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PROCESSING TECHNOLOGY Processing of Polymer Melts Made in Germany

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  • Processing technology

    Processing of Polymer MeltsMade in germany

  • welcoMe to gneussIt´s good that you´re here

    2 | The company

    With more than 30 years of experience and over 60 international patents, the family-owned and

    operated company Gneuss has made a name for itself as a supplier of innovative solutions for the

    plastics processing industry. The optimization of extrusion processes with numerous innovative

    developments: this is our focus with regard to Processing Technology.

    Business areas

    Based in Bad Oeynhausen, Germany, Gneuss is

    committed to the expectations of products

    “made in Germany” while serving its customers

    worldwide.

    With its daughter company in the USA, offices in

    Brazil and China, a cooperation partner in Japan

    and together with representatives worldwide,

    Gneuss is present throughout the world. The

    best possible technical support, excellent service

    and spare parts availability is provided on all five

    continents. Support is available around the clock

    via a telephone service hotline. Pilot lines for trials

    and development work are available at several

    locations.

    Filtration TechnologyProcessing Technology Measurement Technology

  • content

    Modular Processing Technology

    With its modular design, Gneuss Processing Technology combines the individu-

    al Gneuss product elements for economic, high quality and high performance

    production processes in the most diverse areas of plastics processing and their

    manufacture.

    MRS Extrusion Concept

    The patented MRS Multi Rotation System offers completely new possibilities with

    regard to the efficient degassing and extrusion of polymer melts. Additionally,

    this system also offers excellent dispersion performance for the introduction of

    gases and / or all forms of additives.

    Rotary Filtration Systems

    The patented Gneuss Rotary Filtration Systems enable fully automatic, process and

    pressure constant filtration. The main characteristic of these Filtration Systems is the

    Rotary Disk with its ring of screen cavities, rotating between two solid steel blocks.

    Online Viscometer VIS

    The Online Viscometer VIS provides reliable and accurate measurement of the

    melt viscosity according to DIN 53014 guidelines. The unit operates without

    material loss. It is simple to operate and cleaning of the capillary can be carried

    out without any influence on the production process.

    Vacuum Technology

    The standard vacuum systems operate with a simple and robust water ring pump

    with a standard vacuum level of down to 25 mbar. Systems for vacuum levels

    down to 1 mbar can be supplied. The gas and particle separation is simple and

    environmentally friendly.

    Control System Technology

    The use of patented measurement and control technology permits Gneuss to

    simplify extrusion processes while at the same time increasing their reliability.

    Application Case Examples

    The performance offered by Gneuss Processing Technology is already well pro-

    ven. These advantages are described by means of case examples from PET sheet,

    bottle-to-bottle-recycling and fiber production as well as PE and PP recycling.

    Content | 3

    Page 4

    Page 6

    Page 10

    Page 12

    Page 14

    Page 16

    Page 18

  • eXtrusion technologyExtrusion line with MRS Technology

    The extensive range of Gneuss technologies and products is designed specifically so that modu-

    les can be combined, resulting in a high performance extrusion line for the manufacture of high

    quality products.

    Gneuss Filtration System

    Process-constant, pressure and

    fully automatic melt filtration.

    g Page 10

    Gneuss Online Viscometer

    High precision, online and real time

    monitoring of polymer properties.

    g Page 12

    Gneuss Melt Pressure

    and Melt Temperature Sensors

    Accurate measurement and monitoring of

    melt pressure and temperature.

    g Page 13

    4 | Processing Technology

  • Gneuss MRS Technology

    Unique Multi Rotation System for

    polymer melt devolatilization (venting)

    during extrusion and compounding.

    g Page 6

    Gneuss Control Technology

    Central control system for all

    line components.

    g Page 16

    Gneuss Vacuum Technology

    Rugged system for efficient

    extraction of volatiles from the

    polymer melt.

    g Page 14

    Processing Technology | 5

    Gneuss Pressure Overload Protection

    g Page 17

    Typical Applications:

    • Pellets (e.g. recycling)

    • Bottle to bottle recycling

    • Thermoforming sheet

    • Monofilaments

    • Staple fiber

    • Textile yarns

    • Technical yarns

    • Nonwovens

    • Strapping tape

  • 6 | MRS Extruder

    DesignMrs eXtruder

    The polymer melt is delivered into a large single

    screw drum. The drum contains 8 small extruder

    barrels, parallel to the main screw axis. Installed

    in these small extruder barrels are the „satellite“

    screws, which are driven by a ring gear in the main

    barrel.

