Professional Documents
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Mezclado Del Caucho
Mezclado Del Caucho
Mezclado Del Caucho
and
Rubber Technology
R. H. Schuster
Consultant to LANXESS /German Rubber Institute
12 Jornadas Latino-Americanas de Caucho
Buenos Aires 23/24 Sept. 2013
1.Day
-
Mixing of Rubber
Filler Dispersion
Filler Distribution
Rubber-Filler Interaction
Influence of Mixing on
Dynamic-Mechanical Properties
2.Day
-
Elasticity
Energy Dissipation
Abrasion Resistance
Traction
Tensile Strength
Wear
Elastomers
Resistance
Oil Resistance
Ageing Resistance
Tires
928.000 t
5.100 Mrd
+7 %
Elastomers
Mixing of
Rubber Compounds
Filler
Manufacturing
Aggregates
Aggregates
Incorporation
Agglomerates
Pellets
Size reduction
Pellets
large size
hardness and strength
low density (voids)
stability in pneumatic transport
Mixing
Material properties changing Process
- Rheological Properties
- Further Processing
- Dispersion and Distribution of Fillers
- Phase Morphology
- Physical Properties Set
- Life Time of Rubber Products
Mixing
Compound
Properties
Processing
Part Properties
Filler(s)
Raw Material
Quality Control
Process oil(s)
Mixing Process
- Mastication and Blending
- Incorporation of Fillers
- Filler Dispersion/distribution
- Dispersion of ingredients
- Oil incorporation
- Curing reaction is not allowed
to start
Curing Agents
Quality check
of the mixture
FurtherProcessing
Mixing Equipment
Discontinuous Mixing
Batch Mixing
Two-Roll Mill
Internal Mixer
well established
State of the Art
Can use every form
of the raw materials
Continuous Mixing
promising starts for
some production lines
Relies merely on
free flowing raw materials
i.e. granulates
Two-Roll Mill
Two rolls which rotate in
opposite sense
(Edwin Chaffe, 1835)
stock
blender
Courtesy: Vredestein
Two-Roll Mill
Advantages
Mixing Process is
followed easily
Mixed Material forms
sheets suitable for
Compression Molding
Disadvantages
Handling of Fillers and
Additives cause housekeeping problems
Prolonged Mixing Times
Less Process Control
Internal Mixer
Closed Mixers equipped with
counter-rotating rotors
Rotors with a
screw-like geometry
Axial mixing along the
rotors towards the center
Rotors may or
may not overlap
Ram:
- seals the mixing chamber
- Presses Polymers into
the mixing chamber
- compress large volumes
of fillers
Temperature Control
Cooling systems
Intermeshing Rotors
Tangential
5
Intermeshing
4
3
2
1
0
Energy
Efficiency
Thermal
Performance
Co-mastication Plasticizer
Blending
Machine
Utilization
Intake and
Discharge
Behavior
Void Volume [m ]
350
tangential
intermeshing
250
150
50
0
1
3
4
5
6
7
Cooling Surface [m ]
tangential
Intermeshing
courtesy: Techint Pomini
Tandem Mixing
Combination of
a master batch mixer (Intermix)
a larger ramless mixer (Tandem)
effectively cooled
intermeshing rotors
Consecutive mixing
Rubber and Filler into the hot
Intermix (upper mixer)
After premixing the compound is
dropped into the tandem mixer.
Mixing time reduced
Cooling and Dispersion
by remilling in the Tandem
J. Peter (1987)
Tandem Mixing
From Tandem Mixer
The final batch is dumped
on a mill or into an
extruder were it will
be sheeted and
conveyed to the batch off
unit.
Advantage:
1) the batch does
not need to be stored between
1st and 2nd stage
Temp.
Add Curatives
110C
3) Higher troughput
Discharge
Constant process
conditions
Fast ram
movement
Little operation
costs
Precise ram force
control
Corosion
Resistance
Equal coating
thickness
Hard Coating
free of Cracks
High tensile
Strength
High Hardness
Intensive Cooling
Rotors
Functions of the Rotors
Impart shear and elongation into the compound
Dispersive Mixing
Cooling
Rotors occupy a high portion
of the mixing chamber
Cooling of rotors improves
mixing efficiency by
increasing the viscosity
of the mix.
Ring cooling
Spray cooling
Strength is achieved by rotor
body walls
Better cooling efficiency with
Ring cooling.
