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Update in Rubber Mixingand
Rubber Technology
R. H. Schuster
Consultant to LANXSS !"er#an Rubber $nstitute
%& 'ornadas Latino(A#ericanas de Caucho
)uenos Aires &*!&+ Sept. &,%*
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%.-ay( Mixing o Rubber
( /iller -ispersion
( /iller -istribution
( Rubber(/iller $nteraction( $nluence o Mixing on
-yna#ic(Mechanical 0roperties
&.-ay( $nluence o Mixing on Ulti#ate 0roperties
( 1ulcani2ation3 Che#istry and 0rocess
( Speciality Rubbers( 4xidati5e Ageing
( 4il Resistant T01
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Abrasion Resistancenergy -issipation
lasticity
Lo6 Te#perature /lexibility
Ageing Resistance
Tensile Strength
7earResistance
4il Resistance
Traction
lasto#ers
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lasto#ers
Tires
8&9.,,, t
:.%,, Mrd ;
Technical Rubber "oods?=&.,,, t
:.+,, Mrd ;
< &9 >Source3 7d@ Report &,%,
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Mixing o
Rubber Co#pounds
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Aggregates
Agglo#erates
/illerManuacturing
0elletslarge size
hardness and strengthlow density (voids)
stability in pneumatic transport
Role o Mechanical Mixing
$ncorporation
Si2e reduction
0ellets
Aggregates
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MixingMaterial properties changing 0rocess
( Rheological 0roperties
( /urther 0rocessing( -ispersion and -istribution o /illers
( 0hase Morphology
( 0hysical 0roperties Set
( Lie Ti#e o Rubber 0roducts
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0art 0ropertiesMixing Co#pound0roperties
0rocessing 0art 0ropertiesMixing Co#pound0roperties
0rocessing
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/urther0rocessing/urther0rocessing
0oly#ersB
/illersB
0rocess oilsB
Special Che#icals
Curing Agents
Mixing 0rocess
( Mastication and )lending( $ncorporation o /illers
( /iller -ispersion!distribution
( -ispersion o ingredients
( 4il incorporation
( Curing reaction is not allo6edto start
Mixing 0rocess
( Mastication and )lending( $ncorporation o /illers
( /iller -ispersion!distribution
( -ispersion o ingredients
( 4il incorporation
( Curing reaction is not allo6edto start
Ra6 Material
uality Control
Ra6 Material
uality Control
uality checDo the #ixtureuality checDo the #ixture
0urpose o the Mixing 0rocess
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Rating Criteria or Mixing uality
-egree o /iller -ispersion
Methods do not allo6 any in(process control
Retroacti5e inor#ation E
Tensile Strength
Tear 0ropagation Resistance
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Mixing Fuip#ent
-iscontinuous Mixing
)atch Mixing
Continuous Mixing
T6o(Roll Mill
$nternal Mixer
T6in Scre6 xtruder
Ring xtruder
0lanetary Roller xtruder
6ell established
State o the Art
pro#ising starts or
so#e production lines
Can use e5ery or#
o the ra6 #aterials
Relies #erely on
ree lo6ing ra6 #aterials
i.e. granulates
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T6o(Roll Mill
#illing o rubber sheets
Cutting o the blanDet
-ierent speed o the rolls
/rictionB
Stea#(heating
/or#ation o a band 6hich
adheres to one o the rolls
Mixing iciency is high
High strains in the Nip region
stocD
blender
T6o rolls 6hich rotate in
opposite sensed6in ChaeG %9*:B
Cooling
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Mixing on an open #ill
