ZSK Mc18

Transcription

ZSK Mc18

| page 1
Twin screw compounder ZSK and STS
- perfect performance and economic solution
Dipl.-Ing. Roland Elsaesser,
Sales Manager Compounding&Extrusion, Coperion GmbH Stuttgart
Jakarta 2014 | page 2
Content
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Company information
ZSK Mc18 – technology, key figures, design
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
Content
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Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
Company history
Werner &
Pfleiderer
Waeschle
1879
Foundation
Werner &
Pfleiderer
1900
Foundation
Waeschle
1957
First ZSK twin
screw extruder
2001
2007/2008
Merger to form the
Coperion Group
Realization of the
world´s largest
plants for polyolefin
production
2002
1955
2008
ZSK NT
development
Bulk materials
processing in the
plastics industry
Hartmann
Keya
2007
Acquisition and
integration into the
Coperion Group
2004
Acquisition and
integration into the
Coperion Group
Brand
consolidation /
merger to form
Coperion
2012
Hillenbrand, Inc.
acquires Coperion
2010
Successful
launch of ZSK Mc18
series
2012
PELL-TEC
Majority stake
in PELL-TEC
2012
Majority stake
in Weicom
Weicom
Coperion part of the
Process Equipment
Group
Hillenbrand, Inc.
Process Equipment Group
Coperion worldwide
Headquarters
Stuttgart, Germany
Competence Center
Compounding & Extrusion
Stuttgart, Germany
Materials Handling
Weingarten, Germany
Service
Stuttgart / Weingarten, Germany
Coperion companies and
offices
Agencies
Facts and figures
Key figures of Coperion
Compounding systems installed worldwide, over
10,000
Bulk materials handling systems installed worldwide, over
8,000
Employees worldwide, over
1,700
Network of locations worldwide
29
Coperion Twin screw compounders
- Portfolio
ZSK series
STS series
Mc18: Md/a3 < 18 Nm/cm3
Md/a3 < 10 Nm/cm3
Mv PLUS: Md/a3 < 11.3 Nm/cm3
CTE / CKY series Md/a3 < 5.6 Nm/cm3
Content
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Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
General twin screw extruder layout
Feed
Motor
Safety clutch
Gear box
Drive section
Shaft coupling
Barrels
Screws
Process section
Die head
Discharge
Self-cleaning screw profile
Self cleaning intermeshing twin screw
Working principle
D
Screw Elements.
H1
Conveying
elements
Kneading
elements
Mixing
elements
Left-handed
elements
V
>
H2
V
>
H3
V
Design criteria of twin screw compounders
Do = Outer diameter
Di = Inner diameter
a = Centerline distance
Do / Di = Diameter ratio
determines shear, degassing and powder intake
Do
Md / a3 = Specific torque
determines power density and filling degree
Di
a
n = Screw speed
determines shear and mixing
Do / Di = 1,5 to 1,6
Md / a3 ≥ 11,0 Nm/cm3
n ≥ 800 min-1
ZSK – evolution of torque and volume
1955: ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
1970: ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
1985: ZSK Supercompounder
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
Increase of
free volume
and of specific torque
Increase of free volume
(additional 40%)
2001: ZSK MEGAvolume
Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3
Increase of torque
1995: ZSK MEGAcompounder
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
2010: ZSK Mc18
Do / Di = 1,55
Md / a3 = 18 Nm/cm3
PLUS
Do / Di = 1,80
Md / a3 = 11,3 Nm/cm3
Series of Coperion twin-screw compounders
Taylormade
ZSK Mc18
Made by Coperion in Germany
(for world market)
Standard Twin-Screw / Two Stage
STS Advanced
made by Coperion (Nanjing), China
(for world market)
CTE and CKY machine series
made by Coperion (Nanjing), China (for China + Asia)
ZSK Mc18
The new dimension in compounding technology
Specific torque of 18 Nm/cm3
Do/Di = 1.55
Screw speed 1.200 min-1
Why Mc18-torque ?
Specific energy / shear: Influence of rate and screw speed
Low feed rate
High feed rate
Low screw speed
High screw speed
barrel
Q2
High feed rate
Low screw speed
barrel
barrel
Q2
Q1
Q2
Q1
Q1
h
Shear rate
Shear rate
Average value
Average value
screw
Shear rate
screw
screw
Average value
With higher torque, a higher fill grade can be realised.
The higher the fill grade, the lower the screw speed, the lower is the shear stress
ZSK Mc18
Most appropriate applications
For all torque limited processes like e.g.
• PP + 30 % GF
• PA 6.6 + 30 % GF
• PBT + 30 % GF
• ABS+PC + 20 % GF
• undried PET
•
Higher output: as higher fill grades can be realised, which in parallel allows higher screw
