New Developments in Compounding Biomaterials · New Developments in Compounding Biomaterials 18 By...

New Developments in Compounding Biomaterials

Prof. Daniel SchwendemannDep. Head of IWKInstitute of Material Sciences and Plastics ProcessingUniversity of Applied Sciences Eastern Switzerland, Rapperswil

Content

IWK - Institute of Material Science and Plastics Processing

Overview of the Compounding systems

Process needs, machine requirements

New developments in Compounding

Feed Enhanced Technology

Feeding of Liquids

Injection Nozzles

Side Degassing

Project presentation “FluidSolids”

New Developments in Compounding Biomaterials2

Welcome to the Hochschule für Technik, RapperswilPart of the University of Applied Science Eastern Switzerland


Biomaterials / Biopolymers

Biomaterials:

Biopolymers as PLA, PHA (PHB), Starch, etc.

Biofibers/Biomass as Cellulose, Hemp, Flax, Woodfibers etc.

Material performance (concerning processing):

Shear sensitive -> low shear

Temperature degradable -> low temperature

Moisture sensible -> good degassing behavior

Processed in water -> high moisture content


Typical steps in plastics processing


RawMaterial

Material Handling

Compounding

InjectionMolding Testing

Compounding systems


+

Single screwextruders Twin screw extruders

Co-rotating counter-rotating

intermeshing

+ + + + + +

notintermeshing

Multiple screwextrudersBuss-Kneader

+

Bulk material handling

Bulk materials are solid goods, the behavior could vary between solid goods and liquids

solid bulk liquid


Bulk material handling


Bridgebuilding or flow problems in the hopper

Feed section design


Feed section: feed limitation

Wrong design

Bulk density0,25 g / dm³

Bulk density0,08 g / dm³

Extruder

FeederFilter bag

Filter bag

Specially fine powders arecatching a lot of additionalair in the feeding pipe.

feederFilter bag

Extruder

Filter bag

Correct design

Co-rotating Twin Screw Extruder / process section


𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝐿𝐿𝑃𝑃𝐿𝐿𝐿𝐿𝐿𝐿𝐿 =𝐿𝐿𝐷𝐷𝑎𝑎

Scale up – Influence of cooling and heating

Cooling or heating surface versus volume or throughput


Screw diameter in mm

Do

Dia

0.00

10.00

20.00

30.00

40.00

50.00

60.00

0

5

10

15

20

25

30

25 40 50 58 70 92

Area in sqm/40 D

Volume in l/40 D

Ratio l/sqm

Scale up factorbased on ZSK 25

𝐷𝐷𝐷𝐷𝑎𝑎𝐷𝐷𝑃𝑃𝐿𝐿𝑃𝑃𝑃𝑃 𝑅𝑅𝑎𝑎𝐿𝐿𝐷𝐷𝑃𝑃 =𝐷𝐷𝑎𝑎

𝐷𝐷𝐷𝐷

http://www.coperion.com/index.php?eID=tx_cms_showpic&file=fileadmin/images/Presse/111004_Ensinger/PM_2011-0281_Bild.JPG&md5=f792a782adfa0e97ec2bc883b99f593ba6273024&parameters%5B0%5D=YTo0OntzOjU6IndpZHRoIjtzOjU6IjEwMjRtIjtzOjY6ImhlaWdodCI7czo1OiIx&parameters%5B1%5D=MDI0bSI7czo3OiJib2R5VGFnIjtzOjg2OiI8Ym9keSBiZ2NvbG9yPSIjZmZmZmZm&parameters%5B2%5D=IiBsZWZ0bWFyZ2luPSIwIiB0b3BtYXJnaW49IjAiIG1hcmdpbndpZHRoPSIwIiBt&parameters%5B3%5D=YXJnaW5oZWlnaHQ9IjAiPiI7czo0OiJ3cmFwIjtzOjM1OiI8YSBocmVmPSJqYXZh&parameters%5B4%5D=c2NyaXB0OmNsb3NlKCk7Ij58PC9hPiI7fQ==

http://www.coperion.com/index.php?eID=tx_cms_showpic&file=fileadmin/images/Presse/111004_Ensinger/PM_2011-0281_Bild.JPG&md5=f792a782adfa0e97ec2bc883b99f593ba6273024&parameters%5B0%5D=YTo0OntzOjU6IndpZHRoIjtzOjU6IjEwMjRtIjtzOjY6ImhlaWdodCI7czo1OiIx&parameters%5B1%5D=MDI0bSI7czo3OiJib2R5VGFnIjtzOjg2OiI8Ym9keSBiZ2NvbG9yPSIjZmZmZmZm&parameters%5B2%5D=IiBsZWZ0bWFyZ2luPSIwIiB0b3BtYXJnaW49IjAiIG1hcmdpbndpZHRoPSIwIiBt&parameters%5B3%5D=YXJnaW5oZWlnaHQ9IjAiPiI7czo0OiJ3cmFwIjtzOjM1OiI8YSBocmVmPSJqYXZh&parameters%5B4%5D=c2NyaXB0OmNsb3NlKCk7Ij58PC9hPiI7fQ==

Feed Enhancement Technology

FET: Technology to increase the throughput of feed limited products

Solids conveying is improved byapplying vacuum in the feed zone toa wall section which is porous andpermeable to gas


This wall section is realized by an insert with a filter membrane installed in an open barrel.