Two body rotor with reduced wall
Thickness. Good heat transfer
N -Rotors
Full-4-W-Rotors
Unwined
Rotor Geometry
Flight Angle at 40
Length of fhe flight is shorten
Distributive mixing capacity
Temperature control
Discharge temperature is reduced
30 % throughput than N-rotor
Mixes for Technical Rubber Goods
Intermeshing Rotors
Cooke, 1934
Interlocking Technology
Johnson (1980)
Intermeshing Rotors
PES Technology
Wiedemann & Schmidt (1982)
Processing Aspects of
Rubber Mixing
Rubber Bales
Softener/Plasticizer
Carbon black
Deformation behaviour
Yield point
Wall slippage
Wall adhesion
Surface activity
Agglomerate size
Strength of
agglomerate
Operating param.
Rotational speed
Geometry
Ram pressure
Fill factor
Thermal boundary
conditions
Feed sequences
viscoelasticity
density
heat capacity
heat transfer
Result of mixing
Degree of dispersion
Fluctuations in viscoelasticity
Thermal loading
Incorporation and
dispersion of carbon black
or other fillers
Elongational Flow
Shear Stress
Dispersive Mixing
Breakage
No Breakage
Time
Distributive Mixing
Homogenization of ingredients
Even concentration of ingredient
Laminar Mixing
strain
Influences to Flow
- rotor geometry
- angle of the rotor blades
- number of the main
and side blades
- fill factor
mA
Converging Flow
mB
II
C
Leakage Flow
III
Axial Direction
Mixing Cycle
and
Influence of Material Parameters
Polymer
charging
Incorporation
Dispersion
5 6
Filler
incorporation
Mastication
Filler
charging
Oil injection
Distribution
8
Discharge
Ram
sweep
After
mixing
Rubber
Filler
Incorporation Time
depends on:
- type of Filler
- type of Rubber
- content of oil
- type of Mixer
- Processing Parameters
Incorporated Filler
5 6
2000
200
1500
150
1000
100
500
50
0
0
50
100
150
time (s)
G. Nijman, DIK Seminar 2007
200
0
250
Temperature (C)
GK400N
Rotor:
4 Wing
Fixed speed
Power
Ram position
Avg Power
Temperature
16
14
12
10
8
6
20
40
60
80
120
30 C
60 C
100
90 C
80
60
40
30
40
50
60
Rotor Speed
70
80
End of
Incorporation
Ram Displacement
Ram Displacement
N 347
N 330
N 326
Mixing Time t
Addition of
the Filler
Mixing Time t
Lecture_POA_11.06.2007_54
100
80
60
CB
40
NBR
HNBR
20
CNT
12
Filler [Vol.%]
Mixing Temperature
Mixing time t
Mixing time t
NBR
CNT
5
4
3
CB
2
12
Filler [Vol.%]
Mixer Energy-Balance
(Typical example)
15% 10%
compound enthalpy
for cooling
30%
45%
mechanical
mixer enthalpy
Automatic intermitent
Oil injection
Energy uptake
Shorter mixing cycle
Lecture_POA_11.06.2007_60
Scaling-Up
Important Step for Production
Requirements
- Geometrical Similarity
same clearance between rotor and
mixing chamber
Frequency of the rotors should be inversely
proportional to the width of their tips
Throughput
Quality
Power kW/h
Experimental Design
Fill factor
Rotor speed (rpm)
Blending time (s)
Dispersion time (s)
low
0.58
40
30
42
high
0.63
60
60
60
FRbD
crumby
160
180
loose black
FRBD
homogeneous
162C
182 s
completed
Results
Blend appearance
Dump temperature
Cycle time
CB incorporation
Mixer: GK45E
Rotor: PES-3 fixed speed
Fingerprints
FRBD
Power kW/h
Power kW/h
FRbD
Time (s)
Time (s)
Mixer: GK45E
Rotor: PES-3 fixed speed
Material
Polymer
Filler
Plasticizer
Additives
Curing system
Quality
Equipment
Dosage
Weighing tolerance
Calibration
Discontinuous
Continuous
Tandem
Feeding Sequence
Duration of
Mixing Phases
Human
Education
Qualification
Motivation
Geometry
Maintenance
Cooling
Control
Sensors
Dimension
3,2
3,1
3
2,9
2,8
1
Sample
10
Mixing Chamber
Temperature
Rotor Speed
Power
ring electrode
Chamber wall
Electrode
Rotor wing
Amplifier
Picoamperemeter
El. Source
Disadvantages
High power peaks
Batch to batch variation
heat history
material weight variation