EXTRUDER AND

ADDITIVATION

DEEPAK KUMAR
SUMANTO CHATTERJEE
Extruder what it does?

Receives feed material (powder) & additives via. hopper
into the mixer barrel.
Mixes the polymers & additives in the barrel by co-
rotating twin screws.
Pumps the molten polymer by melt gear pump.
Extrudes the polymer through the die nozzle as hot melt
strands and cut the extruded strands into pellets in a water
chamber filled with circulating cooling water.
These pellets are then conveyed to dewatering & drying
equipment & from there pellets go to classifier to separate
oversize,undersize & regular size pellets.

EQUIPMENTS
Extruder it is the general name of the
system consisting of various equipments
Main system
Auxiliary system

Main system
Starting Unit
Mixer Motor
Gear Pump Unit
Pellet Conveying Water Unit
Cutter Unit


Auxiliary system
Cylinder Cooling Water Unit (CCW)
Lube Oil Unit For Mixer motor & Mixer motor gear
reducer,Gear Pump gear reducer
Hydraulic Unit Oil Unit For Diverter valve, Slot, Screen
Pack Change over
Hot oil unit

STARTING UNIT
The starting unit consists of a starting
motor and a gear reducer with a cam
clutch attached on the reducers output
shaft . Before the main extruder drive motor
is started , the starting unit initiates the
extruder operation to fill the extruder with the
polymer and perform initial purging .After the
main motor is shut down , the starting unit is
also used to empty the extruder.
The primary function of the starting unit
is to avoid dry running of the extruder
at the speed of the main motor . The
cam clutch installed on the output shaft
of the starting unit permits the start of
the main motor while the starting motor
is driving the extruder screws . The
starting motor stops automatically 15
seconds after starting the main motor.

Item No. : 7X-1401-2/
7XM-2401-2
(1)Gear Reducer Part
(A) Construction & Design
Type: Enclose helical 3-stage speed reducer center split
gear casing
Capacity: 55KW
Input / Output Speed : 980rpm / 21.1rpm
Gear ratio : 1:46.45
Bearing Life : B-10 > 40000hr
Input Coupling : Gear coupling
Lubrication : Oil Bath

(B)Material
Pinion & Gears : Special alloy Steel
Surface treatment
Of Teeth : Carburizing
Casing : Fabricated Steel Plate

(2) Cam Clutch Part :
One way clutch to transmit torque in one direction of
rotation and to allow overturning of the mixer gear shaft
connecting to the cam clutch.
Lubrication : Water cooled oil bath
Manufacturer :The Japan Steel Works Ltd.
MIXER MOTOR
Item No. : 7XM-1401-1/7XM-2401-1
Name-- CMP 280 X 12 AW
Continuous Mixer Pump
Nominal Diameter Of
Heating & Kneading Zone
Co-Rotation Of Screw
L/D Ratio
Electrical Heating
Water Cooling

(1) GEAR REDUCER
The extruder gear reducer is driven by the
main motor through a friction clutch and a
flexible coupling .The flexible coupling
absorbs minor misalignment between the
two connecting shafts . The friction clutch
slips to protect the machine parts when
overloaded . Two output shafts are
connected to the extruder screws by spline
couplings and drive the screws at either high
or low speed as selected by the speed
change lever .

Name Plate Capacity
Parameter Unit Train-1 Train-2 Speed
Motor 3300 3300 High
capacity KW 3300 3300 Low
Speed RPM 980 980 H/L
Screw RPM 223.6 245.2 High
Speed 157.2 223.6 Low
Reduction 1:4.382 1:3.997 High
Ratio 1:6.234 1:4.382 Low
Manufacturer : JSW
(A)Construction & Design
Type : Enclosed helical gear reducer with 2- stage speed
casing center shift split gear
Gears : AGMA service factor => 1.5
Bearing Life: Radial bearing(B-10 >40000hr)
Main thrust roller bearing(B-10 > 100000hr)
Input Coupling : Torque Limit (Desh make)
Winterization : Not applied

(B)Material
Pinion & Gears : Special Alloy
Steel
Surface Treatment Of Teeth : Carburizing
Gear Shaft : Forged Steel
Casing : Cast Iron

(C) Instrumentation & Control
Thermometers : For Bearing on Input Shaft

Limit Switches : For Change Lever of Speed
Shaft



(D)Lubrication System
The lube oil for the main extruder
motor is supplied by one of two lube oil
pumps . The lube oil reservoir is
heated by low pressure steam as
needed for start up and the oil is
circulated through the lube oil cooler
during operation .


The lube oil unit for the mixer gear reducer is a closed
loop forced lubrication system that lubricates and
cools the bearing and gear surfaces of the extruder
gear reducer .The lube oil is pumped via one of two
gear pumps .The lube oil passes through a shell and
tube heat exchanger and is then filtered through one
of two oil filters . The oil then travels to the extruder
gear reducer where it branches of and enters
various injection and spray points on the gear
reducer . The oil then drains to the bottom of the
gear box where it is picked up by the suction of the
lube oil pumps .

