Theory

Extrusion:
Act Of Shaping A Material By Forcing It Through The
Die

Extruder type:
1. Screw extrusion
2. Ram extrusion
Ram extrusion: Plastic is extruded through a die
by the direct force of ram in a reservoir of
material Fluorocarbon & Cellulose nitrate
 RAM EXTRUDER

1 Products:
2 Powder feeding:
3 Pressing cylinder for moving the ram
4 Retracting cylinder for retracting the mandrel
(in tube production)
5 Ram for compressing the powder
6 Extrusion pipe
7 Heating sleeves for heating the
extrusion pipe
8 Drive for the stirring device
9 Movable mandrel
 Screw extrusion

Screw extrusion : Single & twin screw

Single screw : low cost, straight forward design,
ruggedness & reliability but lack of mixing ability
Twin screw :
Higher output rate, good mixing and extruding
performance
Divided into : Co rotating & Counter rotating
Comparison Co & Counter rotating

Counter : rolling motion, low speed

Co : translation movement,
higher speed with greater throughput,
positive displacement type Of transport
 EXTRUDER

Manufactured by JAPAN STEEL WORKS

( JSW ) in Hiroshima, Japan.
Model CMP 280 X-AW
Type : COROTATING TWIN SCREW
Extruder barrel have electrical heating
elements on jacket and hot oil at approx.
280 0C, controlled by cooling water
 GENERAL DESCRIPTION
Feed, metering and mixing section before
the polymer molten reaches a vent
section where any water or gaseous vented
Gear pump pick up the polymer and raises the
pressure to force the polymer through
fine screen and then through circular holes
in die plate to pelletising using blades on a
continuously rotating knife
 GENERAL DESCRIPTION
Pellets are cooled using water at 600C and
carried to pelletisation system
Pelletisation system separates the water
from pellets, removes residual water
and classifies the pellets
Water returned to pelleter water tank to
reuse
Pellets fall into a surge hopper and
transferred to silo
 LUBE OIL SYSTEM

G843 - L/O Unit G/P Gear Reducer

G842 - L/O MIXER MOTOR

H840
M

M M

BARREL A - B - C

G845 - L/O MIXER GEAR REDUCER

Diverter Valve Screen Pack
G847 - Hydraulic Unit for SLOT Control
G847 - Hydraulic Unit for D/V and S/P

G840 - EXTRUDER COOLING WATER SYSTEM

 EQUIPMENT
MX840 MIXER MOTOR ( MAIN MOTOR )
G840 EXTRUDER COOLING WATER SYSTEM
MX841 AUXILIARY / STARTING MOTOR
G841 EXTRUDER HOT OIL SYSTEM
G842 LUBE OIL UNIT for MIXER MOTOR
G843 LUBE OIL UNIT for GEAR PUMP GEAR REDUCER
G845 LUBE OIL UNIT for MIXER GEAR REDUCER
G847 HYDROLIC UNIT for SLOT CONTROL
G849 HYDROLIC UNIT for SCREEN CHANGER and DIVERTER
VALVE
 EQUIPMENT
P844A/B PELLET WATER PUMP
E844A/B PELLETIZING WATER COOLER
S844A/B PELLETIZING WATER DISCHARGE FILTER ( not used )
S846 AGGLOMERATE CATHER
R847 PELLET DRYER
C847 PELLET DRYER FAN
S847 PELLET CLASSIFIER
S848 PELLETIZING WATER POLYMER SEPARATO
T848 PELLET WATER TANK
 AUXILIARY / STARTING MOTOR ( cont )

Used :
start up
when needed to clear the barrel
Starting motor stops automatically
after main mixer motor start
 MX841
AUXILIARY / STARTING MOTOR