    The satellite screws rotate in the opposite direction

    to the main screw while they rotate around the

    screw axis.

    This disproportionately increases the surface area

    exchange of the polymer melt. The extruder barrels

    which are cut into the drum of the Multi Rotation

    System are approximately 30% open to ensure the

    optimum melt transfer into the barrels, so that the

    devolatilization can take place without restrictions.

    Further, precise control of the melt temperature is

    possible as the temperatures of all the surfaces in

    contact with the melt can be controlled accurately.

  • MRS Extruder | 7

    Transition of single screw to Multi Rotation Section

    Multi Rotation Section

    Transition of Multi Rotation Section to Discharge Screw

  • 8 | MRS Extruder

    High Performance DevolatilizationMrs eXtruder

    Thanks to its Multi Rotation Element, the

    surface area – and the surface area exchange

    rate – available for devolatilization are far

    greater than in other extrusion systems

    available on the market. The surface area of

    the steel parts in contact with the melt is

    exchanged at a rate of more than 25 times

    greater than with a co-rotating twin screw

    extruder. Due to the opposite rotation

    direction and high speed of the satellite

    screws, the polymer surface area is increased

    by a factor of 100 compared to a single screw

    extruder and a factor of 40 compared to a twin

    screw extruder. The devolatilizing

    performance of the MRS extruder

    can be summarized as follows:

    MRS-Extruder

    * These values were calculated on the following basis: Throughput rate = 1000 kg / h

    Residual moisture level = 10 000 ppm

    Vacuum = 25 mbar

    MRS section = 800 m³ / h*

    Twin screw = 20 m³ / h*

    Single screw = 8 m³ / h*

    Ss

    Ts

    MRS Technology Devolatilization Performance

    MRSExtruder

    Twinscrewextruder

    Singlescrewextruder

    Multiple screw extruder

    Planetaryextruder

    Important differences between the Gneuss MRS system and other screw concepts:

  • technical data Mrs*

    MRS 35 MRS 50 MRS 70 MRS 90 MRS 110 MRS 130 MRS 160 MRS 200

    Length of the processing section L/D 38 38 38 38 38 38 42 42

    Screw diameter Ø mm 35 50 70 90 110 130 160 200

    Extrusion drum Ø mm 64 95 130 160 190 225 265 320

    Drive rating kW 18 41 105 165 235 335 520 860

    Max. screw speed (rpm) 220 210 165 135 120 110 90 75

    Extrusion height H mm 1000 1000 1150 1150 1300 1300 1450 1450

    Length L mm 2750 2800 3850 4800 5700 6700 10000 12150

    Width B mm 750 850 1080 1400 1475 1600 1750 2150

    Weight approx. kg 1400 2900 4000 6000 6500 9100 13500 16500

    Throughput rate in kg/h

    PET 35 80 180 400 600 1000 1400 2000

    PP + PE 25 60 130 300 450 750 1000 1600

    PA 28 70 160 360 560 880 1200 1900

    Technical dataMrs eXtruder

    B

    H

    L

    MRS Extruder | 9

    * Standard values. Specific variations and individual configurations of the components are possible.

    Subject to modifications.

  • 10 | Filtration Systems

    rotary filtration systeMsConstant. Guaranteed.

    Filtration is the key to ensuring quality and cost efficiency not only in recycling applications.

    Rotary Filtration Systems from Gneuss represent the ideal solution, thanks to their continuous

    and pressure-constant operation.

    • Fully-automatic mode of operation

    (with integrated self-cleaning for RSFgenius)

    • Constant melt pressure, temperature, viscosity

    and throughput

    • Guaranteed melt purity and quality, short dwell

    time of the melt

    • Simple and safe screen changes, low filtration costs

    • Compact size and minimal installation effort

    • Rheologically optimized flow channel

    • Minimal backflushing losses with self-cleaning

    RSFgenius model

    The advantages of Rotary Filtration Systems

    Overview of Gneuss Melt Filtration Systems

    The lines below the Rotary Disks show the pressure curves in operation.