Complete forced lubrication system with pump ,
Cooler, Filter, Piping and necessary instruments.
Main drive motor is to be interlocked to prevent
start up until adequate oil pressure is
established in the lubrication system.
Piping material is Carbon Steel ( JSW Standard )
Piping material after filter is stainless steel
(I) Lube Oil Pump With Stand-By
Item No. : 7P-1408/2408 A/B-X
Type : Gear Pump With Relief Valve
Drive : 11KW * 6P
Delivery : 346 Liter / Min.
Pressure : Max. 5 Kg/Cm2g
Design : API 676 With Delivery
(II) Oil Cooler ASME VIII (TEMA C)
Without U- Stamp
Item No. : 7E-1463/2463 A/B X
Type : Shell & Tube
Heat Duty : 85140 Kcal/h

(III) Filter-ASME VIII
Without U - Stamp
Item No. : 7ZZ-14306/24306 A/B X
Type :Dual Oil Filter
Screen : 100 Mesh
(2) MIXER SCREWS & BARREL
The extruder barrel is comprised of feed , mixing and discharge
zones. Each zone has cooling water jackets and electric
heaters for temperature control . The feeding zone conveys the
polymer down the barrel to the mixing zone by means of two
co-rotating and intermeshed screws. In the mixing zone,
kneading disks impart high mechanical shear and mix work to
the polymer converting it to a homogeneous melt . The molten
polymer is fed from the mixing zone through a funnel shaped
variable clearance slot, called Slot Clearance. Material hopper is
connected to mixer barrel feed opening via flexible joint . Two
liquid additive injection ports are provided on the mixer barrel.
Mixer screws are sealed with melt seal device in connecting
flange upstream of the hopper. Seal housings are jacketed for
water cooling or low steam heating for effective sealing .

Dimension Of Screw
993

HEATING
Zone
2230
1447
Kneading
Zone
1085
Discharge Zone
217

149
210
70
450,
Hopper
300
203
Screw Construction & Design
Model : CMP 280 X 12 AW
Type : Twin screw, Co-rotating & Intermeshing Type
Diameter : Feeding Section 300mm
Mixing Section 300mm
Discharge Section 226mm
L/D Ratio : Feeding + Kneading Zone 12
Discharge Zone - 5
Screw Speed : High Speed 222
Low Speed 155
Slot Clearance : 8 to 70 mm (Screw axial direction)

MATERIALS : Forged Alloy Steel
Feed and mixing section are machined, ground &
polished with screw ridges nitrided and other
outer surfaces chrome plated.
Discharged section is machined , ground and
polished with screw flight edges hard fusing with
wear resistant material and other outer surfaces
chrome plated.
Hopper Cylinder
Feed hopper is mounted on inlet port of hopper
cylinder.
Two hydraulic cylinders connect hopper cylinder
to gear reducer to control mixer cylinder position
for slot clearance adjustment.
Cylinder jacket is designed for cooling water
circulation only.
To prevent powder leakage from gap between
cylinder bores and rotating screws, sealing device
is provided at rear side of hopper section.
Design Data
Operating pressure : 4.7 Kg / Cm^2 g
Design pressure : 30 Kg / Cm^2 g
Hydrostatic test pressure : 45 Kg / Cm^2 g
MOC : Hopper Cylinder is of Nitrided
Steel
MIXER CYLINDER
Mixing cylinder are composed of three
cylinder barrels and supported on either
side by cylinder support
Each mixing cylinder has drilled jackets
for water cooling.
Four nozzles for additive injection are
provided on the top of mixing barrel with
plug

Design Data
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 30 Kg / Cm^2 g
Hydrostatic test pressure : 45 Kg / Cm^2 g
MOC : Hopper Cylinder is of Nitrided Steel
Instrumentation and control :
Heating of mixing cylinders are auto-
controlled by respective electric heaters and
thermocouple
DISCHARGE CYLINDER
Discharge cylinders is composed of one cylinder
barrel bolted to mixing cylinder and supported on
either side by cylinder support.
Discharge cylinder has drilled jackets for water
cooling
Vent port is provided on discharge
cylinder.(Normally closed)
Two replaceable liner coated with N- alloy are
fitted inside discharge cylinder.
Design Data
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 30 Kg / Cm^2 g
Hydrostatic test pressure : 45 Kg / Cm^2 g
MOC : Hopper Cylinder is of Nitrided Steel
Instrumentation and control :
Heating of mixing cylinders are auto-
controlled by respective electric heaters and
thermocouple

HYDRAULIC UNIT FOR SLOT
CLEARANCE CONTROL
The hydraulic oil unit controls the slot
clearance of the mixer in either auto or
manual mode by actuating the hydraulic
cylinders attached to connecting flange of
the mixer . When the actual slot clearance
deviates from the set point in auto mode , a
two stage hydraulic oil pump is automatically
actuated to supply hydraulic oil through
flexible hoses . The hydraulic pump is
housed in oil tank . The clearance range is
from 8 to 70 mm.


