Coperion – The Full Service Partner

COMPOUNDING
COMPOUNDING BULK
BULKMATERIALS
MATERIALSPLANTS
PLANTS GLOBAL
GLOBALSERVICE.
SERVICE.
SYSTEMS.
SYSTEMS. AND
ANDCOMPONENTS.
COMPONENTS.
Coperion – Confidence Through Partnership.

 The Company
 Powerful partner with long-standing tradition for innovative
products

 Products and Services

 Integrated approach to provide creative solutions

 New Improvements in Extrusion

 Geometry
 Power
 Materials
 Controls

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October 2006
 Coperion – 240 Years of Combined Experience
2001 – Merger to Form the Coperion Group

Founded 1993 Founded 1900 Founded 1879

Global Presence:
Compounding systems installed approximately 7,000
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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October 2006
Coperion Corporation:
Complete Solutions Provider

Complete Turnkey
Systems

Process Engineering Design Engineering

Manufacturing Field Service

Replacement Refurbishing &

Parts Upgrades
Process Laboratory

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October 2006
Coperion Corporation - Ramsey, New Jersey

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October 2006
Coperion Corporation - Wytheville, Virginia

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October 2006
Coperion – Confidence Through Partnership

 The Company
 Powerful partner with long-standing tradition for innovative
products

 Range of Products and Services

 Integrated approach to provide creative solutions

 New Improvements in Extrusion

 Geometry
 Power
 Materials
 Controls

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October 2006
 Coperion Range of Products and Services

 Products
 Compounding Systems, Bulk Materials Plants and Components

Global presence in
the plastics,
chemical and food
processing
industries.

 Services
 Global Techncical Solutions and After Market Sales Support

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October 2006
Coperion Businesses

Compounding Systems Polyolefins

Polyolefins
Engineering Plastics and Engineering Plastics,
Masterbatch Masterbatch, Long-fiber technology
Special Applications and PVC, Heat and shear sensitive plastics,
Engineered Process Systems Powder coating, Toner, General
chemicals, Food, Full Turnkey Systems,
System upgrades and Modular systems
Bulk Materials Plants Polyolefins, Engineering Plastics,
and Components Preliminary Products, General
chemicals, Food, Minerals
Global Service Coordinated Global Techncical
Solutions and After Market Sales
Support across the entire range of
products and the process chain

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October 2006
Coperion Compounding Systems
Experience and Statistics

Compounding Systems Worldwide

 Polyolefins 760
 Engineering plastics 2,300
 Masterbatch 565
 Long-fiber reinforced plastics 25
 Heat and Sheat Sensitive Material 1,035 More than 25% of all
PVC, Cable, TPE installed compounding
 Powder coatings, Toner 525 systems worldwide
 Direct Extrusion / Calander 290 were supplied by
 Chemical reaction technology 510
Coperion
 Food processing 250
 Others 635
 Total 6,890

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October 2006
ZSK 101 Coperion Compounding Systems Training
From Plastics to Cereal and Everything in Between

www.zsk101.com
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October 2006
 Coperion Compounding Systems
Advantages of the ZSK Series

 Co-rotating twin screw:

closely intermeshing and self-wiping

 Reduced cost due to wear:

modular system design

 Greater flexibility:
speed (1200 / 1800 rpm),
residence time and
throughput

 Two design series:

ZSK MEGAcompounder for the highest
torques
ZSK MEGAvolume for the highest
volume requirements

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October 2006
 Coperion Compounding Systems
Advantages of the ZSK Series
Basic layout and main components of the ZSK MEGAcompounder
With drive powers from 10 kW up to 12 MW for rates between 5 kg/h and 75 t/h
Processing
Motor Gear box section Die head

Operating principle

Modular design
for screw elements and kneading blocks
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October 2006
Coperion Compounding Systems
Advantages of the ZSK Series

ZSK series with screw diameters from 25 to 380 mm

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October 2006
 Coperion Turnkey Technology
Capabilities of Coperion Engineered Systems Group

 Thirty Five years experience

 Over 220 installations

 Upgrade existing lines

 New lines in existing facilities

 Complete new facilities

 Modular Systems

 Single Source Responsibility

 Firm Price Contract

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October 2006
 Coperion – The Full Service Partner
Complete Compounding Plant Design and Installation

Additional handling, weighing,

blending

Structural steel
and civil work

Hydraulic
transport Conticon
and drying of
pellets
Powder handling,
storage, blending,
and conveying

Pellet handling, storage, Railcar loading and

Extrusion & pelletizing blending, conveying bagging packing
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October 2006
 Coperion Bulk Materials Plants and Components
Experience and Statistics

