Leistritz Compounding ENG

Download as pdf or txt
Download as pdf or txt
You are on page 1of 9

COMPOUNDING

Extruders and extrusion lines

1
Overview Overview

COMPOUNDING HIGH THROUGHPUTS TYPICAL COMPOUNDING TASKS INCLUDE:

IN THE BEST QUALITY reinforcing polymers, e.g. by incorporating glass, carbon or natural fibers
improving the dimensional stability and breaking strength of polymers, e.g. by incorporating
inorganic fillers, glass beads
Focus on material characteristics
improving the flow behavior and flame resistance of polymers, e.g. by incorporating
low-viscosity substances or flame retardants
Compounding is a process in which the polymer is Compounding, in other words the processing of plastics,
the manufacture of polymer blends, e.g. by mixing compatible or incompatible polymers
melted and mixed with e.g. additives, fillers or reinforc- is one of the prime disciplines of Leistritz twin screw
(impact-resistant modification of thermoplastic materials)
ing materials. This process changes the physical, thermal, extruders. Diverse incorporation options for filler and
electrical or aesthetic properties (conductivity, flame resis- reinforcement materials into the polymer matrix are enhancing the chemical/physical durability of polymers, e.g. by incorporating stabilizers,
tance, wear resistance, color etc.) of the polymer. The final possible and lead to new material properties, which are anti-static agents
product is called a compound. used in a multitude of applications.

Examples of final products


e.g. computer case
Compounding
Filling (e.g. CaCO, wood compounds, talcum)

Basis: raw polymer Reinforcing (e.g. glass or carbon fibers) e.g. car front-end

Additivation (e.g. flame retardants,


UV stabilizers)

e.g. garden furniture


Cross-linking of elastomers (e.g. TPE-V)

Reactive extrusion

Blending (e.g. PC + ABS)


e.g. tool handles

e.g. shoe soles,


ski boots

Compounding means satisfying the requirements


specification of the end product in an ideal way.
e.g. headlight
housing for cars

2 Leistritz Extrusion Technology 3


Applications Applications

INCORPORATING FILLERS
Its all about good dispersion

Fillers are added to polymers to improve their proper- The polymer can be mixed with up to 85% of fillers such Example of a formulation: 0 - 0% CaCO + 1 - 0% polyolefins + 0 - % additives
ties and/or reduce the price of the compound. The good as chalk or talcum.
incorporation options for fillers in the polymer matrix are Side feeders are used to incorporate fillers (see p. ).
used in a wide variety of applications, such as the manu- Two or more may be used for larger shares of fillers. gravimetric gravimetric gravimetric feeder:
facture of computer cases. Another example: drain pipes. The modular extruder is simply extended in such cases. Line layout: feeder: feeder: raw polymer
filler filler (+ possibly filler)
The filler is used here as sound insulation so that flush- The volume flow of the added materials is distributed
ing noises cannot be heard in apartment buildings, for amongst the existing feed options - depending on the
example. Leistritz extruders are able to incorporate a very formulation - to minimize abrasion and
Example of to wet thesystem
a customized filler
high share of fillers, for example in the filler masterbatch. as well as possible.

The main demand on the extruder is to incorporate large quantities of the filler. The primary task is to disperse the filler
optimally and distribute it in the polymer matrix.

The dispersion process can be split into the following steps:

melting of the polymer matrix


wetting the filler with the melt
dispersion of agglomerates and aggregates (dispersive mixing)
homogeneous distribution in the matrix (distributive mixing)
homogenization and degassing of the melt

FILLER CRITERIA

Fillers are incorporated in plastics to improve the material characteristics of the compound and/or to save costs. There
FREQUENTLY USED INORGANIC are three important criteria that affect the interaction between the filler and the polymer matrix:
FILLERS
Particle shape of the filler
Talcum is flaky; is preferably added to the Particles with a small aspect ratio (e.g. glass beads, CaCO3 or BaSO4) do not significantly improve the tensile
melt via a side feeder; gives the final product strength and tear resistance, but do normally improve the modulus of elasticity. Particles with a large aspect ratio
special surface properties (e.g. talcum or wollastonite) help improve the tensile strength and tear resistance as well as the modulus of elasticity.
Calcium carbonate (CaCO) is cubic; avail Particle size distribution of the filler
able in three states: chalk, limestone and The behavior of filler particles during processing depends on both the Van-der-Wals forces acting between the
marble; cost-ecient particles (with particle sizes > 1 m) and the dispersive shearing forces in the extruder (with particle sizes < 10 m).
Barium sulfate (BaSO) are rhombic crystals Surface of the filler
(cuboid); added via a side feeder, has a high The specific surface (m/g) indicates the number of adhesion points between the filler and polymer chains: large
specific weight and density surface > numerous adhesion points > better mechanical properties (higher stiffness and surface gloss of the poly-
mer, better tensile strength and tear resistance as well as impact strength). The surface coating is also important
Wollastonite is fibrous: added via the side
because it changes the surface energy: a hydrophilic surface becomes hydrophobic. This hydrophobing means that
feeder
fewer agglomerates form and the free-flowing property is improved. The wetting is essentially affected by how far
apart the surface energies of the particles and the polymer matrix are. The closer together they are, the better the
wetting.
Example of a compounding plant to incorporate calcium carbonate
(further details on p. /)

