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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
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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
ZSK 101
ZSK Design Characteristics
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 2
ZSK 101
Process Technology
ProcessEngineering
Laboratory
ProcessApplications
(Field PE)
ProcessDevelopment
(PE & Modeling)
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 3
ZSK 101
Werner & Pfleiderer History
● 1873 Patent for Universal Mixer to Paul Freyburger ● 1878 Paul Pfleiderer and Herman Werner
Purchase Patent from Freyburger ● 1879 Production begins
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 4
ZSK 101
UK-A universal mixing and kneading machine
Sigma
Masticator
Hub design
Double-hub design
Shredder
Rotors
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 5
ZSK 101
Werner & Pfleiderer History
1913 Rubber Mixer
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 6
ZSK 101
1913 Rubber Mixer
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 7
ZSK 101
1913 Rubber Mixer
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 8
Werner & Pfleiderer History
● 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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ZSK 101: Design I Jan 2009 I Page 9
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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ZSK 101: Design I Jan 2009 I Page 10
Coperion Corporation - Ramsey, New Jersey
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ZSK 101: Design I Jan 2009 I Page 11
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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ZSK 101: Design I Jan 2009 I Page 12
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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ZSK 101: Design I Jan 2009 I Page 13
Compact unitfor snacks
Cereals
Pet food
More complex units for cereals,
pet food, starches
Food Technology
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 14
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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ZSK 101: Design I Jan 2009 I Page 15
In-line Compounding Tech: Compression and IM
PP with Glass or Cellulose Rovings
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ZSK 101: Design I Jan 2009 I Page 16
Biomass Technology: Solids ProcessingGrinder turns the wood pulp into a mash that
can be broken down further into glucoses.
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ZSK 101: Design I Jan 2009 I Page 17
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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ZSK 101: Design I Jan 2009 I Page 18
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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ZSK 101: Design I Jan 2009 I Page 19
Extruder Systems
+ + + + + +++
+ +
+
Single screwextruders
Multiple screwextrudersTwin screw extruders
Co-rotating Counter-rotating
IntermeshingNon
intermeshing
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ZSK 101: Design I Jan 2009 I Page 20
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
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 21
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
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 22
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
ZSK 101
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ZSK 101: Design I Jan 2009 I Page 23
OD
P i t c h ( m m
)
P i t c h ( m m
)
π OD
Conveying Elements
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ZSK 101: Design I Jan 2009 I Page 24
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 101: Design I Jan 2009 I Page 25
ZSK - 83/1100
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ZSK-120/1500
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ZSK 101: Design I Jan 2009 I Page 27
ZSK 70 MEGA Compounder
Small and Medium-size Machines
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ZSK 101: Design I Jan 2009 I Page 28
ZSK 320 Process Section
ZSK 101
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ZSK Building Block System for Screw & Barrel
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ZSK 101: Design I Jan 2009 I Page 30
ZSK Series: Screw Diameters from 18 to 380 mm
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ZSK 101: Design I Jan 2009 I Page 31
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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ZSK 101: Design I Jan 2009 I Page 32
O D
ID
O D
ID
A
= 2
= 1 . 2 5
O D
I D
Do to D i Ratio
Do = ODDi = ID
ZSK 101
Eff f D /D & RPM h
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ZSK 101: Design I Jan 2009 I Page 33
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
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ZSK 101: Design I Jan 2009 I Page 34
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
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ZSK 101: Design I Jan 2009 I Page 35
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
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ZSK 101: Design I Jan 2009 I Page 36
= 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
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ZSK 101: Design I Jan 2009 I Page 37
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
ZSK 101
Basic Data Comparison: D /D = 1 80
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ZSK 101: Design I Jan 2009 I Page 38
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
ZSK 101
Important Definitions
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ZSK 101: Design I Jan 2009 I Page 39
Important Definitions
Specific Mechanical Energy (Sme): Kwh/Kg
% Torque: Machine Constant(C) x Power(Kw)rpm
ZSK 101
Power Interlocks: Gearbox or Motor
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ZSK 101: Design I Jan 2009 I Page 40
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
ZSK 101
Segmented Screw
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Segmented Screw
ZSK 101
Screw Cross Section
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ZSK 101: Design I Jan 2009 I Page 42
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
ZSK 101
Stress distribution in a involute tooth
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ZSK 101: Design I Jan 2009 I Page 43
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
ZSK 101
ZSK screw and kneading elements
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ZSK 101: Design I Jan 2009 I Page 44
g(click image to play video)
ZSK 101
Material Flow
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(click image to play video)
ZSK 101
Conveying element flow channels
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ZSK 101: Design I Jan 2009 I Page 46
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
ZSK 101
Material Flow Pattern
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ZSK 101: Design I Jan 2009 I Page 47
3-flighted profile 2-flighted profile
ZSK 101
Identification of screw elements
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ZSK 101: Design I Jan 2009 I Page 48
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. - / --
ZSK 101
Screw Bushing Variations
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ZSK 101: Design I Jan 2009 I Page 49
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
ZSK 101
Pitch vs. Degree of Fill
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ZSK 101: Design I Jan 2009 I Page 50
Large Pitch(Feeding / Venting)
Medium Pitch(Conveyance)
Narrow Pitch(PressurizationHeat Transfer)
(Click image to play video)
ZSK 101
Kneading Blocks
