The RingExtruder RE. Benefits of the RingExtruder RE :

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1 The RingExtruder RE

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3 The RingExtruder RE Over a number of years, Extricom have worked intensively on developing and launching a multi-shaft extrusion system - the RingExtruder RE. The RingExtruder technology opens up new innovative possibilities in terms of product quality, economic efficiency and flexibility. Consistent further development of the co-rotating twin screw has resulted in the extruder series RingExtruder RE. Its optimized design enables users to gain competitive advantages in production and product quality. The RingExtruder RE sets new standards for dispersion and degassing of high viscosity materials. It allows execution of nearly all high viscosity processes. Compared to other extruder systems, a very long residence time can be achieved. For this reason, batch processes are increasingly being converted to continuous processes on the RingExtruder RE. Benefits of the RingExtruder RE : Improved product quality provides a crucial competitive advantage through superior degassing and dispersion performance, reduced energy input and therefore lower operating costs.

4 PET-Recycling with the RingExtruder RE The special degassing performance in combination with low shear stress on the product make the RingExtruder highly suitable for processing PET flakes in bottle-to-bottle recycling. The optimised feed geometry allows the RingExtruder to process even low density products very efficiently. Recycling facilities based on the RingExtruder RE with a total capacity of approx. 400,000 metric tons per year have already been installed worldwide. The advantage: minimum energy consumption and excellent product quality!

5 Option a Option b Option c Extrusion system for PET-Recycling Extruders with throughput rates up to 6,500 kg/h are available. 1) Collection of post consumer bottles 2) bottle handling 3) flake processing 4) RingExtruder RE XPV extrusion system Option a) flakes to melt Option b) bottle-to-bottle recycling Option c) flakes to film

6 Processing of rubber and natural rubber products as well as thermoplastic elastomers Processing of rubber and natural rubber products with the RingExtruder RE demonstrates its excellent dispersion action with minimum energy input into the plasticised material. Rubber products require particularly high filler contents, especially carbon black and silica, as well as liquid components to be finely dispersed and distributed. The 12 parallel chanels of the extrusion screw allow the RingExtruder RE to develop high elongation flows in the intermeshing sections. These can be used very efficiently for dispersion while also saving energy. The connection between droplet dispersion and flow type is crucial. It is known that from a certain viscosity ratio onwards droplet dispersion is only possible in the field of elongation flow. The RingExtruder RE produces a high rate of these elongation flows while also being capable of controlling the product temperature very precisely. Application examples: floor coverings, rubber profiles, bellows, seals, rubber soles, tyres, cable sheathing, expansion joint strips and construction elements for bridges and buildings.

7 Processing of shear sensitive products such as PVC, Linoleum, EPDM/EVA Products which are sensitive to shearing require a very gentle processing method. These products usually undergo batch processing. They are very difficult to use in continuous processes as there are limitations mainly with regard to material quality and monitoring of material temperature. Localised temperature spikes which could lead to material degradation or unintentional chemical reactions have to be avoided. The RingExtruder RE overcomes these limitations and can replace the often used internal mixer as well as the subsequent calender or multi stage processes. Overcoming Limits The design of the RingExtruder RE with 12 tightly intermeshing screw shafts arranged on a ring has a significant influence on the flow processes. The increased elongation flow component in the intermeshing sections results in a significantly improved mixing and dispersion action. This enables the use of much gentler screw designs, consequently allowing the production of excellent extruded products at significantly lower product temperatures. The RingExtruder RE additionally features a large surface-to-volume ratio. This provides large heat transfer surfaces in relation to the throughput, ensuring efficient cooling of the products which are often sensitive to high temperatures. Special advantages of the RingExtruder when processing shear sensitive products to shearing: excellent mixing and dispersion capability homogeneous energy input very good cooling options no local temperature spikes reduced shear flow, intensive elongation flow close distribution of residence time very good self cleaning action

