GPCA Plastcon 2013 I April 7-9, 2013 I Page 2

Intermeshing Co-rotating Twin-screw Extruders:

Integrating the Highest Torque Technology with Direct
Extrusion for Improved Productivity

Paul Andersen
Director, Process Technology
Coperion Corporation
Ramsey, NJ Proud Supporter
GPCA Plastcon 2013 I April 7-9, 2013 I Page3
Overview

• Coperion: Customized solutions are our response

to complex challenges

• Co-rotating Twin-screw Compounder

• Benefits of High Torque Processing

• Benefits of Direct Extrusion / In-line Processing

• Summary

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Coperion: Worldwide market and technology leader -
Compounding & Extrusion, Materials Handling and Service

Over 130 years experience with mixing and kneading

processes

Pioneering work and continuous development of the

closely intermeshing, co-rotating twin-screw extruder

Over 10,000 compounding systems worldwide

Comprehensive product portfolio: laboratory extruder

ZSK 18 MEGAlab to largest extruder ZSK 420 Mc

Throughput rates from 1 kg/h to 100 t/h

Turnkey compounding systems from raw material

feeding to downstream pelletizing / in-line
handling equipment
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Original Extruder (Date Unknown): David B. Todd Design

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Modular Design: Twin-screw Extruder

Drive power from 10 kW up to 12 MW for rates between 0.5 kg/h and 100 t/h
Motor
Process section
Gear box Die head

Operating principle

Modular design for screw elements and

kneading blocks
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Characteristic Dimensions: Co-rotating Twin-screws
2-flighted profile

Do/Di: Diameter ratio

Do
Md / a3: Specific torque

Do = Outer screw diameter

Di Di = Inner screw diameter
a a = Center distance

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ZSK – Evolution of Torque and RPM
1985: ZSK Sc
Do / Di = 1.55
Md / a3 = 8.7 Nm/cm3
n = 600 min-1
1995: ZSK Mc
Do / Di = 1.55
Md / a3 = 11.3 Nm/cm3
n = 1200 min-1
2004: ZSK Mc PLUS
Do / Di = 1.55
Md / a3 = 13.5 Nm/cm3
n = 1200 min-1
2010: ZSK Mc18
Do / Di = 1.55
Md / a3 = 18.0 Nm/cm3
n = 1200 min-1
GPCA Plastcon 2013 I April 7-9, 2013 I Page 9
ZSK Mc18: Highlights of latest extruder generation: 2012
Power
Density: 18 Nm/cm3 FET: Feed
Enhancement ZS-EG
1.55 Do/Di Technology Twin-screw Side
geometry Devolatilization

Temperature control for

Maximum energy efficiency:
a) shrink fit barrel liners Screw Shafts
b) cartridge heaters made of new
c) optimized cooling system high performance
d) new insulation covers materials
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Benefits of Higher Torque

• Utilize higher % fill factor OD/ID = 1,55

vu
hmax
• Reduced average shear
gamma = vu /h
• Lower material temperature OD/ID = 1,55
vu
hmax
• Typically lower residence time
• Reduced stress on product: Improved Product Quality/Energy Efficiency
• Enables utilization of higher screw rpm: Improved Productivity

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Benefits of Higher torque: Processing Undried PET
Step 1: Avoid i.v. degradation
• PET equilibrium moisture content approximately 0.33 %
• Plastification of „wet“ product  immediate hydrolytic degradation
- 104 times faster than thermal degradation
- ~ 5,000 times faster than thermo-oxidative degradation

Removal of retained moisture is the main problem for

processing / compounding of PET

Options for achieving a low processing moisture content:

• Standard crystallization at 150°C and drying at 150–180°C
• Air-drying process at temperatures of max. 60 °C without crystallization
• Combination of pre-drying or conditioning and vacuum degassing
• Vacuum degassing at extrusion
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Benefits of Higher torque: Processing Undried PET
Step 1a: Compounding to avoid i.v. degradation

1 PET
2 Atmospheric vent
3 Vacuum pump 2
3
4 Discharge 1
4

ZSK Mc18

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Processing Undried PET
Impact of Higher Torque on Rate

40%

Parameters: ZSK 45 Mc18, Md ~ 85%

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Processing Undried PET:
Impact of Higher Torque on Energy

~ 10%

Parameters: ZSK 45 Mc18, Md ~ 85%

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 Benefits of Higher torque: Processing Undried PET
Combined 60% Increase in Throughput

350 0.84
Throughput [kg/h]

iV [dl/g]
Raw material
0.83
300 Smaller IV drop iVo=0.83 dl/g
At same screw speed

0.82
60% rate increase
250 with constant IV
drop
0.81
Same IV drop
30% 200 with 25% higher screw speed
increase 0.80
in rate at
same rpm
150 0.79