  • Filtration Systems | 11

    The control system reacts to this pressure

    increase and makes the filter disk index by 1-2

    angular degrees. Thus, contaminated screen area

    is continuously moved out of the melt channel

    and clean screen area is moved into the melt

    channel without changing the active filter area.

    Due to this mode of operation, the filtration system

    operates process- and pressure-constantly. The

    variation of the pressure differential across the filter

    ( p) amounts to max. 2 bar.

    The Rotary Filtration System explainedExample: RSFgenius

    • A high pressure, sequential back flushing

    systems cleans the contaminated screen

    packs before they re-enter the melt channel.

    • Polymer from the clean (filtered) side of the

    screen changer is siphoned into a hydraulically

    operated piston that shot with 30 to 80 bar

    across the filter element (in the reverse direction).

    • Only one small segment (approx. 1 % of

    the filtration area) is cleaned at a time,

    with a defined, high pressure impulse.

    The self-cleaning (backflushing) system

    Rotary Filtration Systems consist of three main

    parts – an inlet block, an outlet block and a filter

    disk rotating between them. The system is sealed

    by a metal to metal sealing with very narrow gaps

    as well as very hard and flat surfaces. It is guaran-

    teed that all components in contact with melt are

    not in contact with the environment (e. g. oxygen).

    The screen elements are located in a ring pattern

    on the filter disk, moving through the melt

    channel. When melt flows through the screen,

    hard particles get caught and the differential

    pressure increases slightly.

    Safety cover

    Junction box

    Back-flush piston

    Filter block

    Melt channel

    Melt discharge opening

    Hatch door forscreen change

    Screen

    Filter disk

    Drive

  • online ViscoMeter VisReliable and accurate viscosity measurement

    12 | VIS

    Measuring capillariesMain melt flow

    Gear pump

    Temperature sensor Pressure transducers

    Bypass

    The Gneuss Online Viscometer offers precise

    measurements of those polymer properties

    which have a decisive influence on the product

    quality. The measured viscosity is in direct

    relationship to the physical properties of the

    material such as tensile strength and impact

    resistance. Quality assurance can be improved

    through the monitoring and recording of this

    data.

    By means of a high precision metering gear

    pump, a small part of the polymer melt is

    separated from the main melt channel. This is

    pumped through a precisely manufactured slot

    capillary.

  • VIS | 13

    Pressure Transducer

    Melt Pressure transducers used in plastics proces-

    sing operate using the principle of a medium to

    transfer the pressure from the hot environment to

    the sensitive measurement electronics. A dia-

    phragm in contact with the polymer melt deforms

    due to the melt pressure. This deformation forces

    a liquid in a capillary to transfer the pressure to a

    second diaphragm, equipped with a Wheatstone

    bridge sensor, which translates deformation into

    an electric signal. The liquid medium in the capil-

    lary is typically mercury; however the use of these

    sensors in the manufacture of food packaging is

    not permitted. The Gneuss sensors on the other

    Melt Temperature Sensor

    The Gneuss TF range of Melt Temperature Sen-

    sors is ideal for the exact measurement of highly

    sensitive media. The ceramic insulation guarantees

    a direct measurement of the melt temperature at

    all times, independent of the temperature of the

    surrounding steel components, such as a flange

    barrel or die.

    Ceramic insulation

    Galvanically isolated thermocouple

    hand use a non-mercury liquid. Through the

    replacement of mercury with an environmentally

    safe substitute medium, melt pressure measu-

    rements with

    the required

    accuracy can

    be obtained

    in all applica-

    tions, including

    in the area of

    food contact

    packaging

    materials.

    Both the melt temperature and the melt pressure

    (measurement in 2 positions) are monitored. Based

    on internal calculations, the Online Viscometer

    calculates a value for the representative shear rate

    and the corresponding representative viscosity.

