Abstract: Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) melting polymer (e.g., derived from post-consumer PET bottles) to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt; (3) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 5 millibars; (4) allowing the multiple streams of polymer melt to fall into a receiving section of a melt processing unit; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

Abstract: An extruder screw conveying raw materials while kneading them includes a screw main body, conveyance portions, barrier portions, and paths. The conveyance portions convey the raw materials in an axial direction. The paths each include an entrance and an exit. The raw materials, the conveyance of which is limited by the barrier portions, flow in from the entrance. The raw materials flowing in from the entrance flow through the paths in the same direction as a conveyance direction of the conveyance portions. The exit is opened in the outer circumferential surface of the screw main body at a position outside the conveyance portions in which the entrance is opened.

Abstract: An extruder screw conveying raw materials while kneading them includes a screw main body, conveyance portions, barrier portions, and paths. The conveyance portions convey the raw materials in an axial direction. The paths each include an entrance and an exit. The raw materials, the conveyance of which is limited by the barrier portions, flow in from the entrance. The raw materials flowing in from the entrance flow through the paths in an opposite direction to a conveyance direction. The exit is opened in the outer circumferential surface of the screw main body at a position outside the conveyance portions in which the entrance is opened.

Abstract: Systems for manufacturing bulked continuous carpet filament from polymer, where the systems are configured for: (1) melting polymer (e.g., derived from post-consumer PET bottles) to create a first single stream of polymer melt; (2) separating the first single stream of polymer melt into multiple streams of polymer melt; (3) exposing the multiple streams of polymer melt to a pressure of between about 0 millibars and about 5 millibars; (4) allowing the multiple streams of polymer melt to fall into a receiving section of a melt processing unit; (5) recombining the multiple streams of polymer melt into a second single stream of polymer melt; and (6) providing the second single stream of polymer melt to one or more spinning machines that are configured to form the second single stream of polymer melt into bulked continuous carpet filament.

Abstract: A continuous mixer includes a barrel with a hollow interior, and a pair of mixing rotors housed in the barrel and that rotate in mutually different directions, each mixing rotor including a mixing portion with plural mixing flights formed about an axial center of the mixing rotor and projecting radially outward. The mixing rotors have a center distance therebetween smaller than a rotation outer diameter of each of the respective mixing flights. An inter-rotor clearance, which is the smallest clearance between the mixing portions at each rotation phase of the mixing rotors in a cross section perpendicular to axial directions of the both mixing rotors, has a dimension allowing an extensional flow to be generated in a material passing through the inter-rotor clearance. The continuous mixer can reliably and efficiently mix a material having a large viscosity difference between a dispersed phase and a matrix phase.

Abstract: A polymer synthesis system has a polymerization reactor and a deliquifying-quench extruder downstream of and in fluid communication with the polymerization reactor. The polymerization reactor has an inlet and an outlet with a rotatable shaft positioned axially within the reactor. The deliquifying-quench extruder has an inlet and an outlet, with a shaft assembly positioned axially within the extruder. The shaft assembly includes multiple helical flight configurations and multiple processing zones defined by the multiple flight configurations. The processing zones include an extraction-compaction zone, a sealing zone downstream of the extraction-compaction zone, a vent-cooling zone downstream of the sealing zone, a quenching zone downstream of the vent-cooling zone, and a conveying zone downstream of the quenching zone.

Abstract: Disclosed are a method of preparing a resin powder and an integrated reactor for the same. When a coagulation process is performed using an acidic coagulant in the integrated coagulator for latex coagulation and aging according to the present invention, a remaining acidic coagulant is also removed from a reactor through neutralization, and thus, a resin powder having enhanced moist-heat resistance and thermal stability may be prepared.

Abstract: An initial processing of natural raw rubber through an initial processing machine, comprising the steps of: (a) providing a coagulated latex which contains water and volatile compositions; (b) dewatering the coagulated latex through a screw-pressing process to remove free water; (c) forming a first pretreated latex material; (d) aging the first pretreated latex material through an aging process to remove water and volatile compositions; and (e) forming a final product of aged latex material. The screw-pressing process makes use of the temperature and pressure increase along the elongated channel structure. The aging process makes use of the further temperature and pressure increase of the rubber materials, together with the screwing effect of the screw-shaft component, the squeezing effect of the nozzle and additional heating at a particular location, which is around the mouthpiece of the nozzle to complete the aging process, which is energy saving, effective and efficient.

