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Compounding Polymers Processes

Compounding Polymers Processes

4 days
PCH/CPP-E
Sessions
This course is not scheduled.
Who should attend?

Audience

    • Operating staff in charge of a Compounding Plant.

Level

  • Advanced
  • This course provides the know-how for an autonomous job position in the operation and maintenance (first level) in compounding polymers area.
Learning Objectives
  • Upon completion of the course, participants will be able to:
  • know about the phenomena in each sectors of these processes,
  • use of all equipment and analyze of the settings, security and automation,
  • interpret drifts and incidents in order to react efficiently and in safety ways.
Course Content

PROCESS DESCRIPTION

0.5 day

  • Aim of the extrusion, general layout description and the various steps of the polymer treatment.
  • Operating principle and different cross section areas: Storage area, conveying system, feeding system…
  • Different types of screws, advantages and drawbacks.
  • Different types of extruders: single screw, conter-rotating or co-rotative twin screw, BUSS type mixers, advantages and drawbacks.
  • Granulation
  • Different types of pellets handling.

TECHNOLOGY & OPERATION OF THE COMPOUNDING AREA

1.75 days

  • Conveying system: Lean Phase, Strand phase, Fluid phase, Stabilized fluid phase, Stabilized slug, Slug, Hydraulic. Advantages and drawbacks (dust, angels hair).
  • Feeding system: Gravimetric, single screw/spiral, double screws/spirals, belt system, vibrating system, side feeder, agitators, venting system… Advantages and drawbacks.
  • Drivetrain: the drivers and launch, variable speed drives, gearboxes, sustained efforts, safety and overload structure of abutments, the extruder auxiliary.
  • Extruder: power, force feeder, preventing jams, different section of screw and barrel, vent, temperatures adjustments, starting diverter valve and start-up operation, fouling filters monitoring and filter changing device.
  • Die plate: technology, pressure monitoring, calculating the percentage of blocked holes, die plate heating system. Principle of heat exchange in the die plate and temperature control. Risk of damage.
  • Pelletizer: speed calculating, water flow, knife adjustment, monitoring of pellets size. Parameters adjustment to have a good pellets.
  • Pellets handling: centrifugal dryer, fluid bed dryer, classifier screen, rotary valves. Advantages and drawbacks.

AUTOMATION & SAFETY

0.5 day

  • Review of the machine logic (flow charts, logic diagrams). Link between automaton sequences feeders, extruder, pelletizing, pellets handling.

PRODUCT QUALITY

0.25 day

  • Different grades manufactured, specifications in relation to the applications.
  • Laboratory tests: equipment procedures, visualization of various types of defects. Fluidity, viscosity dynamic, kinematic viscosity, definition, effect of shear rate, melt index (MI).

INFLUENCE OF OPERATING PARAMETERS

1 day

  • Monitoring the temperature as a function of grade and load.
  • Required power: the influence of the load, the MI and temperature recommendations.
  • Rules to heat the extruder after period of shut down (cold to hot).
  • How to start the extruder.
  • Die plate purge before start.
  • Analysis of bad cut and actions.
  • Which parameters are important to follow to have a good reliability and productivity, always in safety conditions. How to identify bad actors.
  • Cartography of extruder behavior.
  • Safety of operators.
  • Application: study of possible causes of troubles, solutions, points to be checked.
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Ways & Means
  • Content may be customized for a particular type of machine or for products if information are provided at least one month in advance. Otherwise, standard products are covered: PE, PP, PVDF, etc.
  • Case studies based on industrial situations.