Leistritz Extrusionstechnik GMBH PDF

refreshing extrusion technology
Di sper si on and Mi x i ng Char ac t er i st i c s of Hi gh

Vol ume and Hi gh Tor que Tw i n Sc r ew Ex t r uder s
and opt i mi sed l i ne l ayout
Michael Thummert Head of Marketing
Leistritz Extrusionstechnik GmbH, Germany
2 - Leistritz Extrusionstechnik GmbH - 15.02.2013
Agenda
Factors that have an impact on pigment dispersion and mixing
Extruder Configuration
Processing Parameters
Line Configuration
Dispersion Study with BASF
Ener gy Bal anc e i n t he Tw i n Sc r ew Ex t r uder
P
drive
= drive power
Q
heat
= heating power
out
= enthalpy
of product
in
= enthalpy
input
P
shafts
Q
cool
= Cooling
energy
Loss due to
gearbox and
frequency converter
.
.
evap
= Evaporation
Introduction of power into the extruder

0 0
0
~ ~
~
+ + + A + A =
melting n evaporatio barrel shafts
H H Q V U P
( )
( ) A + = A + A =

V T T c m V U P
in out v
T T c m
shafts
in out v
v
V
v
kg
kWh
e
shafts
v
shafts
in out
c m
V
c m
P
c m
V P
T T
A
=
A
=
1
v v
in out
c c
e
T T
A
=

Specific energy input
E
s
= M
act
/M
max
* N
act
/N
max
* P
nom
kW * (0,97)/output kg/h
E
s
= specific energy input
M
act
= actual torque
M
max
= maximum torque
N
act
= actual speed
N
max
= maximum speed
P
nom
= nominal power
The specific energy input is specified in k Wh/k g.
Comparison of gearboxes by means of the torque factor [ f ]:
unit for power density
independent from the extruder size
f
Md
= T / a
3
[ Nm / cm
3
]
(1)
(1) source: Schenkel, G.: Kunststoff-Extrudertechnik. Mnchen,
Wien, New York, Carl Hanser -Verlag, 1963
Compar i son of Ener gy I nput
HP Standard Screw ZSE HP
HP=XX identical screw for the ZSE MAXX Series
Resi denc e Ti me Di st r i but i on
0,0
0,2
0,4
0,6
0,8
1,0
1,2
1,4
1,6
1,8
0 20 40 60
t / s
E
(
t
)

