compounding plants for the cable industry · 2015-11-18 · formulation changeovers. advantages of...

A Company of the

TROESTER Group

Compounding Plants for the Cable Industry

131011 X-COMP_RZ.indd 3131011 X-COMP_RZ.indd 3 11.10.2013 17:51:21 Uhr11.10.2013 17:51:21 Uhr

Continuous Cable Compound Processing

The cable industry requires more and more consistency,

reproducibility and consistent product cleanliness towards

the use of continuous compounding systems.

Since founding, X-Compound manufactured and continuously

developed suitable compounding plants for the processing of

any kind of wire & cable materials.

The major demands are

Accurate dosing >Perfect dispersion and homogeneity >Energy-saving process >Versatility >

Due to a high expertise X-Compound advanced to a market leader.

X-Compound supplied complete compounding plants to important

cable manufacturers.

The design and versatility of the process relevant parts allows a

smooth and intensive kneading and mixing as well as the accurate

control of the required process temperature profi les.

2


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Halogen-free Flame Retardant Compounds (HFFR)

HFFR Line

Flame retardant cable compounds are designed to have

reduced fl ammability in order to protect the operation

of the cable.

HFFR halogen-free cable compounds are the optimum solution

for a broad range of cables meeting IEC fi re test standards. Used

for both insulation and jacketing, HFFR halogen-free cable com-

pounds maximize value by providing superior process effi ciency.

Its innovative low-density formulation increases yield, lends to

minimizing waste and processes under lower extruder motor load.

Applications

Low price cables for buildings, ultrathin wires for >automobile up to military/aerospace cables

Advantages of the X-Compound Kneader Technology

Work in of high fi ller content up to 80% by a >split feed system

Special degassing system related to the kneader and >the product inlet zones to allow optimal fi ller-intake

Injection of coupling agent liquids into the melt >Accurate process temperature control to prevent >degradation of the fi llers. (e.g. ATH < 185°C)

High fl exibility for the processing of a large variety of >compounds with a unique screw profi le

H F F R 3


PVC CableCompounds

PVC Line

PVC cable compounds are divided into the categories

Insulation >Sheathing >Bedding >

For PVC compounding combined with the pelletizing system

X-Compound use the established cascade kneader design.

Requirements, such as homogeneous gelifi cation by controlling of

product temperature and/as well as dispersive distribution of the

fi llers and additives will implement superbly in the X-Compound

Kneader. Furthermore a large operation window can be covered

with a single screw confi guration, which is decisive for frequently

formulation changeovers.

Advantages of this two stage process are easily handling, fast

recipe changeovers and excellent self cleaning behavior.

X-Compound offers

Turn key projects >Hybrid (PVC/HFFR) compounder >

P V C

Line

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product temperature and/as well as d

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Kneader. Furthermore a large operat

with a single screw confi guration, wh

formulation changeovers.

Advantages of this two stage proces

recipe changeovers and excellent se

X-Compound offers

Turn key projects>Hybrid (PVC/HFFR) compounde>

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A signifi cant role in the cable industry is the use of PVC

insulation material. The market share is worldwide more than

70% of the cable sector.

PVC cables are mainly used in the low voltage segment

in applications as:

Telecommunications >Installations >Machinery and equipment >Automotive industry >Household >Communication- and >control cables

Semi conductive PVC cables >

4


Peroxide cross-linkable XLPE (PEX-A)

The peroxide cross-linkable XLPE compounds are applicable

for medium and high voltage cables.

The peroxide cross-linkable XLPE compounds have to fulfi ll

ex ceptional demands in cleanliness and quality to reach high

physical requirements on dielectric strength and lifetime.

The X-Compound inline process is designed as follows:

In the fi rst step the polymer with the additives (except >peroxide) have to be mixed to a homogeneous well

dispersed compound and fed through a high performance

fi lter system to assure the highest possible purity degree.

The second step contains the inline transport of the pure >polymer pellet into a specially designed mixing tumbling

machine which incorporates the peroxide mist over a

controlled time period.

The process as described allows the production of

super clean material on high throughput rates.

Cross-linkable PE Compounds (XLPE)

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Cross-linkable PE Compounds (XLPE)

SilaneXLPE Line

Silane cross-linkable XLPE (PEX-B)

Silane grafted (Sioplas) cross-linkable Polyethylene (XLPE)

compounds are suitable for the use in the manufacture of low

voltage as well as medium voltage cables up to 33 kV.

Independent steps:

1. Preparation of the grafted polymer

2. Cable extrusion with addition of catalyst masterbatch (~5%).

Both compounds are produced on the X-Compound Kneader.

Due to economic reasons it is recommendable to buy the catalyst

masterbatch from specialised manufacturing companies.

The X-Compound kneader technology is perfectly capable to

process any kind of grafted polymer compounds. The crosslinking

process is worldwide established.

The process to produce grafted polymers can be implemented

on a relatively short process length maintaining optimal mixing

(dispersion) and grafting results. The same proven technique is

also suitable to process fl ame retardant compounds.

Advantages of the X-Compound Kneader

Direct injection of silane into the polymer melt >Minimum material deposits inside the process area due to >the self cleaning kneader principle

Perfect mixing behavior allows reduction of silane quantity >Reproducible grafting reaction >

LV, MV

X L P E I n s u l a t i o n6


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Semi Conductive Compounds

One of the key components in power cables are

semi conductive compounds.

The main task on the manufacturing of semi conductive com-

pounds is the perfect incorporation of high structure carbon

black into the polymer matrix. In order to keep the required

conductivity it is of importance to prevent any damage of the

carbon black structure.