    The depth of the capillary slot is specified accor-

    ding to the material properties within a range of

    0.5 to 2.0 mm. The unit is supplied complete with

    a precision metering pump, its drive, melt pressu-

    re transducers, melt temperature sensor, heater

    elements and the complete evaluation and control

    software and hardware package. The control

    elements can of course also be integrated into a

    process control system.

  • 14 | Vacuum

    VacuuM technology

    The vacuum system is the key to the whole devola-

    tilization process. Not only is it important to create

    a vacuum – the separation of solid particles from

    the volatiles which are extracted from the material

    presents a particular challenge. Many extruders

    require an absolute pressure of < 5 mbar, using dry

    vane vacuum pumps.

    During the devolatilization of polymers, it is ine-

    vitable that monomers, oligomers and other solid

    particles or sublimates are sucked out. If these

    enter the pump, they will drastically reduce its ope-

    rating life and for this reason, separating systems

    are needed which under tough industrial operating

    conditions are extremely maintenance intensive.

    Advantages of the MRS vacuum system:

    • Handles liquids, vapor and solid particles

    • Isothermal compression

    (no contamination during condensation)

    • Oil free compression

    (no contamination during condensation)

    • Simple design with water ring pump and

    belt filter

    • Robust and not sensitive to blocking of

    suction and pressure pipes

    • Standard vacuum level of 25 mbar

    (Water ring pump technology),

    special solutions for 1mbar

    Thanks to its extremely high surface area exchange

    rate, the MRS extruder can in most cases provide

    excellent devolatilization with a vacuum of only

    30 mbar. This permits the use of much simpler

    and less sensitive water ring pumps which create a

    vacuum using a rotating impeller, mounted eccen-

    trically to the liquid ring.

    The liquid in circulation can be passed over a belt

    filter under atmospheric conditions. In this way,

    the maintenance of the system can be reduced to

    an absolute minimum.

    The circulating fluid is heated through the process.

    In order to avoid an increase in the steam pressure,

    the liquid is pumped through a heat exchanger

    where it is kept at a steady temperature of around

    10°C. The intelligent design permits simple

    cleaning of the heat exchanger while the system is

    operating.

    High efficiency devolatilization

    Suction inlet Pressure outlet

    Liquid ring

  • Vacuum | 15

    The rugged VAC vacuum system for devolatilization during polymer extrusion

    Even sticky monomers and oligomers and hard contaminants do not endanger the performance

    of the vacuum system, thanks to the combination of a water ring pump and a belt filter.

    Pressure connection

    Filterbelt

    Vacuum control valve

    Water ring pump

    Suction from extruder Drive

    Heat exchanger

  • The control system is a key element in any extrusion line. Today, a control system is expected to

    link all the line components together in an efficient and operator friendly central system.

    16 | Control

    control technologyThe MRS control system

    Gneuss developed the MRS control system in order

    to take effective advantage of all the measurement

    data and set points provided. The various line com-

    ponents are linked together by the control system

    to a central operating system. Changes in the pro-

    cess are identified immediately and if necessary, can

    be corrected. The production data is stored for later

    diagnosis or documentation and is processed by

    the control system to trends with history function.

    Most extruder operators will find that working with

    the lean, user- friendly operating system is intuitive

    with little need for explanation. Only a few clicks

    on the touchscreen monitor are necessary to get

    the line into production.

    The standard control system hard- and software

    supports the following line components:

    • Heater controls for the complete line

    • Extruder drive

    • Melt pump drive

    • All melt pressure measurements

    • Vacuum system

    • Online Viscometer

    • Rotary Melt Filtration System

    • Dosing

    • Pelletizer

  • Control | 17

    The individual integration of the interfaces and

    Bus systems permits the communication of control

    systems from various suppliers. The data transfer

    within the MRS control system is divided into 3

    Bus systems.

    The measurements on the extruder are gathered

    centrally and are transferred to the PLC via CanBus

    or Profibus. In this way, only two data cables

    are necessary, instead of the conventional cable

    bundle.

    This technology keeps the level of installation and

    maintenance to a minimum. The communication

    within the control cabinet is handled by the Profi-

    bus DP protocol.

    The MRS can be supplied with a telemaintenance

    facility via the internet. The telemaintenance client

    is integrated in the customer network and when

    required, connects with the Gneuss server. In this

    way, the security of the customer’s network is

    protected.