speed with same average shear stress.
and/or
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Better product quality due to lower screw speed / higher filling degree / lower shear stress
/ lower melt temperature
and a lower specific energy consumption
ZSK McPLUS - Mc18
Increase in throughput
ZSK Mc - McPLUS - Mc18
Optimised price-performance ratio
ZSK Mc - McPLUS - Mc18
Reduced energy input with increased throughput
ZSK Mc18 – Features
Wear protection
hard cast chromium steel oval liners with
high wall thicknes and a solid apex area for sturdiness & long life
Liners are shrink fit for improved heat conduction
Liner
Direct coated surface
directly soldered, hiped
or welded wear- or
corrosion protection
surface
ZSK Mc18 – fully protected electrical manifold
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Assembly optimized parts groups
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Fully closed cable trays in IP54 or IP65
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Cable entry from bottom - no cable glands
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New heater cartridges „4-in-1“ with junction
box
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Heater cartridge can easily be replaced as
single part
ZSK Mc18 – new insulation covers
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New, user-friendly, segmented barrel insulation covers around the whole barrel!
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For optimum energy efficiency
„pampered“ insulation, even on the
bottom side!
ZSK Mc18
Technical data
ZSK
Max. torque per
shaft [Nm]
Specific torque
Md/a³ [Nm/cm³]
Max. screw
speed [min-1]
Max. drive
power N [kW]
Screw diameter
[mm]
18 MEGAlab*
38
11.3
1,200
10
18
26 Mc*
106
11.3
1,200**
28
25
32 Mc18
315
18
1,200
83
32
45 Mc18
930
18
1,200
246
45
58 Mc18
2,000
18
1,200
529
58
70 Mc18
3,500
18
1,200
926
70
82 Mc18
5,700
18
1,200
1,508
83
92 Mc18
7,500
17
1,000
1,654
92
106 Mc18
10,400
17
1,000
2,293
103
119 Mc18
15,300
17
1,000
3,373
118
133 Mc PLUS
18,100
13.6
1,000
3,791
133
* Laboratory extruder. ** max. 1,800 min-1 at reduced torque. ZSK 32 - ZSK 82 available in compact version.
ZSK Mc18
ZSK 106
Max. Throughput (depending on process, raw materials and products)
Content
•
•
•
•
•
•
Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
ZSK – evolution of torque and volume
1955: ZSK Standard
Do / Di = 1,22
Md / a3 = 5,0 Nm/cm3
1970: ZSK variable
Do / Di = 1,44
Md / a3 = 5,0 Nm/cm3
1985: ZSK Supercompounder
Do / Di = 1,55
Md / a3 = 8,7 Nm/cm3
Increase of
free volume
and of specific torque
Increase of free volume
(additional 40%)
Do / Di = 1,80
Md / a3 = 8,7 Nm/cm3
Increase of torque
Do / Di = 1,55
Md / a3 = 11,3 Nm/cm3
PLUS
Do / Di = 1,55
Md / a3 = 13,5 Nm/cm3
2010: ZSK Mc18
Do / Di = 1,55
Md / a3 = 18 Nm/cm3
PLUS
Do / Di = 1,80
Md / a3 = 11,3 Nm/cm3
ZSK MEGAvolume
MEGAvolume
MEGAcompounder
- Do/Di= 1,8
- Do/Di= 1,55
ca. 40 % more free volume
for compounding processes with
high torque demand
- optimised ratio regarding
mechanical strength vs. free volume
less shear stress due to
- deeper channels and
- smaller screw crests
Do/Di= 1,8
Do/Di= 1,55
Di
Do
ZSK MEGAvolume
Deeper screw channels offer advantages
- improved intake
- higher screw speed applicable
- higher throughput
- reduced shear
- lower stock temperatures
- lower product stress
- improved product quality
- more reliabily venting performance
Do/Di = 1.8
v
u
h
max
ZSK Mv
Shear rate gamma = vu /h
Do/Di = 1.55
v
u
h'
max
ZSK Mc
ZSK MEGAvolume
Most appropriate applications
• for products with low bulk density
• for processes with low specific energy input (< 0,15 kWh/kg)
ZSK MEGAvolume
Example: max. throughput Powder Coating production
Machine
ZSK
27Mv
34Mv
43Mv
54Mv
62Mv
76Mv
max. Capacity
[kg/h]
160
350
750
1.200
1.600
3.200
max. Speed
[rpm]
1.200
1.200
1.200
1.200
1.200
1.200
max. Power
[kW]
27
54
112
214
329
600
ZSK MEGAvolume PLUS
Example: max. throughput Carbon Black - Master Batch
LDPE
+ 40 %
RCF 20 nm particle size
[kg/h]
LDPE
+ 40 %
RCF 30 nm particle
size
[kg/h]
PP
+ 35 %
RCF 20 nm particle
size
[kg/h]
ZSK 34 Mv PLUS
150
165
100
ZSK 43 Mv PLUS
300
330
200
ZSK 54 Mv PLUS
600
650
400
ZSK 62 Mv PLUS
930
1.000
620
ZSK 76 Mv PLUS
1.700
1.800
1.100
ZSK 98 Mv PLUS
3.700
4.000
2.500
ZSK 125 Mv PLUS
7.800
8.400
5.200
Content
•
•
•
•
•
•
Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