Power 55KW, Speed 980 rpm

Function :
initiates mixer operation to fill the
mixer with polymer and performs initial
purging
utilized to avoid mixer dry running by
the drive of mixer motor
 MIXER GEAR REDUCER
Mixer gear reducer is driven by mixer drive
motor through flexible coupling ( friction
coupling )
N2 to friction coupling
Start up : 4.8 bar g
Running Low speed : 2.3 bar g
Running high speed : 3.2 bar g
This coupling absorbs miss alignment between two
connection shaft
Two output shaft of mixer gear reducer are
connected with mixer screw ( high or low speed
could be selected by speed change lever )
 MX840
MIXER MOTOR ( MAIN MOTOR )

Power 4100 KW, speed 980 rpm, output shaft

rotates at 224 rpm ( high speed ) or 156
rpm ( low speed )
Water cooled and has its own lubricating oil
system
Main motor connected with gear box by slip
clutch
 BARREL

Comprised of feed, mixing and venting

/ discharge zones.
Combined flow ( powder and additive )
entered to hopper is mixed and
vented in this zone
Two lines for IA injections
Improving bubble stability
 IA to Barrel
Legends To
AI841
New Line for IA
Existing Line for NL

Inst.
Tubing
Existing Line for IA Powder
New Manual Valve Injection Point-1

2AI840
O 2
Vent Gas

New M/V - 2 New M/V - 1

New Line-2 2FI842

New Line-1
( IA )
Powder
Injection
Point-2

New M/V - 3

2FI841 2FI840
( N2 ) ( N2 ) Injection
Point-3
(to feed hopper
throat)
Gland Seal

NL Supply IA Supply
Extruder
Screw
 DIVERTER VALVE
Attached at end of mixer barrel
Hydraulic power unit for diverter valve can
supply max 210 bg fluid to operate diverter
valve hydraulic cylinder

Divert - diverts polymer molten to the floor

( clean the barrel )

Through polymer allowed enter to gear pump

( clean the die plate )
 GEAR PUMP
To generate / raise the pressure to force
polymer through screen changer and
then die plate for pelletizing

G/P speed is controlled to keep suction

pressure to a set point

Variable speed, positive displacement pump

high volumetric efficiency
 HYDRAULIC OIL UNIT

Hydraulic oil pump is automatically

actuated to supply hydraulic oil through
flexible hose
SLOT CONTROL
DIVERTER VALVE and SCREEN
CHANGER
 SLOT

Slot clearance between screws and

barrel can be adjust by hydraulic
power ( range 8 - 70 mm )
G847 HYDRAULIC UNIT for SLOT
CONTROL
 SCREEN CHANGER / SCREEN PACK

Used to remove small foreign particles or

carbonized polymer from molten to
enhance final product quality

Located between gear pump unit and die plate

Diff. pressure not exceed 150 bg

Size 20X40
 G849
HYDRAULIC UNIT for SCREEN
CHANGER and DIVERTER VALVE

Used when carry out change over screen

pack
Hydraulic unit for diverter valve is used
when
Start up extruder to operate diverter
valve divert or through
Extruder down, to divert the molten
 DIE PLATE
Attached to the other end of die holder
Drilled with 3.2 mm diameter approx 1030 holes
Has eight inlet and four outlet hot oil
Stainless steel with tungsten carbide on cutting
surface with thickness 3 mm
Pellet uniformity is determined by :
o Hole size
o Knives speed and condition
o Die plate face and temperature
o Water temperature
All above condition must be correctly preset to
guarantee a good pellet
 G841
EXTRUDER HOT OIL SYSTEM

Hot oil unit is a heat transfer system

designed to operate up to 2800C
N2 to remove Oxygen
Heat transfer fluid ( HOT OIL ) circulates
to heat and maintain jacket temperature of
diverter valve,
gear pump,
screen changer
die holder
 G841
EXTRUDER HOT OIL SYSTEM ( cont )