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ZSK 101
Working principles of kneading blocks
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ZSK 101: Design I Jan 2009 I Page 52
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
ZSK 101
Identification of kneading blocks
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ZSK 101: Design I Jan 2009 I Page 53
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
ZSK 101
Kneading Block Geometry: Disc Width(Cli k i l id )
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ZSK 101: Design I Jan 2009 I Page 54
(Click image to play video)
Conveying
WideDiscs
MediumDiscs
SmallDiscs
Distributive DispersiveMixing Mixing
ZSK 101
Kneading Block Geometry: Disc Orientation(Cli k i l id )
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ZSK 101: Design I Jan 2009 I Page 55
Conveying
BackPressureComponent
Neutral
Righthanded
Lefthanded
(Click image to play video)Distributive Dispersive
Mixing Mixing
ZSK 101
Action of restriction elements(Cli k i t l id )
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ZSK 101: Design I Jan 2009 I Page 56
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
(Click image to play video)
Melt Seal
Mixing & Seal
P1
P1 P 2
P2
ZSK 101
Action of restriction elements
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ZSK 101: Design I Jan 2009 I Page 57
Type of element Back-up effect
right-handed
small-pitchscrew element
neutralkneading block
left-handedkneading block
left-handedscrew element
ZSK 101
Residence Time Distribution
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ZSK 101: Design I Jan 2009 I Page 58
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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ZSK 101
Special Function Elements
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ZSK 101: Design I Jan 2009 I Page 60
● 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
ZSK 101
Comparison of standard vs. undercut (SK) elements
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ZSK 101: Design I Jan 2009 I Page 61
UndercutStandardMaterial
Flow
ZSK 101
Comparison of undercut (SK) vs. standard elements
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ZSK 101: Design I Jan 2009 I Page 62
SK end view Normal Profileend view
ZSK 101
SF: Single Flight Element
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ZSK 101: Design I Jan 2009 I Page 63
ZSK 101
Working principle of SF elements(Click image to play video)
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ZSK 101: Design I Jan 2009 I Page 64
SINGLE-FLIGHTED ELEMENT PAIR NORMAL FLIGHTED ELEMENT PAIR
(Click image to play video)
ZSK 101
Transition between different profiles
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ZSK 101: Design I Jan 2009 I Page 65
Profile A Profile B Profile A Profile B
ZSK 101
Three Lobe KB
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ZSK 101: Design I Jan 2009 I Page 66
Two Lobe Three Lobe
Unequal width, 2 lobe to 3 lobe transition
ZSK 101
Three lobed elements
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ZSK 101: Design I Jan 2009 I Page 67
ZSK 101
SAM Kneading Disc
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ZSK 101
SAM Kneading Blocks
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Narrow Disc30 Degree Stagger Angle Wide Disc45 Degree Stagger Angle
ZSK 101
Tapered Kneading Block
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ZSK 101
Igel Element
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ZSK 101
SME: Screw Mixing Element
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ZSK 101
Comparison of gear type mixing elements
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ZME Element TME Element
ZSK 101
Two piece screw tips
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ZSK 101: Design I Jan 2009 I Page 74
Left-hand Thread Left-hand Thread
Cap
Threaded Bolt
ZSK 101
Mixing screw tips
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ZSK 101: Design I Jan 2009 I Page 75
Cone-shaped screw tip Mixing screw tip (MSSP)
ZSK 101
Standard screw tip
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ZSK 101: Design I Jan 2009 I Page 76
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
ZSK 101
Mixing screw tip
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ZSK 101: Design I Jan 2009 I Page 77
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
ZSK 101
Barrels: rectangular vs round opening
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ZSK 101: Design I Jan 2009 I Page 78
1
1
2
3 1
1
2
3
1Lor
4D
1Lor 3D
ZSK 101
Vent port adapter design
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ZSK 101: Design I Jan 2009 I Page 79
Form C
Form BForm A
ZSK 101
Twin screw vent port stuffer
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ZSK 101: Design I Jan 2009 I Page 80
Previous design:DSE principle
New design:ZS-EG principle
Vertical arrangement over the ZSK Horizontal arrangement on ZSK side
ZSK 101
ZS-EG General layout
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ZSK 101: Design I Jan 2009 I Page 81
Sight glass
Vacuum port
Devolatilization barrel
Collecting container for melt residues
ZSK 101
Barrel Cross Section
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ZSK 101: Design I Jan 2009 I Page 82
Available Volume Screw Elements
Heater Barrel
Heating orCooling Bores
ZSK 101
Water Flow - ZSK 177 and smaller
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ZSK 101: Design I Jan 2009 I Page 83
InletOutlet
ZSK 101
Cooling system for barrels
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ZSK 101: Design I Jan 2009 I Page 84
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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ZSK 101: Design I Jan 2009 I Page 85
ZSK 101
Strand Pelletizing
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ZSK 101: Design I Jan 2009 I Page 86
1. Extruder Die 2. Water Bath3. Air Knife 4. Pelletizer 5. Pellet Discharge
ZSK 101
Coperion Pelletizer Systems
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ZSK 101: Design I Jan 2009 I Page 87
ZSK 101
Underwater Pelletizer
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ZSK 101
Coperion Compounding Systems
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ZSK 101: Design I Jan 2009 I Page 89
From plastics to cerealand everything in between
S l i F d
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1
Selecting a F eeder-
Some of the I ssues Presented to the Coperion ZSK101 Workshop
K-Tron Institute
Rev: D
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The Technologies of F eeding
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• 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
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Bulk Solids Engineering
Electronics/Controls Mechanical/Weighing
Electr ical Engineer ing F actors
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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
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Includes the design and fabrication of:
• 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
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Includes the design and fabrication of:
• 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
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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=
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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
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• 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
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• 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 ?
