Process training ZSK 2011(english chinese) (004)

mô tả máy tạo hạt nhựa dùng trong quá trình thí nghiệm,sẽ hữu ích cho ai học tập và nghiên cứu về ngành nhựa hiện naymáy móc ổn định,sử dụng tốt,nhanh đạt nhiệt độ tiêu chuẩn,lllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll

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。

History of the ZSK and Extrusion Systems

More than 2000 years ago

The need for „kneading“.

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

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

1944 (Meskat,Erdmenger): Principle patent for

self cleaning co rotating twinscrew

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

The Single Screw 单螺杆

Gearbox

传动箱

Process Section with Hopper

Feeding mechanism in a single screw 在单螺杆上的输送原理

The conveying mechanism of a single screw is determined by the ratio of the friction between product and the barrel wall and the product and the screw element.

Feeding mechanism in a single screw 在单螺杆上的输送原理

- only friction and surface slipping determine the feeding rate in a single screw

只有摩擦力和表面润滑决定物料在单螺杆上的输送率

- for newton fluids the conveying efficency is around 50% of the maximum

theoretical conveying power of the screw

对牛顿流体的输送效率是螺杆最大理论输送能力的 50% 左右

- the conveying efficeniency will further decrease if pressure has to be build up

如果压力建立起来，输送效果会进一步降低

the limitations of the single screw in combination with the demand for a self

cleaning system lead to the development of twinscrew systems

单螺杆的局限性在需要自洁性的要求下，导致了双螺杆系统的产生

- Erdmenger, Meskat & Geberg developed the first twinscrew systems in the first half

of the 40s during the second world war

Erdmenger ， Meskat 和 Geberg 于 40 年代上半叶，在二战期间发明了第一个双螺杆系统

- they continued their development after the war for Bayer AG in the nowadays famous high-viscous group

在战后，他们为 Bayer AG 继续着他们的发明，生产了如今著名的高粘系统

The Single Screw.

单螺杆

- L/D 20 to 40, screw diameter up to 800 mm, screw speeds up to 1000 rpm (usually 50-150)

- low shear level allows the processing of shear-sensitive materials

低剪切，适用于加工剪切敏感性物料

- the screw design is always fixed (one piece), different screw‘s are available but they are mostly

The Single Screw.

喂料的速度取决于螺杆与机筒内的磨擦，由于螺杆光洁度高，而机筒内壁没有，所以筒体的温度

- to improve mixing, various shear and mixing elements

can be added to the screw

为了提高混炼效果，不同的剪切和混炼元件被选用到螺杆中

The Single Screw.

单螺杆

- single extruders can be equipped with grooves for better feed intake (higher friction)单螺杆上开槽可以更好的喂料（更高的摩擦）

The Single Screw.

喂满后落料

Feed zone 喂料段 Melting zone 熔融段 Degassing

Zone

Metering zone with mixing head

The Co-Kneader 捏合机

The Co-Kneader 捏合机

kneter_simulation.exe

The Co-rotating intermeshing twinscrew 同向啮合双螺杆挤出机

The Co-rotating intermeshing twinscrew.

The Co-rotating intermeshing twinscrew.

The Co-rotating intermeshing twinscrew.

The Co-rotating intermeshing twinscrew 同向啮合双螺杆挤出机

- good axial mixing

The Co-rotating intermeshing twinscrew.

同向啮合双螺杆挤出机

- Good product conveying capability Separate feeders are required The output rate is independant of the screw speed Therefore fix speed or variable speed drive is possible.良好的输送能力，需要单独的喂料机，产量取决于螺杆转速，因此可选择恒速或变速驱动

Product feed喂料

M

Degassing Zone 排气段

Discharge 排料段 Melting zone

熔融段 Feed zone 喂料段

The Counter-rotating intermeshing twinscrew 异向啮合双螺杆挤出机

The Counter-rotating intermeshing twinscrew.

The Counter-rotating intermeshing twinscrew.

异向啮合双螺杆挤出机

- due to the occuring forces, the screws try to move outwards, high risk of wear, therfore the screwspeed is very limited (20-60 rpm)

- very low axial mixing effect, not suitable for compounding

The Counter-rotating intermeshing twinscrew.

M

Degassing Zone 排气段

Discharge 排料段 Melting zone

Feed zone 喂料段

Counter-rotating non-intermeshing systems 异向非啮合双螺杆挤出机

Counter-rotating non-intermeshing systems.

Counter-rotating non-intermeshing systems.

M

Multiple Screw Extruders 多螺杆挤出设备

Multiple Screw Extruders.

Multiple screw systems 多螺杆系统

Survey about different Extrusion Systems.

