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主题:在双螺杆共混中优化喂料赚更多的钱

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Another highly effective technique for getting powders into a twin-screw extruder is with the use of Feed Enhancement Technology (FET). In this technology (Fig. 4), a vacuum is applied through a porous filter in the barrel wall. Air is removed, while the powders are kept in the barrel. It works primarily by forming a cake of material on the barrel, increasing the coefficient of friction on the barrel wall. This increases the conveying efficiency. The secondary effect is to remove some of the entrained air from the powder, reducing its volume.

 

另一个高度有效的将粉末加入到双螺杆挤出机的技术是使用喂料喂料强化技术(PET)。在这种技术中(图4),通过一个微孔过滤器安装于机筒壁上,由此施加一个真空。空气被除去,同时粉末留在机筒内。它的工作原理主要是在机筒上形成一个材料饼,增加了在机筒上的摩擦系数。这增加了输送效率。第二个效果是从粉末中除掉了困住的空气,减少了物料的体积。

 

The magnitude of the effect of FET is not the same for all powders, and depends on attributes such as bulk density and particle size. For talc, it has been proven to increase throughput rate by over 250%, while for calcium carbonate, the increase in throughput is mostly negligible. The limitation is that FET can only be used in zones where only dry, unmelted powders are present. Wet or molten materials will plug the filter; and large, solid particles such as pellets will damage it. For compounding processes, this technology is typically applied to the side- feeder barrel, though it is also available in the main extruder barrels as well.

 

PET技术效果的大小不是对于所有材料都是一样的,取决于堆密度和粒子尺寸之类的特性。对于滑石粉,证明可以增加产率达250%,而碳酸钙几乎不增加产率。该技术的限制是,只能用于未熔融的干粉末存在的区段。湿的或熔融材料将堵塞滤网;并且,大的固体粒子,例如颗粒,会破坏这一技术。对于共混工艺,该技术一般使用于侧喂料机筒,尽管它也用于主喂料机筒。



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  发帖心情 Post By:2017/5/2 1:57:00 [只看该作者]

 

To calculate the profitability of installing FET, consider an example of a 45-mm twin-screw extruder compounding polypropylene with 40% talc for an automotive application (Table 2).

 

要计算安装PET的赢利,可以考虑一个45mm双螺杆挤出机共混填充40%滑石粉聚丙烯用于汽车的例子(表2)

 

For this process, the throughput is limited by the volume of talc that can be fed. At rates higher than 600 kg/hr, the side feeder starts to back up(堵塞), and the extruder is able to use only 54% of its total motor power. By installing FET, the conveying efficiency of the side feeder is greatly increased, and the throughput can be increased until the motor power becomes the limitation at same screw speed, the specific mechanical energy input to the material also decreases, and less power is used per kilogram of material. With a profit margin of 20¢/kg, the 500 kg/hr increase in rate could mean an increased profit of $600,000 annually, offsetting the cost of FET several times over. The specific energy requirements are reduced by 4% or 33 MWh annually.

 

对于这个工艺,产量受限于喂入的滑石粉的体积。在高于600 kg/hr 的速率下,侧喂料器开始堵塞,挤出机只用到54%的总马力。通过安装PET,侧喂料的输送效率极大增加,产量可以增加到马达动力在同样螺杆转速下受限为止,输入到材料上的比机械能也随之减少,每公斤材料使用了较少的动力。具有20¢/kg的利润幅度,在速率上增加500 kg/hr,就意味着每年增加利润$600,000,抵消了PET的几倍以上的成本。比能耗减少4%或每年减少33 MWh。

 

The examples offered highlight just a few common limitations in feeding twin-screw extrusion processes. There are many more areas where limitations can occur. The principle of first identifying the limitation, understanding it, and implementing a solution, then repeating for the next limitation, can be applied for those limitations not discussed in this article. Factors such as energy cost, profit, and ability to sell excess production should be evaluated for your specific business. These calculations can provide the framework to justify taking on these optimization projects. As always, your twin-screw extruder manufacturer is a good first point of contact for process-optimization advice.

 

上述这些例子阐明了在双螺杆挤出喂料工艺中的一些常见限制。有更多的地方会发生限制。首要原则是,甄别限制,理解它,并实施一个方案,然后重复寻找下一个限制,该原则适用于本文没有讨论过的那些限制。诸如能量成本、利润和销售过剩产量的能力等因素,应该针对你的具体业务作出评价。这些计算可以提供框架以合理讨论这些优化项目。一如既往,对于工艺优化建议,你的双螺杆挤出机制造商是一个好的第一接触人。

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