Leistritz Extrusion Technology


Applications Applications

REINFORCING COMPOUNDS
Break resistant and stiff

Particularly for applications requiring properties such as The addition and combination of the polymer chains to Application example: incorporation of glass fibers (40%) into polycarbonate (60%)
strength and stiffness, the polymer (e.g. PP or PA) is rein- and with the fiber structures creates a very strong bond
forced with materials such as glass fibers, carbon fibers, that matches, and sometimes even exceeds the proper-
and also natural fibers. The filler content of PP with glass ties of metallic materials. Their low weight make rein-
gravimetric gravimetric
fibers, for example, can be up to 60% depending on the forced thermoplastic materials a very popular material, feeder: feeder:
application. particularly in automobile manufacturing. Line layout: glass fibers raw polymer
(+ possibly filler)

Example: glass fibers


The goal of processing glass fibers in a twin screw extruder is to distribute the fibers homogeneously in the polymer matrix
and achieve an optimum length distribution in the final product with the lowest possible destruction of the fibers. The size
on the fibers makes them smoother and more resistant to mechanical loads. However, the size has to be compatible with
the polymer matrix.
Chopped or short glass fibers with initial fiber lengths of approx. 3 mm are usually used. Alternatively, rovings (filaments)
may also be added.

long fiber lengths better mechanical product properties, poorer flow behavior in the melt
(e.g. during further processing in injection molding)
short fiber lengths poorer mechanical product properties, better mold-filling behavior during
injection molding

Test: ZSE MAXX (Da/Di = 1.66) v. ZSE HP (Da/Di = 1.5)


Processing in a twin screw extruder
PC + 40% GF Results:
Fibers are usually fed into the polymer matrix after the plasticiz- ZSE 50 HP
A ZSE MAXX extruder is the right choice for
ing step during compounding. If the fibers are added through the ZSE 50 MAXX
running shear-sensitive applications.
main feed port, they will be fragmented too heavily in the plasti-
cizing unit and cause too much abrasion in the melting zone. Up to 55% more throughput can be realized
here.
throughput (kg/h)

When working with higher filling degrees


energy savings of up to 18% are possible
due to a higher volume and high torque.

REM image: glass fibers well embedded in a PC matrix

Source: Technische Hochschule Nrnberg Georg Simon Ohm


screw speed (rpm)

6 Leistritz Extrusion Technology 7


Applications Applications

THERMOPLASTIC ELASTOMERS POLYMER BLENDS


Elastic, pliable, flexible Cost ecient and performance-optimized

Thermoplastic elastomers (TPE) are materials in which TPEs are used in a wide variety of industries: in the Blends offer the possibility of creating a whole series of new, more ecient and less expensive polymers with customized
elastic polymer chains are incorporated in a thermoplas- automotive sector, for example, they are used as window properties from the available potential of basic polymers. Their main field of use is in the automotive and electrical indus-
tic material. They can be processed in a purely physical surrounds or control elements. They are also used in try. They are found here in shock absorbers or hub caps as well as the casing material for telephones and computers.
process through the use of high shearing forces, expo- industry for tool handles or sealing rings, for example. Or
sure to heat and subsequent cooling. They can be melted in the consumer sector for toothbrushes or packaging. The compatibility of the basic polymer is crucial and plays an important role for the compounding. There are three groups:
and shaped by heating again.
blends with full compatibility between the basic polymers (e.g. SMA + SAN, PPO + HIPS)
The production of numerous different thermoplastic
partially compatible blends: basic polymers form a two-phase matrix, but with good
A number of TPEs exist that differ greatly in both their elastomers calls for a profound knowledge of machines
physical interaction (e.g. PC + ABS, PC + PBT)
polymer structure and their properties. Their common and process engineering. Depending on the type of
blends with incompatible basic polymers (e.g. PA + ABS, PPO + PA)
feature is the basic structure in the form of block poly- elastomer (from a standard SEBS through to dynamically
mers in which the elastomer segments copolymerize cross-linked TPE-V systems) various machines concepts
with the basic polymer. The share of elastomer chains in are applied. What is important is the necessary process
the overall polymer can be varied broadly for a number engineering know-how and flexible extruders. The pro-
of TPE classes. This means that settings from very stiff to cess lengths of the twin screw extruders used here range Application example: PC + ABS blend
gravimetric
almost gel-like are possible. from 8 L/D up to 8 L/D. The addition of oil, fillers or feeders:
various cross-linking agents varies depending on the PC + ABS
possibly additives
application.