    • Designed according to EN1114 -1

    • Two redundant sensors 4…20 mA, to

    which the same pressure is applied

    • Two safety-related analogue inputs

    • Self-monitoring

    • Two safety-related relay outputs, the

    emergency stop of the unit

    • 4...20 mA signal for pressure evaluation

    • Optional Bus interface

    Gneuss Solution:

    Safety System EPM

    Protection against Over Pressure for Extrusion Lines

    Throughout the world, the requirements on

    plastics processing and rubber machinery with

    regard to safety protection against over pressure

    are increasing.

    With Gneuss‘ safety system EPM, the use of

    stretch bolts, fail safe components, rupture discs

    or movement sensors can be avoided.

    Extruders, melt pumps or components which

    are under pressure can be protected against

    excess pressure by the EPM safety system, with a

    duplicated and monitored pressure measurement.

    The safety-relevant components of the monitoring

    system conform to EN ISO 13849 -1, with a perfor-

    mance level of “c”.

  • 18 | Sheet

    sheet ManufactureApplication case example

    MRS extruders are in use throughout the world

    on PET thermoforming sheet lines. A typical case

    example is a line for the processing of PET with the

    MRS 130 at a throughput rate of 1,000 kg/h. The

    main application of this line is the manufacture of

    sheet for subsequent thermoforming to containers

    for packaging fruit. The MRS extruder plasticizes

    and devolatizes the material, the RSFgenius filters

    Gneuss´ Processing Technology is already well proven worldwide. The energy intensive and

    therefore costly step of pre-drying and crystallization of the material can be eliminated, when

    manufacturing PET sheet for thermoforming with the MRS extruder.

    the material (at a fineness of 56 to 75 microns).

    The Online Viscometer VIS measures the viscosity

    immediately upstream of the die and controls the

    vacuum pump at the devolatilizing section of the

    extruder in order to maintain the viscosity within

    a narrow range. The quality of the sheet and also

    the sheet thickness are maintained at a consistent

    level.

    An MRS 110 extruder was supplied for a PET ther-

    moforming sheet line for packaging containers. It

    replaced a single screw extruder with pre-drying,

    saving 25 % of the footprint and 15 to 25 % of

    the energy due to the MRS not needing pre-dried

    or crystallized material. Additional benefits are the

    increased flexibility with regard to the raw material

    used, color changes etc. thanks to the elimination

    of pre-drying and crystallization.

    On this line, a mix of reground skeletal waste, bot-

    tle flake and virgin material is processed, with no

    pre-drying and with simple vacuum technology,

    without gas purification and without the corres-

    ponding high maintenance requirements.

    Analysis by the Fraunhofer Institute have shown

    that the MRS concept not only does an excellent

    job of devolatilizing with regard to extracting the

    moisture from PET, but it also removes harmful

    volatiles efficiently, for example from post

    consumer PET bottle flakes.

    The MRS extrusion concept is therefore able to

    process 100 % PET bottle flakes for products with

    food contact.

  • Bottle to Bottle recyclingApplication case example

    The MRS extruder processes PET bottle flake

    without drying or other pre-treatment directly into

    pellet or sheet. The polymer surface is rapidly and

    intensively renewed in the Multi Rotation System

    in the extruder, providing excellent decontamina-

    tion even with a moderate vacuum of 25 to 40

    mbar and with a limited, controlled IV drop. The

    material is processed gently so that the final pro-

    duct has a high quality with regard to the yellow

    value, for example.

    Thanks to its excellent and unique performance characteristics, the MRS also lends itself to the

    processing of PET bottle flakes to bottle grade chip.

    Early 2010 a “Letter of Non Objection“ (LNO) was

    issued by the American Food and Drug Administ-

    ration (FDA) for Gneuss‘ bottle to bottle recycling

    process. The FDA LNO is for up to 100 % recycled

    material and means that the entire chip manufactu-

    red on this process can be used for food containers

    of any kind in the USA, regardless as to whether

    the containers are for cold or hot fill applications.

    The bottle to bottle recycling process consists of

    the MRS extruder, a fully automatic Rotary Filtration

    System and a short solid state polymerization (SSP)

    in order to lift the IV to 0.8 or higher.