/

s
-
1
HP
XX=HP
XX+
XX (Igel)
XX (Rck)
SEI [kWh/kg]
0,276
0,253
0,275
0,254
0,399
of ZSE HP und ZSE MAXX E (t) :
Four Maj or Topi c s f or Pr oc essi ng Par amet er s
There are four main problems that can
occur while running a line:
Volume problems
Air problems
Temperature problems
Torque problems
Vol ume pr obl ems
venting
degassing
feeding zone
feeding
polymer
melting side feeder
additives/powder
mixing
kneading
mixing
sealing
pressure
building zone
gravimetric
feeder #2
gravimetric
feeder #1
Pressure (bar)
How is the material stream split up?
Screw geometry / process setup
Screw speed
Ai r pr obl ems
venting
degassing
feeding zone
feeding
polymer
melting side feeder
additives/powder
mixing
kneading
mixing
sealing
pressure
building zone
gravimetric
feeder #2
gravimetric
feeder #1
Pressure (bar) Where are seals?
Where are venting ports?
Does vacuum port work?
Temper at ur e pr obl ems
venting
degassing
feeding zone
feeding
polymer
melting side feeder
additives/powder
mixing
kneading
mixing
sealing
pressure
building zone
gravimetric
feeder #2
gravimetric
feeder #1
Pressure (bar) Energy Input
too much energy input by the screw
too high screw speed
Check specific energy input
Tor que pr obl ems
venting
degassing
feeding zone
feeding
polymer
melting side feeder
additives/powder
mixing
kneading
mixing
sealing
pressure
building zone
gravimetric
feeder #2
gravimetric
feeder #1
Pressure (bar) Energy Input
too low screw speed
Material viscosity temperature too low
Check specific energy input
Ex t r uder Set up ZSE MAXX Pr emi x
Option:
Setup with LSB as
Side Vent
Option:
Setup with LSB as
Side Vent
Large Feed Opening Large Feed Opening
Option:
2nd closed barrel when
using a fine screen or UWP
Option:
2-4 barrels for dispersion depending on pigment
and neccessary quality
Premix Premix
Ex t r uder Set up ZSE MAXX Pr emi x Fac t s
Large feed opening for more volume in the feed zone
3 barrels for melting and wetting of the mix
Atmospheric opening can be done with a side feeder less dust!
Depending on desired quality: 2-4 barrels for dispersion
Optional second barrel at the discharge zone in order to create enough
pressure for the use of fine screens and underwater pelletizers
Process length between 36L/D and 48L/D
Screw speeds up to 1,200 rpm
OD/ID = 1.66
Torque factor 15 Nm/cm for MB with technical polymers
Ex t r uder Set up ZSE MAXX Spl i t Feed
Pigment Pigment Polymer Polymer
Large side feeder
for high volume
pigment
Large side feeder
for high volume
pigment
Large Feed Opening Large Feed Opening
Option:
Option:
Ex t r uder Set up ZSE MAXX Spl i t Feed Fac t s
Larger side feeder for higher mass flow when feeding pigments
Wetting zone with forward venting
Process length between 44L/D and 52L/D
Screw speeds up to 1,200 rpm
Do/Di = 1.66
Torque factor 15 Nm/cm for MB with technical polymers
New Bar r el f or ZSE MAXX
Large Feed Opening
approx. 50% increase!
Large Feed Opening
approx. 50% increase!
Tw i n Oper at i on of t he Ex t r usi on Li ne
Two control panels facilitate control of the line from
two positions
Two control panels facilitate control of the line from
two positions
28
Di sper si on st udy w i t h BASF
Our Goals:
Transfer of the dispersion properties to the extrusion process
Effects of the dispersion characteristics on:
Homogenizing / dispersive pre-mixing
Free volume of the extruder (HP / MAXX)
Operating parameters (rpm, fill level)
General parameters for optimally dispersed pigments
29
Pr oc ess var i abl es
Pre-mixing
Homogenizing mixing (tumble mixing)
Mixing with fast running chopper
Leistritz ZSE 18 HP
Leistritz ZSE 18 MAXX
For both machines:
300, 600, 900 rpm
Partially filled and almost filled screws
throughput limited for the ZSE 18 HP: 3-12 kg/h
Constant:
10% MB in LDPE MFI 25, 110C, premix-screw design
30
Anal ysi s qual i t at i ve over vi ew
Pal iotol Yel low K 2270
80
85
90
95
100
105
110
115
120
125
130
135
140
0 30 0 6 00 900 12 00
Ex tr ud er [r pm]
C
o
lo
u
r
S
t
re
n
g
th
[%
]
HP , tumbl e, part l y fi l l ed
HP , tumbl e, fi l l ed
HP , di s pers i v e, partl y fi l l ed
HP , di s pers i v e, fi l l ed
MAX X, tumbl e, part l y f i l l ed
MAX X, tumbl e, fi l l ed
MAX X, di spersi ve, partl y fi l l ed
MAX X, di spersi ve, fi l l ed
Cromophtal Yel low 2GF
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 30 0 6 00 90 0 12 00
Ex tr ud er [r pm]
C
o
lo
u
r
S
tr
e
n
g
th
[
%
]
H P, tumbl e, part l y f i l l ed
H P, tumbl e, fi l l ed
H P, di s persi ve, partl y fi l l ed
H P, di s persi ve, fi l l ed
MAX X, tumbl e, par tl y fi l l ed
MAX X, di s pers i v e, part l y fi l l ed
MAX X, di s pers i v e, fi l l ed
Cromophtal Yel low 3GNP
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 3 00 600 90 0 1 200
Ex tr ud er [r p m]
C
o
lo
u
r
S
tr
e
n
g
t
h
[
%
]
H P, tumbl e, par tl y fi l l ed
H P, di spers i v e, partl y fi l l ed
H P, di spers i v e, fi l l ed
MAX X, tumb l e, par tl y fi l l ed
MAX X, tumb l e, fi l l ed
MAX X, di s persi v e, part l yf i l l ed
MAX X, di s persi v e, fi l l ed
Cr omophtal Red BNFP
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 3 00 600 90 0 1 200
Extr ud er [r p m]
C
o
lo
u
r
S
tr
e
n
g
t
h
[
%
]
H P, di s pers i v e, part l yf i l l ed
H P, di s pers i v e, fi l l ed
MA XX, tumb l e, p ar tl y fi l l ed
MA XX, tumb l e, f i l l ed
MA XX, di spers i v e, par tl y fi l l ed
MA XX, di spers i v e, fi l l ed
Cr omophtal Pink PT
80
85
90
95
100
105
110
115
120
125
130
135
140
0 30 0 6 00 900 12 00
Ex tr ud er [r pm]
C
o
lo
u
r
S
t
re
n
g
th
[%
]
HP , tumbl e, part l y fi l l ed
HP , tumbl e, fi l l ed
HP , di s pers i v e, partl y fi l l ed
HP , di s pers i v e, fi l l ed
MAX X, tumbl e, part l y f i l l ed
MAX X, di spersi ve, partl y fi l l ed
MAX X, di spersi ve, fi l l ed
Pal iogen Red Violet K 5011
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 30 0 6 00 90 0 12 00
Ex tr ud er [r pm]
C
o
lo
u
r
S
tr
e
n
g
th
[
%
]
H P, tumbl e, part l y f i l l ed
H P, di s persi ve, partl y fi l l ed
H P, di s persi ve, fi l l ed
MAX X, tumbl e, par tl y fi l l ed
MAX X, di s pers i v e, part l y fi l l ed
MAX X, di s pers i v e, fi l l ed
Cromophtal Vi ol et GT
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 3 00 600 90 0 1 200
Ex tr ud er [r p m]
C
o
lo
u
r
S
tr
e
n
g
t
h
[
%
]
H P, di spers i v e, partl y fi l l ed
H P, di spers i v e, fi l l ed
MAX X, tumb l e, par tl y fi l l ed
MAX X, tumb l e, fi l l ed
MAX X, di s persi v e, part l yf i l l ed
MAX X, di s persi v e, fi l l ed
Hel iogen Bl ue K 6902
8 0
8 5
9 0
9 5
10 0
10 5
11 0
11 5
12 0
12 5
13 0
13 5
14 0
0 3 00 600 90 0 1 200
Extr ud er [r p m]
C
o
lo
u
r
S
tr
e
n
g
t
h
[
%
]
H P, di s pers i v e, part l yf i l l ed
H P, di s pers i v e, fi l l ed
MA XX, tumb l e, p ar tl y fi l l ed
MA XX, tumb l e, f i l l ed
MA XX, di spers i v e, par tl y fi l l ed
MA XX, di spers i v e, fi l l ed