Line layout:

Application example: TPE-V


TPE-V is the name given to thermoplastic elastomers with a cross-linked rubber component. Very long process lengths
of up to 68 L/D are used in the production of TPE-V. This means that the necessary residence time and respective process
steps (blending the EPDM with the polymer matrix, mixing in of additives, dynamic cross-linking) can be generated. The
design of such a plant relies on the wealth of experience of our process engineers who set up the processing unit to match
the individual process steps.

Knowing which machine


concept is to be used calls for the
necessary process engineering
know-how. This polymer blend combines the advantages of polycarbonate (PC) and acrylonitrile butadiene styrene (ABS). It is one of
the few blends that achieves a synergistic effect alongside the mere benefits of the basic polymers: the resulting material
has properties that none of the basic polymers have. For example, the low-temperature impact strength of the blend is far
superior to that of either of the basic polymers. PC gives the blend a high tenacity at room temperature and heat defor-
mation temperature, ABS a good resistance to stress cracks and processibility. However, the blend also has an exceptional
impact strength, even at an ambient temperature of -3 C.
An important process engineering aspect that has to be taken into account here is that the two different polymers also
have different viscosities in the melt. Therefore, the choice of the accurate screw geometry is crucial. A good morphology
can only be achieved with an adequately designed setup.

Leistritz Extrusion Technology


Plant example Plant example

EXTRUSION LINE FOR HIGHLY FILLED


COMPOUNDS
High engineering competence

High-tech compounding plant for


highly filled compounds

Process engineering concept:


Task:
The art of producing highly filled compounds lies in the optimum distribution of the material streams. Great process engi-
design and construction of a plant for the stable and
neering expertise is required to incorporate large quantities of fillers in the most homogeneous way in a polymer matrix.
largely automated production of highly filled com-
The air streams brought in with the material feeding in particular have to be controlled. A further challenge is posed by the
pounds of a constant product quality
material moisture, which may complicate the process. Accordingly, the processing unit and screw geometry must have an
optimum configuration for this task.
Plant concept:
This plant example convinces through state-of-the-art technology. The high volume (OD/ID = 1.) and the high specific
material supply from sacks, big bags and torque of up to 1 Nm/cm of the ZSE MAXX twin screw extruder means that not only can maximum throughputs be
silos run, but an energy-ecient production can also be realized. The topic of flexibility is also taken seriously: whereas the
formulation-controlled suction system for plant was built to produce highly filled compounds with up to 8% calcium carbonate, various other processes can also be
premixes run on it with minimum adjustments, for instance talcum, titanium dioxide or barium sulfate. Aluminum or magnesium
hydroxide can also be processed for the field of flame retardancy.
gravimetric feeding system

twin screw extruder ZSE 5 MAXX


gear pump and screen changer
underwater pelletizing
filling station
control system + control panel

1 Leistritz Extrusion Technology 11


Plant example Plant example

LARGE-SCALE COMPOUNDING
FOR PP STABILIZATION
Competent system supplier

Task:
design, planning and construction of a large-scale Panorama view of the overall plant
compounding plant (climate zone from -40 +40 C).

