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Coperion Process Training 2011 科倍隆 工艺培训 2011 Mc18 ZSK 82 Mc18 P = 1,500 kW Output = 6,000 kg/h Coperion – ZSK Process Training 科倍隆ZSK机型 培训教程 DISCLAIMER: 声明： 声明： This document and all contributions and illustrations contained ther 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 这份文件包括所有的文字和图表受版权保护。任何使用有超越版权的范围没有 经过作者的事先书面同意都视为非法的，会将被检控。这应特别适用于对该文 件的翻译，复制，微型拍摄等电子处理方式。 Table of Contents 内容目录 - History of the ZSK & Extrusion Systems - ZSK挤出系统的发展历史 挤出系统的发展历史 - Principles of the ZSK Design - ZSK设计的理念 设计的理念 - Screw Elements and their Functions - 螺纹元件和功能介绍 - Process Technology -工艺应用技术 工艺应用技术 History of the ZSK and Extrusion Systems ZSK挤出系统的发展历史 挤出系统的发展历史 More than 2000 years ago 在2000年以前 - Archimedes invented the screw feeding principle using a single screw 阿基米德使用单根螺杆做了螺纹输送原料的虚拟 - the system is still in use today in Egypt, the Netherlands and most water purification plants 这个系统目前在埃及、荷兰及大多数水净化工厂仍在使用。 The need for „kneading“ 啮合的需要 - since the 2nd half of the 19th century single screws were used to knead and extrude products in different industry branches 在19世纪下半叶，单螺杆在不同的生产领域被用于啮合和挤出制品。 • Ceramic Industry 陶瓷工业 • mixing of components 组分的混合 • profile extrusion 型材挤出 • Rubber Industry 橡胶工业 • processing of natural rubber 天然橡胶的处理 • plastification 塑化 • profile extrusion 型材挤出 • Food Industry 食品工业 • oil pressing 压油 • seperation of solid and liquid parts 固液分离 First kneading machines 第一台捏合机 1873 discontinuous universal kneader UK with two SIGMA screws 斯图加特第一台非连续性 生产的由两根SIGMA螺杆 组合的捏合机诞生 1881 First continuous twinscrew kneader, patented by P.Pfleiderer 第一台连续的双螺杆捏合机 由P.Pfleiderer申请专利 First co-rotating twinscrew 第一台同向啮合双螺杆挤出机 1944 (Meskat,Erdmenger): Principle patent for self cleaning co rotating twinscrew (Meskat,Erdmenger):取得带自洁性的 啮合双螺杆生产专利 1953 License given to Werner & Pfleiderer 专利授权给WP公司 1957 First ZSK 83 in production 第一台ZSK83生产 First co-rotating twinscrew 第一台同向啮合双螺杆挤出机 Different Extrusion Systems.不同的挤出系统 Multiple Screw-Extruders 多螺杆挤出 Twinscrew Extruders 双螺杆挤出 Counter-rotating 异向 non Intermeshing 非啮合 + + + + + + + + + + + + + + + + Intermeshing 啮合 + Co-rotating 同向 + Co-Kneader 同向捏合机 + Single Screw 单螺杆 Scale up: specific torque Md / a³ = constant 放大：比扭矩= 常数 Md / a3 [ Nm / cm3 ] 13.0 12.0 11.0 10.0 9.0 8.0 7.0 6.0 5.0 4.0 3.0 ZSK 3rd generation 2.0 ZSK 4th generation (High torque drive) ZSK 5th generation (Supercompounder) 1.0 ZSK 6th generation (MEGACompounder) 0.0 50 100 150 200 250 300 Screw diameter 螺杆直径 [ mm ] 350 400 Scale up: specific torque Md / a³ = constant 放大：比扭矩= 常数 ZSK 90 两种机型比较 Comparison of ZSK 90 Super Compounder with ZSK 300 low torque 最大功率 Max power =524 kW 最大转速 Max speed =600 rpm 最大扭矩 Max torque =4,170 Nm 中心距 Center distance: a =76 mm Torque equiv a3 扭矩相当 Equivalent torque [Nm] of the ZSK 90 最大电机负载 ZSK90用于放小 Max motor load[%] of the ZSK 90 to be used for scale-down ZSK 300 90 = Torque 90 equiv = Torque 90 equiv = 最大功率 Max power =5,950 kW 最大转速 Max speed =218 rpm 最大扭矩 Max torque =130,000 Nm 中心距 Center distance: a =261 mm Torque max a3 a90 a300 300 Torque 300 max 3,210 Nm Torque 90 equiv Torque 90 pos = Torque 92 pos = 77 % Torque 90 max Torque 320 = 100 % The average shear rate is an indication for the product treatment 平均剪切率是物料处理的一个指标 It is defined as the integral value of the total screw channel 它是作为整个螺槽必须的数值 Average shear rate 平均剪切率 [ 1/sec ] Scale up: average shear rate = constant 放大：平均剪切率=常数 Production (Do/Di)P (flat channels) 生产机 平槽 Lab (D.o/Di)L (deep channels) 试验机 （深槽） 深槽） nP nL Screw speed 螺杆转速 [rpm] Approximative calculation of the screw speed 螺杆转速近似计算: 螺杆转速近似计算 2-flighted profile 双头: 双头 nL / nP = [ (Do/Di)L / (Do/Di)P ]3 3-flighted profile 三头: 三头 nL / nP = [ (Do/Di)L / (Do/Di)P ]5 Scale up: fill factor = constant 放大：填充率=常数 Production rate = n * F * H * e * h * g Calculation of the production rate 计算产量 Product density Conveying efficiency Fill factor Screw speed Free cross section Screw pitch ZSK 90 Example ZSK 90 PV SV ZSK 300 Free