wear Protection Processes




Process Application ExamplesNitriding Direct on barrel Nitrided barrel

Solid thru-hardening Direct or liner Combi barrel, cast ovalliners,

Solid tool steels

Furnace Braze Coating Direct or liners WPR-29 process

Centrifugal Casting Liners or Xaloy, Wexcospecial design

HIP Process Direct or liners CPM10V, Ni 50/60,Coperion PROTECT extreme

Coperion HIP-65S

ZSK 101Standard Barrel Construction for ZSK




Standard materialLow alloy steelCore hardness: 28 - 30 RCCase hardened by nitriding 15 - 20 mils thickSurface hardness 65 - 70 RC

ZSK 101Wear Resistant Barrel Constructions for ZSK




Wear protectionBarrel liners of high alloy steel (Cast Oval)Barrels directly coated with brazed coating (WPR 29)Barrels directly HIP layered ( )

Barrel withexchangeable

oval liner

Barrel withwear coating

ZSK 101ZSK Advanced Barrel Material:




Strong apex areaHIP layer is very denseand crack-freeWear and Corrosion

Resistant Material> 3 mm thick

ZSK 101ZSK Barrel Materials: Optimum Liner Design

h ll




Thin Wall “Figure 8”Liner is not a goodsolution for co-

rotating twin screwextruders

ZSK Design – Thick wall and a

solid apex areafor stability &long life

ZSK 101 Abrasive Wear Tests for Barrel Materials ASTM-G65 Sand Abrasion Test

60HOPPER




0

10

20

30

40

50

60

NitraloyNitrided

Cast WPLiner

WPR-44Coating

CPM-10V"15"

Wexco 777 Xaloy WPR-29Coating

PROTECTextreme

Note: The wear data are based on tests performed in the Coperion Materials Lab.The exact wear rate relationships may vary for different applications.

W e a r

R a t e

i n m m

3> 225

NOT

TO

SCALE

OTTOWA SAND

WEIGHT

WEAR SPECIMEN

RUBBER LINED WHEEL

ZSK 101Corrosion Resistance Options




Corrosion ProtectionBarrel liners of Nickel based alloy (i.e. Supermet Ni 50)Barrel directly coated with corrosion resistant coating applied

by HIP or fused processBarrel of solid corrosion resistant material: i.e. SS, Inconel,Hastelloy with or without fused coating

ZSK 101ZSK Extruder Barrel Materials

Type Description

WearSurface

WearResistance

CorrosionResistance




Type Description Surface Resistance Resistance

Nitrided015-001

Low Allow Steel BarrelCase hardened Nitrided

Nitrided½ mm thick X X

Cast Liner

015-043

Low Alloy Steel Barrelwith solid hard cast chromiun oval liner

ThroughHardened

XXX XXX

CPM10V Liner015-095

Low Alloy Steel Barrelwith CPM10V oval liner

CPM10V2-3 mm thick XXXX XX

WPR-29015-016

Low Alloy Steel Base Material

with WPR-29 coating directly applied

WPR-29

1 mm thickXXXXX XXX

Ni-50/60 Liner015-098

Low Alloy Steel Barrelwith solid Supermet Ni-50/60 oval liner

Ni-50/603-4 mm thick XXX XXXXX

Xaloy Liner015-097

Low Alloy Steel Barrelwith Xaloy X-800 oval liner

X-8003-4 mm thick XXXXX XXXX

PROTECT extreme 015-099.3

(direct or liner)

Low Alloy Steel Barrel withPROTECT extreme directly applied

or oval liner

S 60+3-4 mm thick XXXXX XXXXX

Special Stainless, Inconel, etc. -- -- --

ZSK 101Elements




NitridedStainlessThrough hardenedCrest weldedBi-metallicPowder metallurgical

ZSK 101ZSK Screw Element Materials:Screw Wear Protection Processes




Process Application Examples

Nitriding Nitralloy Steel

Solid thru-hardened Stainless Steel, Tool Steels

HIP Material CPM9V, CPM10V, S90V, Coperion Material “25”(either “solid” or with a soft core)

