K THUT CN LUYN

Tran Minh Khai, Thai Duong J.S.Co.

01/2012, cp nht 08/2015.
Da trn ti liu hun luyn ca Farrel
 CN LUYN HN HP CAO SU
Mc ch cn luyn l to mt hn hp ng nht gm
cao su, cht n, cc loi ha cht khc. Hn hp phi thch
hp cho giai on ch bin sau: p xut, p khun, c
tim
Cht lng ca hn hp rt quan trng, quyt nh cht
lng sn phm ca cng on sau.
Nguyn vt liu dng cn luyn:
Cao su: dng bnh, tm, bng, bt.
Cht n:
n tng cng: than en, kaolin (bt t)
n tr: CaCO3, bt talc.
Cht ha do, lm mm: du, paraffine, acid stearic
Cc cht b tr: phng lo, mu, tho khun, PVI..
Cht lu ha: lu hunh, peroxide, xc tin.

01/08/15 2
 CC LOI MY CN LUYN
My cn 2 trc
My luyn cao su th h u.
u im:
Linh hot, ph hp vi sn xut nh
Chp nhn nhiu dng u vo: khi, tm..
Khuyt im:
Kh kim sot, khng t ng ha c.
Cht lng cc m luyn khng ng u
Khng sch, khng an ton.
Nng sut thp, cn nhiu lao ng.

My luyn kn : Kneader, Banbury

My luyn ph bin hin nay.
u im:
T ng ha c.
Cht lng m luyn ng u hn.
Sch s , an ton hn.
Nng sut cao hn. My kneader c thi gian cn di hn my Banbury (khong gp 2 ln)
Khuyt im:
Chi ph u t cao.
Pht sinh nhit nhiu. My kneader pht nhit t hn do lc ct x thp hn Ban bury.

01/08/15 3
 CC LOI MY CN LUYN
My luyn lin tc
My luyn c bit.
u im:
Nng sut cao, tit kim nng lng.
D dng ti u ha qu trnh, t ng ha.
Lc ct v nhit ng u.
Khuyt im:
Vt liu u vo phi l dng chy t do.
H thng cn v np liu phc tp..
Chi ph u t cao, khng thch hp cho sn xut nh.

My n hai trc vis

Cng ngh mi, dng trong cc ng dng c bit.
u im:
Nng sut cao, tit kim nng lng.
D dng ti u ha qu trnh, t ng ha.
Lc ct v nhit ng u.
huyt im:
Chi ph u t cao.
Pht sinh nhit nhiu.

01/08/15 4
 QA TRNH LUYN
Qu trnh Qu trnh
phn tn phn b

Cao su

Cht
n

Ha cht

01/08/15 5
 MY LUYN H
Cc thng s c bn:
ng knh, chiu di trc.
Khe h trc.
Trc trc: trc pha CN thao tc, thng
thng l trc chm.
T tc: t tc gia trc nhanh v chm. T tc
1.15-1.25: lc ct x cao, tc dng phn tn ln,
s dng cn luyn. T tc: 1-1.15: thng s
dng xut tm.
Nc lm ngui trc.
B o.

01/08/15 6
 LUYN H
Khi lng m luyn ph
thuc ng knh v
chiu di trc.
Khi lng m luyn t l
thun vi LxD
Ch quan st bng cao
su ln trn trn trc.
Dng b o h tr
xut tm, xut bng cao
su.

01/08/15 7
 LUYN H
Khuyt im
Thi gian luyn di.
Ph thuc vo tay ngh CN.
Bi, d.
Kh tiu chun ha c quy trnh.
Kh t ng u gia cc m luyn

01/08/15 8
 LUYN KN
My luyn kn : gm 2 rotor
quay c t tc trong bung luyn,
bn trn bung luyn c ba p
xung. Sau khi luyn, hn hp
x ra di y bung luyn.
C 2 loi rotor: tip tuyn
(tangential) v n khp
(intermeshing).
Hn hp chu lc ct sinh ra
gia rotor v thnh bung luyn.
H thng lm ngui bung luyn
ng vai tr quan trng.

