STR 2012 2 e Complete

2/2012
Polymers
Polymer production technology Customized foam manufacturing New polymer pilot plant Flexible pumps for polymers Solutions for the plastics industry Efficiency through coated tools Successful polymer analysis Panorama World-famous in motor sports Insightful hot spots
EDITORIAL
About Sulzer
!<3A-9 P<47: Pump technology and solutions !<3A-9 P<47: 6..-9: 7<4715/ :63<;165: )5, 9-3);-, -8<174-5; )5, :-9=1+-:. Customers benefit from intensive research and development in fluid dynamics, process-oriented products, and reliable services. The global manufacturing and service network of Sulzer Pumps ensures high customer proximity.
New benchmarks for polymer technology
!<3A-9 M-;+6 Surface technology !<3A-9 M-;+6 -50)5+-: :<9.)+-: >1;0 +6);15/ :63<;165: )5, -8<174-5;. Customers benefit from a uniquely broad range of surface technologies, coating solutions, equipment, materials, and services, as well as specialized machining services and components. The innovative solutions of Sulzer Metco improve performance and increase efficiency and reliability.
Dear Technology Professionals, Customers, and Partners,

Polymers are considered the material of choice for the cost-effective production of mass products. However, the need for technically demanding solutions continues to grow, so that many factors other than the material and manufacturing costs have become decisive for success in the plastics market. Plastics manufacturers are looking for flexible manufacturing processes in order to be able to offer tailor-made products to their customers. The right mix of raw materials and additives is just as decisive as the scalability, efficiency, and controllability of the processes. Ecological aspects, such as energy consumption, alternative raw materials, and degradability, play an increasingly important role. In this edition of the Sulzer Technical Review, you can find out how Sulzer is setting new sustainable benchmarks for technological development in the polymer industry. Thanks to a significant investment, new polymer pilot installations and an expanded test center are available to our clients in the process technology business. A number of articles in this issue provide insight into our latest mixing and reaction technology for polymers. Because of the wide range of fluid properties needing to be processed, polymer processes are a great challenge for pump technology. We will show you how our pumps master these challenges with the greatest flexibility. Tools for the manufacture of plastic products require special surfaces. Our surface technology division offers coating solutions and surface treatments for a multitude of requirements. Metrological analyses are essential in order to guarantee optimal plastic properties. In this edition, you can read how we support our clients in polymer analysis and solve even the most difficult cases with a detective-like flair. I hope you enjoy reading these articles.
!<3A-9 C0-4;-+0 Separation, mixing, and service solutions !<3A-9 C0-4;-+0 6..-9: 796,<+;: )5, :-9=1+-: .69 :-7)9);165, 9-)+;165, )5, 41?15/ ;-+05636/@. Customers benefit from advanced solutions in the fields of process technology, separation equipment, as well as two-component mixing and dispensing systems. The global footprint of Sulzer Chemtech ensures local knowledge and competence.
!<3A-9 "<9*6 !-9=1+-: Service solutions for rotating equipment !<3A-9 "<9*6 !-9=1+-: 6..-9: 9-7)19 )5, 4)15;-5)5+- :-9=1+-: .69 ;<9*64)+015-9@, /-5-9);69:, )5, 46;69:. Customers benefit from reliable and efficient repair and maintenance services for gas and steam turbines, compressors, motors, and generators of any brand. The global network of Sulzer Turbo Services ensures high-quality local service.
Sulzer was founded in 1834 in Winterthur, Switzerland, and today is active in machinery and equipment manufacturing and surface engineering at over 170 locations worldwide. The divisions are global leaders in their respective customer segments, which include the oil and gas, hydrocarbon processing, power generation, water, aviation, and automotive industries. www.sulzer.com
Klaus Stahlmann CEO Sulzer
| Sulzer Technical Review 2/2012
CONTENT
Polymers
4
Flexible foam production
Customized manufacturing of expandable polystyrene
Sustainable pumping solutions for polymer manufacturing

Flexible and durable high-efficiency pumps for the chemical process industry
12
New bioplastics pilot plant

Interview with Lorenzo Ghelfi, Sulzer Chemtech
14
More effective manufacturing through coated tools

Efficient processing of plastics
19
Spider silk as a superpolymer

Sulzer analogy
20
Following the trail of polymeric evidence

Polymer analysisbetween measurement and interpretation
Panorama
25
Welcome to Sulzer Metco in Limoges
Sulzer world
26
Insightful hot spots

Thermographic inspection of industrial gas turbine components
30 31
Events & News
Imprint
O5 ;0- +6=-9: A scanning electron micrograph of polystyrene foam shows the air-filled hollow cells that make the material an excellent insulator.
Keystone / Science Photo Library / Eye of Science
Sulzer Technical Review 2/2012 | 3
POLYMERS
Customized manufacturing of expandable polystyrene
Flexible foam production