8 Degassing and dispersion applications Degassing The RingExtruder RE has a very large ratio of melt surface to volume. This is why the machine can be used for degassing very effectively. Frequent shifting of the melt and therefore the formation of a new surface are equally important in this process. With the introduction of the Z-technology the RingExtruder RE was further developed into a high performance degassing machine. The special design of the RingExtruder RE allows defined product layers to be created on the surface of the screw and the barrel which are then scraped off again at the next half revolution of the screw. This can be referred to as coating and cleaning. This technology is supplemented by special degassing barrels with very large openings or the use of degassing stuffers for foaming products. Dispersion One of the most important tasks of extruders is the mixing and dispersion of substances in a high viscosity matrix. This allows solid as well as viscous materials to be dispersed. A distinction is made between distribution and dispersion for both partial processes. The precondition for distribution are multiple flow divisions with thorough cross mixing. In the RingExtruder RE this is provided by the design of the machine. Separation (dispersive mixing) requires separation of the particles by transferring forces to the particles through the matrix. It can be shown in theory that such forces can be produced much more effectively through elongation flows than through shear flows. The many intermeshing sections of the RingExtruder RE produce exactly these elongation flows to a great extent. It is therefore not surprising that the RingExtruder RE is particularly suitable for the dispersion of nano particles or for the manufacturing of extremely high filled compounds.

9 Reactive extrusion application The basis: the design of the RingExtruders RE The geometric design of the RingExtruder RE with 12 shafts arranged in a circle allows chemical reactions to be carried out continuously in a high viscosity phase. This involves several advantageous characteristics of the machine. Residence time range The surface of the double flighted screw is scraped twice during each revolution of the screw. This results in a very narrow distribution of the residence time range and therefore exactly defined conditions for the entire product volume. Mixing and dispersion through Z-technology The processing options are supplemented by the Z-technology which creates defined reaction volumes without stagnation zones. In areas with Z-technology elements, defined layers are alternately scraped off and mixed back in. The machine design defines the reaction volume. Frequent changes in position promote chemical reactions and the degassing of associated products. Residence time Efficient reaction turnover often requires a defined reaction time. In the RingExtruder RE this is not necessarily the same as in the batch process and can be realised up to more than 20 minutes through corresponding lenght of the process section and suitable process guiding. Temperature control and degassing In many cases the product temperature has to be kept within a very narrow range for reactive extrusion processes. The high ratio of heat exchange surface to volume is particularly beneficial for this. The same surface is often also used for degassing by-products of the reaction.

10 Extruder control and plant engineering On request, we can supply turnkey systems to our customers rather than just the RingExtruder RE. The control concept REcontrol allows control and monitoring of the entire extrusion process. State-of-the-art hardware and software components provide the option of condition monitoring for continuous machine monitoring and preventive maintenance as well as integrated energy measuring to monitor the current energy consumption of the system. Our services include process development in the Technology Centre including set-up of a corresponding system configuration as well as a scale-up to the industrial level. Preparation and implementation of a technically advantageous concept (basic engineering and detail engineering) with dosing technology, RingExtruder RE, melt pump, screen changer, granulating and vacuum system are also part of our range of services. We additionally offer construction of the system, commissioning and handover to the operating company.

11 Design basics and machine structure The RingExtruder RE with 12 screw shafts can be regarded as the evolution of the well-known twin screw extruder with tightly intermeshing screws. 12 screw shafts arranged symmetrically in a circle rotate in the same direction, each on its own axis. The outer barrel and the stationary core enclose the screws with a narrow gap. Basic principle of the RingExtruder RE XP The material is transported in conveying zones in the shape of a double helix: around the stationary core and around each screw. The process chamber in the transfer zone from screw to screw, often called the intermeshing section, is used as an important part of the processing technology in the RingExtruder RE. Machine design The RingExtruder RE consists of the assemblies electrical drive, safety coupling, reduction and distribution gearbox as well as the processing unit. Barrels, screws and the core are divided into individual segments with modular configuration. Solids or liquids can be added downstream on combi barrels using side feeders. Special barrels with a large opening are available for degassing; alternatively stuffers can be used. The barrels are heated electrically and cooled with water. The entire Extricom design portfolio is available for the segmented screw. Screws and barrels can also be customised to suit customer requirements by selecting a suitable material which is adapted to the processing task. Z-technology The introduction of the Z-technology allows defined gaps with different gap widths to be used for dispersion and degassing tasks. This combination of screw arrangement and screw design, which is only possible in the RingExtruder RE, spreads the product in defined layers and then scrapes it off and mixes it in again during the next half revolution.