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• 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
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• 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
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• JR Johanson Indicizer ® System @ $50,000
– Hang-Up Indicizer – Flow Rate Indicizer – Hopper Indicizer
Analysis Tools for Selection
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• Hosokawa Powder Tester and Sieve @ $13,000
Bulk M ater ials; the I ssues
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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
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The bin opening isnot large enough!
Piping Condition
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The hopper wall is too shallow
Stable pipe
A Good Solution??
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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
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• 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
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• 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
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• 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
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• 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
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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
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• 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
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α
Kinematic Angle of F r iction
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• Surface friction between the bin wall and bulk solids
’
Pressure
Gas Permeabili ty
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• 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
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• The characteristic of how easily a bulk solid particle
will crush or break.
Compressibility/Springback
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• 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
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We may simply define bulk material flow properties into fourglobal categories as:
Flooding
Easy FlowingDifficult FlowingCohesive, Sticky
Test for F looding Solids
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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
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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
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Visual test
If the material is stringy and tends to mat together, itis considered difficult flowing.
Test for Sticky, Cohesive Solids
T t t
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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
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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
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Concave feed
screws
Rotary Valve F eeder
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F eeding Easy F lowing Solids
Consider the following metering devices:
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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
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Single Screw Volumetr ic F eeder
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Auger
Spiral
Disk F eeder
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Bulk Solids Pump F eeder
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F eeding Diff icult F lowing Solids
Consider the following metering devices:
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Consider the following metering devices:
• 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
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45Trays may be of differing shapes for selected applications.
Twin Screw F eeder
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Twin auger screws
F eeding Cohesive & Sticky Solids
Consider the following metering devices:
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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
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Twin spiral screws
Twin auger screws
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Volumetr ic Belt F eeder
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With agitator flow-aid
L ow Rate M icro F eeder
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F low Aid Devices
Flow aid devices are used to improve flow quality of solids inbins hoppers and feeders They include:
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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
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Matcon Discharger
Flexible Hopper Liner
Now Specify the M eter ing Device
• Pick the best method of bulk material classificationd l d d f
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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)
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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
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MF
Weight signal
Tach signal
SPTime
Power
DriveController
Weigh Belt Advantages
• Low cost for high volumes of flow
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• 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
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• 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
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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
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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?
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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.
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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
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63
Process I nterfaces
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64
Process I nterfaces
• Add hopper venting as required.• Pressure/vacuum control at discharge must be
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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?
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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
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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
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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.
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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
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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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 2
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 3
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 4
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 5
ZSK 101
PremixMaterials A + B Material A Material B
Feed Sequencing Configurations
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 6
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 7
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 8
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
Impact of Feed Sequencing
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 9
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 10
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
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ZSK 101
Peroxide PP-powder Peroxide
PP-powder
PP-powder P id
Impact of Feed SequencingFeeding Mechanisms For Peroxide Addition
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 12
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
Impact of Feed Sequencing
Relative X-Sectional Area: ZSK 58 vs. ZSK 320
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 13
ZSK 101
Compounding of pharma tablets
P ff d B kf t C l
Typical Feed Zone Layout for Various Applications
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 14
Compounding of filledand reinforced materials
Puffed Breakfast Cereal
Compounding of powder coatings
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ZSK 101
Filled hopper
Single screw extruder Twin screw extruder
Feeding system
M
Comparison of SSE & TSE Mechanisms Feeding
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 16
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 17
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 18
Wrong Correct
ZSK 101
Filter
Feeder
Filter sack
Density35 lb/cf
Incorrect Correct
Feedstock Aeration
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 19
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 20
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 21
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 22
Large Pitch(Feeding/Venting)
Medium Pitch(Conveying)
Narrow Pitch(PressurizationHeat Transfer)
ZSK 101
Feedstock Material Form
●
Pellets● Powder ● Low Bulk Density Powder ● Liquid
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 23
q
ZSK 101
Material Handling OptionsLow Bulk Density or Difficult to Feed Materials
● 2L vs. 1L Feed Barrel● SK Profile Elements● SF Profile Elements
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 24
● SF Profile Elements● 2 X D Pitch Elements
ZSK 101
1
1
2 1Lor
(non-Super and Mega Compounder Systems)
Feed Barrel Options
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 25
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 26
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 27
ZSK 101
STANDARD PROFILE ELEMENT SK PROFILE ELEMENT
Review of SK & SF Elements
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 28
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 29
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 30
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 31
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 32
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 33
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 34
ZSK 101
Product Quality vs. Feed Location
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 35
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 36
Melting andMixing Zone
Wear
Dispersion
Fiber Length
Wear
Dispersion
Fiber Length
Melting Zone Mixing Zone
ZSK 101
ZS-B Twin-Screw Side Feeder
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 37
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 38
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 39
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 40
11
13
50 100 150 200 250 300
RPM
R a
HDPE Powder TiO2 LIME
ZSK 101
Down Stream Feeding - Solids
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 41
2 x
6 0 / 6 0
3 x
9 0 / 9 0
2 x
6 0 / 6 0
ZSK 101
Down Stream Feeding - Solids
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 42
2 x
6 0 / 6 0
4 x
6 0 / 6 0
3 x
9 0 / 9 0
ZSK 101
Down Stream Feeding - Solids
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 43
2 x
6 0 / 6 0
3 x
9 0 / 9 0
2 x
6 0 / 6 0
ZSK 101
Down Stream Feeding - Liquids
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 44
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)
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 45
ZSK 101
I II III
Filler Feed & Mix CompressionFeeding andPreheat
Plastification Devol
Typical Pressure Profile (radial & axial) &Temperature Profile Along the ZSK
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 46
Liquid Feed& DischargePreheat
ZSK 101
Extrusion Energy Input
100
1000
[ K W ]
Viscous Dissipation vs. Heat Transfer As a Function of Machine Size
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 47
10
0 50 100 150
Machine Diameter (mm)Installed Drive Power
Heater Shell Power
10 Barrel MC, 300 RPM
ZSK 101
Thermal Energy Input
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 48
ZSK 101
Heating for a ZSK 70
Heater Design KW / ClosedBarrel Watts / Sq. In.