Twin-screw extruder 双螺杆挤出机 counter-rotating 异向

Principles of the ZSK Design

Principle design of the ZSK

Modular barrel system.

自然排气侧喂料

Vacuum degassing

真空排气

Modular screw configuration.

Short kneading disks 短啮合盘

Undercut profile elements

Special elements 特殊件

Barrel section of ZSK 30 and ZSK 300 ZSK 30 和 ZSK 300 筒体比对

ZSK 380 barrel ZSK 380 筒体

Coperion ZSK Design Criteria.

科倍隆 ZSK 的设计标准

Do/Di=Diameter ratio 内外径比 Md/a3=Specific torque 比扭矩

n = Screw speed 螺杆转速 Do = Outer diameter 外径

Di = Inner diameter 内径 a = Centerline distance 中心距

D o

D i

a

Final confirmation of the Coperion

Werner & Pfleiderer Patent EP 0 852 533 B2 on 20.1.2004

at the European Patent Office against 6 competitors!

Flight depth 螺槽深度 Free volume and permissible torque

as a function of flight depth 自由容积、扭矩与螺纹深度的关系

Free volume 自由容积

Balanced ratio between free volume and torque

自由容积和扭矩的平衡点

Do/Di = 1,55

Range of Coperion twin-screw compounders.

CTE and CKY manufactured by Coperion Nanjing

(China + Asian market) 科倍隆南京生产的 CTE 和 CKY （供应中国和

/工

艺 工 艺 工 艺 工 艺

P

价 格 价 格 价 格 价 格

Standardized Twin-Screw / Two Stage STS

Advanced assembled by Coperion Nanjing

(for world market) 科倍隆南京组装的 STS

ue

扭 矩 扭 矩 扭 矩 扭

Md: 8.7-10

Md: 5.5

ZSK – evolution of torque and volume

Comparison of operational window 使用比较

Example例子:

CTE: 200 kg/hSTS Advanced

600 rpm: 340 kg/hSTS Advanced

800 rpm (T8.7): 450 kg/hSTS Advanced

800 rpm (T10): 520 kg/hZSK Mc+: 1000 kg/hZSK Mc18: 1300kg/h

Less product stress on ZSK Mc PLUS.

在 ZSK Mc PLUS 上较低的压力

0,120,130,140,150,160,170,180,190,2

Process applications for twinscrew compounders.

双螺杆挤出机的工艺应用

plastics, caoutchouk塑料，弹性橡皮

extrusion, forming, pelletizing

挤出，成型，切粒

organica, pesticide有机物，杀虫剂

Geometrical basics 几何模型

- Geberg found that the rotation of two shafts around their fixed axes is equivalent to

the rotation of one shaft around the other

- the rotation of one screw around a cylindrical shaft will automatically lead to a

corresponding geometry where every point of the rotated screw will have a

counterpart on a circle with the radius of the axial distance

Geometrical basics 几何模型

-the geometrical basics are valid independed from the number of flights 所有不同头螺纹元件的几何模型都是这样

Do a

Do Outer screw diameter 外径

a Center line distance

2 - flighted profile 双头元件剖面

Do a

3 - flighted profile 三头元件剖面

Geometrical basics 几何模型

Theoretical drawing of a „ultra-sharp“ screw

“ 超灵敏 ” 螺杆的理论图形

Melt streams within a twinscrew extruder 在双螺杆挤出机中的熔体流

Melt streams within a twinscrew extruder – two flighted profile 在双螺杆挤出机 - 双头螺纹元件中的熔体流

Free cross section.

Maximum values for Do/Di.

Constant diameter-ratio Da/Di for volumetric Scale-up m ~ n*D³ 在内外径比 Da/Di 不变时按比例扩大的自由体积 m ~ n*D³

Da/Di

free Volume

较 好 的 轴 与 元 件 的 连 接

较 好 的 轴 与 元 件 的 连 接

较 好 的 轴 与 元 件 的 连 接

H Ig he

r p ow de

r d en sit y in th

e f ee din

g s ec tio n

Best Da/Di is depending on

construction, process and product

最佳的 Da/Di 值取决于结构、工艺和产品

Da Di

Da Di

a

Constant screw speed n for volumetric Scale-up m ~ n*D³.

Da/Di=1,55 (SC)

Da/Di=1,80 (Mv, Mv PLUS)

Da/Di=1,55 (Mc, Mc PLUS)

Shear rate γ = γ = γ = velocity v / height h

Shear energy in conveying sections 在输送部分的剪切能量

- about 50% of the particles passing will be

affected by the maximum shear energy

- the maxium shear stress applied is depending

on shear speed and viscosity Usual values reach

from 0,8 bar to 50 bar

使用的最大剪切压力取决于剪切速度和黏度。通常

- the highest shear stress can be found in the

melting section as a result of the

compression of solid material

最高的剪切压力发生在固态物料受挤压导致熔融的部分

Influence of the torque level 扭矩等级的影响

Average value

- , - , -

Less product stress on ZSK Mc PLUS.