The properties of expandable polystyrene (EPS), one of the most important foamed plastics in the world, can be significantly influenced by additives. Such additives can repel insects, make the material flame resistant, or improve thermal insulation. Sulzer Chemtech has developed a flexible process particularly suited for the economical production of customized, special-grade EPS.
he industrial polymerization of styrene to polystyrene (PS) started in the early 20th century and was followed by the development of expandable PS beads around 60 years ago. EPS is a particle foam made by expanding PS beads that contain a blowing agent usually pentane. Steam heating causes the beads to expand, and the final shape is achieved by molding the pre-expanded beads with steam and pressure. There
are numerous applications for EPS on the market, and block and shape molding are the most important conversion processes currently employed to fabricate foam products from EPS. In particular, by using shape molding, various products can be obtainedfor example, packaging solutions, plaster, or sports equipment many of which profit from customized EPS formulations that add color or mechanical properties.
Melt impregnation allows customized production

In the common process chain, EPS resin suppliers produce impregnated polystyrene resin granulates with the blowing agent in large-scale industrial facilities. The EPS is then sold to EPS molders. They manufacture end productssuch as packaging, construction material, or drinking cupsaccording to customer specifications.
Sulzers EPS pilot plant allows process optimization, sample production, and feasibility testing for customers.
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POLYMERS
Sulzer Chemtech offers a continuous process for producing EPS granulates from PS on an industrial scale of up to 100 000 t per year (see STR 1/2009, p. 6). In this process, the melt is directly impregnated with the blowing agent and the required additives, and it is then sent to an underwater pelletization process. The melt impregnation has several advantages over the conventional suspension process. The product quality is consistent and can be easily controlled, as the additives and the blowing agent are directly injected into the melt.
Environmental benefits and energy savings

