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Compounding of Filled Polymers with the Co-rotating Twin Screw Extruder ZSK Page 1
Compounding
with the
Co-rotating Twin Screw Extruder ZSK
P=m. h
m.hi
Qheat + cool
~3%
loss PVt
m.ho
. .
maximum 30 average
. .
minimum 0,9 average
. circumferential speed v
Shear rate
channel depth
screw screw
Average value
of Shear rate
Average value
of Shear rate
SEI [kWh/kg]
PBT + 30 % GF (ZSK45)
PE + 85 % CaCO3
10 11
8
6 9
Mc PLUS Mc18
+
50 %
650
672 1089
Mc PLUS Mc18
0,201
0,167
672 1089
ZSK Mc18: 600 rpm ZSK Mc18 : 900 rpm ZSK Mc18 : 1,100 rpm
1 mm
Operation:
- 530 kg/h
- 600 rpm
- 0,146 kWh/kg
- 315 °C
Operation:
- 1040 kg/h
- 900 rpm
- 0,147 kWh/kg
- 318 °C
1 PET
2 Atmospheric vent
3 Vacuum pump
4 ZSK Mc18
5 Die head
6 Water bath
7 Air knife unit
8 Pelletizer
2
1
3
7 8
5
350 0,84
Throughput [kg/h]
iV [dl/g]
Raw material
0,83
18 Smaller IV drop iVo=0,83 dl/g
300 Mc
5 With same screw speed
K4
e
ZS
op as
0,82 ZS
dr re
K4
IV inc 5M
c 18
nt put
250
ns gh
0,81
co hrou
c+ Same IV drop
ta
45
K 0,80 ZS
ZS
60
200
th
K4
30% increase in 5M
c+
throughput at 0,79
same rpm
150
0,78
Glass-
Form of particles Talc CaCO3 Fibres Beads
Filler Filler
Strand Pelletizer
venting
atm. vac.
Waterring Pelletizer
Underwater Pelletizer
Atm. ZSB
ZSB M
M
P1 P2
5 3 4 5 5 7 8 9 12 SW AV UG
1 10 11
0,14 160
0,12 140
Specific Energy Input [kWh/kg]
120
100
0,08
80
0,06
60
0,04
40
0,02 20
SEI
0 0
Pressure
74 76 78 80 82 84
CaCO3 [wt%]
• Filling Degree > 80 % requests a very good processing Know-How together with a
suitable formulation for highest throughput.
• Feeder layout & arrangement, screw configuration, temperature profile and processing
parameters are essential.
• Coperion GmbH started to focus on these formulations many years ago and initiated
internal trials (also with customers). In the meantime machines specifically configured for
these highly filled polymers are successfully in operation:
With the patented FET equipment, the product feed can be optimized so that drive power of the
ZSK Mc18 is fully transferred into the process section – even when processing powder bulk
materials.
ED*
T
TEN
PA *European Patent
U.S. Patent Application
Japanese Patent Application
Chinese Patent Application
FET active
Filler
Additives
Polymer
FET - ZSB
ZSK 92
+ 10 %
+ 40 % PP + 3 types of Talcum
Talcum Luzenac
120 Steamic OOS:
+ 200 %
Throughput
0,25 g/cm3
80
Flame retardant :
0,20 g/cm3
40
Graphite:
0,08 g/cm3
0
60 % Talcum 43 % Flame 50 % Graphite
Retardant
ZS-B 1: ZS-B 2:
Polymer, ATH, ATH
Additives
PVDF powder
+ 130 % barrel 1 open
barrel 2 feeding PVDF
through ZS-B 58 with FET
barrel 3 additional FET at
ZSK
To be considered:
• Effect of FET always depends on the type of product, its particle shape and size distribution
• The extruder and its auxiliaries have to be adapted to higher capacity, e.g.
- installed motor power and screw design,
- feeding system,
- degassing system,
- pelletizer, pellet cooling, conveying and handling system
20 - 80% Masterbatch
Organic / Mixing hot or cold Extruding in customized colour
inorganic
pigments
+
80 - 20%
virgin
polymer
Masterbatching
11
10
8
20 - 80%
Organic /
inorganic
pigments
+
0 - ~20%
wax Extruding Masterbatch
powder/ in customized colour
micronized
20 - 80%
virgin
polymer
pellets
Masterbatching
20 - 80%
Organic /
inorganic Mixing
pigments
+
0 - ~20%
wax Extruding Masterbatch
powder/ in customized colour
micronized
20 - 80%
virgin
polymer
pellets
Masterbatching
9 9 10 11
13
12
8
Polymers can be
Higher pigment load processed in pellet form
possible
No premix needed
for monobatches
Reduced residence time of
the pigments
no pigment deterioration
Less wax or no wax
at all needed
Pressureless handling
and mixing of pigments Product feed distributed
better product quality to two openings
higher throughputs
1. Masterbatching 2. Colouring
„Light green“
20 - 80% yellow SPC
customized
1 pigment masterbatch
SPC +
e.g. yellow
80 - 20%
+
virgin
polymer
white SPC
5 6
3 8
7
4
Color-matching ++ +
Additiv-Masterbatch + ++
Barrels exchangeable
with ZS-B
STS