在 ZSK Mc PLUS 上较低的压力

0,120,130,140,150,160,170,180,190,2

Shear and elongational stresses define the level of dispersion.

Shear velocity allocation

剪切速度分配

Shear and elongational stress define the level of dispersion.

Shear stress and elongational stress.

剪切和拉长压力

Cross-section with partial filling 部分充满熔体的双螺杆横截面

Axial- and radial velocity define the effect of mixing.

Axial velocity allocation

轴向速度分配

axial speed.avi

Cross-section with partial filling 部分充满熔体的双螺杆横截面

Screw Elements & their Functions

螺纹元件及其功能作用

Principle effects of screw elements.

螺纹元件的作用

Kneading (dispersing)

啮合啮合（（（分散分散分散））

Mixing elements

左旋元件

Different screw profiles.

How to construct a double flighted screw element 如何画双头螺纹元件

1 You need to know Do, Di and the axial distance

How to construct a double flighted screw element 如何画双头螺纹元件

1 Draw a 45° line with the length of the half axial distance

How to construct a double flighted screw element.

如何画双头螺纹元件

1 At Point P draw a circle with the radius of axial distance,

you get the profile of the flank, the profile

of the flight and the root are given

by the circles of Do and Di

How to construct a double flighted screw element 如何画双头螺纹元件

Do/Di = 1,55

Differences between one, two and three-flighted elements 单头、双头和三头螺纹元件的区别

- Depending on the process the elements

have to be selected carefully

- in most cases the two flighted elements are

the best compromise, therfore all Coperion

extruders are designed for two flighted elements

在大多数情况下，双头螺纹元件时最好的选择。

所以所有的科倍隆挤出机都使用双头螺纹元件。

Free Volume Conveying efficency

Extruder 挤出机

Right handed elements 右旋螺纹元件

Conveying direction of the element

same as

direction of product flow in the extruder

螺纹元件的输送方向与料流在挤出机中的方向

相同

Left handed elements 左旋螺纹元件

Conveying direction of the element

Extruder 挤出机

Product movement 物料移动方向

1-flighted elements

单头螺纹元件 Reduced movement of the product

from one screw to the other one.

This means: improved transportation

of the product in axial direction.

很少的物料从一根螺杆移动到另一根螺杆。 这意味着：物料在轴向方向上的大的移动。

2-flighted elements

双头螺纹元件

Most amount of the product moves from one screw to the other one.

This means: reduced transportation

of the product in axial direction.

大多数物料从一根螺杆移动到另一根螺杆。 这意味着：物料在轴向方向上的小的移动。

Product movement.

物料移动方向

Working principle of conveying elements.

输送元件的工作原理

Type of element

类型

Free Volume

自由容积

Conveying Efficiency

With reduced pitch, the volume in the screw channels is reduced.

As a consequence the fill factor will be increased.

在小导程元件中，螺杆间的自由容积减小。

所以导致了物料充满度上升。

Fill factor in conveying elements.

在输送元件中的物料充满度

Special (undercut) conveying elements.

特殊输送元件（ Undercut ）

A modification of the free cross section in order to get more free volume

is only possible, if there no self-cleaning profile anymore.

There is the risk, that product sticks to the screw.

The self-cleaning profile will then be rebuild automatically.

In the intermeshing area of the two screws an open gap is formed, which reduces the conveying efficiency

如果没有自洁型元件 如果没有自洁型元件， ， ，自由交叉部分的改变才能得到更高的自由体积 自由交叉部分的改变才能得到更高的自由体积 自由交叉部分的改变才能得到更高的自由体积。 。

Free cross section: approx 130%

Special profile (KP)

特殊型

这会有物料粘在元件上的危险 这会有物料粘在元件上的危险。 。 。自洁型元件接着会自动的重新建立 自洁型元件接着会自动的重新建立 自洁型元件接着会自动的重新建立。 。

在两螺杆的啮合区域 在两螺杆的啮合区域， ， ，一个空间隙的形成 一个空间隙的形成 一个空间隙的形成， ， ，降低了输送效率 降低了输送效率 降低了输送效率。 。

SK Element SK 元件

Dt Do

= Break up agglomerates and

Mixing mechanisms in twin screw extruders 在双螺杆中的混合

2

3

4 (5)

Kneading blocks.

啮合元件

Working principle of kneading blocks.

啮合元件的工作原理

Kneading blocks.