Bulk Materials Plants installed Engineering capacities

Hrs. / Year
 PE 1,060
 Europe 130,000
 PP 990
 Worldwide 220,000
 PVC 1,010
 PET 700  can be extended to 300,000
 PA 320
 PC 220
 PS 230
 ABS 60
 PMMA 80
 PTA 350
 Others 1,280
 Total 6,300

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October 2006
 Coperion Bulk Materials Plants and Components
Experience in Plant Design

Plants for bulk materials handling and logistics

Project Basic & Detail Global Delivery & Installation &

Management Engineering Procurement Supply logistics Comissioning

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October 2006
 Coperion Bulk Materials Plants and Components
Know-How in Components

Components for handling of powder and granular bulk

materials

Rotary valves
Feeding into pneumatic conveying systems,
discharge from hoppers

Diverter valves
Distribution, convergence of bulk solid flows

Slide valves
Closing devices

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October 2006
Coperion Bulk Materials Plants and Components
Know-How in Components

Rotary valve Slide gate

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October 2006
 Coperion Global Service
Productivity and Efficiency from the Beginning

Process Technology Services Replacement Parts

 www.zsk101.com  Plant Upgrades and  Largest

 Process Lab Modernization Replacement Parts
Most complete facility  Extruder Refurbishing Stock In The
in NAFTA  Gearbox Refurbishing Industry
 ZSK 101/102  Barrel and Parts  24 Hours Service
Process training at Refurbishing Service  Gear Box Exchange
Coperion or your Site  Barrel Bore Wear program
 De-bottleneck your Measurement  Screw Assembly
process  System and Machine Change-out
Inspection Services Program
 Develop a new
process  Field Service and
 Improve screw design Emergency Repairs
data with EXCO 32  Local Service Centers

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October 2006
Coperion – Confidence Through Partnership.

 The Company
 Powerful partner with long-standing tradition for innovative products

 Range of Products and Services

 Integrated approach to provide creative solutions

 New Improvements in Extrusion

 Geometry
 Power
 Materials
 Controls

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October 2006
Design Criteria

Degrees of Freedom in
Twin-Screw Extruder Design
Geometry Power (torque)
D
O

OD = 2
ID

Balanced
OD ratio Free volume Torque
of free volume Speed
ID

and torque A

OD
= 1.25
ID ID
OD/ID
a 23
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October 2006
What is % Torque

Speed (RPM)
1,400

1,200
MB etc 35%Torque Nylon +
1,000 Glass
800

600 70%Torque 100%Torque

400
H&S
200
Matl.
0
0 50 100 150 200 250 300 350
Drive Power (kw)
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ZSK 58 MC
October 2006
 ZSK MEGAvolume
Compounding with large screw channel volume

MEGAvolume with large volume

for products with low bulk density

for processes with low
specific energy input (< 0.1 kWh/kg)

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October 2006
ZSK MEGAvolume
Compounding with large screw channel volume

Development of free screw channel volume

Free volume [%]

[ Do / Di ] = 1.55
MEGAcompounder
Md/a3 = 11.3

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October 2006
ZSK MEGAvolume
Compounding with large screw channel volume

Development of free screw channel volume

Free volume [%]

[ Do / Di ] = 1.55 [ Do / Di ] = 1.71
MEGAcompounder Continua
Md/a3 = 11.3 Md/a3 = 4.5

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October 2006
ZSK MEGAvolume
Compounding with large screw channel volume

Development of free screw channel volume

Free volume [%]

[ Do / Di ] = 1.55
MEGAcompounder
[Da / Di] = 1,55 Md/a3 = 11.3 [[D
Doa / Di]] == 1,71
1.71 [ Do / Di ] = 1.8
MEGAcompounder Continua MEGAvolume
Md/a3 = 11,3 Md/a3 = 4.5 4,5 Md/a3 = 8.7

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October 2006
ZSK MEGAvolume
Compounding with large screw channel volume

Increased channel volume through larger barrel bore and reduced

inner (root) diameter

MEGAcompounder MEGAvolume
Do / Di = 1.55 Do / Di = 1.8

Di

Do

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October 2006
ZSK Screw and Barrel Materials
The Types of Wear

Mechanical Wear
• abrasion (product/metal)
• erosion (product stream)
• adhesive (metal/metal)
• surface fatigue (product/metal)
Chemical Wear
• corrosion (product)

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October 2006
Types of Wear in Plastics Processing

Unmolten Polymer
Abrasive Unmolten Mineral
Filled Polymer

Mineral
Metal Metal

Molten Mineral
Filled Polymer

Metal

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October 2006
Types of Wear in Plastics Processing

Adhesive

Metal Metal

Metal Metal

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October 2006
Schematic Representation -
Radial Pressure Profile of the ZSK Extruder

Active Side of Apex

(Pressure Build up)