100 0.78
200 300 400 200 300 400
Screw speed [rpm] Screw speed [rpm]
Parameters: ZSK 45 Mc18, Md ~ 85%
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Benefits of Higher Torque: Processing Undried PET
Summary of the Mc18 technology:

• Mc18 ZSK can achieve 30% higher throughput as compared to Mc+

• Higher filling level reduces specific energy
• Reduced specific energy decreases material temperature 5-10°C
• High torque compounder: lower iV drop for high viscosity PET
• For equivalent iV drop, 60% increase in throughput achievable

GPCA Plastcon 2013 I April 7-9, 2013 I Page 17

Co-rotating Twin-screw Extruders and In-line Processing

High density
PET, PMMA sound insulation and
Thermoforming sound deadening
products

Natural and
Honeycomb
wood fiber
catalysts
composites

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Direct extrusion: Combination of Compounding and Extrusion

Process in two steps: standard procedure

Compounding- Melting- Shaping
Silo Silo Semi product
plant / extruder extruder die

Compounding and in-line-extrusion in one step

Compounding- Shaping
Silo Semi product
plant / extruder die

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Benefits of Direct Extrusion / In-line Processing

Improved Quality:
Thermal degradation is reduced
Elimination of second heat cycle

Improved Economics:
Reduction of energy cost
Cooling of intermediate product
Re-heating of intermediate product

Improved Productivity
Faster change over for pigmented resins
No dryer clean out
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In-line processing / Direct Extrusion Applications

• Cast Film/Sheet from PET, PLA

• Film from PVB for compound glass window
• Sheet Extrusion: PMMA for optical applications
• Biaxial orientated film from PP, PET, PLA, PA, or PE
• Foamable sheet from PP or PE
• Sheet for noise reduction out of high filled (EVA, PP, PE, PEO)
• Sheet from PP and wood flour or talc
• Conductive film for the electronic industry
Throughput from 15 kg/h to 12,000 kg/h

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Direct extrusion / In-line Processing Undried PET:
Step 2: Integration of Cast Film Set up
Undried polyester 1. Pellet feeding 8. Film die
pellets or recyclate 2. ZSK Mc18 9. Chill-roll-plant
3. Venting 10. Edge trim
4. Degassing 11. Pelletizer
5. Vacuum pump (1-5 mbar) 12. Process control unit
6. Melt pump 13. Film thickness control unit
7. Screen pack changer 14. Winder

1 11 10 12

3 5

4 4
2 6 14
13
8 9
7

ZSK 119: 2.5 t/h PET

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Twin-screw Extruder vs. Drying/Single-screw: PET

• No pre-treatment of feedstock (i.e. crystallization, agglomeration or

predrying), results in energy savings of 30-40%

• High flexibility, fast start up and quick product change over,

( i.e. no dryer clean out is required)

• Minimal iV-drop of about 0.04 dl/g

• Combination of raw materials (pellets) and recycled materials (flakes)

in any ratio without prior agglomeration / crystallization

• Good product homogenity when additives, fillers or color pigments /

masterbatches have to be incorporated

• Effective degassing of residual moisture and monomers/oligomers

• Production at throughput rates even beyond 4 t/h without problems

(i.e. ZSK 133 instead of Ø 250/275 single screw cascade)
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Twin-screw extruder vs. Drying/Single-screw: PET

Twin-screw Extruder Single screw cascade

System capacity 4,000 kg/h 4,000 kg/h
Installed drive power 750 kW
Installed capacity dryer ——
998 kW ca. 1,300 kW
Installed capacity vacuum
48 kW
pump
Installed capacity other
100 kW
equipment, incl. heating
Energy consumption in
0.22 kWh/kg 0.32 kWh/kg
production
Energy saving p.a. (8,000h)
693,440 € 1,008,640 €
0.0985 €/kWh
Energy saving 30%
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Plant for the Production of Sheet: PMMA …

3 4

2 5 6

1 Feeding 4 Calender
2 ZSK Mc18 5 Cutting device
3 Degassing 6 Deposit table

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Direct Extrusion of Foamable Films: PE, PP ….

2
1

2 3 4
12
5 10 7
7
6 8

9 11

1. Silos 7. Start-up valve

2. Feeders 8. Sheet die
3. ZS-B twin screw side feeder 9. Calender
4. Liquid silo 10.Thickness gauge
5. Liquid pump 11.Edge trimming device
6. ZSK Mc18 12.Film winder
GPCA Plastcon 2013 I April 7-9, 2013 I Page 26
Summary

 Flexibility – High Torque Twin-screw Compounder

is adaptable to multiple applications

 Economic efficiency – Coupling compounding with in-line extrusion

minimizes costs and maximizes product quality

 Reliability – Processing of un-dried PET is commercially proven

 Productivity – High throughput with good product quality
 Quality – Minimal iV loss occurs with PET

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