NORMAL 7 0 30
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 49
NORMAL 7.0 30
HIGH WATTDENSITY 10.5 45
ZSK 101
Mechanical Energy Input
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 50
ZSK 101
Powder Melt
re
Time
Powder
Incorrect Melting Process
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 51
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 52
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 53
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 54
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 55
No premelting of the powder upstream of the kneading blocks due to powder compression
ZSK 101
Effect of Screw Configuration on Energy Input
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 56
Feed Plastification Mixing Discharge
ZSK 101
Effect of Element Sequence on Energy Input
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 57
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 58
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 59
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
)
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 60
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 61
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 62
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 63
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 64
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 65
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 66
THREE LOBE KB MIX/MELT
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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 )
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 68
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)
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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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 70
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
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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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 72
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
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ZSK 101: Unit Ops 1 I Jan 2009 I Page 73
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 1
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ZSK 101
Do
DispersiveDistributiveMixing Functions
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 3
Dt
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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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 5
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 6
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
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ZSK 101
Increasing Distributive Mixing Intensity LowViscosity Additives
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 8
ZSK 101
ZSK 101
Devolatization
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 9
ZSK 101
VACUUM
Devolatilization Section
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 10
DEVOLATILIZATION ZONE
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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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 12
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 13
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 14
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 15
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 16
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 17
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 18
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 19
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)
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 20
DAV GP SWZ UG
ZSK 101
Start-up position Operating position
X
Combined Start-up / Throttle Valve (DAV)
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 21
X
ZSK 101
150
50
100
Pressure difference
new
OldOld design New design
0°
Butterfly Throttle in DAV
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 22
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 23
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 24
0.15 50 100 150 200 300
Pressure
[ bar ]
ZSK 101
Gear Pump Operation
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 25
ZSK 101
Gear Pump with Drive
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 26
ZSK 101
1. Suction Pressure2. Drive Power 3. Speed
4. Throughput Rate
Control System for Gear Pump
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 27
ZSK 101
Melt FiltrationConstruction Nomenclature
Mesh Width
Mesh Width Approximate Size Equivalence
Mesh Number Mesh(M/cm ) (M/inch)(um)
Screen Mesh
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 28
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 29
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 30
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
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ZSK 101
SWZ > 2800
Screen Cartridges for SWZ
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 32
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 33
0 100 200 300 400
0
SWZ 300
Diameter of the Breakerplate (mm)
Flatplate Screenchanger
ZSK 101
ZSK 101
Pelletization
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 34
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 35
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 36
ZSK 101
Pelletizerhood
Knife arm
Dieplate
Motor
Eccentric Knife Pelletizer
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 37
ZSK 101
PneumaticControl
Strand Cutter MWGStrand and Knife Rotor Pelletizing
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 38
ZSK 101
1 Polymer melt 2 Water inlet3 Water ring 4 Pellets in water stream
Water Ring Pelletizer (functional diagram)
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 39
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 40
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 41
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 42
ZSK 101
Die Plate Surface
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 43
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 44
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 45
- 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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 46
ZSK 101
Super intensively heated: Single row designUG525
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 47
ZSK 101
Pelletizer Hub & Knives
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 48
ZSK 101
Knife Orientation to Cutting Surface
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 49
ZSK 101
Underwater Pelletizer System UG 500
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 50
ZSK 101
Dryer Classifier
DAV1 2 3 4 5
GP SWZ UG
Additives
Polymer
MasterbatchMasterbatch
Color Change - Natural to Black
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 51
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 52
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 53
ZSK 101
ZSK 101
Direct Extrusion
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 54
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 55
FilmCoating
Film Caping
Blown film
Monofila-ment
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ZSK 101
● Throughput● Screw Speed● Barrel Temperature● Discharge Pressure● Screw Configuration● Throttle Position● Recipe
Operating Parameters
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 57
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 58
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
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ZSK 101: Unit Ops: part 2 I Jan 2009 I Page 59
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
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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.