    B2B recycling | 19

    Sorted and washed bottle flakes

    Melt decontamination

    Underwater chip cutter / pelletizer

    Filtration

    SSP (Solid State Polycondensation)

    Vacuum

    Hydraulic

  • 20 | Fiber

    fiBer ManufactureApplication case example

    Many synthetic fiber manufacturers throughout

    the world have already chosen the MRS extrusion

    system from Gneuss.

    One of these is a Brazilian company which uses two

    MRS extruders to produce bicomponent staple fiber

    with two extruders: an MRS 130 for the main com-

    ponent with a throughput rate of up to 900 kg/h

    and an MRS 110 for the second component with

    a throughput rate of up to 500 kg/h. Both are fed

    with the same undried post-consumer PET bottle

    flake material and extrude the PET with different

    IVs on each extruder.

    Silon s.r.o. is another leading Eastern European

    manufacturer of staple fibres. Silon also operates an

    MRS extruder: an MRS 130 with vacuum, melt filter

    RSFgenius 200 and gear pump. The MRS 130 re-

    placed a conventional single screw extruder, dispen-

    sing with pre-drying of the material. It was possible to

    increase the production capacity by 30 %. Thanks to

    the Multi Rotation System MRS extruder pre-drying or

    crystalliztation can be eleminated and flakes with a re-

    sidual moisture level of as high as 2 % are processed.

    For fiber manufacturing the unique multiple screw extruder can supply a high quality melt from

    quality reclaim. 100 % recycled content can be used, resources are saved, energy use is mini-

    mized and raw material costs are reduced.

    The Belarussian company, Mogilevkhimvolokno is

    another Eastern European manufacturer of staple

    fiber and also decided to use the MRS extruder.

    Mogilevkhimvolokno manufactures a wide range of

    staple fiber including bicomponent fiber with a low

    melting point and an IV value of 0,55 to industrial

    quality fiber with an IV of up to 0,9.

    When manufacturing these fibers, production waste

    of all types is created, some including spin finishing

    oils. In order to recycle this wide range of waste, an

    MRS 90 extruder from Gneuss was installed which

    is used to devolatilize the undried material and to

    glycolyse the material to a uniform IV before it is

    filtered and pumped into the final reactor (finisher)

    where polycondensation takes place. This process

    permits recycling of practically all the production

    waste and the quality of the fiber manufactured with

    this recycled content is practically no different to that

    of fiber manufactured using virgin material.

  • 123456

    Devolatilizing extruder

    Filtration System RSFgenius 90

    Gneuss Online Viscometer VIS

    Melt pump

    Double stretching system (SIMA)

    Extuder downstream equipment (SIMA)

    1

    2

    3

    4

    5

    6

    Polyester straPPing taPes Application case example

    The MRS Extrusion technology was installed in a

    line for strapping tape from the Italian manufac-

    turer SIMA GROUP SRL., processing 100 % of non

    dried post consumer bottle flakes. There is only a

    small amount of PE based additive used for impact

    modifying (splicing inhibitor) of 1.2%, which is

    normal to be used in strapping applications.

    The throughput of the line is around 350 to 400

    kg/h.

    By avoiding the need for crystallizing and drying and with the use of a simple vacuum system,

    the MRS extruder permits energy savings of approx. 20 % and thanks to its compact design

    requires 12 % less space in the factory.

    The die head contains 3 gear pumps producing 6

    tapes with a dimension of 12.5 mm wide x 0.65

    mm to 0.8 mm thick. Stretching ratio is around 1

    to 8 and the haul off speed is up to 120 m/min.

    Strapping tape / PE/PP recycling | 21

    Pe/PP recycling

    The MRS devolatilization concept can not only remove water vapor from the melt efficiently; it is

    also an efficient system for the removal of harmful or unwanted volatiles from the polymer melt.

    Heavily contaminated materials can therefore be reprocessed with a drastic reduction in odor.

    A manufacturer of film for packaging processes

    scrap printed LDPE blown film to carrier bags.

    As this film had been previously used for packing

    fish, it had assumed an unpleasant odor.