Passive Side of Apex

(Pressure Release)

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October 2006
 ZSK Screw Elements
Materials of Construction

 Nitrided

 Stainless

 Thru Hardened

 Crest Welded

 Powder Metallurgical

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October 2006
 ZSK Screw Element Materials
Screw Wear Protection Processes

Process Application Examples

Nitriding Nitralloy Steel

Solid thru-hardened Stainless Steel, Tool Steels

HIP Material CPM9V, CPM10V, CPM S90V, Material “25”

(either “solid” or with a soft core)

Solid Screw with Carbon Steel with Tungsten Carbide weld coating
Welded Coating Stainless Steel with Colmonoy 4 welded crests
Inconel with Colmonoy 4 welded crests

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October 2006
 ZSK Barrel Materials
HIP Manufacturing

• Hot Isostatic
Pressing
(HIP)
• Solid state
diffusion
• High pressure
(1000 bar)
• High temperature

(1000 °C +)

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October 2006
 ZSK Screw Element Materials
Screw Element Composite Barstock with a Soft Core

Powder Metallurgical HIP Barstock

HIP - capsule

PM - material

soft core

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October 2006
 ZSK Advanced Barrel Materials

Coperion’s new development of a wear and corrosion resistant

material for extruder barrels made of a NiCrBSi-matrix
material filled with hard boride and carbide materials.
 Very high abrasive wear resistance
 Very good adhesive and corrosive wear resistance
 Constant distribution of the hard materials in the matrix
 HIP- technology advantage, 3 mm thick HIP Layer
 Layer hardness HRC 63 - 65
 Free of cracks and pores (spider webs)
 Direct application on barrels or oval liners
 Greater than 3 times the lifetime comparedHIPto– wear
standard wear
protection layer base material
protection (hard cast chromium steel)

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October 2006
 Coperion ZSK Screw Element Materials
Popular Softcore Screw Element Types

Material Code Softcore Outside PM Steel

15 Carbon steel CPM 10V
272 Carbon Steel S90V Stainless Steel
25 Stainless Steel X235 Stainless Steel

Soft
core
steel Through-hardened
sleeve powder metallurgical
(PM) steel, chromium
and vanadium carbide
based for wear life

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October 2006
 Coperion ZSK Screw Element Materials
Welded Screw Element Types

Material Code Body Weld Overlay

236 Carbon steel Full TC body weld
245 17-4pH SS Colmonoy 4 crest weld
229 Inconel 625 Colmonoy 4 crest weld

Crest Weld
or
Full Body &
Crest Weld
Body
Material
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October 2006
ZSK Extruder Screw Wear

Wear pattern Displacement of screw shafts Explanation

Outward forces

Inward forces due to the

elasticity of the melt

When the diameter of the screw

is reduced very much, screws
tend to climb up onto each other.

Axial displacement
of screw shafts.

Twisting of
one screw shafts.

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October 2006
Abrasive Wear Test Set-Up

HOPPER

OTTOWA SAND

WEIGHT

WEAR SPECIMEN

RUBBER LINED WHEEL

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October 2006
Abrasive Wear Tests for Screw Material
ASTM-G65 Sand Abrasion Test

Wear Rate in mm3

60

220 HOPPER
50
OTTOWA SAND
180
NOT
40
TO
NOT
SCALE WEIGHT
30 TO
SCALE WEAR SPECIMEN

20 RUBBER LINED WHEEL

18 16
10 13

0
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.
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October 2006
 ZSK Extruder Barrel Materials
Barrel or Liner Wear Protection Processes

Process Application Examples

Nitriding direct on barrel nitrided barrel

Solid thru-hardening direct or liner combi barrel, cast oval

liners,
solid tool steels

Furnace Braze Coating direct or liners WPR-29 process

Centrifugal Casting liners or Xaloy, Wexco

special design

HIP Process direct or liners CPM10V, Ni 50/60,

HIP65S
Coperion
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October 2006
ZSK Extruder Barrel Materials

Barrel with wear protection Barrel with

directly applied to the exchangeable
barrel bore oval liner

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October 2006
 ZSK Extruder Barrel Materials

Wear &
Corrosion
Resistanc WPR-29
e -Highest wear
protection
-HIP Layer 3 mm thick
Vautid -Advanced wear and
-High wear protection
corrosion resistance
-Braze Coating 1 mm thick
-Good corrosion resistance
Nitrided
-Thru-hardened liner
-Cast chromium steel
-Basic wear & corrosion
-Standard base
protection Technology
material Improvements
-Nitriding ½ mm thick
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October 2006
Coperion ZSK Barrel Materials
Optimum Liner Design

Thin Wall “Figure 8”