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Controls 2009 I 11/2/2009 I Page 2
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
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Controls 2009 I 11/2/2009 I Page 3
ZSK 101
MEGAcompounder
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Controls 2009 I 11/2/2009 I Page 4
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
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Controls 2009 I 11/2/2009 I Page 5
Feeder InterlockNot Bypassed
No ExtruderImmediate or Timed
Shutdown
ZSK 101
Immediate Trip Interlocks
Bank Angle Sensor
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Controls 2009 I 11/2/2009 I Page 6
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
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Controls 2009 I 11/2/2009 I Page 7
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
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Controls 2009 I 11/2/2009 I Page 8
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
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Controls 2009 I 11/2/2009 I Page 9
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
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Controls 2009 I 11/2/2009 I Page 10
t n e
ZSK 101
Cruise Control
Set Point Entry
Controller
Throttle
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Controls 2009 I 11/2/2009 I Page 11
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
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Controls 2009 I 11/2/2009 I Page 12
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
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Controls 2009 I 11/2/2009 I Page 13
Solenoid
ZSK 101
Dual Output with Single Set Point Control
Output
100% On
50% On
0% On
HeatingOutput
CoolingOutput
HeatingPB
CoolingPB
Temperature
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Controls 2009 I 11/2/2009 I Page 14
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)
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Controls 2009 I 11/2/2009 I Page 15
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
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Controls 2009 I 11/2/2009 I Page 16
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
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Controls 2009 I 11/2/2009 I Page 17
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
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Controls 2009 I 11/2/2009 I Page 18
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
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Controls 2009 I 11/2/2009 I Page 19
ZSK 101
Zero Speed Interlock - Brunel Coupling
Gearbox
Speed Sensor
Motor
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Controls 2009 I 11/2/2009 I Page 20
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 )
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Controls 2009 I 11/2/2009 I Page 21
.20 .25 .30 .35 .40
Nut Gap Dimension (inches)
ZSK 101
COPERION: Moving to meet your needs
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Controls 2009 I 11/2/2009 I Page 22
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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
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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
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ZSK 101: Troubleshooting I Jan 2009 I Page 3
ZSK 101
Safety
Always use the correct safety procedures.
Keep ALL personnel informed about changes.
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ZSK 101: Troubleshooting I Jan 2009 I Page 4
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 5
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 6
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
● Product, Process, & Equipment Knowledge
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ZSK 101: Troubleshooting I Jan 2009 I Page 7
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 8
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
● Product, Process, & Equipment Knowledge
● Good Troubleshooting Technique
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ZSK 101: Troubleshooting I Jan 2009 I Page 9
ZSK 101
Define the problem
● Observe and record the problem (symptoms)
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ZSK 101: Troubleshooting I Jan 2009 I Page 10
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 11
– 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
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ZSK 101: Troubleshooting I Jan 2009 I Page 12
ZSK 101
Define the Problem
● Observe and record the problem (symptoms).
● Can the problem be reproduced?
● Can you make it disappear and reappear?
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ZSK 101: Troubleshooting I Jan 2009 I Page 13
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.
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ZSK 101: Troubleshooting I Jan 2009 I Page 14
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ZSK 101
Example
Symptom: Extruder temp zone 2 (melting) does not maintain setpoint. It is25 degrees too low. Product quality appears unaffected
– Equipment issue
Reproducibility: Happens immediately after start up and remains.
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.
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ZSK 101: Troubleshooting I Jan 2009 I Page 16
ZSK 101
Cooling Manifold
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ZSK 101: Troubleshooting I Jan 2009 I Page 17
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?
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ZSK 101: Troubleshooting I Jan 2009 I Page 18
ZSK 101
Example
Symptom: Extruder temp zone 2 (melting) does not maintain setpoint.It is25 degrees too low. Product quality appears unaffected
– Equipment issue
Reproducibility: Happens immediately after start up and remains.
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.
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ZSK 101: Troubleshooting I Jan 2009 I Page 19
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 20
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.
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ZSK 101: Troubleshooting I Jan 2009 I Page 21
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 ’
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ZSK 101: Troubleshooting I Jan 2009 I Page 22
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 23
ZSK 101
Thermocouple types
FLOW
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ZSK 101: Troubleshooting I Jan 2009 I Page 24
ZSK 101
Example solution
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ZSK 101: Troubleshooting I Jan 2009 I Page 25
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
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ZSK 101: Troubleshooting I Jan 2009 I Page 26
Prioritize
ZSK 101
Dec Feb April
A l PM
Start up
Time Line
T C t l P bl
Powder Resin
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ZSK 101: Troubleshooting I Jan 2009 I Page 27
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.
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ZSK 101: Troubleshooting I Jan 2009 I Page 28
ZSK 101
Compounding Systems
Mixing Materials Using aTwin-Screw Extruder
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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.