Courtesy3 1redestein
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T6o(Roll Mill
Ad5antages
-ispersi5e Mixing actionis high
Mixing 0rocess isollo6ed easily
Mixed Material or#s
sheets suitable or
Co#pression Molding
-isad5antages
Handling o /illers andAdditi5es cause house(
Deeping proble#s
0rolonged Mixing Ti#es
Less 0rocess Control
xposure o large
suraces to at#osphere
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$nternal Mixer I )rie History
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$nternal Mixer
Closed Mixers eFuipped 6ith
counter(rotating rotors
Rotors 6ith ascre6(liDe geo#etry
Axial #ixing along the
rotors to6ards the center
Ra#3( seals the #ixing cha#ber
( 0resses 0oly#ers into
the #ixing cha#ber
( co#press large 5olu#es
o illers
Rotors #ay or
#ay not o5erlap
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$nternal Mixer I basic ele#ents
Modular design
( /eeding hopper( Mixing cha#ber
( )ase 0late
Mixing Cha#ber
( Mixing cha#ber hal5es( Rotor end plates
( Rotors
Te#perature Control
Cooling syste#s
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$nternal #ixers in tyre industry adopt #aterials
in any Dind o trade or#
Courtesy3 Harburg /reudenberger Maschinenbau "roupor#erly @rupp ! 70B
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$nternal #ixers or technical rubber goods
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Types o $nternal Mixers
Tangential Rotors $nter#eshing Rotors
( The rotors do not o5erlap
( Cur5ed lights 6hich
pu#p in opposite direction
( $ndependent speed on each
rotor( "ap bet6een the rotors a5ours
i#pro5ed eeding
( larger batch 5olu#e
( Short incorporation ti#e
( The rotors o5erlap
( $nter#eshing o the
rotor lights
( s#all interdistance
( sa#e angular 5elocity( high surace!5olu#e ratio
( )etter cooling
( Less batch 5olu#e
( "ood dispersi5e #ixing
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,
%
&
*
+
:
?
nergy
..iciency
Ther#al
0er.or#ance
Co(#astication 0lastici2er
)lending
Machine
Utili2ation
$ntaDe and
-ischarge
)eha5ior
,
%
&
*
+
:
?
nergy
..iciency
Ther#al
0er.or#ance
Co(#astication 0lastici2er
)lending
Machine
Utili2ation
$ntaDe and
-ischarge
)eha5ior
Tangential
$nter#eshing
Technological Co#parison $B
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Sa#e batch si2e
courtesy3 Techint 0o#ini
tangential $nter#eshing
Technological Co#parison $$B
,
:,
%:,
&:,
*:,
% & * + : ? =Cooling Surace J# K
1oid1
olu#eJ#L
tangentialinter#eshing
,
:,
%:,
&:,
*:,
% & * + : ? =Cooling Surace J# K
1oid1
olu#eJ#L
tangentialinter#eshing
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Tande# Mixing
Co#bination oa #aster batch #ixer $nter#ixB
a larger ra#less #ixer Tande#B
eecti5ely cooled
inter#eshing rotors
Consecuti5e #ixing
Rubber and /iller into the hot
$nter#ix upper #ixerB
Ater pre#ixing the co#pound is
dropped into the tande# #ixer.
Mixing ti#e reducedCooling and -ispersion
by re#illing in the Tande#
'. 0eter %89=B
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Tande# Mixing
/ro# Tande# MixerThe inal batch is du#ped
on a #ill or into an
extruder 6ere it 6ill
be sheeted andcon5eyed to the batch Io
unit.
Ad5antage3
%B the batch does
not need to be stored bet6een
%st and &nd stage
&B )etter te#perature controli.e. or Silani2ation
*B Higher troughput
-ischarge
%%,C
Add Curati5es
Te#p.
