Compounding Polymers ProcessesPCH/CPP-E

Who should attend?

  • This course provides the know-how for an autonomous job position in the operation and maintenance (first level) in compounding polymers area.
Audience :
  • Operating staff in charge of a compounding plant.

Level : Advanced

Course Content

  • PROCESS DESCRIPTION

      • 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, counter-rotating or co-rotative twin screw, BUSS type mixers, advantages and drawbacks.
      • Granulation.
      • Different types of pellets handling.
  • TECHNOLOGY & OPERATION OF THE COMPOUNDING AREA

      • 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

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

      • 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

      • 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.

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.

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.