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Compounding I 11/2/2009 I Page 2
ZSK 101
Typical Compounds
● Mineral filled polyolefins
● Mineral and/or glass reinforced engineering resins
● Impact modified resins
● Color concentrates
● Filled masterbatches
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Compounding I 11/2/2009 I Page 3
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
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Compounding I 11/2/2009 I Page 4
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
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Compounding I 11/2/2009 I Page 5
ZSK 101
Process for Compounding 20% Talc Filled PP
Filled Compounds
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Compounding I 11/2/2009 I Page 6
ZSK 101
Screw Design for 20% Talc Filled PPBack Venting of Side Feeder
Polymer Feed
ATMVent
TalcFeed
Filled Compounds
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Compounding I 11/2/2009 I Page 7
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
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Compounding I 11/2/2009 I Page 8
ZSK 101
Process for Compounding Semi-Conductive Material
Filled Compounds
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Compounding I 11/2/2009 I Page 9
ZSK 101
Distributive Mixing Screw forSemi-Conductive Compounds
Polymer feed
CarbonBlack
Filled Compounds
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Compounding I 11/2/2009 I Page 10
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
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Compounding I 11/2/2009 I Page 11
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
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Compounding I 11/2/2009 I Page 12
ZSK 101
High Viscosity Polymer
Low Viscosity Polymer
Fiber Filled Compounds
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Compounding I 11/2/2009 I Page 13
ZSK 101
Fiberglass Compounding Using ZME’s
Fiber Filled Compounds
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Compounding I 11/2/2009 I Page 14
ZSK 101
Liquid - Liquid Mixing
● Reactive processing
● Masterbatches of liquid additives – Lubricants – Process aids – Anti-stats
● Solvation of polymers – Adhesives – Gum Base
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Compounding I 11/2/2009 I Page 15
ZSK 101
Liquid - Liquid Mixing
● 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
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Compounding I 11/2/2009 I Page 16
ZSK 101
Process for Compounding Pressure Sensitive Adhesive
To Transfer Pump
Liquid - Liquid Mixing
POLYMER
LIQUID INJECTION
VACTYPE A
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Compounding I 11/2/2009 I Page 17
ZSK 101
Max Rate: 600pphr
Rate Limitation : Gels
Max Rate: 800pphr
Rate Limitation : Gels
Liquid - Liquid Mixing
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Compounding I 11/2/2009 I Page 18
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ZSK 101
Test Machine Set-up
Liquid - Liquid Mixing
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Compounding I 11/2/2009 I Page 20
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
Liquid - Liquid Mixing
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Compounding I 11/2/2009 I Page 21
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
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Compounding I 11/2/2009 I Page 22
ZSK 101
Lab Operations
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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
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ZSK 101: Lab Operations I Jan 2009 I Page 2
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
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ZSK 101: Lab Operations I Jan 2009 I Page 3
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
Application of the FutureDevelopment Steps
2) Precision Metering
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ZSK 101: Lab Operations I Jan 2009 I Page 4
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
Application of the FutureDevelopment Steps
3) Painstaking Sample Collection
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ZSK 101: Lab Operations I Jan 2009 I Page 5
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
Application of the FutureDevelopment Steps
4) Quality ControlComparison Testing
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ZSK 101: Lab Operations I Jan 2009 I Page 6
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
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ZSK 101: Lab Operations I Jan 2009 I Page 7
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
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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.
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ZSK 101: Homework I Jan 2009 I Page 2
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
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ZSK 101: Homework I Jan 2009 I Page 3
ZSK 101
Maintenance
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ZSK 101: Maintenance I Jan 2009 I Page 1
ZSK 101
Types of Maintenance
● PREVENTIVE ($)
● PREDICTIVE ($$)
●
CRASH ($$$$$$$$$$$$)
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ZSK 101: Maintenance I Jan 2009 I Page 2
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
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ZSK 101: Maintenance I Jan 2009 I Page 3
ZSK 101: Maintenance I Jan 2009 I Page 4
ZSK 101
Screw Shaft
Coupling
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ZSK 101: Maintenance I Jan 2009 I Page 4
ZSK 101: Maintenance I Jan 2009 I Page 5
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
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ZSK 101: Maintenance I Jan 2009 I Page 5
ZSK 101: Maintenance I Jan 2009 I Page 6
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 !!!
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ZSK 101: Maintenance I Jan 2009 I Page 6
ZSK 101: Maintenance I Jan 2009 I Page 7
ZSK 101
Installation of the machine
screw barrel
gland sealing
screw shaftgear lantern
Screw shaft sealing
Torque toSpecification
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g
ZSK 101: Maintenance I Jan 2009 I Page 8
ZSK 101
Gearbox Process section
Woodex Seal – For Gas tight Processing Needs
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ZSK 101: Maintenance I Jan 2009 I Page 9
ZSK 101
Woodex assembled
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ZSK 101: Maintenance I Jan 2009 I Page 10
ZSK 101
Woodex Dismantled
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ZSK 101: Maintenance I Jan 2009 I Page 11
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
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ZSK 101: Maintenance I Jan 2009 I Page 13
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.
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ZSK 101: Maintenance I Jan 2009 I Page 14
ZSK 101
Installation
of theMachine
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ZSK 101: Maintenance I Jan 2009 I Page 15
ZSK 101
ZSK- Installation Space
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ZSK 101: Maintenance I Jan 2009 I Page 17
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.
