Buss Ag PDF

Latest achievements in the compounding of high performance carbon black concentrates
AMI's Thermoplastic Concentrates 2012
Mike Irish, Vice President, BUSS, INC., Carol Stream, IL - USA Hans-Ulrich Siegenthaler, BUSS AG, Pratteln, Switzerland
CONTENTS
Contents
Carbon Blacks and their characteristics
Uses and applications of black concentrates Quality requirements and control principles Key features of the Buss Kneader and actual results Buss Kneader plant concept and layout Summary
Page 2
CB BASICS
The Fundamental Properties of Carbon Blacks

A carbon black is characterised by a number of important properties
Microstructure (crystalline layers) Surface area / Particle size Structure (morphology of primary aggregate) Surface chemistry
Page 3
CB BASICS
Commercial availability of Carbon Black

Primary particle
Available as Powder (fluff) Pellets
Aggregates
LOW STRUCTURE
HIGH STRUCTURE
Page 4
CB BASICS
Properties related to Carbon Black particle size
Fine particles Darker Stronger Harder Higher Higher Slower
Property Masstone colour Tint strength Dispersion Conductivity Viscosity Wetting
Large particles Lighter Weaker Easier Lower Lower Faster
Page 5
CB BASICS
Properties related to Carbon Black structure
High Structure Easier Slower Lower Lighter Lower Higher Higher Lower
Property Dispersability Wetting time Gloss Masstone colour Tint strength Conductivity Viscosity Loading capacity
Low Structure More difficult Faster Higher Darker Higher Lower Lower Higher
Page 6
CB APPLICATIONS
Uses of carbon black

Carbon blacks are combined with polymers in order to impart a variety of properties
Electrical conductivity Colour and opacity UV resistance Thermal conductivity Reinforcement
Page 7
CB APPLICATIONS
Applications for carbon black masterbatch

The production and subsequent let down of 40 to 50% black masterbatch is commonly used in: General purpose (colouring) Engineering plastics (colour, jetness, UV, conductivity, antistatic) Speciality film, geomembranes (UV) Pipes (UV, antistatic) W&C compounds (UV) Fibres (colour, tint, gloss)
Page 8
CB APPLICATIONS
Value added applications

Where the highest level of dispersion is needed for: End-user specifications / requirements or Severe conditions imposed during the transformation step Examples - Pipe - Cable extrusion compounds - Fibre production - Electrostatic Discharge (ESD) application
Page 9
CB COMPOUNDING
Steps in the compounding of carbon blacks
Feeding Wetting Dispersive mixing (break up of pellets to particles/aggregates) Distributive mixing
Page 10
CB COMPOUNDING
Requirements of the compounding system

Highest degree of dispersion No thermal degradation of temperature sensitive polymers No damage to physical structure of carbon black Consistent and reproducible product quality Highest possible throughputs
Page 11
BUSS KNEADER
Shear mechanism in the Buss Kneader

relaxation reorientation splitting
shearing
relaxation reorientation rotation + - stroke
product flow
Page 12
BUSS KNEADER
Buss Kneader mixing mechanism
Page 13
BUSS KNEADER
Differential features of Buss Kneader compounding technology
Controlled and uniform shear mixing Precise temperature control Very high filler loading capability
Page 14
BUSS KNEADER
Drilled pins for thermocouple placing
Direct immersion in polymer

Precise stock temperature Temperature profile of process Process control ON-LINE
Thermocouple located in pin and directly immersed in polymer
Page 15
MX TECHNOLOGY
Process Technology: Features

Optimised screw geometry: Newly designed and patented process elements for balanced conveying, mixing and energy dissipation. Balanced Volume and Torque
MKS: 3 flight design
Do/Di = 1.55 Do/stroke = 6.67
quantec EV: 4 flight design

Do/Di = 1.56 Do/stroke = 4.77
MX: 4 flight design

Do/Di = 1.71
Do/stroke = 5.50
Page 16
PROCESS RESULTS
CB Concentrates compounding MX
Formulation 1: Formulation 2: PE + 40% carbon black PE + 40% carbon black and mineral filler
Page 17
PROCESS RESULTS
Results of CB Concentrates compounding

Formulation 1 PE + 40% carbon black Formulation 2 PE + 40% carbon black + inert filler
Data
Output (kg/h)
Screw speed (rpm)
Spec energy (kWh/kg)
TempT7 (C)
T / 100 rpm (C)
Formulation 1
Formulation 2
525
800
750
750
0.171
0.114
242
208
7.9
3.5
Page 18
PROCESS RESULTS
Results Semicon-processing MX vs MKS
PE Copolymer + 35 - 40% Conductive CB

Buss Kneader Type Throughput (kg/h) Screw speed (rpm) Spec. Energy (kWh/kg) Saving (%) Temp T7 (C) T7 (C) T (C) / 100 rpm
MKS Pilot MX Pilot
180 500
450 750
0.250 0.172
0 31
212 209
---3
20.0 7.0
Page 19
QUALITY ISSUES
Quality Characteristics for Plastics Pipe Systems for Water Supply Polyethylene (PE)
Page 20
QUALITY ISSUES
Filter Pressure Value Test
Page 21
QUALITY ISSUES
Filter Pressure Value Test
Page 22
QUALITY ISSUES
Filter Pressure Value vs. Output Rate