Series of Coperion twin-screw compounders
Taylormade
ZSK Mc18
Made by Coperion in Germany
(for world market)
Standard Twin-Screw / Two Stage
STS Advanced
made by Coperion (Nanjing), China
(for world market)
CTE machine series
made by Coperion (Nanjing), China (for China + Asia)
Coperion’s Standard compounding machines STS Advanced
Standard Twin Screw
additional series of co-rotating twin screw compounders
- well proven Coperion quality, ZSK MEGAcompounder screw geometry, Do/Di = ca. 1,55
- specific torque: 10 Nm/cm³
for standard compounding tasks:
- Engineering Plastics
- Masterbatch
- Recycling
- certified
Coperion (Nanjing) Machinery Co. Ltd.
Coperion (Nanjing) Machinery Co. Ltd.
Assembly hall
Production capacity
more than 450 machines
per year
(STS and CTE)
Coperion Nanjing Manufacturing
Machine assembly
Assembly floor for control panels
Quality Control Incoming Goods
Chemical elements test for monitoring the raw materials quality
Test Equipment for Chemical elements analysis
Production Quality Control
3D Measuring System to Ensure Precise Dimensions
Strict control of manufacturing precision on barrels, gearbox houses and
screw couplings by 3D Measuring System
Factory acceptance test (FAT) with polymer
allows for fast and troublefree installation and start-up on customer‘s site
Factory acceptance test with product
CE certification
proper over-sea crating
Coperion Standard machine STS Advanced - Torque 10
STS Advanced type
screw diameter [mm]
Md/a³
motor power [kW]
screw speed [1/min]
expected capacity [kg/h]
35
35,6
10
55
80-800
80-230
Standard Twin Screw
50
65
75
96
50,5
62,4
71
93,6
10
10
10
10
132
250
400
900
80-800
80-800
80-800
80-800
300-690
500-1.150 800-1.840 1.200-3.800
Number of STS Sold by Region
America
19%
Europe/Middle
East
17%
almost 500 STS machines sold 2004 - 2014
Asia
64%
Applications
Wood Plastic
Comp
5%
TPE
5%
Recycling
2%
Others
17%
Masterbatch
20%
Engineering
Plastics
51%
total ≈ 500 STS
Twin screw compounder ZSK and STS –
perfect performance and economic solution
Content
•
•
•
•
•
•
Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
Service
Coperion’s three promises given with its service structure
Global operation
Confidence
Customers‘ benefit
Innovation
Spare parts service
With over 48,000 parts managed Coperion‘s warehouse is one of the largest in the industry. It
includes both original Coperion spare parts and parts from suppliers.
Spare parts produced to the highest production standards
Short delivery times and 24-hour express delivery service for
stock parts
Provision of substitute types for parts which are no longer
available
Gearbox and barrel replacement service
Emergency stock for the quick replacement of core
components
Screw and kneading elements
Twin screw compounder ZSK and STS –
perfect performance and economic solution
Content
•
•
•
•
•
•
Company information
ZSK MEGAvolume PLUS
STS Advanced
Service
Summary
Summary
Coperion is the worldwide market and technology leader in Compounding & Extrusion,
Materials Handling and Services. We are a partner for global corporations as well as for small
and medium-sized enterprises in the plastics, chemical, food and aluminium industries.
Coperion has over 130 years of experience with mixing and kneading processes.
Pioneering work and continuous development of the closely intermeshing, co-rotating twinscrew extruder. Our twin-screw compounders continually set new standards in the plastics,
chemical and food processing industries.
Over 10,000 compounding systems are installed worldwide.
30 compounding systems worldwide for testing.
More than 25 process specialists, high skilled technical support for our customers
Global service and suport.
Coperion – confidence through partnership
Your Contact in Indonesia
WAHANA MITRA ABADI
Mr. Bernadus Slamet
Jl. Telesonic
Komp. Pergudangan Surya Kadu
Blok I No. 10
Jatake - Tangerang
Phone: +62 21 2943 8030 +62 811 849706
+62 21 2943 8031 +62 817 0066675
Fax:
+62 21 2943 8059 Email: bernadus@wahana-mitra.com
This document and all contributions and illustrations
contained there in are protected by copyright. Any use
there of beyond the scope of the copyright without
editor’s prior written consent is illegal and will be
prosecuted. This shall in particular apply to translations,
reproductions, micro filming and processing in
electronic systems.
| page 57

ZSK Mc18

Transcription

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