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ZSK 101: Maintenance I Jan 2009 I Page 18
ZSK 101
Installation
Leveling shoe
Bolt for adjusting the heightof the leveling shoe
+/- 5 mm
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ZSK 101: Maintenance I Jan 2009 I Page 19
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
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ZSK 101: Maintenance I Jan 2009 I Page 20
ZSK 101
Installation and Removal of the Screw Shaft
Screw shaft Screw shaft
hole for lifting device
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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
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ZSK 101: Maintenance I Jan 2009 I Page 22
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
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ZSK 101: Maintenance I Jan 2009 I Page 23
ZSK 101
Alignment of the
Machine
ZSK 101
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ZSK 101: Maintenance I Jan 2009 I Page 24
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
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ZSK 101: Maintenance I Jan 2009 I Page 25
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
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ZSK 101: Maintenance I Jan 2009 I Page 26
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
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ZSK 101: Maintenance I Jan 2009 I Page 27
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
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ZSK 101: Maintenance I Jan 2009 I Page 28
ZSK 101
Quickie check for timing & shaft twist problems
Gap MUST be symmetrical !!!
ZSK 101
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ZSK 101: Maintenance I Jan 2009 I Page 29
ZSK 101
Interlocks& Shutdowns
ZSK 101
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ZSK 101: Maintenance I Jan 2009 I Page 30
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
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ZSK 101: Maintenance I Jan 2009 I Page 31
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
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ZSK 101: Maintenance I Jan 2009 I Page 32
Machine Shutdown Options
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ZSK 101: Maintenance I Jan 2009 I Page 33
Clutches
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ZSK 101: Maintenance I Jan 2009 I Page 34
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)
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ZSK 101: Maintenance I Jan 2009 I Page 35
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)
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ZSK 101: Maintenance I Jan 2009 I Page 36
Autogard-Clutch
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ZSK 101: Maintenance I Jan 2009 I Page 37
Maintenance of theMachine
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ZSK 101: Maintenance I Jan 2009 I Page 38
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
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ZSK 101: Maintenance I Jan 2009 I Page 39
Spare Parts Quote Recommended list
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ZSK 101: Maintenance I Jan 2009 I Page 41
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
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ZSK 101: Maintenance I Jan 2009 I Page 42
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
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ZSK 101: Maintenance I Jan 2009 I Page 43
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
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ZSK 101: Maintenance I Jan 2009 I Page 44
Torque Transmission through a twin screw extruder
1 2 3 4 5 6 7 8 9
99-3123.008
Lockup point
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ZSK 101: Maintenance I Jan 2009 I Page 45
Total Power Transmission Path
1 2 3 4 5 6 7 8 9
99-3123.008
Clutch
Gear
box
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ZSK 101: Maintenance I Jan 2009 I Page 46
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.
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ZSK 101: Maintenance I Jan 2009 I Page 47
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.
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ZSK 101: Maintenance I Jan 2009 I Page 48
Do not use a screwdriver on the “Touch” screen!
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ZSK 101: Maintenance I Jan 2009 I Page 49
Thanks for your attention !!
● Steven Jackson Manager Coperion Technical Services
– Process
– Electrical – Mechanical
● 1 888 Coperion 24-7 Access
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ZSK 101: Scale up I Jan 2009 I Page 1
Twin Screw Process Scale-up
… Or how to take a process commercial with fewerheadaches
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ZSK 101: Scale up I Jan 2009 I Page 2
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
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ZSK 101: Scale up I Jan 2009 I Page 3
What is Going On Inside a Twin-Screw Extruder?
● Mechanical power transmission
(RPM x Torque)
● Heat transfer
(heating & cooling)
● Devolatilization
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ZSK 101: Scale up I Jan 2009 I Page 4
Heating
Cooling
+100%
-100%
Visualization of the Inside of an Extruder
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ZSK 101: Scale up I Jan 2009 I Page 5
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
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ZSK 101: Scale up I Jan 2009 I Page 6
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
Company ScrewID Mach ID Product S.L (-380) B.Length Name Date
Drawing Nr. Revision Process Spec Nr. Shaft Length
PROPRIETARY NOTICE Description App/Rel
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.
COPERION US EXCO32 Ver 3.26/pessj
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ZSK 101: Scale up I Jan 2009 I Page 7
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
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
Drawing Nr. Revision Process Spec Nr. Shaft Length
PROPRIETARY NOTICE Description App/Rel
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.