01/08/15 9
 LUYN KN
Cc giai on luyn kn:
Lm mm, ha do cao su, sau cao su kt
hp vi cht n, lc ny nng lng tng ln.
Sau nng lng gim xung do nhit luyn
tng nhanh lm gim nht cao su.
Cao su v cht n tng tc nhau, nng lng
bt u tng ln, giai on phn tn ca cht n
trong cao su bt u. Nng lng bt u tng
tr li v t n cc i khi cht n phn
tn ht vo cao su.
Giai on phn b: cc im kt hp gia than
v cao su phn b u trong hn hp. Giai on
ny nng lng hu nh khng thay i.
01/08/15 10
 Biu m luyn kn

01/08/15 11
 LUYN KN
u im ca my luyn kn:
Thi gian luyn nhanh.
Khng ph thuc vo tay ngh CN.
Nng sut cao.
Sch, t bi.
Khuyt im
Nhit luyn tng nhanh -> cn c h thng
lm ngui tt.
u t cao.

01/08/15 12
 MY LUYN KN-CC THNH PHN
QUAN TRNG.

01/08/15 13
 MY LUYN KN-P SUT NN CA
BA KH NN
p sut nn = Trng lc ba +p sut trn piston p sut di piston.

01/08/15 14
 MY LUYN KN
CC THNG S V BA.

Cht qu:
Thp qu:
Bung luyn b b.
Bung luyn b b.
Ba b kt.
Hn hp kh di chuyn, gim
Rng qu:
cht lng luyn.
Bi thot ra.
Gim trng lng m luyn.
Ting n, dao ng,
Nhit tng nhanh.
ba mau mn.
Cao qu:
Gim cht lng luyn.
01/08/15 15
 C CU XC NH V TR BA

01/08/15 16
 H THNG GHI NHIT
BUNG LUYN

01/08/15 17
 CC KIU LP T DY
CHUYN LUYN.

MY LUYN KN & MY CN

MY LUYN KN & MY N
2 TRC VIS/ U XUT TM

01/08/15 18
CC KIU LP T MY LUYN.

MY LUYN KN & MY N 1
TRC VIS + TRC P
01/08/15 19
CC KIU LP T MY LUYN.
MY LUYN GHP I (TANDEM
MIXER)

My luyn kn u

My luyn th cp (Kneader)

My to phi

01/08/15 20
 DY CHUYN SN XUT SN PHM CAO SU TIU BIU

01/08/15 21
 CHT LNG SN PHM
Cht lng m
luyn
p ng cc yu cu v tnh nng c l: t
trng, cng, cng lc, gin t, bin
dng nn

Kh nng ch bin cho cng on sau:

n, p, tim.

01/08/15 22
 CNG NGH LUYN

Phi liu: cn
Cn luyn
ha cht, cao su

01/08/15 23
 QA TRNH LUYN
Qu trnh Qu trnh
phn tn phn b

Cao su

Cht
n

Ha cht

01/08/15 24
 LUYN KN
CC YU T NH HNG QUAN TRNG
Cc yu t quan trng:
Fill factor.
Hn hp n cng nhiu th factor cng nh v d: khong 0.6,
trnh hin tng b nghn cht n c bung luyn.
Nhit x hn hp
Mi loi cao su c nhit x ra thch hp. V d: hn hp SBR
nhit x khong 150oC.
Th t cho nguyn liu vo bung luyn.
Thng thng cao su c a vo trc ha do, sau
l cht n phn tn tt trong cao su. K n l cc cht lm
mm, ha do, cao su ti sinh c thm vo sau cht n.
Tc rotor.
Tc rotor ph thuc vo bn cht cao su, nht ca hn
hp, giai on luyn.
p lc ba.

01/08/15 25
 TH TCH BUNG LUYN

01/08/15 26
 LUYN KN
H s lm y (Fill Factor)

Trng lng m luyn (kg) = Th tch

bung luyn (Lt) x Fill Factor x T trng.
Fill factor (Intermix) = 0.85 Fill factor
(Banbury).
Fill factor ca my Kneader=1

01/08/15 27
 LUYN KN
H s lm y (Fill Factor)
Fill factor (Intermix) i vi Fill factor (Banbury)

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01/08/15 29
 H s lm y
bung luyn (Fill
factor): nh hng
ln n cht lng
hn hp.
H s lm y ph
hp: sau 1/3 chu k
luyn th ba s
xung v tr n
nh v dao ng
ln xung trong
khong 1-2cm.
01/08/15 30
 H s lm y
thng l 0.75. i
vi EPDM,
Chlorobutyl th cn
phi ln hn
khong 10%, ngha
l khong 0.8-0.85.
T l n cng cao,
fill factor cng nh
trnh b nghn
khi np liu.