Colour strength a function of rpm
Different processing parameters: premix and extruder type, fill level
Pigments with big impact of processing parameters: up to 35% difference in colour strength
Pigments with low impact: < 10% difference in colour strength
Source: Dr. Ch. Guckel, BASF Schweiz AG;
Leistritz Compounding Workshop 2011, Nuremberg
31
Robust , easy di sper si bl e, l ow i nf l uenc e of
mac hi ne par amet er s
Dispersibility: excellent
Calendering Effect: medium
Compaction tendency: no
Colour strength in narrow
range: A < 10%
Dispersion energy through
mixing and increase in rpm
deliver the optimum
ZSE MAXX better develops
advantage of dispersive mixing
Cromophtal Red BNFP
95
100
105
110
115
0 300 600 900 1200
Extruder [rpm]
C
o
l
o
u
r

S
t
r
e
n
g
t
h

[
%
]
HP, tumble, partly filled
HP, tumble, filled
HP, dispersive, partly filled
HP, dispersive, filled
MAXX, tumble, partly filled
MAXX, tumble, filled
MAXX, dispersive, partly filled
MAXX, dispersive, filled
32
Si mpl e pr oc essi ng,
w i t h a Pl us f r om pr e-mi x i ng
Dispersibility: ok
Calendering Effect: no
Colour strength in medium
range: D ~ 15%
Dispersive mixing
shows an advantage
Lower rpm gives longer
residence time (more important than shear:
Dispersibility versus Calendering)
Cromophtal Violet GT
85
90
95
100
105
110
0 300 600 900 1200
Extruder [rpm]
C
o
l
o
u
r

S
t
r
e
n
g
t
h

[
%
]
HP, tumble, filled
33
St r ai ght f or w ar d hi gh t hr oughput w i t h bi g
mac hi ne vol ume
Calendering Effect: no
Colour strength in medium
range: D ~ 15%
Best results with
intensive pre-mixing
Machinery advantage: with
ZSE MAXX at high rpm / high
throughput, absence of dispersive
pre-mixing gets compensated
Paliotol Yellow K 2270
90
95
100
105
110
115
0 300 600 900 1200
Extruder [rpm]
C
o
l
o
u
r

S
t
r
e
n
g
t
h

[
%
]
HP, tumble, filled
34
Di sper si on pr oper t i es w i t h hi ghest i mpac t
of mac hi ner y set up
Calendering Effect: strong
Pigment develops full colour
strength at short residence
time
Optimum with bigger volume
(MAXX) and higher rpm
With no compaction tendency, the excellent dispersibility and
potential for colour development is observed during pre-mixing
and extrusion process
Paliogen Red Violet K 5011
95
100
105
110
115
120
125
130
135
140
145
0 300 600 900 1200
Extruder [rpm]
C
o
l
o
u
r

S
t
r
e
n
g
t
h

[
%
]
HP, tumble, filled
36
Summar y
The dispersion characteristics of a pigment can be transferred well to the
operating conditions of the dispersion process on a twin screw extruder
Results from the dispersion process can be explained with the
characteristics of the dispersed pigment
The results help to optimize existing processes and production plants
In many cases, optimum results could be achieved using the bigger free
volume of the ZSE 18 MAXX, especially with high throughput
Dispersive pre-mixing showed good results, especially with pigments
offering excellent dispersibility and showing no compaction tendency
... any quest i ons???
Michael Thummert
Head of Marketing
Leistritz Extrusionstechnik GmbH
Markgrafenstr. 29-39
D - 90459 Nrnberg
Phone: +49 911 4306 550
mthummert@leistritz.com
... see f i l ms @
w w w.x x t r usi on.t v

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refreshing extrusion technology

Di sper si on and Mi x i ng Char ac t er i st i c s of Hi gh

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