COPERION US EXCO32 Ver 3.26/pessj
ZSK 101
Wh M k P S l E
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ZSK 101: Scale up I Jan 2009 I Page 8
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
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ZSK 101: Scale up I Jan 2009 I Page 9
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 )
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ZSK 101: Scale up I Jan 2009 I Page 10
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
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ZSK 101: Scale up I Jan 2009 I Page 11
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)
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ZSK 101
ZSK 40 MC Element List
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ZSK 101: Scale up I Jan 2009 I Page 13
ZSK-40 MC Element List
ZSK 101
Matching Average Shear Rates by
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ZSK 101: Scale up I Jan 2009 I Page 14
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
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ZSK 101: Scale up I Jan 2009 I Page 15
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
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ZSK 101: Scale up I Jan 2009 I Page 16
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
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ZSK 101: Scale up I Jan 2009 I Page 17
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
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ZSK 101: Scale up I Jan 2009 I Page 18
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
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ZSK 101: Scale up I Jan 2009 I Page 19
p j
ZSK 101
Rate Calculations
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ZSK 101: Scale up I Jan 2009 I Page 20
● 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
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ZSK 101: Scale up I Jan 2009 I Page 21
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
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ZSK 101: Scale up I Jan 2009 I Page 22
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
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ZSK 101: Scale up I Jan 2009 I Page 23
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
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ZSK 101: Scale up I Jan 2009 I Page 24
ZSK 101
Rate Calculation
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ZSK 101: Scale up I Jan 2009 I Page 25
● 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
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ZSK 101: Scale up I Jan 2009 I Page 26
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
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ZSK 101: Scale up I Jan 2009 I Page 27
● 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
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ZSK 101: Scale up I Jan 2009 I Page 28
● 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
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ZSK 101: Scale up I Jan 2009 I Page 29
● 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+
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ZSK 101: Scale up I Jan 2009 I Page 30
● 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
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ZSK 101: Scale up I Jan 2009 I Page 31
● 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
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ZSK 101: Scale up I Jan 2009 I Page 32
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
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ZSK 101: Scale up I Jan 2009 I Page 33
● 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
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ZSK 101: Scale up I Jan 2009 I Page 34
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
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ZSK 101: Scale up I Jan 2009 I Page 35
● 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
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ZSK 101: Scale up I Jan 2009 I Page 36
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
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ZSK 101: Scale up I Jan 2009 I Page 37
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
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ZSK 101: Scale up I Jan 2009 I Page 38
● 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 ??
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ZSK 101: Scale up I Jan 2009 I Page 39
ZSK 101
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ZSK 101: Materials I Jan 2009 I Page 1
Extruder Wear Materials of Construction
ZSK 101
Types of Wear in Plastics Processing*
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ZSK 101: Materials I Jan 2009 I Page 2
* from Reinhard
Unmolten MineralFilled Polymer
Metal
Unmolten Polymer
Mineral
Metal
Abrasive
Molten MineralFilled Polymer
Metal
ZSK 101
Types of Wear in Plastics Processing*
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ZSK 101: Materials I Jan 2009 I Page 3
* from Reinhard
Metal
Metal
Metal
Metal
Adhesive
ZSK 101
Schematic of Radial Pressure Profile of the ZSK
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ZSK 101: Materials I Jan 2009 I Page 4
Active Side of Apex(Pressure Build up)
Passive Side of Apex(Pressure Release)
ZSK 101
Outward Forces Due to Action of Screw Elements
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ZSK 101: Materials I Jan 2009 I Page 5
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
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ZSK 101: Materials I Jan 2009 I Page 6
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
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ZSK 101: Materials I Jan 2009 I Page 7
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
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ZSK 101: Materials I Jan 2009 I Page 8
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
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ZSK 101: Materials I Jan 2009 I Page 9
-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
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ZSK 101: Materials I Jan 2009 I Page 10
-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
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ZSK 101: Materials I Jan 2009 I Page 11
P r o
d u c
t f l o w
ZSK 101
Wear Due to Radial Forces at the Screw Tip
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ZSK 101: Materials I Jan 2009 I Page 12
ZSK 101
Heat Transfer in LDPE as aFunction of Element/Barrel Gap & RPM
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ZSK 101: Materials I Jan 2009 I Page 13
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
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ZSK 101: Materials I Jan 2009 I Page 14
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
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ZSK 101: Materials I Jan 2009 I Page 15
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
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ZSK 101: Materials I Jan 2009 I Page 16
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
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ZSK 101: Materials I Jan 2009 I Page 17
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:
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ZSK 101: Materials I Jan 2009 I Page 18
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
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ZSK 101: Materials I Jan 2009 I Page 19
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
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ZSK 101: Materials I Jan 2009 I Page 20
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
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ZSK 101: Materials I Jan 2009 I Page 21
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
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ZSK 101: Materials I Jan 2009 I Page 22
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
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ZSK 101: Materials I Jan 2009 I Page 23
NitridedStainlessThrough hardenedCrest weldedBi-metallicPowder metallurgical
ZSK 101ZSK Screw Element Materials:Screw Wear Protection Processes
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ZSK 101: Materials I Jan 2009 I Page 24
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
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ZSK 101: Materials I Jan 2009 I Page 25
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
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ZSK 101: Materials I Jan 2009 I Page 26
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
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ZSK 101: Materials I Jan 2009 I Page 27
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
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ZSK 101: Materials I Jan 2009 I Page 28
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
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ZSK 101: Materials I Jan 2009 I Page 29
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
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ZSK 101: Materials I Jan 2009 I Page 30
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
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ZSK 101: Materials I Jan 2009 I Page 31
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
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ZSK 101: Materials I Jan 2009 I Page 32
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
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ZSK 101: Materials I Jan 2009 I Page 33
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
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ZSK 101: Materials I Jan 2009 I Page 34
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
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ZSK 101: Materials I Jan 2009 I Page 35
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
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ZSK 101: Materials I Jan 2009 I Page 36
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
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ZSK 101: Materials I Jan 2009 I Page 37
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
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ZSK 101: Materials I Jan 2009 I Page 38
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
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ZSK 101: Materials I Jan 2009 I Page 39
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.
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ZSK 101: Materials I Jan 2009 I Page 40
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