FPV vs. Output Rate
1.70 1.60 1.50
FPV [bar*cm^2/g]
1.40 1.30 1.20 1.10 1.00 0.90 0.80 150
Trial 1.2 Trial 1.1
Ref Split-Feed 70/30 Split-Feed 60/40
Trial 1.3
160 170 180 190 200 210 220 230 240 250
Test Mixture: MB 100g Base Polymer 400g Total 500g (containing 40g C.B.)
G [kg/h]
70/30
60/40
Ref.
Linear (Ref.)
Linear (60/40)
Linear (70/30)
Page 23
QUALITY ISSUES
Film Test
Page 24
QUALITY ISSUES
Film Test
Page 25
QUALITY ISSUES
Film Test
Page 26
TYPICAL LAYOUT MX
Typical Layout CB Concentrate Plant

water transport system for pellets pellet outlet centrifugal dryer water bypass system drive cabinet control cabinet vertical inlet screw degassing unit oil heating / cooling units water heating / cooling units
fines removal sieve water tank
kneader
control PC with rack melt pump diverter valve under water pelletiser
Page 27
TYPICAL LAYOUT MX
CB Concentrate Plant with gravimetric feeding system
BUSS COMPOUNDING PLANT
Page 28
TYPICAL LAYOUT MX
Applications
CB Compound Type Buss Kneader line configuration
CB Concentrates
15 or 22 L/D, Melt Pump 2 or 3 Inlet Screws, under water pelletiser (screen changer optional)
Semiconductive CB Compounds
Black jacketing Compounds
15 or 22 L/D, Melt Pump 2 or 3 Inlet Screws, under water pelletiser (screen changer optional)
15 L/D, Melt Pump 1 Inlet Screw, under water pelletiser
Page 29
TYPICAL LAYOUT MX
MX Sizes and Output Rates (kg/h)

CB Concentrate Semi-conductive CB Compound
5-25
150-250 500-750 700-1300 1500-2500 2500-3500
Black Jacketing Cable Compound

5-25
250-350 650-950 1200-1900 2400-3200 3000-4500
MX 30
MX 58 MX 85 MX 105 MX 125 MX 140
5-25
250-350 650-950 1200-1900 2400-3200 3000-4500
Page 30
TYPICAL LAYOUT MX
References
Most recently installed MX Kneaders for CB compounding in addition to the MX 58-15/22 in Buss lab: Major Producer, BE Major CB prod., CN Major Compdr., CN Major Producer, RU Major Producer, RU Major Producer, TH MX 140-15 F 260-8 MX 140-22 P 140 MX 105-15 F 200-6 MX 125-15 P 140 MX 125-15 F 250-6 MX 105-15 P 110 Semicon & CB Masterbatch CB Masterbatch Talcum Masterbatch CB Masterbatch CB Masterbatch Semicon & CB Masterbatch
Totally world wide sales CB MB: approx. 30-40 machines (incl. older types)
Page 31
SUMMARY
Summary - Carbon Black Compounding

Successful compounding of carbon black masterbatch requires Highest output rates while maintaining an on-going level of quality and consistency Optimum dispersion and product homogeneity as the key for: End-user properties Extrusion properties Processing parameters Controlled shear mixing without damage to polymer and carbon black structure The Buss Kneader provides the optimum in product dispersion leading to improved product and end-user performance
Page 32

Buss Ag PDF

Uploaded by

Copyright:

Available Formats

Buss Ag PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Buss Ag PDF

Uploaded by

Copyright:

Available Formats

Latest achievements in the compounding of high performance carbon black concentrates

AMI's Thermoplastic Concentrates 2012

The Fundamental Properties of Carbon Blacks

Commercial availability of Carbon Black

Available as Powder (fluff) Pellets

Properties related to Carbon Black particle size

Fine particles Darker Stronger Harder Higher Higher Slower

Property Masstone colour Tint strength Dispersion Conductivity Viscosity Wetting

Large particles Lighter Weaker Easier Lower Lower Faster

Properties related to Carbon Black structure

Uses of carbon black

Applications for carbon black masterbatch

Value added applications

Steps in the compounding of carbon blacks

Feeding Wetting Dispersive mixing (break up of pellets to particles/aggregates) Distributive mixing

Requirements of the compounding system

Shear mechanism in the Buss Kneader

relaxation reorientation rotation + - stroke

Buss Kneader mixing mechanism

Differential features of Buss Kneader compounding technology

Drilled pins for thermocouple placing

Direct immersion in polymer

Thermocouple located in pin and directly immersed in polymer

Process Technology: Features

quantec EV: 4 flight design

MX: 4 flight design

Results of CB Concentrates compounding

Screw speed (rpm)

Spec energy (kWh/kg)

T / 100 rpm (C)

Results Semicon-processing MX vs MKS

PE Copolymer + 35 - 40% Conductive CB

MKS Pilot MX Pilot

Filter Pressure Value Test

Filter Pressure Value Test

Filter Pressure Value vs. Output Rate

1.40 1.30 1.20 1.10 1.00 0.90 0.80 150

Trial 1.2 Trial 1.1

Ref Split-Feed 70/30 Split-Feed 60/40

Typical Layout CB Concentrate Plant

fines removal sieve water tank

CB Concentrate Plant with gravimetric feeding system

BUSS COMPOUNDING PLANT

MX Sizes and Output Rates (kg/h)

Black Jacketing Cable Compound

Summary - Carbon Black Compounding

You might also like