    It was previously necessary to use a mixture of

    6 % washed „fish“ film waste with 94 % virgin

    material to reduce the odor problem. Thanks

    to the MRS extruder it is possible to add 40%

    recycled material instead of the previous 6%.

    The efficiency of the MRS technology was also

    proven in the manufacture of PP recycled com-

    pounds for the automotive industry. This work was

    carried out together with the Fraunhofer Institute

    in Pfinztal (Germany) which proved the results

    using themal desorption analysis. A large propor-

    tion of the volatiles are extracted from the polymer.

    The residual volatile level is 22 % at 50 mbar and

    only 10 % at 20 mbar.

    Application case example

  • In many polymerization processes, it is necessary

    to remove residual monomers after polymerizati-

    on. In most cases, in a complex and cost intensive

    process, the residual monomer content of approxi-

    mately 10 to 12 % is washed out with hot, distilled

    water and returned to the process (hot water

    extraction).

    This extraction process can be greatly simplified

    with the help of the MRS technology.

    The monomers can be extracted in the melt phase

    (before chip cutting) and are extracted in a form

    that permits them to be returned directly to the

    process.

    22 | Mixing

    further aPPlication eXaMPles

    further applications for the Mrs technology

    • Extraction of residual water and monomer from polycarbonate (PC)

    • Monomer extraction and removal of monostyrene from acryl nitrile butadien copolymer

    (ABS) or styrene acryl nitrile copolymer (SAN)

    • Reduction of effluvia (VOC/fog) in final product, for example from vehicle interior

    components manufactured from polyacetal (POM), polypropylene (PP), acryl nitrile

    butadien copolymer (ABS)

    • The introduction of chemical or physical blowing agents and/or other components in gas

    form for the manufacture of foamed products from polystyrene (PS), polyethylene (PE),

    polyester (PET) or polypropylene (PP)

    devolatilization of Pa

    The inclusion and dispersion of additives in poly-

    mers is normally carried out in the polymer melt

    prior to the mixing process. With the MRS Disper-

    sion Technology, the approach is quite different.

    The introduction of the additives does not take

    place under pressure and with a shear gap, but by

    a constant and drastic change of flow direction in

    a pressure-free environment.

    Mrs dispersion technology

    In this way, major differences in speed are created

    between the particles to be mixed and the mo-

    lecule chains. This creates an extremely efficient

    mixing process which is extremely gentle to both

    the polymer melt and the additive.

    The MRS system also provides excellent results in

    the dispersion of extremely small (nano) particles

    and in the homogenization of polymers (alloying)

    with different viscosities.

  • Locations | 23

    Subsidiary

    always soMewhere near you

    Gneuss, Inc.

    10820-G Independence Pointe Parkway

    Matthews, NC 28105, USA

    Telefon: +1.704.841.7251

    Telefax: +1.704.841.7254

    Email: [email protected]

    Gneuss Kunststofftechnik GmbH

    Moenichhusen 42

    32549 Bad Oeynhausen, Germany

    Telefon: +49.5731.5307.0

    Telefax: +49.5731.5307.77

    Email: [email protected]

    Gneuss - Divisão America do Sul

    Al. Rio Negro, 1084 - cj 114

    06454-000 - Barueri - SP, Brazil

    Telefon: +55.11.4191.1449

    Telefax: +55.11.4191.1449

    Email: [email protected]

    Sales and Service Centers

    Headquarters

    Gneuss´ headquarters in Bad Oeynhausen. Pilot

    lines are also available for trials at our subsidiary,

    Gneuss Inc. in the USA and at our cooperation

    partner, SysTech in Japan.

    Our Locations

    Based in Bad Oeynhausen, Germany, Gneuss is

    committed to the expectations of products “made

    in Germany” while serving customers world-wide.

    A technology center for processing technical

    trials and development work is available at

    G

    G N E U S S

    Servicehotline: +49 700 463877 24 www.gneuss.com

    Gneuss Office Shanghai

    Room 6B5, Harvest Building,

    No. 585 Longhua Road West,

    200232 Shanghai, China

    Telefon: +86.21.6469 7706

    Telefax: +86.21.6469 7916

    Email: [email protected]

  • www.gneuss.com