Solid Screw with CS base material with Tungsten Carbide weldcoating

Welded Coating Stainless Steel with Colmonoy 4 welded crestsInconel with Colmonoy 4 welded crests

ZSK 101Materials for Screw Components




Standard materialLow allow steelCore hardness: 28 – 30 RCCase hardened by nitriding 15 – 20 mils thickSurface hardness: 65 – 70 RC

ZSK 101Wear Resistant Material for Screw Components

M i l




Material

High alloy PM steelSoft Core: Spline

Through Hard: Keyed

Hardness: 60-63 RC

ZSK 101ZSK Screw Element Materials:Composite barstock with a soft core

Powder Metallurgical HIP Barstock




HIP - capsule

PM - material

Soft core

Powder Metallurgical HIP Barstock

ZSK 101

ZSK Screw Element Materials:Popular Softcore Screw Element Types

Material Code Softcore Outside PM Steel




Through-hardened powdermetallurgical (PM) steel,chromium and vanadiumcarbide based for wear life

Soft coresteel

sleeve

Material Code Softcore Outside PM Steel15 Carbon steel CPM 10V272 Carbon Steel S90V Stainless St.

25 Stainless Steel X235 Stainless St.

ZSK 101

Materials for Screw Components




Corrosion resistant materialsStainless steels i.e. 304, 316, 329 ssHardenable stainless steels i.e. 17 - 4 PHSuper alloys: i.e. Inconel 625, Hastalloy C 276.All corrosion resistant screw components equippedabrasive wear resistance with welded crests forimproved adhesive and abrasive wear resistance

ZSK 101

ZSK Screw Element Materials:Welded Screw Element Types

Material Code Body Weld Overlay




Crest Weld

or

Full Body &Crest Weld

BodyMaterial

y y236 Carbon steel Full TC body weld245 17-4pH SS Colmonoy 4 crest weld

229 Inconel 625 Colmonoy 4 crest weld

ZSK 101

ZSK Screw Element Materials

MaterialCode Description HardnessHRC WearResistance CorrosionResistance




00 Nitraloy 135 (nitrided) 65-70 X X

05 Thru-Hardened Stainless Steel 48-52 XX XXX

39 PM Tool Steel CPM9V (solid) 53-56 XXXX XX15

(244)PM Composite Tool Steel

CPM10V with soft core 59-61 XXXX XX

25 PM Corrosion Resistant Tool SteelMV11K with 316SS soft core 59-61 XXXX XXXX

212 Nitraloy withWPR25 (carbide filled) crestweld 58-60 XXX X

229 Inconel 625 withWPR22 (Colmonoy 4) crestweld 40-44 XXX XXXXX

245 17-4 PH SST with

WPR22 (Colmonoy 4) crestweld40-44 XXX XXXX

258 PM Composite Tool Steel CPM 10V withsoft core WPR25 (carbide filled) crestweld 59-61 XXXXX XX

271 / 272 PM Composite Tool SteelCPM420V (272 with soft core) 56-58 XXXX XXXX

ZSK 101

Abrasive Wear Tests for Screw Material ASTM-G65 Sand Abrasion Test

60

HOPPER

OTTOWA SAND




0

10

20

30

40

50

60

Nitraloy Nitrided Colmonoy 4 Crest Material 272 or 25 Material 39 Material 15

Note: The wear data are based on tests performed in the WP Materials Lab.The exact wear rate relationships may vary for different applications.