(A) Hydraulic oil unit
Item No. : 7P-1409/2409-X
Type : Axial plunger type
Delivery pressure : 400 Kg / Cm^2 g(High)
50 Kg / Cm^2 g (Low)
Delivery volume : 0.6 Liters/Min. (High)
4.0 Liters/Min. (Low)
Drive : 0.75 KW*4P
Oil tank : Volume 25 Liters
Item No.- 7V-1407/2407-X
(B) Attachments provided
Solenoid Valve
Filters
Valve
Internal piping for hydraulic oil unit and
rubber hoses .
Pressure gauge , Pressure switch
Mixer cylinder supports
(A) Construction & Design
Mixer cylinder supports have sliding faces on
their tops to allow slot adjustment and
expansion of the cylinders.
(B) Material
Welded carbon steel plate fabrication
Internal piping for cylinder jackets
(A) Construction & Design
Internal piping consists of solenoid valves ,
Check valves, glove valve, piping and
necessary fittings.
(B) Material : Carbon Steel (JSW Standard)

Compactor
(A) Construction & Design
Type : Conical Type
Drive : 75 KW
Screw speed : 3.4 to 34 rpm
Screw Diameter : 440 mm
(B) Material : Stainless steel
CYLINDER COOLING
WATER UNIT(CCW)
The CCW unit provides a closed loop tempered
water system designed to circulate cooling water at
a maximum of 80 deg.C through mixer barrels . The
cooling water must have non-fouling characteristic
Therefore pure water or treated water is used as
cooling water . This unit is provided for stable
temperature control of mixer barrels and to avoid
fouling of mixer jackets by the cooling water . The
system includes a demineralised water ( steam
condensate)
reservoir with level indication and low level switch ,
pumps and a cooler with ccw flow control and four
temperature controllers on the extruder barrel.

(A) CCW Tank
Item No. : 7V-1408/2408-X
Type : Cylindrical type
Volume : 100 Liters
Material : Stainless Steel
CCW Internal piping
Size : 3 Inch
Material : Carbon Steel
(B) CCW Pump (With Stand-By)
Item No. : 7P-1410/2410 A/B X
Type : Centrifugal type with mechanical Seal
Capacity : 450 Liters / Min. * 40 Meters Aq.
Material : Cast Iron
Drive : 11 KW * 2P
(C) CCW Cooler
Item No. : 7E-1464/2464 X
Type : Plate Heat-Exchanger
Capacity : 255000 Kcal/Hr
Material : AVESTA 254 SMO for parts in
contact with water
Design : ASME without stamp
DIVERTER VALVE
The diverter valve is attached to the end
of the mixer barrel and is used to divert
the flow of molten polymer to the floor
during start up to avoid damage of the
gear pump by un-melted polymer or
other solids and to prevent
contamination of the pelletization
system with the off specification
product .

With the diverter valve in divert position,the flow of
molten polymer from the extruder barrel is diverted
to the floor ( i.e. away from the gear pump ) until the
polymer is clean with good melt properties ( melt
condition of the melt is to be checked ).This is called
globing and the diverter valve is often called the
globing valve .When the globing operation is
complete , the diverter valve is switched to the
through position ,sending the flow of molten polymer
to the gear pump

(A) Construction & Design
Diverter valve is bolted to mixer cylinder end
to divert degraded or unflexed polymer to
the floor by activation of hydraulic
cylinder
Polymer design pressure : 150 Kg/Cm^2g
Valve body has jacket for oil heating

Operating pressure : 4 Kg / Cm^2 g
Design Pressure : 60 Kg / Cm^2 g
Hydraulic test Pr. : 90 Kg / Cm^2 g
Hydraulic Oil Cylinder
Hydraulic Pressure : 600 Kg / Cm^2 g

(B) Materials
Body : Cast Steel
Piston : Carbon Steel
All surface in contact with polymer is
chrome Plate
(C) Instrumentation and Control
Limit Switch : Diverter valve stroke ends
GEAR PUMP
The melt gear pump is designed to receive the
molten polymer from the mixer through the
diverter valve and to generate pressure to
force the polymer through the screen
changer and the die plate for Pelletizing .The
gear pump is a positive displacement pump
with short residence time and high
volumetric efficiency . Polymer pressure
sensors are provided at both the suction and
discharge parts of melt gear pump.

GEAR PUMP DRIVE AND GEAR
REDUCER
Melt gear pump is driven by gear pump motor
via gear reducer unit and thrust box. Gear
reducer , thrust box and gear pump are
connected by respective one pair of flexible
couplings .Thrust box is attached to prevent
both axial and vertical forces being
transmitted to the melt gear pump shaft from
gear reducer Therefore the pump gear can
pump the melt without any gear contact even
when loaded .


