Mixing process pellet products

Many extruder manufacturers now produce dump extruders which are fitted beneath the discharge door of an internal mixer and receive into their feed hopper the full charge of the mixer. The speed of extrusion of the machine is governed by a series of sensors in the feed-hopper, to ensure that the process is continuous and that the screw will not be starved of compound, thus ensuring a continuous production of the mixed rubber compound. Product from such a machine can be slab or pellets. 

The mixing process for concentrate pellet product production via Leistritz-type extrusion equipment is essentially identical to that of dry color product mixing. Once weigh-out has been completed, the formula is usually transported to a mixer where the ingredients must be mixed to uniformity. The ingredients are usually manually dumped into the mixer, after which the lid is sealed and the mixer is operated until the formula reaches the desired uniformity. After mixing, the formula is manually removed from the mixer and placed into a hopper or container with a controlled outlet and is ready for the next operation. 

In this case study, 60t/h of FFB is sent to POM, producing 14.04 t/h EFB, 4.38 PKS and 7.80 t/h PMF. DLF and pellet production pathways are selected to produce palm products in the POB, while boiler and steam turbine pathways are selected as steam and electricity generation in the CHP. As shown, aU EFBs are pretreated in steam drying before they are sent to DLF production and boiler combustion. A total of 3.04 t/h DLF, 1.61 t/h WSF and 0.23 t/h DSF are produced throughout the DLF production. All by-products (WSF and DSF) are sent to pelletising processes to produce 1.49 t/h pellet. There is 2.12 t/h pretreated EFB sent to CHP and mixed with all PMF and PKS before being further combusted in the boiler. 

Many methods for the conversion of acid copolymers to ionomers have been described by Du Pont (27,28). The chemistry involved is simple when cations such as sodium or potassium are involved, but conditions must be controlled to obtain uniform products. Solutions of sodium hydroxide or methoxide can be fed to the acid copolymer melt, using a high shear device such as a two-roU mill to achieve uniformity. AH volatile by-products are easily removed during the conversion, which is mn at about 150°C. A continuous process has been described, using two extmders, the first designed to plasticate the feed polymer and mix it rapidly with the metal compound, eg, zinc oxide, at 160°C (28). Acetic acid is pumped into the melt to function as an activator. Volatiles are removed in an extraction-extmder which follows the reactor-extmder, and the anhydrous melt emerges through a die-plate as strands which are cut into pellets. 

Both the Toth and Alcoa processes provide aluminum chloride for subsequent reduction to aluminum. Pilot-plant tests of these processes have shown difficulties exist in producing aluminum chloride of the purity needed. In the Toth process for the production of aluminum chloride, kaolin [1332-58-7] clay is used as the source of alumina (5). The clay is mixed with sulfur and carbon, and the mixture is ground together, pelletized, and calcined at 700°C. The calcined mixture is chlorinated at 800°C and gaseous aluminum chloride is evolved. The clay used contains considerable amounts of silica, titania, and iron oxides, which chlorinate and must be separated. Silicon tetrachloride and titanium tetrachloride are separated by distillation. Resublimation of aluminum chloride is requited to reduce contamination from iron chloride. 

The productive stock, ie, the curable compound, is made up by mixing the nonproductive stock in the Banbury once more with the curative package (sulfur, accelerators, etc). This time the drop temperature is lower, in the range of 95—112°C. The productive stock is then sheeted or pelletized and coated with the dip coat, cooled, and finally stored, ready for further processing for final fabrication. 

Reaction conditions are generally mild, but they differ from one process to another. In the newer Unipol process (Eigure 12-1) used to produce both HDPE and LLDPE, the reaction occurs in the gas phase. Ethylene and the comonomers (propene, 1-butene, etc.) are fed to the reactor containing a fluidized bed of growing polymer particles. Operation temperature and pressure are approximately 100°C and 20 atmospheres. A single-stage centrifugal compressor circulates unreacted ethylene. The circulated gas fluidizes the bed and removes some of the exothermic reaction heat. The product from the reactor is mixed with additives and then pelletized. New modifications for gas-phase processes have been reviewed by Sinclair. ... 

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