Extrusion International 6-2023

40 Extrusion International 6/2023 New Energy-Efficient Process for Manufacturing ABS Blends C operion has developed a process solution for par- ticularly energy-efficient manufacturing of acrylo - nitrile-butadiene-styrene copolymer (ABS) blends, with the Coperion ZSK Mc18 twin screw extruder playing a key central role. Thanks to short raw material residence time in the ZSK extruder and gentle product handling, Coperion’s process solution achieves an extraordinarily high ABS blend product quality. ABS is a thermoplastic engineering plastic which com- bines numerous positive mechanical properties and chemical stability, which make it ideal for multiple uses in the electric and automotive industries. Technology licensing and engineering company Zheji- ang Zonepic Petrochemical Technology Co., Ltd. located in Hangzhou City, Zhejiang Province, People’s Repub- lic of China, is a licensor for the emulsion grafting-bulk polymerization ABS blend method which allows for the production of ABS blends in general grade, food grade, flame retardant grade and electroplating grade. For this solution the company has permitted to design several large installations withmultiple ZSK 133Mc18 twin screw extruders. Two systems have recently started production: one plant is at Lihuayi Lijin Refining & Chemical Co. Ltd. with an output of 200 KTA, and the other at Zhejiang Pe- troleum & Chemical Co, Ltd. with an output of 400 KTA. ZSK Extruders for maximum energy-efficiency ABS blends consist of synthetic rubber polymers HRG and SAN (styrene-acrylonitrile). Coperion has devel- oped a particularly energy-efficient process solution for manufacturing ABS blends. The ABS emulsion emerges wet from a reactor following its manufacture. In Co- perion’s solution, it passes through a screw press before the HRG – still damp – is introduced downstream via a Coperion ZS-B side feeder into the process section of a ZSK extruder. The energy-intensive thermal pre-drying of the ABS is thus eliminated. Using gravimetric Coperion K-Tron feeders, SAN and additives are likewise introduced into the ZSK extruder. SAN, additives and HRG are intensively and homoge- neously mixed in the ZSK process section, all the while handled very gently, so that the product does not yel- low, nor does the polymer break down. In comparison to conventional manufacturing pro- cesses, Coperion’s solution operates with markedly lower energy consumption. Moreover, the portion of residual monomers is reduced to an absolute minimum. Frank Lechner, General Manager of Process Technol- ogy and Research & Development at Coperion, is con- vinced of the importance of Coperion’s development: “We’re proud to see how both of these large installa- tions from Zhejiang Zonepic Petrochemical Technology Co., Ltd. have successfully taken over production for ABS blends. These machines are already proving on a daily basis how energy-efficient their operation is. At the same time, they deliver a constant, extremely high product quality that underscores how our innovative process development precisely meets our customers’ re- quirements. Even our newest development, providing a way to further reduce ABS production’s energy con- sumption, has already met with great interest – as has our solution for manufacturing ABS blends for direct contact with food products.” Coperion GmbH Theodorstr. 10, 70469 Stuttgart, Germany www.coperion.com EXTRUSION TECHNOLOGY Coperion’s ZSK Mc18 twin screw extruder is playing a key central role in this system for particularly energy-efficient manufacturing of acrylonitrile-butadiene-styrene copolymer (ABS) blends (Photo: Zhejiang Zonepic Petrochemical Technology Co., Ltd.) Coperion has developed a process, built around the ZSK Mc18 twin screw extruder, for manufacturing ABS blends that operates markedly more energy-efficiently than conventional processes while delivering constant, very high product quality (Photo: Coperion, Stuttgart Germany)