Abstract: A twin-screw extrusion kneader includes: two rotating shafts provided side by side in an internal space; a rotational driving portion configured to rotationally drive the rotating shafts; and paddles provided in the rotating shafts and configured to rotate along with the rotating shafts so as to knead a kneading material. Further, the twin-screw extrusion kneader includes movable portions provided as members constituting a part of the housing, the part of the housing including an inner wall surface of the housing, the inner wall surface being opposed to radially outer peripheral surfaces of the paddles. The movable portions can be moved in a direction to approach the paddles and in a direction to be distanced from the paddles. The twin-screw extrusion kneader can control the viscosity of electrode paste by moving the movable portions.

Abstract: An apparatus and process for removing moisture from sludge. The apparatus comprises a housing having an inlet and outlet for respective receipt and discharge of the sludge. A conveyor is located in the housing and is configured to transport the sludge from the inlet to the outlet. The apparatus further comprises a heater to heat the sludge to remove moisture therefrom whilst the sludge is being transported by the conveyor. The apparatus also comprises a vacuum pump arranged to extract air from the apparatus and, at the same time, to cause moisture removed from the sludge to flow therefrom together with the extracted air.

Abstract: An extruder (1) includes a cylinder (2) and a screw (3), and one or more front vents (8a) are provided on the cylinder (2) upstream of a hopper (5) and downstream of a rear vent (7). The cylinder (2) is provided with, between the hopper (5) and the rear vent (7), a liquid supply device (9) for spraying water into the cylinder (2) to cool an interior thereof and a liquid discharge port (12) that is opened in a lower portion of the cylinder (2).

Abstract: A process for the extrusion of plastics, such as plastics that tend to adhere or stick to parts of an extruder, using a planetary roller extruder in the feed part.

Abstract: A thermoplastic composite structure is produced by extruding a bead of composite material to a desired cross sectional shape. An extruder extrudes the polymer bead containing reinforcing fibers, using a low compression first extruder stage where the polymer is mixed and de-gassed, and a high compression second stage where the polymer is consolidated and extruded. The cross sectional profile of the polymer bead may be altered using a variable extruder gate.

Abstract: The invention relates to a device for producing polymers, preferably for processing and polycondensation of polyester, having a substantially cylindrical reactor (1), which has an inlet opening (2) on one side and an exit opening (4) on the other side and an outlet (20) for discharging gases. According to the invention, said device is developed such that the device has a compact design, and such that the device allows the use of higher-viscosity initial substances, even when generating smaller volumes, which is optimally adjustable in respect of the process conditions thereof and which represents a variable, cost-effective solution.

Abstract: Device for lateral flow charging of an extruder in which material is fed to at least one conveyor screw disposed in an extruder housing. The material contains gaseous concomitant materials, wherein a degassing housing for receiving an air flow is disposed on the extruder housing, which air flow acts in the extruder housing and which is directed contrary to the conveying direction of the conveyor screw.

Abstract: Apparatus, methods, and systems for separating a fluid mixture are provided which employ gas-handling equipment operable to introduce a gas into the liquid mixture prior to being dispersed within the apparatus, vacuum conditions, and internal condensing. The liquid mixture is dispersed within the separation apparatus as micro-sized droplets. A more volatile portion of the liquid mixture is vaporized when exposed to the vacuum conditions and separates from the non-vaporized liquid portion. The vaporized portion is directed to a condensing structure within the apparatus, which condenses the vaporized portion into a liquid product.

Abstract: The present invention relates to water and solvent-free halogenated butyl rubber products as well as a process for the production thereof.

Abstract: The present invention concerns a method for processing and detoxification of a material, especially a thermoplastic material, and for removal of contaminants or impurities from this material, wherein the material is heated under vacuum in at least one receiving tank, mixed and possibly comminuted, and wherein a rinsing medium is introduced into the receiving tank beneath the material level, conducted through at least a partial region of the material, and the rinsing medium enriched or saturated with contaminants is brought out from the receiving tank once more. According to the invention, the quantity of rinsing medium introduced into the receiving tank is less than 0.1 liter per hour per kilogram of material or material throughput per hour, while at the same time the vacuum in the receiving tank is kept constantly below 100 mbar.

Abstract: The present invention relates to water and solvent-free polymers, in particular water and solvent-free synthetic rubber products like non-halogenated and halogenated butyl rubber products as well as a process for the production thereof. The invention further relates to a device suitable to accomplish said process.

Abstract: A double-screw extruder for thermoplastic materials, with a first and a second extruder screw, whereby the extruder screws have an inlet and an outlet and a core, helically extending screw flights being arranged through the core from the inlet to the outlet, so that the screw peaks and valleys are circumferential, and the peaks of the first screw penetrate into the valleys of the second screw, and vice versa. The screw flights may have a geometry which is step-shaped in cross section, whereby the steps may be provided such that the stepped course of the peaks is congruent with the stepped course of the valleys.