01/08/15 31
01/08/15 32
 LUYN KN
p lc ba.
p lc ba
Ln qu s cht
lm rotor hot ng
qu ti, ba b mn
do tip xc vi rotor.
Nh qu s khng
gi c nguyn liu
trong bung luyn,
khng lc ct x
cao su nn cht n
khng phn tn
c.
01/08/15 33
 LUYN KN
p lc ba.

t p lc ba thp khi x hn hp, tim

du hoc cn trn cc loi hn hp mm.
t p lc ba cao khi bt u chu k
luyn, hoc khi luyn hn hp cng (c
nht cao).
t p lc ba cao khi bt u chu k
luyn v p lc ba thp cui chu k
luyn s tng hiu qu v cht lng
luyn.
01/08/15 34
 LUYN KN
Quy trnh luyn.
Phng php luyn
Luyn 1 giai on, 2 hoc nhiu giai on.
Quy trnh luyn
Th t cho nguyn liu.
S ln v sinh ba.
Phng php x hn hp (theo thi gian, nhit hay nng lng).
Thng s luyn
H s lm y fill factor.
Nhit .
Thi gian luyn
p sut ba.
Tc rotor.
Kim sot chu k luyn
Theo thi gian.
Theo nhit .
Theo nng lng.

01/08/15 35
 LUYN KN
Phng php luyn 1 giai on (A compound).
Luyn 1 giai on (phng php truyn thng)
Thng p dng cho hn hp CSTN, SBR, NBR.
1. Cho cao su, cht ha do.
2. Cht n, ha cht, lu hunh, xc tin.
3. Du.
_Thng thng cht n cho vo trc, lc lc ct x cao nn
d phn tn.
_Trng hp t l cht n v du cao, c th chia thnh 2 ln
cho vo.
Luyn 1 giai on (upside down)
Thng p dng cho hn hp EPDM do lng du s dng
cao.
1. Cht n, du, ha cht
2. Cao su.
Hoc: cao su, sau cho ngay cht n, du, ha cht.

01/08/15 36
 LUYN KN
Phng php luyn nhiu giai on.
Giai on 1: lm mm cao su.
1. Cao su + cht ha do.
2. Luyn, x.
Giai on 2: phn tn cht n.
1. Hn hp giai on 1 + cht n. (khong 2/3 cht n)
2. Du. (khong 1/3 du)
3. Luyn, x.
Giai on 3: gim nht, phn tn n.
1. Hn hp giai on 2 +Cht n cn li.
2. Du cn li.
Giai on 4: gim nht, thm h lu ha
1. hn hp giai on trc.
2. Lu hunh, xc tin.
3. hn hp cn li.
4. Luyn, x.
01/08/15 37
 LUYN KN
Thng s luyn cn quan tm
Trng lng m luyn.
Vn tc rotor
Khi np liu.
Khi ng ba.
Khi v sinh ba.
Khi x hn hp.
p sut ba
p sut ba tng bc luyn.
Thi gian ba di chuyn v t p lc cn bng.
Nhit luyn
Ca rotor, mt hng, ca y, ba.
01/08/15 38
 LUYN KN
Kim sot chu k luyn
Theo thi gian (tnh t lc ba ng hoc
t lc bt u bc luyn)
Theo nhit .
Theo nng lng (tnh t lc ba ng
hoc t lc bt u bc luyn)
Theo tc rotor.
Theo moment xon hoc lc.
Hoc kt hp mt hoc nhiu thng s
trn.
01/08/15 39
 LUYN KN
Ti u ha quy trnh luyn