H840
M

M M

DIVERTER VALVE GEAR PUMP SCREEN PACK DIE PLATE

G841 - EXTRUDER HOT OIL SYSTEM

 CCW
CYLINDER ( BARREL ) COOLING WATER
CCW unit provides closed loop tempered
water system designed to circulate cooling
water to mixer barrels
Circulating pump operates in pressure
Cooling water tank is automatically
controlled by means of level switch and
triggers alarm if the level reaches set
point
 UNDERWATER CUTTER HOOD /
WATER CHAMBER

Molten polymer is extruded into hot water

chamber through die holes in die plate
and cut into pellets by cutting unit
Hot pellets are immediately cooled by hot
water
Hot water slurry containing pellets is
pumped and conveyed to following process
equipment ( dewatering and drying )
 UNDERWATER CUTTER HOOD /
WATER CHAMBER ( cont )
Water chamber is clamped to die plate by means of
quick clamping and and cutter unit is bolted to the
other side
Two hinged opening doors with glass windows on each
side
One scope lamp is provided for servicing and checking
cutting condition Cutter motor is interlock with side
windows and clamp device
Cutter motor can not be started if side window is open
or water chamber is away from die plate
Hot water inlet and outlet parts ( 6 and 10 ) are
located at bottom and top of vertical center of machine
 CUTTER UNIT

Cutter shaft end is connected to drive motor

via slide type gear coupling to absorb
cutter shaft stroke when knife clearance is
adjusted
12 knives are bolted to knife holder, which
operates at max 1150 rpm in hot water
 BLADE
Polymer when passes to die plate is immediately
cooled with water at approx. 600C and
simultaneously the molten cutting by rotating
blade that 4mm from die plate surface
Manufactured from Titanium Carbide or stainless
steel
Blades movement in axial mode is carried out using
NM, pressure applied depend on rotation speed,
any change of speed necessary to change
pressure to maintain distance between die plate and
cutter surface
 CARRIAGES

Gear pump and screen changer assembly is

mounted on a movable carriage on flat
rails, another carriage is for cutter drive
motor assembly
Cutter drive motor is directly bolted to
carriage which movable on rails and
equipped with handle wheel to move on
rack rail turning by hand
 C847

S846 R847
S847

Over Size
Normal
M Under Size

S848
DW

E844A/B LSL849
P844A/B TI848

T844

S844A/B SL
PELLETS WATER SYSTEM

Function
As cooling medium
As transporting medium
 PELLETS WATER SYSTEM

CHARACTERISTIC
Chemical cleanliness
Desalinated water to prevent lime
deposition on pellets
Physical cleanliness
In process generates fines, to keep
acceptable level
 PELLETS WATER SYSTEM

Temperature
Enough to cool down pellets to prevent
pellets deformation
Enough to prevent freezing up of die
plate
Flow rate
To keep pellets separated one from
another to prevent clogging
 PCW
Consists of circulating piping, hot water
tank, polymer separator / screen, PCW
filter, hot water pumps, plate cooler
and 3 way control valves
Three way control valve
directs flow of hot water either to
cutter hot water chamber for pelletizing
operation
directly backs to hot water tank for re-
circulation
 T848
PELLET WATER TANK
Stainless steel tank, volume : 10 m3
desalinated water, make up controlled a
ball float and by pass for emergency
Heating up TI858 before start up by
direct injection low pressure steam
Fitted with low level alarm LSL849, 3 way
valve
NaOH injection To keep PH balance
 P844A/B
PELLET WATER PUMP

( Centrifugal Pump )
Keep the water moving in cycle

Capacity approximately 300m3/hr or 3500

liters / minute
 6E844A/B
PELLET WATER COOLER

Plate type
Temperature also controlled by cooling water
return flow from cooler
 DEWATERING, DRYING AND
CLASSIFYING

After cut into pellets by underwater cutter,

pellets cooled and transported away from
die face by hot water to dewatering and
drying equipment
 S846
AGGLOMERATE CHATCHER
Pellets are picked up by water in pelleter water
system and conveyed to agglomerate catcher
Used on start up where polymer produced are
rejected allowing normal pellets to pass into spin
dryer
Only when pellet quality is satisfactory allowed to
enter the dryer
Pellets slurry first enters assuring gate agglomerate
catcher. Here large chunks and globs
(agglomerate of pellets stands ) are separated from
pellets and hot water by inclined stationary
slitted bars
 DEWATERING SCREEN

