Process training ZSK 2011(english chinese) (004)

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

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声明：
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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

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Intermeshing 啮合

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Co-rotating 同向

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Co-Kneader
同向捏合机

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Single Screw
单螺杆


The Single Screw. 单螺杆

Gearbox
传动箱

Process Section
with Hopper
带料斗的工艺段

Screw

Diehead

Pelletizer

螺杆

机头

切刀


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.
在单螺杆上的物料输送取决于物料和筒体间及物料和螺杆间的摩擦比

No transportation if product
sticks to the screw element.
如果物料粘在螺纹元件上，
则没有输送效果

Good product transportation if
product sticks to the barrel wall.
如果物料粘在筒体内壁上，
则有好的输送效果

Low friction at the screw, high friction at the barrel wall (bolt / nut effect)
在元件上的低摩擦，在筒体内壁上的高摩擦（螺栓/螺母效应）


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)
长径比20-40，螺杆直径最大800mm,螺杆转速可达1000转(一般为50-150转)
- main application is melting and pressure build up 主要应用是熔融建压
- very low mixing effect, not suitable for compounding 剪切能力很低，不适用于配混
- 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
- Coperion uses single screw extruders in two-stage machinery 科倍隆在双阶挤出机中应用单螺杆
- the screw design is always fixed (one piece), different screw‘s are available but they are mostly
manufactured as one piece. 螺杆的设计是固定的，有不同的螺杆可选，但大多数是一体的


The Single Screw.
单螺杆
- only Polymers that stick to the wall of the barrel can be processed in a single screw extruder
只有粘黏在筒体壁上的物料可以被单螺杆处理
- the feed rate depends on the differences on friction at screw and barrel. The Screws are always
polished, the wall of the barrel not (Screw effect), the barrel should be always hotter than the
screw. (more friction)
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
要高于螺杆（更多的摩擦)
- 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.
单螺杆
- Product conveying is not very efficient. Product intake out of full hopper, no feeders are
required. 物料的输送效率低，料斗满了后自动落料，不需要喂料机。
-The output rate is related to the screw speed.
产量取决于螺杆转速。
- In order to control the output rate a variable speed drive is required.
为了控制产量，需要可调速电机驱动装置。
Product feed 喂料
Product feed
out of full
hopper

Degassing 排气

喂满后落料

Feed zone 喂料段

Melting zone 熔融段 Degassing
Zone排气段

Metering zone
with mixing head 计量区


The Co-Kneader. 捏合机

The Co-Kneader.
捏合机
- L/D 15-20, screw diameter up to 140 mm, rotating screw is also axially moving
长径比15-20 ，螺杆直径可达140mm，螺杆旋转的同时可以轴向移动
- instead of the single screw extruder, the co-kneader allows a very good but gentle mixing effect
不同于单螺杆挤出，捏合机的混炼效果很好，而且比较平缓
- suitable for powder coatings, PVC, Carbon Black Masterbatches (sensitive products),
elastomers
适用于粉末涂料，PVC，碳黑母粒(敏感性产品)，弹性体等
- limited throughput, broad residence time distribution, only variable speed drives
产量有限，停留时间长，只可以变速驱动

quantec20.avi


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.
同向啮合双螺杆挤出机
- L/D 24-56 (widely adjustable), screw diameters up to 380mm, screw speeds up to 1800 rpm
长径比24-56 （可调节范围宽），螺杆直径最大可达380mm，螺杆转速可达1800rpm
- very high mixing effect due to the nature of the intermeshing system
由于自身的啮合性能，可以达到很好的混炼效果

- suitable for almost all products, except hard PVC
可适用于除硬质PVC外的绝大多数产品


The Co-rotating intermeshing twinscrew.
同向啮合双螺杆挤出机
- both screw and barrels are modular and can be widely adjusted.
螺杆，筒体都是积木式设计，可调节选用范围广
- Residence time and shear can be adjusted according to the product
根据物料要求可适当调节停留时间和剪切力
- very narrow residence time distribution
很短的停留时间调节范围


The Co-rotating intermeshing twinscrew.
同向啮合双螺杆挤出机
- due to the intermeshing the product is continiously transferred from one screw to the other
由于同向啮合，物料连续的从一根螺杆输送到另一根螺杆
- one screw is cleaning the other therefore the machine has a very good self cleanig effect.
由于两根螺杆相互清洁，使机器具有良好的自清洁性
- mixing happens in the crosssection and within special mixing elements (kneading blocks etc.)
特殊的混炼元件（啮合块等）在相互交错的时候产生剪切效果。
- due to the co-rotating, the occuring forces balance themselves, high screw speeds are possible
由于同向啮合，产生的力自平衡，使较高的螺杆转速成为可能

Working principle


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

- good axial mixing
良好的轴向混炼
- low feeding efficency and low pressure build up capability
较低的喂料和建压能力
- axial open system 轴向开放系统

Working principle
工作原理