GEAR REDUCER

(A)Construction & Design
Type : Enclosed helical gear reducer with 3- stage speed
casing center shift split gear
Capacity : 700 KW
Input Shaft Speed : 115 to 1150 RPM
Output Shaft Speed : 4.5 to 45 RPM
Reduction Ratio : 25.5
Gears : AGMA service factor => 1.5
Bearing Life: B-10 >40000hr
Input Coupling : Gear coupling with shear pin
Output : Universal Joint
Winterization : Not applied


(B)Material
Pinion and gear : Special Alloy Steel
Surface treatment of teeth : Carburizing
Shaft : Forged steel
Casing : Fabricated Steel
(C) Instrumentation & Control
Thermometers : For Bearing on Input Shaft
Lubrication System
One complete forced lubrication system with for gear
reducer with separate gear drive are equipped with pump ,
Cooler, Filter, Piping and necessary instruments.
Gear pump drive motor is to be interlocked to prevent
start up until adequate oil pressure is established in the
lubrication system.
Piping material is Carbon Steel ( JSW Standard )
Piping material after filter is stainless steel

(I) Lube Oil Pump With Stand-By
Item No. : 7P-1413/2413 A/B-X
Type : Gear Pump With Relief Valve
Drive : 2.2KW * 6P
Delivery : 73 Liter / Min.
Pressure : Max. 5 Kg/Cm2g
Design : API 676 With Delivery

(II) Oil Cooler ASME VIII (TEMA C)Without U- Stamp
Item No. : 7E-1466/2466 A/B X
Type : Shell & Tube
Heat Duty : 21000 Kcal/h
(III) Filter-ASME VIII Without U Stamp
Item No. : 7ZZ-14306/24306 A/B X
Type :Dual Oil Filter
Screen : 100 Mesh



Separate Drive Gear
(A)Construction & Design
Type : Enclosed one pair of spur driving gear to prevent gear teeth
contact of gear pump by uniformly distributed gear flank clearances.
Capacity : 700 KW
Input/output Shaft Speed : 4.5 to 45 RPM
Gears : AGMA service factor => 1.52
Bearing Life: B-10 >40000hr
(B) Material
Pinion and gear : Special Alloy Steel
Surface treatment of teeth : Carburizing
Shaft : Forged steel


Coupling
(A) Universal joint connecting gear reducer and separate
drive gear
Universal joint is equipped with shear pin to protect over-torque to gear
pump.
Universal joint absorbs shaft center off-set resulting from mixer cylinder
movement by heat expansion and slot adjustment.
(B) Special coupling connecting separate drive gear and
gear pump
These coupling uniformly distribute gear flank clearance (backlash) on
both side of gear teeth for gear pump preventing metal to metal
contact of teeth.

Gear Pump
(A) Construction & Design
Gear pump is directly bolted upstream diverter valve
and downstream screen changer in tandem on the same
floor level.
Type : Spur gear pump GP 355T
Polymer pressure : Suction pressure is automatically controlled by gear
pump speed control.
Polymer Design Pressure : 350 Kg/Cm^2 g
Speed : 4.5 to 45 RPM
Casing has drilled jacket for oil heating
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 60 Kg / Cm^2 g
Hydrostatic test pressure : 90 Kg / Cm^2 g


(B)Material
Gear : Nitrided Steel
Bearings : Hardened Steel
Casing : Cast Steel with Chrome plate inside
(C) Instrumentation & Control
Pressure transmitter and thermocouple for melt resin on
suction side of casing.
Pressure transmitter and thermocouple for melt resin on
discharge side of casing.
4- thermocouple for bearing temperature measurement.


Screen Changer
Screen changer is connected to the downstream of pump
to enhance polymer quality in process by removing
impurities contained in polymer.Slide bar shifts by
hydraulic cylinder to exchange clogged screen pack.
The screen changer is located between melt gear pump
and die head to filter molten resin , eliminating foreign material
to enhance final product quality. When screen pressure
increases due to clogging by polymer imperfections , the slide
bar is shifted by hydraulic cylinders to push one of the clogged
screen packs sideways for screen replacement ,The two slide
bars are shifted alternatively to allow continuous Pelletizing ,
thereby preventing build up of excess polymer pressure . Main
body is heated by hot oil.
(A) Construction & Design
Type: NSC 305DBW Dual bar
Actual filter area: 1770 Cm^2
Two screen are to be changed slowly and safely during
mixer operation
Two screen are assemblies are in two slide bars.
Polymer pressure
Body Design pressure: 350 Kg/Cm^2 g
Differential Design pressure: 200 Kg/Cm^2 g

Main body has jackets for oil heating
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 60 Kg / Cm^2 g
Hydrostatic test pressure : 90 Kg / Cm^2 g
(B) Material
Main body : Nitrided steel inside surfaces in contact with
polymer is chrome plate.
Slide bar : Nitrided steel
Breaker plate : Alloy steel
Screen : Stainless steel

HYDRAULIC OIL UNIT FOR SCREEN CHANGER
AND DIVERTER VALVE

The screen changer and diverter valve are operated via
hydraulic pressure provided by the hydraulic pump. The
diverter shaft with seal rings is moved up and down by a
hydraulic cylinder attached to the top of the diverter valve
body.
The hydraulic oil unit actuates the hydraulic oil cylinder to
shift the slide bar . Three positions of the slide bar are detected
by cams and used for smooth screen change . When new
screen moves in the process line after screen replacement ,
the slide bar stops at the half way position to bleed air through
grooves on the slide bar preventing air intrusion into the
process line. Air bleeding time is adjustable .