Plant concept:
material supply in a nitrogen atmosphere from a reactor
mixing and supply silos
dosing units
extrusion line with a ZSE 180 MAXX twin screw extruder

gear pump and screen changer


underwater pelletizing
homogenizing silos
bagging station with subsequent palletless palletizing
control with integrated online rheometer

Process engineering concept:


PP is produced in the upstream polymerization plant. The raw polymer pow-
der from the reactor is transported in a nitrogen atmosphere over a distance of
approx. 350 m to the co-rotating twin screw extruder ZSE 180 MAXX where it is
stabilized against auto-oxidation (throughput 10 t/h). The specific adjustability
and uniform viscosity of the stabilized polypropylene during the extrusion process
plays a crucial role in terms of process engineering. This viscosity is measured dur-
ing the process with an online rheometer. By using a special controller integrated
in the Leistritz control unit, metering of the peroxide masterbatch and thus the
viscosity (MFR/MFI) is adjusted to the specifications and any fluctuations in the
raw polymer can be compensated.

Self-controlled adjustment of the MFI value

Plant overview

12 Leistritz Extrusion Technology 13


Optional extras Optional extras

SIDE FEEDING SIDE DEGASSING


Easy material feed - modular adjustment Reliable degassing of volatile substances

The side feeder is mostly used to add powders. Leistritz can offer the right side feeder for every application and all extruder Apart from the generally known process tasks such as melting, mixing or homogenizing, the degassing of volatile sub-
sizes. The LSB XX series convinces through the high OD/ID ratio (2.0) of the screws and can also convey materials with very stances is a key part of plastics processing. Leistritz can offer the perfect side degasser for every application and all extruder
low bulk densities. sizes. As an alternative to conventional passive degassing systems, there are the Leistritz side degassing LSE XX and the
Leistritz vertical degassing LVE XX. They allow a safe degassing of the extrusion process, even in unfavorable process con-
ditions such as during start-up or heavily foaming products.
In connection with the largest possible free volume in the screw flight of the extruder and the constant renewal of the
product surface, it creates optimum conditions for degassing the polymer molten mass. The two screws that rotate in the
same direction that are fitted in the side degassing force any melt that tries to escape back into the process chamber but
allow all gases to pass. This avoids any blockages or deposits in the degassing barrel. The productivity and safety of extru-
sion plants are increased in this way.

SPECIAL FEATURES OF THE LSB XX:

segmented screws can be used (configuration according to LSE XX /


40 0 0 0
the needs of the raw material) LVE XX
ZSE ZSE ZSE ZSE ZSE ZSE ZSE ZSE
adaption of the LSB XX to the extruder with tie rods Extruder size
iMAXX MAXX MAXX 6 MAXX 7 MAXX 7 MAXX 11 MAXX 13 MAXX
(LSB XX can be fastened to the extruder barrel in the cold,
easily accessible area of the gear box with no risk of injuries Screw diameter
(mm) 3. . . 6.3 7. . 112.3 13.1
use of various types of steel (allows feeding both highly
abrasive (e.g. TiO) and highly corrosive products)
option: internal cooling of the screw (possible through
special gear box design)

SPECIAL FEATURES:

OD/ID = (higher free volume)


LSE barrel heated by heating
cartridges
cooled gear box lantern (prevents
overheating of the gear box)
LSB XX 40 0 0 0
horizontal (lateral) attachment
ZSE ZSE ZSE ZSE ZSE ZSE ZSE ZSE on the base frame or vertical via
Extruder size
3 iMAXX MAXX MAXX 6 MAXX 7 MAXX 7 MAXX 11 MAXX 13 MAXX special adapter (barrel insert)
Screw diameter LSE XX (lateral attachment) LVE XX (vertical attachment)
3. . . 6.3 7. . 112.3 13.1
(mm)

Screw speed
infinitely variable -6

A retrofit of LVE XX is easily possible -


(rpm)

with minimum eort.


Drive power (kW) 1. 2. 3. .3 .1 1.3 1.6 3.3

Base frame without with

1 Leistritz Extrusion Technology 1


EXTRUSION TECHNOLOGY
Available for you all over the world

USA GERMANY CHINA

Leistritz Advanced Technologies Corp., Headquarters Leistritz Machinery (Taicang) Co., Ltd.,
Somerville, NJ Leistritz Extrusionstechnik GmbH, Taicang
Nuremberg

ITALY FRANCE SINGAPORE

Leistritz Italia Estrusione, Leistritz France Extrusion, Leistritz SEA Pte Ltd,
Castellanza Ceyzeriat Singapore
LEX-8 en 1/16 0,5' t

 Leistritz Extrusionstechnik GmbH | Markgrafenstrae 36-3 | 045 Nuremberg | Germany


Tel.: +4 11 43 06 - 0 | extruder@leistritz.com

www.leistritz.com

You might also like