FET Installation possibilities


ZSKZS

B

In the side feeder(ZS-B)

In the feed section of the ZSK

downstream of feeding point

In the feed sectionof the ZSK

upstream of the feeding point

FET can only be used for solids conveying!

FET Mechanism


vacuum Filter cake:compacted powder

FET insert

Effects:• air is removed higher bulk density• friction is changed in the area of insert

air

FET Mechanism


Friction and higher bulk densityincrease the conveying angle:

Conveying angle capacity

FET nicht aktiv

Angle of conveying approx. 20°

FET aktiv

Angle of conveying approx. 40°

Q = F * H * n * ε * η * γ

low

high

FET Mechanism


SEI can be reduced by:• increasing capacity at same screw speed• reducing screw speed at same capacity

Cap

acity

[kg/

h]

screw speed [min-1]

without FET

with FETSEI4 < SEI1

SEI4

SEI3

SEI2

SEI1

Biobased Materials processed with water


BiobasedMaterials

processes in water

Drying step

(Milling)

Powder Dosing

Com-pounding

BiobasedMaterials

processes in water

Dosing Liquids

Com-pounding

with a high amoumt of

water

Drying step

(Milling)

Steps in material preparation for the compounding process

Challenges with water based fillers


By adding Filler and water into the extruder, the water evaporates and cools the polymer down.

Energy input is needed, that the aggregate state of the polymer doesn’t change. Polymer should not “freeze”

(Energy input caused by conveying or mixing is not calculated.)

End productExtruder

Polymer

X%

Filler+ H2O

Water Vapor

HeatingCapacity

Compounding water based Fillers/Fibers


A calculation toolInput

Final Product3.5% Fiber + H2O melted

PolymerFiber+H2O Fiber H2O Polymer Compound Unit

Quantity 100 3.5 96.5 5.00 NFC %Density ρ 1.2 kg/dm3Volumetric Flow V 3.76 l/h

Mass Flow m4.51 0.16 4.35 3.00 3.16 kg/h

0.00125 0.00004 0.00121 0.00083 0.00088 kg/sRoom Temperature T1 20 20 20 20 °COperating Temperature T2 200 200 100 200 °CMelting Point Ts 150-160 °CEnthalpie (20°C to 100°C) Δh 2591000 J/kg

Specific Heat Capacity cp 4092.78 1550 4185 1200 J/kgK

Heat Flows of: Result UnitHeating Capacity Hh 3549.94 WPolylactide Hp 180.00 WInput NFC+H2O Hin 0.00 WOutput Water Vapor Hw 3537.70 WEnd product Hpnfc 192.24 WTemperature Endproduct t 200.00 °C

Compounding water based Fillers/Fibers


0

500

1000

1500

2000

2500

3000

3500

4000

0 5 10 15 20 25

Hea

t Cap

acity

[W]

Quantity Fibrous Material in Input [%]

Needed Heat Capacity for Fibrous-Suspension

end product 1% NFC, mp=3kg/h



Injection Nozzle Technology

Injection Nozzle


the spring load must be adjusted according to the extruder pressure to prevent entering of melt

spring preload

pump pressure

extruderpressure

spring preload

extruderpressure ≤

for opening, the pump pressure must be bigger than the spring preload

spring preload ≤ pump

pressure



liquid flow The lifting of the needle creates an annular gap.

Only a small axial movement of the needle is necessary to create the full crosssection area.



0

50

100

150

200

250

300

350

400

450

500

0 10 20 30 40 50 60 70 80

Pressure [bar]

Thro

ughp

ut [k

g/h]

1/ 1 mm; Water

2/ 2mm; Water3/ 3mm;Water

4/ 1mm; Oil

5/ 2mm;Oil6/ 3 mm Oil

7/ 1,7mm;Oil

8/ 1,7mm;Oil+SpringsLoads

Characteristics for throughput

Problem Lab-Scale!!!

Degassing of the process section / Side Degassing Unit


Picture Coperion

Venting Port

Project «FluidSolids»

Process optimization Compounding

Goals

Analysis of the current process Optimization of system configuration

(screw design, position of feeding, process parameters, …)

Operating tests

Partners

FluidSolids AG, Zürich

Funding

Public and Private

25New Developments in Compounding Biomaterials


Project: FluidSolids® - Impressions

Project: FluidSolids®


Project: «FluidSolids®»


Umweltpreis der Schweiz 2016

Environmental Award of Switzerland 2016



Summer 2016New CompoundingPlant starts in Switzerland



Extrusion trials at the IWK Lab

Thank you very much for yourattention!

Prof. Daniel SchwendemannIWK Compounding/ExtrusionUniversity of Applied Sciences Eastern [email protected]+41 55 222 4916

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