Hydraulic pump
Hydraulic unit consists of drive motor,
Pump, Solenoid valve, Pressure gauge and
oil tank for screen changer and diverter
valve.
Item No. : 7P-1412/2412-X
Pump motor : 7.5 KW*4P
Delivery : 5.0 Liters/Min.
Delivery pressure : 600 Kg/Cm^2 g
Adapter
Adapter is installed between gear pump and
screen changer.
(A) Construction & Design
Polymer Design Pressure : 350 Kg / Cm^2 g
Adaptor is designed with jackets for oil heating
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 60 Kg / Cm^2 g
Hydrostatic test pressure : 90 Kg / Cm^2 g
(B) Material
Forged steel inside surfaces in contact with polymer is
chrome plate.
Die Head
The die head consists of the die holder and die plate
.The die holder is connected downstream of the
screen changer via the spacer flange . The die plate
is attached to the other end of the die holder . The
core of the die holder is jacketed and conical to
force polymer into a tubular laminar flow . The die
plate is a drilled , heat channel type . The die plate
has eight inlet and four outlet hot oil circulation
nozzles . Hot oil is distributed to each heat channel
provided inside the die plate for uniform and
effective heating . The die plate is stainless steel
with titanium carbide plates soldered on the cutting
surface to a thickness of 3mm.

Die Plate
(A) Construction & Design
Type : Heat channel die
Number of die holes : 2.6 mm* Appx. 1400 holes
Polymer Design Pressure : 200 Kg / Cm^2 g
Die plate has drilled jackets for oil heating
Operating pressure : 4 Kg / Cm^2 g
Design pressure : 60 Kg / Cm^2 g
Hydrostatic test pressure : 90 Kg / Cm^2 g
(B) Material
Stainless steel with titanium carbide plate on cutting surface
(C) Instrumentation & Control
Thermocouple : For die plate steel temperature

Water chamber
Water chamber is clamped to die holder by quick open/close
mechanism. Hot water is pumped into the water chamber for
underwater pelletizing and conveys pellets to dewatering equipment.
(A)operators side has a peep window.
One scope lamp is provided on the opposite side.
Water chamber design pressure : 4 Kg/Cm^2 g
(B) Material : Cast stainless steel
(C ) Instrumentation and control
One limit switch is provided for a side door.
One limit switch is provided to insure the contact of water chamber with
die holder.
Cutter unit
The cutter unit is bolted to the water chamber to pelletize polymer
strands into pellets .The rear end of cutter shaft is connected to drive
motor via a slide type gear coupling to absorb cutter shaft stroke
when knife clearance is adjusted. Cutter cylinder is provided to
control variable knife pressure on die face caused by cutter shaft
speed adjustment and to automatically forward the cutter shaft
towards the die face to compensate for wear of the knives .
Mechanical stopper for cutter shaft retraction ( or cutter shaft
forwarding device ) and lock nut are provided .The perpendicularity of
the cutter shaft is adjusted by jack bolts and shims between the water
chamber and the cutter unit. Dial indicator is pre-set to 0 when new
cutter knives contact with die face prior to Pelletising . After start of
Pelletising , indicator shows how far cutter shaft has advanced to the
die face due to knife wear . When the cutter shaft moves 2mm
towards the die face from 0 point during operation due to knife wear,
proximity switch functions to trigger an alarm sound .

Cutter motor is directly connected to cutter shaft by gear
coupling covered with safety guard.
Cutter shaft can stroke back and forth by activation of
hydraulic cylinder provided inside cutter unit.
The cutter blades can be kept to contact to the cutting
surface of die plate automatically by activation of
hydraulic cylinder.
Cutter holder is design for ease of exchange after
disconnecting water chamber from die plate by releasing
clamp device.
Cutter shaft adjusting handle and a dial gauge are
provided at rear end of casing.
Design Data
(A) Construction & Design
Type : ADC Type
Drive : 65 KW
Cutter speed : 115 to1150RPM
No. of cutter blade : 12
Lubrication : oil bath , Grease
(B) Material
Casing :Cast Iron
Cutter blade : Titanium carbide stainless steel for start-up
Cutter Holder & cutter shaft : Stainless Steel
(C ) Instrumentation & Control
Dial gauge
Proximity switch for cutter blade wear alarm.