12 Technical data LT respectively XP-RingExtruder RE series with outer diameter to inner diameter ratio of 1,55 Baugröße/Dimension RE 1 (LT/XP) RE 2 (LT/XP) RE 3 (LT/XP) RE 4 (LT/XP) RE 5 (LT/XP) RE 6 (LT/XP) RE 7 (LT/XP) RE 9 (LT/XP) RE 12 (LT/XP) RE 16 (LT/XP) Durchmesser/Diameter [mm] Gangtiefe/Channel depth [mm] 3,2 4,2 5,3 7,1 9,0 10,6 12,4 15,9 21,4 28,4 DA/DI Verhältnis/OD/ID ratio [-] 1,55 1,55 1,55 1,55 1,55 1,55 1,55 1,55 1,55 1,55 Freie Querschnittsfläche/ Free crossectional area [cm 2 ] 9,4 15,7 25,6 45,5 72,3 102,1 140,6 231,6 415,4 734,1 Max. Drehzahl/Max. screw speed [min-1] Wellenleistung/Shaft power LT XP LT XP LT XP LT XP LT XP LT XP LT XP LT XP LT XP LT XP Max. Drehmoment/ Max. torque [Nm] Wellenleistung bei 1500 min-1/ Shaft power at 1500 min-1 [kw] Wellenleistung bei 1200 min-1/ Shaft power at 1200 min-1 [kw] Wellenleistung bei 900 min-1/ Shaft power at 900 min-1 [kw] Wellenleistung bei 600 min-1/ Shaft power at 600 min-1 [kw] Wellenleistung bei 450 min-1/ Shaft power at 450 min-1 [kw]

13 XV respectively XPV-RingExtruder RE series with outer diameter to inner diameter ratio of 1,74 Baugröße/Dimension RE 1 (XV/XPV) RE 2 (XV/XPV) RE 3 (XV/XPV) RE 4 (XV/XPV) RE 5 (XV/XPV) RE 6 (XV/XPV) RE 7 (XV/XPV) RE 9 (XV/XPV) RE 12 (XV/XPV) RE 16 (XV/XPV) Durchmesser/Diameter [mm] 18,8 24,4 31,4 41,9 52,1 62,8 73,6 94,5 126,2 168,0 Gangtiefe/Channel depth [mm] 4,0 5,2 6,7 8,9 11,1 13,4 15,7 20,1 26,9 35,8 DA/DI Verhältnis/OD/ID ratio [-] 1,74 1,74 1,74 1,74 1,74 1,74 1,74 1,74 1,74 1,74 Freie Querschnittsfläche/ Free crossectional area [cm 2 ] 11,7 19,7 32,9 58,3 90,4 131,1 180,0 297,1 530,0 939,3 Max. Drehzahl/Max. screw speed [min-1] Wellenleistung/Shaft power XV XPV XV XPV XV XPV XV XPV XV XPV XV XPV XV XPV XV XPV XV XPV XV XPV Max. Drehmoment/ Max. torque [Nm] Wellenleistung bei 1500 min-1/ Shaft power at 1500 min-1 [kw] Wellenleistung bei 1200 min-1/ Shaft power at 1200 min-1 [kw] Wellenleistung bei 900 min-1/ Shaft power at 900 min-1 [kw] Wellenleistung bei 600 min-1/ Shaft power at 600 min-1 [kw] Wellenleistung bei 450 min-1/ Shaft power at 450 min-1 [kw]

14 Service Process design Our engineers take on new challenges in high viscosity process engineering every day. The Technology Centre provides several RingExtruder RE with many different options for developing new processes or optimising established processes together with our customers. Training We offer an extensive training programme for replacement and wear parts, HPE high performance elements, wear protection, materials, maintenance and training courses customised specifically for your requirements. Remote service Our RingExtruder RE systems are usually equipped with a remote service module so we can provide worldwide customer support at any time. Customer storage Benefit from your exclusive storage programme: Raw Stock: customer specific storage of raw materials, delivery time for any element of your machine: e.g. 4-6 weeks Flex Stock: customer and machine specific storage of blank elements, delivery time for any element of your machine: e.g. 2-3 weeks Full Stock: storage of finished elements, delivery time for any element of your machine: immediately ex-warehouse Maintenance Assessment of the level of wear and preparation of a corresponding quotation, screw refurbishing by stripping old elements and installing new and usable pre-used elements.

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16 Hamburg A 81 Extricom GmbH Blach Extruder & Components Berlin Hoher Steg 10 D Lauffen a.n. A 6 A 6 Tel.: Fax: Köln Frankfurt a. M. info@extricom.de Heidelberg Karlsruhe Baden-Baden Heilbronn Lauffen a. N. Stuttgart A 81 München