Liner is not a good
solution for co-
rotating twin screw
extruders

Coperion Design –
Thick wall and a
solid apex area
for stability &
long life
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October 2006
 ZSK Advanced Barrel Materials

Strong apex area

HIP layer is very dense
Wear and Corrosion
and crack-free
Resistant Material
> 3 mm thick

48
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October 2006
Abrasive Wear Tests for Barrel Materials
ASTM-G65 Sand Abrasion Test
Wear Rate in mm3
60

50
> 225 HOPPER

OTTOWA SAND

40 NOT
TO
SCALE
30 WEIGHT

WEAR SPECIMEN
20
RUBBER LINED WHEEL

10

0
Nitraloy Cast WP WPR-44 CPM-10V Wexco 777 Xaloy WPR-29 PROTECT
Nitrided Liner Coating "15" Coating extreme

Note: The wear data are based on tests performed in the Coperion Materials Lab.
The exact wear rate relationships may vary for different applications.
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October 2006
Adhesive Wear Test Simulating
Screw/Barrel Friction Conditions

Cooling fluid

Plate Rotating Disc

Plate: Of barrel material, solid Diameter: 100MM

material or with applied
Surface 100.5 M/Min
coating - 100KG constant
speed: (5.5 ft/sec)
pressure against disc
Test 5 Hours
Rotating Of screw material,
duration:
disk: solid material or with
coating on outside diameter Cooling Standard cutting fluid
fluid:
Speed: 320 RPM

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October 2006
Adhesive Wear test for Screw and Barrel
Material
(wear rate on plate in cu mm)

70
64 62
60

50

40 36
COOLING
30 FLUID

20 PLATE ROTATING DISC

10 8.4
1.5 1 0.3 0.1
0 0
"15"(10V) Nitralloy "15"(10V) Stellite 12 Colm. 4 "15"(10V) WPR-25 Colm. 4 Colm. 88
on on on on on on on on on
Cast Liner Nitralloy "15"(10V) Cast Liner Cast Liner WPR-29 WPR-29 WPR-29 WPR-29

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October 2006
 ZSK Screw & Barrel Material
Adhesive Wear Compatibility

Screw Element Material Barrel Adhesive Wear Compatibility

Material Nitrided Cast Ni-50/60 PROTECT

Code Description Steel "Vautid" CPM10V WPR-29 or Col 4 Xaloy extreme

00 Nitralloy 135 (Nitrided) Caution Caution Caution

05 Thru-Hardened Stainless Steel NO NO NO
15 CPM-10V with soft core NO
25 MV 11K with 316SS soft core NO
39 PM Tool Steel CPM 9V (solid) NO
212 Nitraloy with carbide crest weld NO Caution NO
229 Inconel 625 with Col 4 crest weld
245 17-4 PH SSl with Col 4 crest weld
236 Carbon Steel fully carbide welded NO Caution NO
271 / 272 CPM 420V (272 with soft core) NO

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October 2006
 Corrosion Test for Screw & Barrel Materials

Specimen Size: 1.5” OD

0.4” Bore Diameter
0.125” Thick Vapor

Condenser
Test Temperature: Boiling temp of
fresh acid/water Boiling
Acid
solution, held Water
constant over Solution
Specimen
test duration
Electric Heater
Test Results: Expressed in mils/year
Calculated based on weight loss,
material density, specimen surface & test time.

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October 2006
 Corrosion Tests for Screw and Barrel Materials

10% Hydrochloric Acid - 100oC - 50 Hrs

10,000
8516 8134
7825
8,000
X 1000 Corrosion Rate
Mils per yr (in)

6,000

3977
4,000

2,000 1309 1057

721
514 486
93
0
17-4 Stellite Nitralloy Colmonoy 316 WPR Inconel Colmonoy WPR Hastalloy
PH 12 1.8519 4 SS 29 625 84 25 C276

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October 2006
 Corrosion Tests for Screw and Barrel Materials

5% Sulfuric Acid - 100oC - 50 Hrs

10,000 8791
X 1000 Corrosion Rate

8,000
Mils-Per Yr (in)

6,000

4,000

2,000 963 883 882 646 384 311 111 5 1.5

0
Nitralloy WP WPR Colmonoy Colmonoy Stellite 17-4 WPR 316 Inconel
1.8519 39 25 84 4 12 PH 29 SS 625

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October 2006
Controls Systems

Extruder Screen

56
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October 2006
Real Time and Historical Trends

57
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October 2006
If you need even high rates

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October 2006
Coperion – The Full Service Partner

COMPOUNDING
COMPOUNDING BULK
BULKMATERIALS
MATERIALSPLANTS
PLANTS GLOBAL
GLOBALSERVICE.
SERVICE.
SYSTEMS.
SYSTEMS. AND
ANDCOMPONENTS.
COMPONENTS.