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| Introduction | |
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| Historical Development of the Co-Rotating Twin Screw | |
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| Introduction | |
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| Early Developments | |
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| Basic Geometry | |
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| Basic Patents | |
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| Basic Patent of the Threaded Screw | |
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| Basic Patent for Kneading Discs, DBP [16], USP [17], DBP [20] | |
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| Basic Patent for Modular Design | |
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| Pioneering Period | |
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| Machine Development | |
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| Use in Chemical Processes | |
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| Licensing | |
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| Recognition for R. Erdmenger | |
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| New High Viscosity Technology with Co-Rotating Extruders | |
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| Screw Machines in Process Engineering | |
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| Similarity Theory for Screw Machinery | |
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| Versatile High Viscosity Processes | |
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| Special Developments from Bayer-Hochviskostechnik (High Viscosity Technology Group) | |
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| Extended Kinematics, Profile Geometries | |
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| Clearance Strategies | |
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| Developments after Licensing | |
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| Developments after Expiration of the Primary Patents | |
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| Rheological Properties of Polymer Melts | |
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| Introduction and Motivation | |
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| Classification of Rheological Behavior of Solids and Fluids | |
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| Comparison of Viscous and Viscoelastic Fluids | |
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| Viscous Fluids | |
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| Viscoelastic Fluids | |
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| Temperature Dependence of Shear Viscosity | |
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| Temperature Dependence for Semi-Crystalline Polymers | |
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| Temperature Dependence for Amorphous Polymers | |
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| Influence of Molecular Parameters on Rheological Properties of Polymer Melts | |
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| Shear Flows | |
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| Flow Profiles of Pressure-Driven Pipe Flow | |
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| Flow Profiles of the Simple Drag Flow | |
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| Extensional Flows | |
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| General Overview of the Compounding Process: Tasks, Selected Applications, and Process Zones | |
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| Compounding Tasks and Requirements | |
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| Tasks and Design of the Processing Zones of a Compounding Extruder | |
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| Intake Zone | |
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| Plastification Zone | |
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| Melt Conveying Zone | |
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| Distributive Mixing Zone | |
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| Dispersive Mixing Zone | |
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| Devolatilization Zone | |
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| Pressure Build-Up Zone | |
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| Characteristic Process Parameters | |
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| Specific Energy Input | |
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| Residence Time Characteristics | |
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| Process Examples | |
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| Incorporation of Glass Fibers | |
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| Incorporation of Fillers | |
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| Production of Masterbatches | |
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| Premix Process | |
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| Split Feed Process | |
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| Color Matching | |
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| Coloring | |
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| Technical Trends in Compounding | |
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| Gear Element | |
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| Ring Extruder | |
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| TPE Production | |
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| ZSK-NT Technology | |
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| Injection Molding Compounder | |
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| Symbols and Abbreviations | |
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| Geometry of the Co-Rotating Extruders: Conveying, and Kneading Elements | |
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| Introduction | |
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| The Fully Wiped Profile from Arcs | |
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| Geometric Design of Closely Intermeshing Profiles | |
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| Dimensions of Screw Elements with Clearances | |
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| Transition between Different Numbers of Threads | |
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| Calculation of a Screw Profile for Production According to Longitudinal Offset | |
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| Conveying Characteristics of Different Geometries | |
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| Kneading Elements | |
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| Modeling: Possibilities and Limitations | |
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| The Motivation for Modeling | |
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| Screw Design | |
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| Modeling Approaches | |
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| Model Dimensions | |
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| Extruder: 0-Dimensional | |
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| Whole Extruder | |
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| Pumping Efficiency | |
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| Extruder Section | |
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| Extruder: 2-Dimensional | |
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| Extruder: 1-Dimensional | |
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| Extruder: 1-Dimensional, Extruder Section | |
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| Extruder: 1-Dimensional, Whole Extruder | |
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| Extruder: 3-Dimensional | |
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| Model Depths and Results | |
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| Extruder: 3-Dimensional, Fields | |
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| Extruder: 3-Dimensional, Scalar Values | |