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/eeding Hopper3 Concepts
0neu#atic /eeding Hopper Hydraulic /eeding Hopper
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Hydraulic /eeding Hopper
Lo6 noise
le5el
/ast ra#
#o5e#ent 0recise ra# orce
control
Little operation
costs
Constant process
conditions
Ad5antages o Hydraulic /eeding Hopper
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Ra# 0osition Control
Usually ra# speedG ra# pressure are adOusted during theinstallation o the #ixer
0roble#s or hopper unctionality3
( -usty illers can deposit on the ra#( SticDy co#pounds on the hopper 6alls
( Ra# Oa##ing
-igital ra# position control
( Co#pound Fuality can
be i#pro5ed
( 4peration disruptions can
be a5oided
-epending on the ra# positionG ra# speed
and ra# pressure can be better controlled
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Mixing Cha#ber $B
Hard Coating
Hard Coating
ree o CracDs
Corosion
Resistance
High tensile
Strength
$ntensi5e Cooling
High Hardness
Fual coating
thicDness
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Mixing Cha#ber $$B
Te#perature ControlTe#perature recording is aected by
( Co#pound lo6
( good ther#al contact
( extension o the sensor( place#ent in side6all or drop door
( Sensiti5ity o the sensor
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Mixing Cha#ber $$$B
0lastici2er 4il $nOection
/eeding liFuid co#ponents into the #ixing cha#ber
$nOection 5al5es are itted into the #ixing cha#ber
Large #ixers are eFuipped 6ith + inOection 5al5es
$nOection in short ti#e and dierent types o plastici2er
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Rotors
/unctions o the Rotors
$#part shear and elongation into the co#pound
-ispersi5e Mixing
-istribute ingredients inside the co#pound
-istributi5e Mixing
-issipate heat out o the co#pound
C li
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Cooling
Ring cooling
Spray cooling
Rotors occupy a high portion
o the #ixing cha#ber
Cooling o rotors i#pro5es
#ixing eiciency by
increasing the 5iscosity
o the #ix.
Strength is achie5ed by rotorbody 6alls
)etter cooling eiciency 6ith
Ring cooling.T6o body rotor 6ith reduced 6all
ThicDness. "ood heat transer
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Tangential Rotors $BTangential Rotors in5ented by
/. H. )anbury
-ia#etrical located
one 6ing extended in length
Relati5e lo6 producti5ity
Most eecti5e #ixing
bet6een the rotor lights and the 6all
0articular eatures or tangential Rotors
( Nu#ber o 6ings
( 0osisition o 6ings( Length o 6ings
( Angularity o 6ings
( 4utline acti5e!passi5e sideB
(Tip 7idth o the 6ings
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Tangential Rotors $$B
&(7ing RotorsLasch P /rei %8*,B
Nor#al Rotor StandardB
( Short 6ings are s#aller in height
( used in older #ixers
/ull(+(7ing Rotors /(+ I7B Tyson and Co#perG %8??B
& long #ain 6ings 6ith
( short pitch angle and large light depth
( & shorter 6ings at higher pitch angle
High speciic energy in a
short period o ti#e
Rapid #aterial intaDe and
good discharge 0roperties
N (Rotors
Un6ined
Rotor "eo#etry
/ull(+(7(Rotors
Un6ined
Rotor "eo#etry
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Tangential Rotors $$$BST (Rotor Synchronous TechnologyNortey %89=B
+(6ing rotor 6ith special geo#etry
ach long and each short light
starts at another end o the rotor.
$#pro5ed #ixing peror#ance
)est 6ith e5en speed o the rotors
QQ &(Rotor7iede#ann P Sch#idt %89&B/light Angle at +,
Length o he light is shorten
-istributi5e #ixing capacity
Te#perature control-ischarge te#perature is reduced
*, > throughput than N(rotor
Mixes or Technical Rubber "oods
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Tangential Rotors $1B
High -ispersion Super Cooled H-SCB
Long 7ings are extended to
9,> o the rotor length
The 6ing arrange#ent supportsThe lo6 o5er the 6ing tips
Application in tire industry
Maxi#u# -ispersion Super Cooled M-SCB
/our 7ings unior#ly distributed
Spiral cooling
1ery agressi5e rotors
Master )atch Mixing in tire industryHigh producti5ity and good
dispersion
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Tangential Rotors 5B
? I7ing(Rotor
"ood #ixing peror#ance
/aster #ixing cycles
1iscosity is reduced aster"ood Co#pound Fuality
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$nter#eshing Rotors
CooDeG %8*+
ach rotor eFuipped 6ith
one helical 6ing extended
o5er the ull length o the rotor
$nterlocDing Technology'ohnson %89,B
Long 6ing o helical or#ation
7ide 6ing tipT6o s#aller 6ings are radially
Spaced beore and ater the long
7ing.