Abstract: A method for handling a product, in particular a viscous, pasty product, with at least one rotating shaft (3, 11) in a product space (5), a driving spindle (11) of the shaft (3) is mounted and sealed outside the product space (5) in a housing consisting of a plurality of parts (7, 8, 12). The sealing is brought about by at least two seals (2, 4), wherein a dynamic seal (2) follows an eccentric movement of the shaft (3) and takes on dynamic sealing of the rotating shaft (3), while another seal (4) compensates for an eccentric movement of the shaft (3) in relation to the housing by plastic or elastic deformation and therefore prevents a leakage between the housing part (12), which moves eccentrically, and a rigid housing (10).

Abstract: A processing installation for the processing of bulk material has a vacuum filter insert for degassing of the bulk material. The vacuum filter insert is arranged in a casing of a screw machine downstream of the feed opening thereof and is provided with at least one filter element so that the vacuum filter insert forms a gas-permeable wall portion which defines the at least one casing bore of the screw machine. Seen in a degassing direction, a protective element comprising a plurality of through-openings is arranged upstream of the at least one filter element. The protective element acts as a granule protection for the at least one filter element and prevents granular bulk material from damaging the at least one filter element. As a result, the vacuum filter insert has a longer service life, thus ensuring a long operating time for the processing installation without interruptions.

Abstract: Apparatus, methods, and systems for separating a fluid mixture are provided which employ gas-handling equipment operable to introduce a gas into the liquid mixture prior to being dispersed within the apparatus, vacuum conditions, and internal condensing. The liquid mixture is dispersed within the separation apparatus as micro-sized droplets. A more volatile portion of the liquid mixture is vaporized when exposed to the vacuum conditions and separates from the non-vaporized liquid portion. The vaporized portion is directed to a condensing structure within the apparatus, which condenses the vaporized portion into a liquid product.

Abstract: A dewatering machine for reducing moisture of a polymer or an elastomer includes a generally solid barrel and a pair of screws disposed in the barrel. At least a portion of the screws are intermeshing, and drive means are coupled to the screws. At least one mechanical filter is connected to the barrel. The machine includes means that enable particles of the polymer or the elastomer to fuse, which reduces the amount of fines that escape from the machine. In addition, the machine reduces the moisture of the polymer from up to about 20 percent water by weight to less than about 0.5 percent water by weight, and the moisture of the elastomer from up to about 50 percent water by weight to less than about 3.0 percent water by weight. A method of dewatering for reducing the moisture of a polymer or an elastomer is also provided.

Abstract: An extruder for feeding material and for removing gas from the fed material. The extruder includes a vent block positioned between a first and second auger. The vent block including a vent cavity having a feed end and an exit end, an inner feed ring that partially extends into said vent cavity at the feed end of the vent cavity, and a screw element rotatably positioned in the vent cavity. A front portion of the outer ring is longitudinally aligned with or overlapping the front end of the inner feed ring. The outer ring forms at least one gap or opening at or adjacent the feed end of the vent cavity to enable gas to flow out of the vent cavity as material is moved though the vent cavity from the feed end to the exit end by the screw element.

Abstract: The invention relates to an apparatus and a process for devolatilizing solvent-containing polycarbonate solutions. By employing the inventive apparatus, polycarbonates with low residual values of volatile constituents are produced from solvent-containing polymer melts, which improved optical properties, especially yellowness index, with the aid of an apparatus combination of a heatable tubular devolatilizer and a vented extruder.

Abstract: The invention relates to an apparatus and a process for devolatilizing solvent-containing polycarbonate solutions. By employing the inventive apparatus, polycarbonates with low residual values of volatile constituents are produced from solvent-containing polymer melts, which improved optical properties, especially yellowness index, with the aid of an apparatus combination of a flash devolatilizer and a vented extruder.

Abstract: Apparatus and methodologies are provided for flash drying liquid materials using a variable die. A die and a die body are provided with an adjustably configured pressure regulating variable obstruction in the material flow path that allows control of the pressure applied to the material and consequent control of the temperature of the material as it enters the die. Optimizing pressure and temperature allows optimization of the flash drying process.

Abstract: Methods to prepare a poly(arylene ether) and poly(alkenyl aromatic) polymeric material having reduced levels of particulate impurities are described. The polymeric material prepared is suitable for use in data storage media applications.