220

180

NOTTO

SCALE

NOT

TO

SCALE

1618

13 W e a r

R a t e

i n m m

3WEIGHT

WEAR SPECIMEN

RUBBER LINED WHEEL

ZSK 101

Plate: Barrel Material

Adhesive Wear Test Simulation ofScrew/Barrel Friction Conditions




PLATE ROTATING DISC

COOLING

FLUID

Plate: Barrel MaterialSolid or with applied Coating100 Kg constant pressure against disc

Rotating Disc: Screw MaterialSolid or with applied coatingOutside diameter

Speed: 320 rpm

Diameter: 100 mmSurface Speed: 100.5 M/Min (5.5 ft/sec)Test Time: 5 HoursCooling Fluid: Standard Cutting Fluid

99% water, 5% oil

ZSK 101

Adhesive Wear Test for Screw & Barrel Material

7064




C o

l m . 4 / W P R - 2 9

" 1 5 " / W P R - 2 9

C o l m

. 4 / C a s t

L i n e r

S t e l l i t e 1 2 / C a s t

L i n e r

N i t r a l l o y / N

i t r a l l o y

" 1 5 " / C a s t

L i n e r

0

10

20

30

4050

6064 62

8.41.5

1 0.1

Note: The wear data are based on tests performed in the WP Materials Lab.The exact wear rate relationships may vary for different applications.

PLATE ROTATING DISC

COOLINGFLUID

W e a r R

a t e i n m m

3

ZSK 101

Adhesive Wear CompatibilityScrew & Barrel Material

Screw Element Material Barrel Adhesive Wear Compatibility




Screw Element Material Barrel Adhesive Wear Compatibility

Material Nitrided Cast Ni-50/60 PROTECTCode Description Steel "Vautid" CPM10V WPR-29 or Col 4 Xaloy extreme

00 Nitralloy 135 (Nitrided) Caution Caution Caution05 Thru-Hardened Stainless Steel NO NO NO15 CPM-10V with soft core NO25 MV 11K with 316SS soft core NO

39 PM Tool Steel CPM 9V (solid) NO212 Nitraloy with carbide crest weld NO Caution NO

229 Inconel 625 with Col 4 crest weld245 17-4 PH SSl with Col 4 crest weld236 Carbon Steel fully carbide welded NO Caution NO

271 / 272 CPM 420V (272 with soft core) NO

ZSK 101

Program for Corrosion Testing

Barrel Materials Screw Materials




Barrel Materials – Nitralloy, nitrided – Cast Liner

– H13, nitrided – D2 – WPR-29

Screw Materials – Nitralloy, nitrided – WP 15 (244) (PM Matl.)

– WP 25 (PM Matl.) – WP 39 (239) (PM Matl.) – WP 05 (400 SS) – WP 48 (17-4 SS)

ZSK 101

Corrosive Medium & Concentration in Water




Hydrochloric Acid 10% 1%Sulfuric Acid 10% 1%

Acetic Acid 10% 1%

Nitric Acid 10% 1%

ZSK 101

Specimen Size: 1 5” OD

Corrosion Test for Screw & Barrel Material




Specimen Size: 1.5 OD0.4” Bore Dia.0.125” Thick

Test Temperature: Boiling temp of fresh acid/water solution, heldconstant overtest duration

Test Results: Expressed in mils/yr,calculated based on weight loss,material density, specimen surface & test time.

VAPOR

ACIDWATER

SOLUTION

CONDENSER

SPECIMEN

EL. HEATER

BOILING

ZSK 101

Corrosion Test, Barrel Materials 10% Hydrochloric Acid - 100 Degrees C, 20 Hrs.

VAPOR




2515022140

12060

6330

2600

5000

10000

15000

20000

25000

30000

Cast Liner H13,Nitrided

D2 Nitralloy,1.8519

WPR-29

Note: Tests were performed in a boiling acid solution

ACIDWATER

SOLUTION

CONDENSER

SPECIMEN

EL. HEATER

BOILING

W e a r

R a t e

i n m m

3

ZSK 101

VAPOR

Corrosion Test, Screw Materials 10% Hydrochloric Acid - 100 Degrees C, 20 Hrs.




Note: Tests were performed in a boiling acid solution

ACIDWATER

SOLUTION

CONDENSER

SPECIMEN

EL. HEATER

BOILING

22300 21890

1283011630

7300

0

5000

10000

15000

20000

25000

"39" WP 25 WP 15"244"

Nitralloy135M

17-4 PH

W e a r

R a t e

i n m m

3

ZSK Compounding manual

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