BOPP 2015 Presentation

Flame Treatment Technology and its

applications Stefano Mancinelli

esseCI srl Sales & Process Manager

esse CIflame treaters®

BOPP FILM 2015 - Berlin – June 24th., 2015

Ø  Located in Italy (1 hour from Rome).

Ø  Established in 1969.

Ø  1972 - 1st Flame Treater for BOPP

Ø  1984 - 1st Flame Treater for automotive industry

Ø About 1000 installations in 48 Countries

Ø Pilot line with a top speed of 1000 MPM

esseCI srl


FLAME CHEMISTRY AND OXIDATION MECHANISM.

COMPARISON WITH CORONA TREATMENT


FLAME CHEMISTRY

Chain/Radical reactions:

�  M ⇒ R ; Initiating step – k1

�  R+M ⇒ αR+M’ ; Chain Branching – k2

�  R+M ⇒ R+P ; Propagating step – k3

�  R+M ⇒ P’ ;Terminating/Production – k4

�  R ⇒ P’’ ; Wall destruction – k5

M = reactants; P,P',P"= reaction products

Multiplication factor αcrit = 1 + [(k4 + k5) / k2]


H2 – O2 COMBUSTION SYSTEM

Chain Branching ⇒ RADICAL POOL

H• +O2 ⇒ •OH+O•

•OH+H2 ⇒ H• +H2O

O• +H2 ⇒ •OH+H•

O• +H2O ⇒ 2 •OH


PP SURFACE FLAME OXIDATION MECHANISM �  C-H link breaking vs. C-C link breaking;

�  OH > O > H >> HO2

RH+OH ⇒ R°+H2O; Initiating step

RH+H ⇒ R°+H2

R°+OH ⇒ ROH;

R°+HO2 ⇒ ROOH; Propagating step

R°+O2 ⇒ ROO;

R°+H2O2 ⇒ ROO+OH

R°+O ⇒ RO

R°+H ⇒ RH; Terminating step


CH3 CH3 PP SURFACE CH2-CH-CH2-CH-CH2

CH3 CH3

CH2-C-CH2-CH-CH2

CH2-C-CH2-C-CH2

CH3 CH3

OOH

OXYGEN

CORONA TREATMENT

CHEMICAL COMPOSITION OF A CORONA TREATED SURFACE


CHEMICAL COMPOSITION OF CORONA TREATED SURFACES

CH2-C-CH2-C-CH2

CH3 CH3

OOH

β-scission reaction

CH2-C

OOH

CH3

O ⇒ alkoxy radicals RO° ⇒ LMWOM

Low molecular weight

C-OH

C=O

C=O O


What is staining ? oxygen level vs Power

0

2

4

6

8

10

12

14

0 5 10 15 20 25 30 35 40

Power density (Wmin/m²)

Oxyg

en le

vel %

Threshold for formation of LMWOM in litterature = 8,3 Wmin/m²

Anchored oxygen level = 4,8%

Threshold for formation of LMWOM= 9,8 Wmin/m²

CORONA TREATMENT SURFACE OXIDATION


PP SURFACE FLAME OXIDATION MECHANISM

�  O/C RATIO �  IMWOM vs. LMWOM

INCREASED SURFACE ENERGY

�  Delamination

�  “Aging” behaviour

�  Metallizing barrier effect & Metal Bond Strength

�  Printing applications


FLAME vs. CORONA SURFACE ADHESION

CORONA TREATED – SLOW PEELING FLAME TREATED – SLOW PEELING

CORONA TREATED – FAST PEELING FLAME TREATED – FAST PEELING


CORONA TREATED FLAME TREATED



CORONA TREATED

FLAME TREATED


FLAME TREATMENT SYSTEM COMPONENTS AND LAST DEVELOPMENTS


s.r.l.Societa' Costruzioni IndustrialiesseCI

The information shown on this drawing is confidential and must not be copied reproduced or comunicatedto a third party wholly or in part without Our written consent

MaterialeMaterial

Customer/JobCliente/Comm.

Rugosità Gen.Roughness

FormFormato File

NameScalaScale Sheet

Foglio diof

DenominationDenominazione

ProgettoProject

Rev.DisegnatoreDrwg.

CheckContr.

DataDate

Toll.Gen

De Divitiis M.