01/08/15 40
 LUYN CAO SU EPDM
Fill factor my luyn kn khi luyn hn hp EPDM cao hn 10-15%
so vi cc loi cao su khc. Tc trc thp, khong 30v/ph.
Hai thng s quan trng khi luyn EPDM l nhit v tc trc.
Nhit gia 2 trc phi chnh nhau t nht 20oC.Nhit trc
trc khong 40oC, trc sau khong 60oC.
Dng my cn iu chnh khe h v tc trc.
EPDM c khuynh hng dnh trn trc nhanh, trc ngui.
EPDM cng c khuynh hng bm vo ni c khe trc thch hp.
Th thut: iu chnh khe trc bn ln, bn nh hn hp t iu
chnh bm vo khu vc c khe h trc thch hp.
Phng php luyn up-side-down cng thng c p dng i
vi cc hn hp mm, c hm lng n cao. Than en + du a
vo trc, sau n cao su.

01/08/15 41
 LUYN CAO SU EPDM
i vi hn hp EPDM c cng cao >80 Shore A, t
l n cao, thng xy ra hin tng ng rn do than
en (black scorch).
Gii php:
Cho khong 0.2phr lu hunh vo giai on u.
Dng fill factor thp: 0.6-0.7.
Luyn nhiu giai on: giai on u 2/3 than + 1/3
du, giai on 2: thm than du cn li, giai on 3:
thm cht lu ha.
S dng EPDM c nht thp.

01/08/15 42
 LUYN CAO SU EPDM
i vi hn hp EPDM c cng thp, <55 Shore A, rt kh t phn
tn tt do hn hp mm, s dng nhiu du.
Gii php:
p dng cn upside-down.
Fill factor cao 0.8-0.85.
Chia du thm thnh 2 ln: ln u du, 2/3 than; ln sau du
than cn li. Ch :
y khng phi l cn 2 giai on. Cn tnh ton khi cho du v
n ln u th fill factor khng thp qu 0.6.
Lng nh than i km vi du tng ma st, du d n vo hn
hp.
Thi im tt cho du vo ln 2 l than en va phn tn vo
cao su (dng in ca Ampe k va tng ln). Nu tng ln qua
cc i lc cho du vo rt kh do hin tng trt ca hn hp
trong bung luyn.
Dng EPDM c du/ EPDM c nht cao.

01/08/15 43
 LUYN CAO SU SBR/NR
Fill factor my luyn kn khi luyn hn hp SBR
cao khong 0.75. Tc rotor cao: 40v/ph.
Nhit xut ra ca hn hp t 130-150oC.
Hn hp SBR cng thp cng phi t nhit
ny.
Thng thng cht lm mm, ha do, n tng
cng c cho vo trc, du c cho vo
sau cng vi cc cht n tr nu c (CaCO3,
talc).
Thi gian luyn kh di so vi EPDM, thng
mt khong 4-5 pht.
01/08/15 44
 LUYN CAO SU SBR/NR

01/08/15 45
 LUYN CAO SU NBR
Tng t cc loi cao su thng thng nh
SBR, NR.
Lu hunh kh phn tn trong NBR, do vy
thng cho lu hunh vo giai on 1. Tuy
nhin cn gi nhit luyn thp <120oC do
NBR c th t lu khi c lu hunh m khng
cn xc tin.
Nu gi nhit giai on 1 thp, c th thm
xc tin cui giai on luyn.

01/08/15 46
 LUYN CAO SU CR (Neoprene)
Fill factor hi thp, khong 0.7 gi nhit
khng tng qu cao.
Nhit gi cng thp cng tt, di 120oC do
CR c khuynh hng tinh th ha nhit
cao.
Cht n tng cng cho vo trc, sau mi
n cc cht ha do, lm mm, du v cc
cht n tr
ZnO cho vo sau cng vi cc cht lu ha.