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$nter#eshing Rotors
0S Technology7iede#ann P Sch#idt %89&B
0artielle 5ol5enten Schauel
0S(* Rotor
$ncreased 6idth o the 6ing tips
Material lo6 bet6een the
Counter(rotating rotors"ood dispersi5e Mixing
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Mixer )ase 0late
To absorb orces bearing upon
$ndi5idual co#ponents
High torsional stability and lo6 6eight
-rop -oor and Latch
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0rocessing Aspects o
Rubber Mixing
/or# o the Main Co#ponents
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Rubber )ales
Acti5e /illers0elleti2ed Materials
/or# o the Main Co#ponents
Sotener!0lastici2er
Changes in Material 0roperties
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0oly#er Carbon blacD 4perating para#.
-eor#ation beha5iour
ield point
7all slippage
7all adhesion
Surace acti5ity
Agglo#erate si2e
Strength o
agglo#erate
Rotational speed
"eo#etry
Ra# pressure
/ill actor
Ther#al boundary
conditions
/eed seFuences
Result o #ixing -egree o dispersion
/luctuations in 5iscoelasticity
Ther#al loading
Material beha5iour during #ixing /eed in beha5iour
Te#perature proile
Change in #aterial properties
I 5iscoelasticity I heat capacityI density I heat transer
$ncorporation and
dispersion o carbon blacD
or other illers
Changes in Material 0ropertiesduring Mixing
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-ispersi5e Mixing
)reaD(do6n o 0article!-o#aine Si2e/or#ation o large $nterphases
-istributi5e MixingHo#ogeni2ation o ingredients
5en concentration o ingredient
longational/lo6
ShearStress
Ti#e
No )reaDage
)reaDage
La#inar Mixing$ncreased interace bet6een
t6o layers
shear strain
/lo6 pattern in an internal #ixer
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$nluences to /lo6
( rotor geo#etry
( angle o the rotor blades
( nu#ber o the #ainand side blades
( ill actor
/lo6 pattern in an internal #ixer
FrontWall(PeriphericalDirection)
Axial Direction
A
B
C
II
III
I
mA
mB
LeaDage /lo6
Con5erging /lo6
Material can be transportediB rotationally 6ith the rotor light
iiB through the gap bet6een
the 6ing tip and the cha#ber 6all
iiiB along the light and pass
around the rotor end
-istributi5e and -ispersi5e Mixing Qones
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-istributi5e and -ispersi5e Mixing Qones
around the Rotor 7ing
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Mixing Cycleand
$nluence o Material 0ara#eters
Masterbatch Mixing Cycle
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:
4il inOection
%
0oly#er
charging
&
Mastication
*
/iller
charging
+
/iller
incorporation
?
Ra#
s6eep
=
Ater
#ixing
9
-ischarge
Masterbatch Mixing CycleMastication
$ncorporation -ispersion -istribution
$ncorporation o the /iller
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/iller is incorporated into the Rubber
Reduction o total 1olu#e o the Mix
-ispersion is not satisactory
$ncorporation o the /iller
$ncorporation Ti#e
depends on3( type o /iller
( type o Rubber
( content o oil
( type o Mixer( 0rocessing 0ara#eters
Rubber /iller
$ncorporated /iller
xa#ple o a #ixing process opti#ised
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,
:,,
%,,,
%:,,
&,,,
, :, %,, %:, &,, &:,
time (s)
Powersupply
(kW)
,
:,
%,,
%:,
&,,
Temperature
(C)
0o6erRa# position
A5g 0o6er
Te#perature
1 2 3 7654 8
Mixer3
"@+,,N
Rotor3
+ 7ing
/ixed speed
xa#ple o a #ixing process opti#ised
or throughput
". NiO#anG -$@ Se#inar &,,=
0o6er -e#and or Mastication
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?