啮合元件

Point of highest wear due to rotation of melt因为熔体的旋转产生了最大的磨

损点

right handed element

Type of

Element

元件类型

Mixing effect

混合效果

Conveying effect

输送效果

Dispersion effect (shear)

混合效果

Conveying effect

输送效果

Dispersion effect (shear)

分散效果

（

（剪切 剪切 剪切） ）

Back up length vs element pitch (Kneading block) 倒退长度 VS 元件厚度（啮合块）

2 - flighted screw profile

A 3-flighted kneading block in the flighted system cannot be made with the same diameter as the

2-flighted element It therefore will exist a larger clearance between the crest and the barrel.

3 flighted kneading elements in two flighted machinery 三头啮合元件在双头系统中的应用

- due to geometric reasons, the maximum

Do/Di in threeflighted machines is 1,37

- therefore centric threeflighted elements

cannot be made with a Do/Di of 1,55

- threeflighted centric elements would have

very large clearances in two flighted machines

Comparision of 2 and 3-flighted kneading blocks.

1 2 3

4 5

Shear rate in screw channel – 2 lobed kneading block.

double flighted

双头

Shear rate in screw channel – 3 lobed excentric kneading block

triple flighted 三头

500

Shoulder kneading blocks/SAM.

- alternate solution for sensitive products

if three flighted kneading blocks are not

available

三头啮合块一般不使用，只是在一些敏感

产品上选择使用

Special elements for dispersive mixing.

用于分散混合的特殊元件

Blister discs for distributive

and dispersive mixing

Single-flighted kneading elements for dispersive mixing

Special elements for dispersive mixing 用于分散混合的特殊元件

Mixing cross wise better than length wise

纵向混合

Distributive mixing.

分布混合

HEDGEHOG SME ZME TME

No conveying 无输送 Conveying 输送 Conveying 输送 No conveying无输送

Mixing elements – (Distribution) 混合效果 – (分布)

Distributive mixing elements – HEDGEHOG 分布混合元件 — HEDGEHOG

Distributive mixing elements – SME 分布混合元件 — SME.

Distributive mixing elements – ZME 分布混合元件 — ZME.

Da

Distributive mixing elements – TME 分布混合元件 — TME.

no lefthanded element necessary

不需要反螺纹

Comparision of different mixing elements 不同混合元件的比较

Product flow

产品流向

Pressure

压力

Right handed elements are

not fully filled with polymer.

This section is pressureless.

反向螺纹元件阻碍聚合物的流动 反向螺纹元件阻碍聚合物的流动。 。 。因此前段部分会充满聚合物 因此前段部分会充满聚合物 因此前段部分会充满聚合物。 。 。啮合块的效果 啮合块的效果 也因此得到加强

Left handed conveying elements 反向输送元件

Element 元件 retaining effect 停留效果

right handed element with small pitch

Influence of the screw configuration on the residence time.

Medium residence time 停留时间

Product: PP Machine: ZSK 90 with free discharge

产品 产品： ：PP

机型 机型： ：ZSK 90 无机头

after 15 min

15分钟之后

Colour change.

颜色的变化

Assembly of conveying elements.

` a b c

Profile cross section

at the end of the element

b c

Profile cross section

at the end of the element

Assembly of kneading blocks.

啮合块的安装

1 2 3 4 5

45 f

Profile cross section

at the beginning of the element

b c

Profile cross section

at the end of the element

a d

1 2 3 4 5

45 f

1 3 5 6 7

2 4

30 f

90f

1 2 3 4 5

Transition between different profiles.

轴向位移可能造成的损害

At the transition of 2 different profiles (A and B) or if one element is staggered with a certain angle to the upstream located one, like the kneading disks in the kneading blocks, a spacer ring or a transition

element has to be installed.

在2种不同剖面 种不同剖面（ （A和B） ）的过渡部分 的过渡部分 的过渡部分， ， ，或者某一元件与前 或者某一元件与前 段元件有一定的角度错位

transition from one

profile to the other

First or last kneading disk

of a 3-flighted kneading block

Numbering system for screw elements.

008040 - 00 21 - 060 / 060 - 24 xxxxxxxx

60 / 60

Parts number.

部件序号

1 2 6

Self cleaning conveying element

Wear & Corrosion.

磨损 & 腐蚀

Aggressiveness of the product

含腐蚀性物料

Mechanical contact of screw / screw or screw / barre

螺杆与螺杆 螺杆与螺杆、 、 、螺杆与筒体之间的机械接触 螺杆与筒体之间的机械接触

Corrosion 腐蚀 Deflection of the shafts

due to forces, caused

by the treatment of the polymer

由于物料的压力导致芯轴偏移

Misalignment of the shafts

Wear and Corrosion Protection 防磨防腐保护

Barrels 筒体

Comparision of wear protection.