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| Simulation: Possibilities and Limitations | |
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| Pressure Generation and Energy Input in the Melt | |
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| Operating States of Conveying Screw Elements | |
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| Dimensionless Representation with Descriptive Impact | |
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| Calculation of the Back-Pressure Length | |
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| Efficiency during Pressure Generation | |
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| Example for the Design of a Pressure Build-Up Zone | |
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| Feed Behavior with Shear Thinning | |
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| Computational Fluid Dynamics | |
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| Why Computational Fluid Dynamics? | |
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| Workflow of a Computational Fluid Dynamics Process | |
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| Pre-Processing | |
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| Flow Computation and Post-Processing | |
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| Computational Examples | |
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| Example 1 | |
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| Example 2 | |
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| Conclusion and Outlook | |
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| Mixing and Dispersing: Principles | |
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| Introduction | |
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| Distributive Mixing | |
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| Mixing in Laminar Flow | |
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| Axial Mixing and Residence Time Distribution | |
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| Dispersive Mixing | |
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| Dispersion of Solid Particles | |
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| Dispersion of Melts, Liquid Droplets, and Gas Bubbles | |
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| Types of Loads and Frequency of Loads in an Extruder | |
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| Determining the Mixing Quality | |
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| Parameters | |
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| Experimental Methods for Determining Mixing Quality and Residence Time Distribution | |
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| Degassing Polymer Melts with Co-Rotating Twin Screw Extruders | |
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| Requirements for Degassing | |
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| Function-Specific Design | |
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| Flash Vaporization | |
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| Multi-Stage Vacuum | |
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| Residual Degassing and Use of Stripping Agents | |
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| Process Set-Up and Design of Degassing Zones | |
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| Process Limits | |
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| Scale-Up | |
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| Process Examples | |
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| Devolatilization of Solvents from LLDPE Melt Solutions | |
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| Degassing Solvents from Synthetic Rubber (Styrene-Butadiene Compounds) | |
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| Degassing Vinyl Acetate from LDPE/EVA Copolymer | |
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| Degassing POM | |
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| Degassing PC | |
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| Degassing PES and PSU | |
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| Degassing ABS | |
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| Degassing Un-Dried PET | |
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| Conclusion | |
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| Simulation or Scale-Up - Alternatives for Extruder Layout? | |
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| Process Sections of the Compounding Extruder | |
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| Feed and Solid Conveying Section | |
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| Plastification and Homogenizing Sections | |
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| Devolatization and Discharge Sections | |
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| Computation Possibilities in the Melt Phase | |
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| Computation Possibilities for Discharge Parts | |
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| Scale-Up | |
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| Screw Elements for Co-Rotating, Closely Intermeshing, Twin-Screw Extruders | |
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| Design of the Screw Element | |
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| Combining Screw Elements | |
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| Screw Elements and How They Work | |
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| Conveying Elements | |
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| Kneading Elements | |
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| Backward-Pumping Elements | |
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| Mixing Elements | |
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| Special Elements | |
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| Overview of Patented Screw Elements | |
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| DE 813154, US 2670188 A | |
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| DE 19947967A1, EP 1121238 B1, WO 2000020188 A1 | |
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| US 1868671 A | |
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| DE 10207145 B4, EP 1476290 A1, US 20050152214 A1 | |
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| DE 940109 B, US 2814472 A | |
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| US 3717330 A, DE 2128468 A1 | |
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| DE 4118530 A1, EP 516936 B1, US 5338112 A | |
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| US 4131371 A | |
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| DE 3412258 A1, US 4824256 A | |
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| DE 1180718 B, US 3254367 A | |
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| US 3900187 A | |
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| US 3216706 A | |
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| EP 2131 A1 B2, JP 54072265 AA, US 4300839 A | |
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| DE 19718292 A1, EP 875356 A1, US 6048088 A | |
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| DE 4239220 A1 | |
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| DE 1529919 A, US 3288077 A | |
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| EP 330308 A1, US 5048971 A | |
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| US 6783270 B1, WO 2002009919 A2 | |
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| DE 10114727 B4, US 6974243 B2, WO 2002076707 A1 | |
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| DE 4329612 A1, EP 641640 B1, US 5573332 A | |
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| DE 19860256 A1, EP 1013402 A2, US 6179460 B1 | |
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| DE 4134026 A1, EP 537450 B1, US 5318358 A | |
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| DE 19706134 A1 | |
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| WO 1998013189 A1, US 6022133 A, EP 934151 A1 | |
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| WO 1999025537 A1, EP 1032492 A1 | |