Hot Oil Unit
A hot oil system is used to control the temperature of the diverter
valve , gear pump, screen changer and die plate . The system
consists hot oil pump with stand-by,electrical heater
,expansion tank, instrument, operating panel and internal
piping which is mounted on one skid.
Operating temperature :Normal 260
Design - 300 (Degree C)
Electrical heating capacity : 240 KW
(7E-1465/2465 A/B X)
Pump capacity (7P-1411/2411 A/B-X) : 600Liters/Min. *7
Kg/Cm^2 g
Pump drive motor with stand-by : 15 KW * 2P


Continuous melt flow index analyzer
The analyzer measure and record continuously the ASTM (ASTM
D 1238/E-CONDITIONAL) of the melted polymer sampled at
process extruder discharge.
(A) Construction & Design
(1) Die unit completed with metering pump, flow barrel, capillary
housing, motor and drive assembly, temperature and pressure
sensor, capillaries.
It also include sampling connections and adapter to sample melted
polymer from the extruder avoiding thin layer of polymer at
extruder wall.
Adapter and connections are supplied with electrical heating and
temperature control.
Furthermore a complete set of capillary to cover the whole range of melt
flow index is provided.
Die unit is installed close to extruder.
(2) Control class is design for panel mounting to be located in extruder
building with temperature control & calibration.
(3) Controllers to be located at extruder control room.
M.I.E. Analyzer is of non-return type.
(C ) Controllers
Controllers in extruder control room & signals for DCS are provided for-
Test Pressure
Test Temperature
Pump Temperature
Melt Flow Index
Technical Data
Melt flow index range : 0.02 60.0
Normal test temperature : 190 C
Temperature control : Electrical
Accuracy of temp. control : -2% to+2%
Chamber pressure rating : 350 Kg/Cm^2 g
Test pressure : 3Kg/Cm^2 g or 7Kg/Cm^2 g
Transdure pressure range : 0 10 Kg/Cm^2 g
Measure repeatability : -2% to +2 %
Sample flow rate : Std. (max. 0.5 Kg/ Hr)
Signal level : 4 20 mA


Carriages
Two independent carries support pelletizing components and move
on rails in direction of mixer screw axis for quick and accurate line-
up.
Carries for Diverter valve , Gear pump , Screen changer and Die
holder
Carries for water chamber and underwater pelletizer with motor.
(A)Construction & Design
Support height of carriages are adjustable with adjusting bolts and shims.
Carriage wheel can driven by either a direct ratchet level (for gear pump,
screen changer and die holder) or a handle (for underwater cutter unit
and drive motor).
(B) Material : Steel Fabrication
Drying System
These are the equipments of drying system:
Dewatering System
Centrifugal Dryer
Vibrating Classifier
Exhaust Fan
Cyclone Separator
Dewatering System

The pellet slurry enters a swing gate agglomerate
catcher . Here large chunks and globs are
separated from pellets and hot water by inclined
stationary slitted bars . When agglomerates
accumulate on a slitted bar , a flapper plate can be
swung by air cylinder to discharge the agglomerate
on slitted plate to outside . Then pellets and hot
water drop to inclined screen plates . There most of
free water is separated from the pellets by the
screen and the pellets roll down towards the
centrifugal dryer with some free water

Dewatering System

(A) Construction & Design
Item No. : 7SE- 1427/2427-X
Type : DS- 7A
Agromerate size : More than 25 mm
(B) Material : Stainless Steel for parts in
contact with slurry and Carbon Steel for
others.

Centrifugal Dryer

De-watering is accomplished by a rotor located in the center of the
dryer. This unit is a vertical series of stainless steel impeller blades
extending from the bottom of the dryer to the top . De-watering is
accomplished by spinning of water by centrifugal action .The
surrounding rotor assembly is a stainless steel stationary perforated
screen casing .This casing retains the pellets within the operating
section as pellets impinge against screen , but allows water to pass
through the screen by its own inertia . The rotating blades continue to
lift the pellets upward to the outlet where they are channeled off at the
top of the dryer. The revolving blades also force to move air through
the dryer .This air is taken in through the air filters located at the top of
the dryer . The air passes through the spaces between the vertical lift
plates , through pellets and perforated casing .One air outlet
opening is provided on the side wall of the dryer for the discharge of
air and is connected to a suction fan to prevent exhausting air
containing water drops being forwarded to vibrating classifier .

Centrifugal Dryer

(A) Construction & Design
Item No. : 7SE-1404/2404-X
Type : N-1000 Centrifugal Type / N-1200
Speed : 330rpm / 290rpm
Drive : 18.5KW*4P / 22KW*4P
(B) Material : Stainless Steel for parts in
contact with slurry and Carbon Steel for
others.

Vibrating Classifier

The centrifugal dryer outlet is connected to the vibrating
classifier by connecting chutes . The top screen holes allow
separation of on -test size and smaller pellets from the large
pellets (oversize). The oversize cannot pass through screen
pores and are fed from the classifier screen to outlet by
vibrating action of the classifier , then drop into an oversize box
by gravity flow . The on-test pellets are fed from the classifier
screen to the product pick up hopper . The smaller pellets and
fines separated , are fed to the other outlet .The connecting
chute between the centrifugal dryer and classifier has an air
operated diverter valve to divert the pellets discharged from the
dryer to the outside of the chute .