cross section = 37.3 cm2 Free cross section = 381.7 cm2 Screw speed = 200 rpm Screw speed = 176 rpm Average shear rate = const (correction only if Da/Di is not const.) Pitch = 120 mm PV Pitch = 400 mm Pitch / Da = const SV Rate90 PV: Product volume SV: Screw volume Rate = 840 kg/h = ( n * F * H )90 ( n * F * H )300 Rate300 Rate = 25,000 kg/h tk ZSK 300 300 0.30 200 0.25 140 0.20 Screw speed 转速 [ rpm ] Spec Energy 比能耗 [ kWh /kg] Scale up: discharge pressure 放大：排料压力 ( HDPE, HLMI = 10 ) 0.15 50 100 150 200 300 8/0 – Pressure 压力 [ bar ] Scale up: temperature profile 放大：温度曲线 „External influence 外在影响“ = constant 常数 Power [kW] Relation for MEGAcompounder Relation for the used example 900 ZSK 90 ZSK 300 L/D of barrels 24 24 700 Screw speed (rpm) 200 176 500 Motor power (kW) 175 5,950 600 Heating power (kW) 48 344 Total power (kW) 324 11,234 % of electrical heating power 27 Motor power at 260 rpm Heating power for L/D = 24 machine 800 400 300 200 100 0 20 40 60 80 100 120 140 ZSK screw diameter [mm] Scale up: temperature profile 放大：温度曲线 „External influence 外在影响 “ = constant 常数 ➔➓ Melting Mixing, dispersing, degassing → ↔➣ ↕ ↔➙ ➜➛ ➅ ➆ ➇ ➈ ➉ ➊ ➋ For the process required energy ➑➌ ➒➊ ➉➍ ➊➎ ➋➏ ➐ Possiblity to get energy from the main drive Cooling Heating ➁➄ Cooling Adiabatic operation ➁➀ ➂➃ Cooling Heating Adiabatic Operation Adiabatic Operation Cooling Cooling Scale up: results 放大：结果 Scale-up based on: motor power 根据电机功率放 大(SEI) Heat exchange 热交换 Scale-up based on: surface for heat exchange 根据热交换能力放大 Scale-up based on: fill factor 根据填充率放大 Test result Product feed 喂料 Degassing 脱挥 Scale-up based on: fill factor, gas volume 根据填充率 根据填充率， ，气体体积 ，放大 Motor power电机功率 电机功率 Possible reasons for scale up discrepancies 放大误差的可能原因 Measurement of motor power 电机功率的测算 Test machine: motor power based on exit gear box (= screw shafts) 实验机：电机功率来自传动箱的计算（螺杆） Production plant: indicated power is the power into the main motor 工厂生产：电机的额定功率 Calibration of the feeders 喂料机的校准 Test: manual calibration of the feeders 实验手动校准 Production plant: to be determined by the weight loss of the powder silo etc 工厂生产：是由失重式的料仓来处理 Nitrogen blanketing 氮气保护 Test: contact of powder with oxygen 实验：物料可接触氧气 Production plant: powder conveying always with nitrogen 工厂生产：物料的运输始终有氮气保护 Possible reasons for scale up discrepancies 放大误差的可能原因 Powder temperature 物料温度 Test: Powder used has ambient temperature (10-30°C) 实验：物料置于环境温度中 Production plant: Powder temperature is normally 50-80°C 生产工厂：料温保持在50-80℃ SEI [kWh/kg] Tmelt [°C] 250°C 0,205 0,030 0,005 60°C 20°C Melting section ➝ ➞ ➟ 0,220 265°C Accuracy of scale up 精确的放大 10 -2 -4 -6 -8 -10 Difference lab machine to production line (%) 实验机与生产机的不同 HDPE MI2=0.7 HDPE MI5=1 HDPE HDPE HDPE PP MI21=3.5 (bimod.) (bimod.) MI2=2 MI5=0.3 MI5=0.3 Specific energy 能量 PP MI2=8 Melt temperature 熔化温度 Comment: All data are based on similar operating conditions (rate, screw speed) Motor power and melt temperature are corrected 注释： 所以的数据是建立在相似的工艺条件上的（产量，转速）电机功率和熔化温 度是修正过的 Plant optimization 设备优化 Sca leUp放 大 Test 实验 Plant 生产机 Sca leDo w n 缩小 Test runs 试运行 改进Improvement Improvement改进 Plant 生产机 Test 实验 A scale-down test is recommended to define a base line before starting optimization work 优化一条生产线之前先进行按比例缩小实验是值得推荐的 History and technology of the Twin-Screw Extruder 挤出机历史和工艺技术 Thank you very much for your attention 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 这个文档的所有稿件以及插图和说明是受版权法保护的 ，任何超越版权的用途如果没有得到作者的书面许可都 将是违法的和会被起诉的。 ... Principles of the ZSK Design - ZSK 计的理念 设计的理念 - Screw Elements and their Functions - 螺纹元件和功能介绍 - Process Technology -工艺应用技术 工艺应用技术 History of the ZSK and Extrusion Systems ZSK 出系统的发展历史 挤出系统的发展历史...Coperion – ZSK Process Training 科倍 ZSK 型 培训教程 DISCLAIMER: 声明： 声明： This document and all contributions and illustrations... processing in electronic systems 这份文件包括所有的文字和图表受版权保护。任何使用有超越版权的范围没有 经过作者的事先书面同意都视为非法的，会将被检控。这应特别适用于对该文 件的翻译，复制，微型拍摄等电子处理方式。 Table of Contents 内容目录 - History of the ZSK & Extrusion Systems - ZSK 出系统的发展历史