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| US 6116770 A, EP 1035960 A1, WO 2000020189 A1 | |
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| DE 29901899 U1 | |
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| US 6170975 B1, WO 2000047393 A1 | |
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| DE 10150006 A1, EP 1434679 A1, US 7080935 B2 | |
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| DE 4202821 C2, US 5267788 A, WO 9314921 A1 | |
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| DE 3014643 A1, EP 37984 A1, US 4352568 A | |
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| DE 2611908 A1, US 4162854 A | |
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| WO 1995033608 A1, US 5487602 A, EP 764074 A1 | |
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| DE 102004010553 A1 | |
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| DE 4115591 A1, EP 513431 B1 | |
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| The ZSK Series and Applications in the Chemical Industry and for Renewable Raw Materials | |
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| Development of High Torques, Volumes and Screw Speeds | |
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| Torque-Limited and Volume-Limited Throughputs | |
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| Process-Dependent Energy Requirement | |
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| Throughput-Energy Diagram | |
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| High Torque for Glass Fiber Reinforcement of Plastics | |
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| High Torque for Film Extrusion of Non-Dried PET or PLA | |
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| Applications of Low Torques and High Volume Requirement | |
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| Chemical and Pharmaceutical Applications | |
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| Silicone Sealants | |
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| Pressure-Sensitive Adhesives | |
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| Ceramic Catalyst Carriers | |
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| Insulating Films | |
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| Battery Separator Films | |
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| Metal and Ceramic Mixtures | |
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| Pharmaceutical Mixtures | |
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| Applications for Renewable Raw Materials in the Plastic and Food Sectors | |
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| Composite Materials Made from Wood Fibers in Polyolefins | |
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| Biodegradable Materials Made from Thermoplastic Starch and Polylactic Acid | |
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| Extrusion Cooking of Cereals for Foodstuffs and Animal Feed | |
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| Applications in the Confectionery Industry | |
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| ZSK-NT the New Two-Stage Processing System for High Throughputs | |
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| Current Requirements for the Processing of Polyolefins | |
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| Two-stage Large-Scale Plants for the Processing of Bimodal Polyethylene | |
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| Quality Assessments for Bimodal Pipes | |
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| ZSK-NT Compared with the Standard Technology | |
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| Design of Pressure Build-Up Zones | |
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| Outlook | |
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| Notation | |
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| Material Selection for Twin Screw Extruder Components in Contact with Resin | |
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| Introduction | |
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| What is Wear? | |
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| Wear in Operating Experience | |
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| Choice of Materials for Extruder Barrel and Screw Elements | |
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| Materials for Extruder Barrel | |
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| Barrel Designs | |
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| Material Variations | |
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| Materials for Screw Elements | |
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| Designs | |
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| Material Variants | |
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| Drive Units for Co-Rotating Twin-Screw Extruders | |
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| Introduction | |
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| Drive Units for Small- to Medium-Size Co-Rotating Twin-Screw Extruders | |
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| Electric Motors | |
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| Drive Configuration | |
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| DC Drives | |
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| Power Converters | |
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| DC Motors | |
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| Asynchronous Drives | |
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| Frequency Converters | |
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| Asynchronous Motors | |
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| Network Feedback and EMC | |
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| Motor Monitoring | |
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| Torque Measurement | |
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| Torque Measurement for Extruder Protection | |
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| Torque Measurement for Scale-Up | |
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| Bearing Currents | |
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| Bearing Currents Caused by Asymmetry | |
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| Bearing Currents Caused by Common Mode Voltage | |
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| Bearing Currents Caused by Circular Flux | |
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| Avoidable Sources of Error | |
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| Corrective Measures | |
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| Drive Units for Large Co-Rotating Extruders | |
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| Drive Types | |
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| Medium Voltage Asynchronous Motor | |
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| Medium Voltage Synchronous Motors | |
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| Fixed-Speed Drives | |
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| Starting Aids | |
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| Direct on-Line Starting | |
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| Variable Speed Drives | |
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| Frequency Converters | |
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| Converter-Transformers | |
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| Emergency Running Properties | |
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| Safety Clutches | |
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| Slip Clutches | |
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| Mechanically Disengaging Clutches | |
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| Gearbox | |
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| Design | |
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| Gear Teeth | |
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| Bearing | |
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| Lubrication | |