PVC processing

Frank Lichtenberger
IKA
Innovative Kunststoffaufbereitung
Bitterfeld-Wolfen, Germany

Januar 2017
 PVC recipes
All plastics: 280 mio to
PVC ~ 13%

pipes

window profiles

sheets

cables

Source: IKA

06.06.2017 2 Innovative Kunststoffaufbereitung IKA

 PVC consumption worldwide pipes
16 mio t / a
D: 0,08 mio t

China
2,3 mio t
2,6 mio t Europe
North America aagr 3% 4,5 mio t
aagr 1%
aagr 8%
India
1,6 mio t
Africa 2 mio t 2 mio t
aagr 5% SEA
aagr 8% aagr 3%

0,9 mio t
South America
aagr 4%

aagr: average anual grow rate

Source: IKA

06.06.2017 3 Innovative Kunststoffaufbereitung IKA

 stabilisation of PVC
• lead stabiliser • CaZn stabiliser

 Pb compounds  inorg. layered compounds

i.e.. 2-bas. Pb phosphite i.e. Hydrotalcite, Calumite
 3-bas. Pb sulfate
 Metallsoaps
 Metallsoaps  Lubricants (internal & external)
 Lubricants (internal & external)  Antioxidants
 Antioxidants  Costabilisers

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 compostion of Stabiliser
100

90

80

70

60 acid scavenger

acrylates
50
PE waxes
40
metal soaps

Co-stabilisers
30

lubricants
20

10

0
Pb CaZn CaZn for colored recipes

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 specific gravity of stabiliser

-40%
~ 1.8
spec. gravity

~ 1.1
[g/cm3]

Source: IKA

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 specific gravity of window profile
S-PVC 100.00 100.00
A/M 5.50 5.50 phr
filler 10.00 10.00 phr
TiO2 3.50 3.50 phr
Pb 5.40 / phr
Ca/Zn / 3.75 phr
spec. gravity

1.48
[g/cm3]

Source: IKA

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 PVC-U pipe formulations
Pressure pipe Sewer pipe

S-PVC K- 66-68 100 S-PVC K-66-68 100

Filler 2-5 Filler 10-40
Pigments x Pigments x
Stabiliser 2.4-3.4 Stabiliser 2.6-3.8

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 PVC-U formulations
injection moulding
knees, T junktions, fittings

S-PVC K 57- 58 100

Filler 0-4
Stabiliser 4-7
Processing aid 1 -4
Pigments X

* depending on complexity of the mould

Source:

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 PVC-U formulations
foam core pipe recipe

S-PVC K 57- 58 100

Filler 0-5
Stabiliser 3 – 6*
Processing aid 2 – 6*

* depending on pipe diameter

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 PVC dryblend mixing process

hot mixer temperatur 90-130 °C, hot mixing time 4-7 min

Cold mixer temp. 40-35 °C, cooling time 4-10 min

Source:

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 PVC dryblend mixing process
aspiration system for reducing water content

intake of dry cold air, starting from 80°C

Pull out of
hot humid air
and volatiles,
vakuum
pump start at
T10
80°C

mixing flights rotating 20-30 m/s

Source:

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 PVC grain before and
after mixing process

Source:

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 types of mixing
• all together from the start
 for recipes with low amount of components,
 i.e. pressure pipe, injection moulding, window profiles
• sequencial mixing by order (CaCo3, TiO2 at 80-90°C)
 for recipe with high filler level
 i.e. window sill, blinds, technical profiles, sewage pipe
• double batch mixing
 to increase output of mixing line
 i.e. technical profiles, plasticised recipes

Source:

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 caracteristics of dryblend mixing

Source:

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 dryblend handling

• feeding from cooler to silo – srew feeder better than air feeder
 risk of demixing connected to speed of particles
• aging certain time to equalize dryblend temperature
 difference between centre and wall
• aged dryblend runs better than fresh dryblend
 density, flowabilty increased by of less electrostatic charging
• full silo runs more stable
 best mixing effect is when silo is full
 more layers flowing into each other for homogenous dryblend
 fresh dryblend from mixer can separate by height of drop
 with full silo homogenation of scattering single batches easier

Source:

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 properties of high quality dryblend
to be checked in laboratory
• high density
• good flowablity
• size distribution dryblend particles mostly between 125 and 200 micron
• low water content < 0,2 %

to be checked in produktion
• constant processing with stable and reproducable extrusion parameters
• long term process stability by low amount of plate out
• good color, without visible differences

Source:

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 extrusion - plastication process
in twin screw extruder
T [°C]
• intake of dryblend, pushback air volume, density ~0,65 kg/l • 20
• precompression, preheating, mixing hot and cold particles • 60
• compression, heating, sheering dryblend particles • 100
• high compression, changing into melt, increase density to ~1,4 kg/l • 140
• degasation of agglomerates and melt • 155
• high compression • 185
• push out melt through adapter and die • 200

Source:

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 plus and minus counterrotating
twin screw extruder
plus
• short residence time in extruder
• good self cleaning abilities
• high pressure stable
• variety of different materials processable: dryblend, recycling or granules

minus
• compromise between design of plastication unit
and costs of construction
• wearing effects lower melt plastication level and
mechanical – physical properties of products

Source:

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 thank you for your attention

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