The X-Compound Kneader is well adapted to requirements

as homogenizing and dispersing (break up of agglomerates),

wetting and distributing of pigments, additives and fi llers into

the polymer matrix.

Advantages of the X-Compound Kneader Technology

Uniform mixing and distribution of high structure carbon >black

Split feeding of conductive carbon black which permits >high level of fi ller loading and minimize the critical formation

of agglomerates

Precise temperature control to prevent degradation of the >heat sensitive polymers

Smooth mixing process to avoid damage of the fi ller >chain structure

Semicon Line

X L P E S e m i c o n 7


Special Applications

Speciality grades, and value added compounds are designated to

make use of the specifi c features of the X-Compound Kneader

technology.

The controlled shear effect of the X-Compound Kneader is the key

to produce any kind of speciality compounds.

Following Specialty Compounds Requiring

the X-Compound Kneader Technology

EPDM/EPR elastomer cable compounds >Irradiated, cross-linked compounds >Thermal resistant Silicone cable compounds >Tailor-made blends and alloys for specifi c mechanical and >chemical resistance

Additive blends used in the cable compounds >Cable compounds with grafted chemistry >

F U R T H E RA P P L I C A T I O N S8


Control Systems & Service

Control Systems

X-Compound designs and builds complete control systems with

visual displays for Turn key plants as well as for replacements or

supplements to existing plants. On request we also manufacture

less sophisticated control systems.

The application of existing peripheral plant components as well as

their incorporation via Profi bus network is also part of our standard

programme.

Basically our control systems are designed as follows: A PC based

Windows system which performs plant monitoring and controlling

together with a programmable logic controller (PLC). The process

and the plant are visualised using a series of on-screen pages and

allowing interactive display and modifi cation of current setpoint

values and alarms.

Service

X-Compound is your reliable partner for the supply of spare

parts covering oscillating single screw compounders of nominal

size up to 600 mm.

X-Compound offers

High quality, durable, and corrosion resistant >- kneading elements

- barrel liners

- kneading teeth

All spare parts, e.g. >- screw shafts

- worm shafts

- lubrication pumps

- process chamber sealing systems

- die plates

- pelletizing knife arms

Interchangeable kneader barrels completely refurbished >and guaranteed

Any individual part for gear boxes or complete >interchangeable gear boxes, all guaranteed

Our spare part service is well-known for

High quality >Low prices >Short delivery times >

C O N T R O L S Y S T E M S& S E R V I C E 9


Technical Data

Process DataHFFR Semicon XLPE

SilaneXLPE

peroxideBlack

Jacketing

PVCInsulation/sheathing/bedding

Process length [L/D]

Spec. energy [kWh/kg]

CK 45

CK 90

CK 120

CK 150

CK 200

16 - 22

0,07 - 0,12

20 - 40

300 - 600

450 - 800

800 - 1500

1500 - 2800

18 - 24

0,15 - 0,25

40 - 70

350 - 700

500 - 900

900 - 1600

1800 - 3000

12 - 16

0,2 - 0,3

40 - 80

500 - 800

600 - 1000

1000 - 1500

1700 - 2200

12

0,12 - 0,16

40 - 60

500 - 800

800 - 1200

1400 - 1900

2000 - 2800

12

0,15 - 0,25

40 - 80

500 - 800

600 - 1000

900 - 1600

1800 - 3000

12

0,06 - 0,08

70 - 110

700 - 1400

1000 - 1800

2500 - 3500

3500 - 5500

Technical Data

Type

CK 45

CK 90

CK 120

CK 150

CK 200

mm

45

98

120

150

200

L/D

8 - 24

8 - 24

8 - 24

8 - 24

8 - 24

rpm

500

500

500

500

500

mm

55

140/150

160

200

250

L/D

6

6

6

6

6

kW

15

75

80

150

300

kW

30

250

350

650

1200

Screwdiameter

Processlength

Speedmax.

Processlength

Max. drivepower

Max. drivepower

Discharge UnitX-Compound Kneader

Screwdiameter

Subject to change without notice.

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X-COMPOUND 2013/10 · 500 · E (U) © TROESTER GmbH & Co. KG 2013. Only the contract between the customer and X-COMPOUND is binding for any guarantees and commitments. The particulars given herein do not represent promises of any special characteristics. They serve purely for general information pur poses and may differ in individual cases. No claims of any nature may be derived herefrom. The observation of commercial trade marks or patents shall in every instance be the responsibility of the customer.

TROESTER Machinery(Shanghai) Co., Ltd.Workshop No. 1, Area CNo. 6999 Chuan’sha Road, PudongShanghai 201202, PR CHINAPhone +86-21-58598308Fax +86-21-58598310E-mail [email protected]

X-Compound GmbHHardmatt 932CH -5082 Kaisten, SwitzerlandPhone +41-62-869 10 30Fax +41-62-874 32 08E-mail [email protected]

TROESTER Machinery, Ltd.300 Loomis AvenueCuyahoga Falls, Ohio 44221, USAPhone +1-330-928-7790Fax +1-330-928-7239E-mail [email protected]

TROESTER MoscowRepresentation Office2nd Sinichkina St. 9A, Bldg 3Moscow, 111020, RUSSIAPhone +79169280672E-mail [email protected]

TROESTER GmbH & Co. KGAm Brabrinke 1-430519 Hannover, GERMANYPhone +49-511-87040Fax +49-511-864028E-mail [email protected]


compounding plants for the cable industry · 2015-11-18 · formulation changeovers. advantages of...

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