Vibrating Classifier

(A) Construction & Design
Item No. : 7SE-1428/2428-X
Type : Mechanically vibrating classifying type
Screen : Top : 4Mesh
Bottom : 9 Mesh
Drive : 4.0 KW * 4 P
(B) Material : Stainless Steel for parts in contact
with pellets and Carbon Steel for others flexible
canvas are provided

Exhaust Fan

(A) Construction & Design
Item No. : 7B-1402/2402-X
Type : Centrifugal fan
Capacity : 150 Nm^3 /Min.
Drive : 15 KW * 4P
(B) Material : Stainless Steel
Cyclone Separator

(A) Construction & Design
Cyclone separator is installed after exhaust
fan to remove fine polymer products
(B) Material : Stainless Steel
Pellet Conveying Water System
(PCW)
(1) PCW Tank
Item No. :7V-1404/2404-X
Type : Box Type
Volume : 8 M^3
(2) Material :Stainless Steel for the parts in
contact with liquid
PCW Cooler
Item No. :7E-1401/2401-X
Type : Plate Type
Heat Exchanged : 2252800Kcal/Hr
Cooling Water: Inlet: 33 C
Outlet : 43 C
Material : AVESTA 254 SMO for parts in
contact with PCW water
OVER ALL CONTROL SYSTEM

Local Start Up panel is installed close to the
Extruder die plate and it is connected to PLC and
DCS.It is used as MMI at field
Most of the field instruments are hardwired
to/from DCS and PLC through local control
panel.
All the logic including interlock function are
configured in the PLC
Motors are started or shut down from field
switches or switches on LSP

General operation concept

Start up & Shut down of extruder by Local
control panel & PC station
Control & Monitoring of the operation after the
start up is done through PC station and DCS
(view only)
The process information (including alarm
condition) can be accessed both on on LCP at
field, PC station & DCS
Other controls (Speed setting of each motor)can
be accessed both LCP & PC station


AUTO START CONDITION
Feeding System run
Compactor Motor Run
Mixer Motor run
G/P Motor not run, not stop ,not electrical fault condition
Cutter Motor not run, not stop ,not electrical fault condition
D/V valve in divert position
PCW inlet 3-Way valve bypass position( when dry mode)
PCW inlet 3-Way valve through position( when wet mode)
PCW pump run,not low flow
Dryer run (speed not low-low)
Classifier run
Pellet Separation hopper Level not High-high
Torque Coupling Engage
Mutual Interlock On
Operation Mode auto
Auto start
Extruder Start Sequence is from downstream to
upstream &
Auto Start Sequence:
a)Cutter Motor Start(*)
b) Cutter Shaft forward(4sec)
c) Gear pump Motor start(7sec)
d) D/V Valve Through.(0.1sec)

AUTO - STOP
When It Activated?
1)Auto stop switch is pressed when mode is auto.
2)Auto Start Fails
3)Heavy Alarm condition occur after Extruder System is
completely running and Mutual interlock is Onposition
4)Emergency switch is pressed
Auto stop Sequence
Stop sequence from upstream to downstream

a)Feeder stop. (*)
b)Mixer Motor Stop.. (5sec)
c)Gear pump motor Stop.. (5sec)
d)D/V diverted ()
e)Cutter Motor Stop (40sec)
f)Cutter Shaft backward .(5sec)
g)PCW inlet 3 Way valve bypass (0.1sec)


Mutual Interlock system

Mutual interlock System
While Auto Stop sequence operates from upstream
to downstream equipment , Mutual Interlock
system operates inversely and shut down the
upstream equipment immediately
If one equipment is stopped,upstream equipment is
stopped Immediately by M/I and down stream
equipment by Auto Stop sequence
***PCW***D/V

SHUT DOWN (emergency)

Shut down sequence is provided to shutdown the
extruder immediately in the emergency
situation(instant shut down)
It Implements the following operations instantly
Shutdown feeding system
Shutdown Starting motor
Shutdown Mixer Motor
Shutdown G/P Motor
Shutdown Cutter Motor
Shutdown Cutter Shaft backward
Shutdown PCW inlet 3 way Valve bypass

S.
No.

TAG

Description

Settings
1

XA4354C

Auto Start Fail



2

SALL 4302C

Centrifugal Dryer Speed L.Low

330 RPM
3

YALL4354C

Compactor motor Stop



4

XA4358C

Compactor motor electrical fault



5

PALL4311C

PCW inlet press L.Low

0.3 Kg/cm2 g
6

YALL4363C

Cutter motor Stop



7

XA4357 C

Cutter motor electrical fault



8

ZAHH4362C

Cutter unit remove



9

PALL4385C

Cutter unit clamp hydra. oil press l.low

140 Kg/cm2 g
10

ZAHH4365C

Cutter unit lock ring unlock.