01/08/15 47
 PHNG PHP C LNG CNG HN HP

100 PHR CAO SU CNG (Shore A)

Neoprene, NBR 44
NR, SBR 40
Butyl 35
SBR 37.5phr du 26

Cht n v du Thay i cng (Shore A)

FEF, HAF +1/2 ca 1 phr thm vo
Kaolin +1/4 ca 1 phr thm vo
Factice -1/5 ca 1phr thm vo
Du lm mm -1/2 ca 1phr thm vo

01/08/15 48
 PHNG PHP C LNG CNG HN HP

EPDM = 60-(Du x 0.33) + (N550 x 0.25) +

(N330 x 0.35) + (Kaolin x0.18) + (CaCO3 x 0.05) +
(Silica x 0.30)

NBR = 44-(Du x 0.5) + (N550 x 0.5) +

(N330 x 0.5) + (Kaolin x0.25) + (CaCO3 x 0.15) +
(Silica x 0.5)

01/08/15 49
 NGUYN TC CHUNG KHI
LUYN HN HP MM
Fill factor cao.
Dng cao su c nht cao/ cao su c ngm du.
Cho du lm 2 ln: ln u du + 2/3 than, ln sau
du than cn li. Mc ch thm than ln 2 tng ma
st.
C th sy du nng ln khong 70-90oC d kt hp
vi cao su.
Ch khng fill factor <0.6 khi cho du ln u.
Thi im thm du ln 2: khi than va phn tn, Ampe
k va tng ln.

01/08/15 50
 NGUYN TC CHUNG KHI
LUYN HN HP CNG
Fill factor thp, khong 0.6.
Dng cao su c nht thp.
Cn 2 giai on: g/ u: 2/3 than+1/5 du; g/
2: than+du cn li.
Hoc c th cn 1 giai on, cho cht n lm 2
ln trnh nghn c np liu.

01/08/15 51
 M BO CHT LNG
QU TRNH PHT TRIN
Ch yu kim tra sn phm cui.
Kim tra Chi ph cao do ph phm ch c pht hin cui quy trnh.
cht lng

Kim tra tng cng on sn xut.

S khng ph hp c ngn chn khng a n cng on k.
Kim sot
cht lng Chi ph gim.

Kim sot tt c cc quy trnh trong Cty bao gm c mua hng, bn hng, k hoch sn
xut, o to
m bo
cht lng m bo cht lng sn phm ng u theo k hoch.

Trch nhim vi mi trng, x hi, ngi lao ng. (H thng ISO14001, 18001).
Sn xut bo
tn

01/08/15 52
 QU TRNH KIM SOT CHT LNG

KHCL:
Thc hin kim
Thng s cn kim tra.
Tn sut kim tra.
tra.
Phng php. Ghi chp kt
Tiu chun. qu.
Trch nhim

Plan Do

Act Check
Hot ng Kim tra l
KPPN, ci tin. hng.
Thng k, phn
tch s liu.

01/08/15 53
CC THNG S LUYN CN KIM SOT

Tng trng lng bao ha cht. V d: 2100 gr +/-5gr.

PHI LIU

Thng s my: nhit , thi gian luyn, quy trnh luyn.

Nhit ra ca hn hp.
T trng. V d: +/-0.02
phn tn.
Rheometer: ts1, t10, t90.
CN
LUYN nht Mooney , Vd: ML1+4(100oC)
Tnh nng c l: cng, cng lc, bin dng nn, ty thuc
tiu chn p dng.

01/08/15 54
NHN BIT V TRUY TM NGUN GC

Mc ch:
Nhn bit tnh trng sn phm.
Truy tm ngun gc gip xc nh nguyn
nhn ca cc vn trong sn xut. H
thng truy tm ngun gc khng chnh xc c
th dn n xc nh sai nguyn nhn.
Quyt nh da trn d liu thc t.
Thay v da hon ton trn cm tnh, kinh
nghim.

01/08/15 55
NHN BIT V TRUY TM NGUN GC

Phi liu: cn ha cht, cao su Cn luyn

Mi cng on phi c s l u vo v u
ra.
Nn s dng m vch s c tin cy cao.
p dng cng ngh thng tin: bng tnh
exel, c s d liu (SQL).

01/08/15 56
 BIU RHEOMETER

Hn hp EPDM

01/08/15 57
 BIU RHEOMTER

Hn hp CSTN

01/08/15 58
 BIU RHEOMETER

Hn hp cn khng u

01/08/15 59
 BIU RHEOMETER

Hn hp cn u

01/08/15 60