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REACTIVE COMPOUNDING | PROCESSING


Reacting to change


Reactive compounding offers performance modifying opportunities not available using blend processing. Mark Holmes finds out more about the latest developments


Reactive compounding techniques offer the opportunity to modify polymers and filler interac- tions to achieve levels of performance not possible through conventional mechanical blending and melt mixing. Interest is being fueled by more demanding end-user requirements and growing interest in compounds such as TPEs, as well as the growing need to handle and enhance complex waste plastic streams. And there’s a clear trend away from traditional batch to continuous reactive processing, with compounding extruders adapting their equipment to suit. Markus Fiedler, Senior Process Engineer with


Coperion, confirms the continuous processing trend. “Our customers are changing over from batch processes to continuous production for a variety of reasons, such as cost-effectiveness, easier cleaning and more precise process control,” he says. “Typi- cally, Coperion supports the changeover from batch to continuous in a two-step process. Firstly, we create a detailed analysis of the existing batch process together with the customer and transfer it to twin screw extrusion. In a second step, a feasibility trial will be done in the Coperion test laboratory in


www.compoundingworld.com


Stuttgart, typically on a small ZSK extruder.” Fiedler says that the modular design of the ZSK


extruder process section and the variety of individual twin screw elements allows the company’s engineers to adjust the extruder setup exactly to the require- ments of the reaction process. Particular attention is paid to residence time and process cooling, which is eased by the ability to configure extruder process sections with L/D rations of up to 80. The Coperion test laboratory in Stuttgart is well equipped with extruders from the smallest sized ZSK 18 MEGAlab up to the ZSK 70. In addition, it can utilise more than 100 gravimetric feeders for different kind of materials as well as more than 60 gravimetric liquid feeding systems. Liquid feeders are available for a broad range of viscosities and options include heated liquid feeding systems and piping to the extruder for test setups. A dedicated aspiration system and special personal safety equipment also allows trials with hazardous materials, such as isocyanates, amines or even selected CMR (carcinogenic, mutagenic and reproduction toxic) categorised materials after individual examination under safe conditions.


Main image: TPU production is among a growing number of opportunities for reactive compounding technology


� September 2018 | COMPOUNDING WORLD 27


PHOTO: SHUTTERSTOCK


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