When agglomerates accumulate on slitted bar,

flapper plate is swung by air cylinder to
discharge the agglomerate on slitted plate
to outside
Pellets and hot water drop to inclined water
divert plates. There most of free water is
separated from pellets through screen and
pellets roll down toward centrifugal dryer
with some of free water
 R847
SPIN DRYER
CENTRIFUGAL DRYER / PELLET DRYER
Pellets separated from water

Slurry ( water and pellets ) comes from base, by

rotational movement, water passes through and
falls down wards to pellet water tank

Rotating blades continue to lift pellet upward to

pellet discharge outlet where they are
channeled off at top of dryer
 C847
PELLET DRYER FAN

Exhaust fan used to remove moisturized

air
 S847
PELLET CLASSIFIER

VIBRATING SCREEN / PELLET SCREEN

Centrifugal dryer outlet is connected to
vibrating classifier by connecting chutes
Classifier is vibrating separator, product
from dryer is fed into classifier screen
 PELLET CLASSIFIER ( cont )

Located at outlet line of pellet dryer

To separate oversized, undersized and
irregular pellets
Top mesh 8 mm diameter, bottom mesh 1.57
mm. Reject from top and bottom mesh is
collected in containers / bags for disposal
Good pellet quality passes by gravity to H850
approx. 2 tones capacity
Dryer outlet is connected to vibrating
classifier by connecting chutes
 S848
PELLETIZING WATER POLYMER SEPARATOR

Located above PCW tank

Separate dust from water before the water
back to PCW tank
 Start up Procedure
Start starting motor -MX-841, Arahkan D/V ke divert
Start mixer motor -MX-840 setelah lampu mixer motor ready start ON
Setelah molten yang keluar divert bersih, arahkan D/V ke Trough
Naikkan rate ekstruder ke 7000 - 10000 kg/jam
Stop gear pump dan kembalikan D/V ke divert
Bersihkan permukaan die plate
Connect cutter unit dan kunci secara diagonal
Reset safety interlock untuk cutter unit (F9)
Switch extruder operation ke mode AUTO dan Start
Secara otomatis dan berurutan divert valve akan berubah posisi dari
BYPASS ke THROUGH, cutter motor ON, gear pump ON dll
Posisikan divert valve di down stream pellet dryer ke CLASSIFIER
Posisikan valve agglomerate catcher ke mode AUTO
 General guidance

Start up untuk parameter di extruder :

Cutter : 300 rpm
G/P : 400 rpm
Slot : 40mm
Forward press. : 4 barg
TC844 : 50C
FC844 : 220 T/hr
 Procedure

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 Trial

Mematikan Electric heater ke Barrel

Tujuan :
1. Memperbaiki kualitas pemotongan pellet
2. Mengoptimalkan pemakaian energy di extruder
3. Menselaraskan dengan extruder design

Screw profile
Tujuan:
Mengurangi energi yang dipergunakan
 MSDS

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Pendukung
 Interlock

Weigh feeder
Extruder
Pellet dan powder conveying sistem
 Critical Parameter

G/P suction
Cuter speed vs Cutter forward pressure
pH PCW
Weigh feeder flow, especially additive rate
E-844 leak???
 Routine job

Tray test
Sampling
Logging
Housekeeping
Cleaning PCW tank
Check pH PCW tankfill Na OH
Filling M/B
 SAFETY RISK

PRESSURE
High pressure required to force the melt through
die plate to form pellets
TEMPERATURE
Hot polyethylene, special attention when extruder
start up
Hot oil unit insulated, oil heater surrounded by flexi
glass
Pellet water conveying
STATIC ELECTRICITY
Earthed wires are important