9
%,
%&
%+
%?
&, +, ?, 9,
0oly#er -osing Te#perature CB
0o6er0eaDJD7
hL
0o6er -e#and or Mastication
Ra# Setting3 Rubber Te#perature
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*, +, :, ?, =, 9,
Rotor Speed
Ra
#
SettingTi#e
+,
?,
9,
%,,
%&,
*, +, :, ?, =, 9,
Rotor Speed
Ra
#
SettingTi#e
+,
?,
9,
%,,
%&,
g p
*, C
?, C8, C
Ra# Setting3 $nluence o C)
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Lecture04A%%.,?.&,,=:+
Ra#-
isplace#ent
Mixing Ti#e t Mixing Ti#e t
Ra#-isplace#ent
ect o /iller Loading ect o /iller Structure-)0B
N *+=
N **,
N *&?
Addition o
the /iller
nd o
$ncorporation
$ncorporation Ti#e increases 6ith
( the /iller Loading
( the -)Inu#ber
g
Ra# Setting3 $nluence o /iller Type
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, + 9 %&
/iller J1ol.>L
9,
?,
+,
&,
,
Ra#
Se
tting
Ti#eJsL%,,
C)
CNT
N)R
HN)R
, + 9 %&
/iller J1ol.>L
9,
?,
+,
&,
,
Ra#
Se
tting
Ti#eJsL%,,
C)
CNT
N)R
HN)R
Ra# Setting3 $nluence o /iller Type
C) 5s CNT
C) needs long incorporation ti#e
Caused by the high structure or
4A Nu#ber
CNTs do not ha5e structure
$ncorporation ti#e is reduced to
%!* co#pared to C)
0o6er Consu#ption P Te#perature
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Mixing ti#e t
MixingTe#p
erature
sp
ec.0o6erConsu#ption
Mixing ti#e t
The second po6er peaD is #ore pronounced 6henthe iller loading increases
The #ixing te#perature increases 6ith loading
The 5iscosity decreases 6ith te#perature o the #ix
p p
nergy $nput3 $nluence o /iller Type
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+ 9 %&/iller J1ol.>
&
*
+
:
?
ner
gy$nputJM
'L
C)
CNTN)R
HN)R
, + 9 %&/iller J1ol.>
&
*
+
:
?
ner
gy$nputJM
'L
C)
CNTN)R
HN)R
C) 5s CNT
nergy input is #uch higher or
CNT co#pounds than or
C) co#pounds
The eect is caused by the increase o
1iscosity in CNT co#pounds.
A li#it or processability is reached or
CNT co#pounds
Mixer nergy()alance
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compound enthalpy
or coolin!
mechanical
mixer enthalpy
15% 10%
30%
45%
Typical exa#pleB
$nluence o oil incorporation
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$ the 4il addition is delayed.
()etter dispersion
(Ti#e should be chosen
$ the 4il addition is strongly delayed.