11

ZAHH4364C

Cutter window open



12

PAHH4382C

Die holder poly press. H.High

190 Kg/cm2 g
13

XA4362C

Emergency stop.



14

LAHH4303C

Feed hopper level h.High

90%

15

YALL4356C

Feeding system stop



16

TAHH4391C

G/p bearing temp H.High

380C

17

PAHH4381C

G/P discharge poly press. H High

340 Kg/cm2 g.

18

PALL4393C

G/P G/R lube oil press. L.low

0.7 kg/cm2 g.

19

YALL4359C

G/P G/R lube oil pump stop



20

TAHH4389C

G/P G/R lube oil temp H.High

65C

21

YALL4358C

G/P motor stop



22

TAHH4382C

G/P motor bearing temp H.High

100C

23

XA4356C

G/P motor electrical Fault



24

TAHH4381C

G/P motor winding temp H High

150C

25

PAHH4389C

G/P suction press H.High

140 Kg/cm2 G.

26

SDAHH4355C

G/P torque coupling Slip

7~8

27

TAHH4374AC

No.1 Hot oil heater temp H High

380C

28

TAHH4374BC

No.2 Hot oil heater temp H High

380C

29

LALL4357C

Hot oil tank level L Low



30

FALL4357C

Hot oil line flow L.Low

400 l/min

31

TAHH4357C

Hot oil line temp H High

320C

32

YALL4360C

Hot oil pump stop



33

FALL4358AC

No.1 Hot oil pump cooling water flow L.Low

1.1 M3/hr.

34

FALL4358BC

No.2 hot oil pump cooling water flow L Low

1.1 M3/hr.

35

TAHH4375AC

No.1 hot oil pump temp H High

224C

36

TAHH4375BC

No.2 hot oil pump temp H High

224C

37

PALL4359C

Mixer G/R lube oil press L Low

0.7 KG

38

YALL4352C

Mixer G/R lube oil pump stop



39

TAHH4365C

Mixer G/R lube oil temp H High

65C




40

YALL4301C

Mixer motor stop



41

TAHH4351C

Mixer motor bearing temp H High

95C

42

IAHH4301C

Mixer motor current H High

347 (H
speed),240 amps
(L Speed)

43

IALL4301C

Mixer motor current L Low

67 amps

44

XA4351C

Mixer motor electrical Fault



45

PALL4354C

Mixer motor lube oil press. L Low

1 Kg/cm2 g

46

YALL4351C

Mixer motor lube oil pump Stop



47

TAHH4357C

Mixer motor lube oil temp H High

65 C

48

TAHH4352C

Mixer motor winding temp H High

150C

49

SDAHH4351C

Mixer Torque coupling Slip

7~8 pulse/20 secs

50

FALL4301C

PCW line flow L Low

113 M3/hr.

51

YALL4304C

PCW pump stop



52

PAHH4368C

Slot back press. H High

400 Kg/cm2 g

53

ZAHH4355C

Slot position Excessive open

75mm

54

IAHH4352C

Starting motor current H High

68 Amps

55

LAHH4302AC

Pellet separation hopper level H High



56

LAHH4302BC

Pellet separation hopper level H High



57

LAHH4302CC

Pellet separation hopper level H High



58

YALL4303C

Centrifugal dryer Stop



59

YALL4305C

Vibrating classifier stop



60

TAH4367A/B/C/D

Cylinder heater temp High

420 C





S No

Description

Settings

O
K

Not
OK
1

Lube oil system of mixer motor







2

Lube oil system of mixer motor G/R







3

Gear pump motor/ G/R







4

Temperature of hopper cylinder

Cooling





5

Temperature of cylinders 2,3,4,5







6

Temperature of D/V, gear pump, die head

240C





7

Temperature of Die

280 C





8

Hot oil temperature

300C





9

Operation mode

Manual(LSP)





10

Mutual interlock

Off(LSP)





CHECK LIST FOR EXTRUDER STARTUP

11

Safety interlock

Reset(LSP)



12

Mixer screw speed





13

Diverter valve

Divert



14

PCW temperature

75~80 C



15

PCW flow( Bypass)

160 T/hr



16

Compactor motor speed

15%(LSP)



17

Gear pump speed

35%(LSP)



18

Cutter speed

55%(LSP)



19

Forward pressure

5.0 KG



20

Backward press.

0.7 KG



21

Classifier,dryer,B-1402

Running





22

Homogenizer Mode

Auto





23

Agglomerate catcher gate

on





24

Nitrogen blanketing

Normal





25

B-1451 A/B

Running





26

Stabilizer system

Ready





27

W-1405

Running





28


All rotary equipment coupling guards in place

OK / Non-OK









TROUBLE SHOOTING:

1)Gear Pump In Manual Mode
2) Wrong Indication Of Compactor Level
3) Auto Start Failure
4)Flowability Of powder from compactor
5) Barrel Temperature
6) F-1 flow
7)F-2 flow