Gioia A.A1

1:20

IT93.2

1 1

Drwg. No.Disegno Num.

FLAME TREATER LAYOUTFLAME TREATER PLANT

5553.LO.1.003.09.2013

BRUECKNER GSU / 5553

5553.lo.1.0.dft

A

Detail A1:10

B

Detail B1:10

180

170

100 ±0.2

39 +0.10

102±0.2

14

30.5±0.1

40

1.5

29 +0.2+0.1

97.9±0.12+0.2

+0.1

4.6

+0.2

+0.1

20 ±0.1

15.5

Burner 406 Type

FILM FLOW

8800BURNER FACE LENGTH = (+2x50mm SIDE PLATE)

9200ROLL FACE LENGTH =

2391

870.5±1

185

425

O600

O475

826 920

9690 ±2

9290

870.5

185

2036

650

660

100

9301184

650

1300

15

240 120

280

18

225

450 ±0.5

180

30

120

240

520

Num. 2+2 M20x40

Num. 2 Ø6H12

185±0.5

35

32.5

230

750

290

280

280

230

4785

4845

4785

4845

C.L.

280

370

290

280

1744

C

Detail C1:10

310141287

230

280

775

230

12°

OPERATOR SIDE

DRIVE SIDE

(*) Mixture InletFlange UNI DN 125

(*) Water OutletFlange UNI DN 50

(*) Water InletFlange UNI DN 50

By esse C.I. s.r.l.

By Customer

SUPPLY EXTENSION

(*) = COUNTER FLANGES INCLUDED

IN SELLERS SUPPLY

Exhaust Duct660x650x9000

824 920 200


s.r.l.Societa' Costruzioni IndustrialiesseCI

The information shown on this drawing is confidential and must not be copied reproduced or comunicatedto a third party wholly or in part without Our written consent

MaterialeMaterial

Customer/JobCliente/Comm.

Rugosità Gen.Roughness

FormFormato File

NameScalaScale Sheet

Foglio diof

DenominationDenominazione

ProgettoProject

Rev.DisegnatoreDrwg.

CheckContr.

DataDate

Toll.Gen

De Divitiis M.

Gioia A.A3

1:20

IT93.2

1 1

Drwg. No.Disegno Num.

TYPICAL FOR INSTALLATION

MIXTURE GENERATOR TYPE 036.900/1200

036.900/120008/04/2013

esse C.I. s.r.l.

036.900/1200.dft

100

2100

1000400 1000 600

2000

892 225

892 413

154586

464

Num. 2 Flanges

UNI DN40

Cooling Water

Inlet / Outlet

Flange

UNI DN125

Mixture OutletFlange

UNI DN50

Gas Inlet

Cable

InletCable

InletMixture Outlet

Optional


φ = EQUIVALENCE

RATIO

MIXTURE COMPOSITION

λ = LAMBDA =

= 1 / φ


λ = LAMBDA

(A/G)USED/(A/G)STOICHIOMETRIC

λ >1 mixture lean;

λ < 1 mixture rich;

λ = 1 mixture stoich.

JCS 122 Oxygen analyzer


FLAME TREATMENT TECHNOLOGY LAST DEVELOPMENTS


DDBS DIFFERENTIATED DOUBLE BURNER SYSTEM


WET & DRY PROCESS


esseCI enriched flame Process

�  Enriched flame;

�  Film surface enhanced in line, through a low cost process at industrial speeds, to deliver film with improved functionality;

�  Large food company is developing this technology together with esseCI.


Summarizing… �  Flame treatment technology can warrant higher quality

on film treated surfaces (higher surface energy and higher adhesion);

�  Flame particularly useful in treating films for tape and for metallization. Also used with good results on sealable and cavitated webs (but with necessary higher attention on process conditions);

�  Flame process has very high improvement potential;

�  Flame treatment system actually improved in its typical point of weakness and fully electronically and mechanically integrated in BMS lines;

�  Best 5 layers extrusion line, the one where you can produce and treat with best results all film types, should be also equipped with a flame treater (better if in bottom position).


THANK YOU FOR YOUR ATTENTION!

Stefano Mancinelli

Ph:+39.348.4912586

Mail: [email protected]

Linkedin link: http://lnkd.in/aZDsbu


BOPP 2015 Presentation

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