(Lubrication il#s i#pair the dispersion
(energy uptaDe is s#all
(Long #ixing ti#e
$ the 4il and C) are added at the sa#e ti#e
(4il is incorporated FuicDly
(Maxi#u# torFue is relati5ely s#all
Strategies or 4il -osage
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Lecture04A%%.,?.&,,=?,
High a#ount o oilMixing ti#e is 5ery long
Mixer reFuires long ti#e
to reco5er torFue
Auto#atic inter#itent4il inOection
nergy uptaDe
Shorter #ixing cycle
Scaling(Up
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g
$#portant Step or 0roductionReFuire#ents
"eo#etrical Si#ilarity
sa#e clearance bet6een rotor and#ixing cha#ber
/reFuency o the rotors should be in5ersely
proportional to the 6idth o their tips
increase the initial te#perature and reduce
cooling o the s#aller #ixer
identical shear strain and shear stress po6er!unit 5olu#e
(
(
(
sa#e reFuency o passage o any s#all ele#ent
through #ixing regions
(
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Ho6 to increase producti5ity and Fuality
-esign o the #ixing process Mixing eecti5ity
Target Conlict3 uality(Throughput
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Wiedmann & Schmidt RCT 1984
"uality
Th
rou!hput
/ill actor or opti#al iller dispersion3
( $ncreases 6ith ra# pressure and te#perature
( -ecreases 6ith rotor speed and te#perature
Design of the mixing Process:
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: Bales are cut
: Crumby structure
: Homogeneous Blenda: Ram down
b: (minimum)
c: Ram at lowest position
d: Maximum density
e: CB incorporation com-
pleted
Effect of Mastication CB !ncorporation
g g
Mixer: "#$%E
Rotor: &E'- fixed speed
". NiO#anG -$@ Se#inar &,,=
0
o6erD7!h
Ti#e sB
Experimental esign
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lo6 high
/ill actor ,.:9 ,.?*
Rotor speed rp#B +, ?,
)lending ti#e sB *, ?,-ispersion ti#e sB +& ?,
#esults
/Rb- /R)-)lend appearance cru#by ho#ogeneous
-u#p te#perature %?, %?&C
Cycle ti#e %9, %9& s
C) incorporation loose blacD co#pleted
Mixer: "#$%E
Rotor: &E'- fixed speed". NiO#anG -$@ Se#inar &,,=
*ingerprints
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*Rb *RB
". NiO#anG -$@ Se#inar &,,=
Mixer: "#$%ERotor: &E'- fixed speed
0
o6erD7!h
0
o6erD7!h
Ti#e sB Ti#e sB
$nluences on Co#pound 0roperties
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Fuip#ent
"eo#etry
MaintenanceCooling
Control
Sensors
0rocess
-iscontinuous
ContinuousTande#
/eeding SeFuen
-uration o
Mixing 0hases
$nluences on Co#pound 0roperties
uality
Material
0oly#er
/iller0lastici2er
Additi5es
Curing syste#
Hu#an
ducation
ualiication
Moti5ation
-osage
7eighing tolerance
Calibration
)atch to batch 5ariation in /ingerprints
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A 5ariation in #ixing Fuality could lead to
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too hea5y co#ponents
too #uch #aterial i. e. ,.: Dg in one 0CR tyreB
a huge a#ount o re6orD
o5er di#ensioned co#pound recipes and thereore a rather ineicient production
&G9
&G8
*
*G%
*G&
*G*
*G+
*G:
% & * + : ? = 9 8 %,
$ample
Dimension
7hat can be #easured on(line
to control the #ixing process V
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to control the #ixing process V
Ra# -isplace#ent
Ra# 0ressure
Mixing Cha#ber
Te#perature
Rotor Speed 0o6er
4n(line lectrical Measure#ents
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ring electrodeRa#
0icoa#pere#eter
A#pliier
Rotor 6ing
l. Source
lectrode
Cha#ber 6all
)eneits and -isad5antages o
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Lecture04A%%.,?.&,,==&
)eneits
Accepts al#ost any
trade or# 0ro5en technology
No need or specialdosing eFuip#ent
)oth auto#atic and#anual control
icient dispersioneect
/lexibility in run length
easyW to #aintain androbust #achine
7ide application ield
-isad5antages
High po6er peaDs
)atch to batch 5ariationI heat history
I #aterial 6eight 5ariation
-ust or#ing by air
#o5e#ent Labour intensi5e
Many adOustablepara#eters
High installation costs
Co#plicateddo6nstrea#
)atch Mixers