The environmental benefits include: Lower water consumption Straightforward recycling of excess material On an industrial scale, the hardware for this process includes Sulzer Chemtech static mixers and heat exchangers. In
distribution, can influence the thermalparticular, when connecting the Sulzer insulation properties of EPS foam. The EPS process directly to a polystyrene genuine advantage of EPS foam as insumelt plant, the static mixing approach lation material over competing insulation results in significant energy savings, as the resin does not need to be melted S0(5!-7. )!(/ %),-!#*a/%+* ,-+c!.. %. /$! ba.%. again. This offers the "+- /$! ,-+ 0c/%+* +" ,%#)!*/! EPS. possibility of operatsolutions like polyurethane, mineral ing competitive styrene-to-EPS plants for global-scale production of EPS commodi- wool, or extruded polystyrene foam (XPS) is its low density and, hence, its ties, for example, for innovative insulation relatively low price. However, the insusolutions. In fact, with the introduction lative properties significantly deteriorate of a melt-based EPS process in the late with decreasing density. Three mecha1990s by Sulzer, the technological basis for the production of pigmented, flame- nisms contribute to the thermal conductivity of EPS (see info box): resistant EPS for housing insulation was Conduction established, and this gave rise to the Convection development of a number of innovative Radiation (mainly infrared). materials using different additives. With decreasing EPS density, the share Improving thermal insulation with of infrared radiation strongly increases. pigments This effect can be avoided through pigSeveral parameters, such as foam density, mentation. Pigments, e.g., graphite, carchoice of blowing agent, and cell size bon, or aluminum particles, added to
Low-lambda development
50
"0-94)3 +65,<+;1=1;@ (10 -3 %/'4DK()
40
total
30
"0-94)3 +65,<+;1=1;@ (10 -3 %/'4DK()
20
gas cd
"0- ;0-94)3 +65,<+;1=1;@ 6. EP! +64791:-:: Conduction in polystyrene cell walls and struts (cd) Convection by gas contained in cells (gas) Radiation, mainly infrared (rad) P1/4-5;);165 Added pigments in EPS material absorb and/or reflect heat radiation, so that rad is reduced and thermal insulation is improved.
C647)91:65 6. 15:<3);15/ 4);-91)3: (;0-94)3 +65,<+;1=1;@ 15 %/'4DK():
C65+9-;0.81.28 %01;- EP! 0.0320.044 P1/4-5;-, EP! 0.0290.033
40
38
white EPS
36
34
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32
10
rad
0 10 20 30 40 50 60 70 80
D-5:1;@ (2//43)
pigmented EPS
30
The thermal conductivity or (measured in watts per meter kelvin W/[mK]) describes the ability of materials to conduct heat. Materials of high thermal conductivity transmit heat at a higher rate than materials of low thermal conductivity. Therefore, materials of low thermal conductivity are used as thermal insulation.
28
10
15
D-5:1;@ (2//43)
20
25
(depending on density) (depending on density)
1 Adding pigments decreases the heat conductivity and improves the insulative properties of the EPS. This kind of low-lambda development allows access to markets for highperformance insulation materials.
POLYMERS
Meeting environmental requirements: alternative flame retardants
1 mm
100 m
2 Prefoamed EPS beads from Sulzers EPS process show excellent
sphericity and cell size distribution.
the EPS can absorb and/or reflect infrared radiation and thus improve thermal insulation 1. This way, the insulative property of low-density EPS can reach the same level as EPS with a density two to three times higher. Using optimized mixing technology as well as the right combination of additives in the process leads to an improved dispersion of the pigments in the final product and helps to lower the additive consumption in the Sulzer process compared to other processes.
A disadvantage of using plastics in construction is their flammability. Polystyrene, in particular, burns readily and EPS foam, unless equipped with flame retardants, does not fulfill common building codes relating to flame spread and smoke development. Therefore, the material has to be either used in combination with an additional flame barrier on the side of the construction method or impregnated with suitable flame retardants. The most Defined distribution of particle sizes widely used additive for this application The EPS quality is not only influenced is hexabromocyclododecane (HBCD), a by the composition of the material but highly brominated flame retardant with more than 70 wt% bromine per molecule. also by the geometry of the molded beads. An even, spherical shape of the beads HBCD has been the flame retardant of choice in EPS for several decades A* !1!*, .,$!-%ca( .$a,! +" /$! b!a . !*.0-!. now, because it is /$! b!./ ,a-/%c(! "0.%+*. very efficient: Typiensures the best particle fusion. The diamcally, HBCD levels between 0.7 % and eter required for the EPS particles 3 %depending on the type of synergist depends on the intended use of the final and process usedare required for product. Different size classes are building insulation to reach the desired typically defined for insulation, packagflame retardancy. In particular, the use ing, food containers, or cups. And an of synergists imposes very efficient optimal mold fill is supported by a temperature and shear control on the narrow, uniform bead size distribution. production process. With decomposition Together with Automatik Pelletizing temperatures as low as 150 C, as is the Systems, part of the MAAG group which case for commonly used peroxide was recently acquired by Dover Corposynergists, it becomes a prerequisite in ration, Sulzer Chemtech has further demelt impregnation to cool and maintain a low temperature and shear profile. veloped the existing underwater pelletization technology for stable production This factor has to be taken into account of uniform EPS, in particular, EPS confor the design of mixers, extruders, and taining pigments and flame retardants. pelletizers. Due to its outstanding sphericity and preFlexible process allows the use of cise pellet size distribution 2, the product HBCD substitutes can be processed like suspension product Recently, the toxicity and the environ- without prior screening or sieving. Due mental impact of HBCD have become to a unique die plate design and efficient matters of concern. Measurements have heating, die freezing can be minimized shown that the material bioaccumulates even for small bead sizes below 1 mm.
and biomagnifies so that several environmental protection agencies have put the chemical on their lists of concerns. This development has prompted the EPS industry to start the search for a substitute for HBCD. Due to its ingenious design and efficient temperature control, the Sulzer EPS process is much more flexible than classic suspension technology as it allows the use of new flame retardants currently in development.
POLYMERS
Premature foaming of the beads is avoided thanks to pressure and temperature control in the closed pelletization water circuit.
Blowing agent Polymer feed (PS, EPS, recyclate) Additives (FR, pigments) EPS micropellets
Gravimetric dosing systems
Small-scale, economical production

The melt impregnation technology represents a tremendous potential for product innovation in the PS foam business, not only on a large production scale but also on a scale suitable for specialized products. EPS converters, who are very closely connected to end customers, typically have vast knowledge of the product requirements and limitations of existing EPS products for the applications they serve. Unlike the big resin producers with their commodity-grade EPS, converters increasingly feel the need to differ from their competition and to develop niche products with special properties. Because annual consumption can easily reach 10 000 t per year, the production of their own EPS resin with a melt impregnation plant suddenly becomes attractive, in particular with PS resin widely available at relatively low prices.
Twin-screw extruder (ZSK MEGA compounder)
SMR melt cooler
Gear pump
Underwater pelletizer
3 Sulzers EPS process is suited for small-scale EPS production (5003000 kg/h).
with the renowned German extruder manufacturer Coperion, allows for the economic production of EPS specialties even on scales adapted to the requirements of larger converters. Sulzer supports EPS converters who want to develop their own foam formulations. They can produce and test customized EPS grades with various additives in Sulzers pilot test facilities. The clients benefit from the broad experience that Sulzer Chemtech and its partners have gathered with melt impregnation technology.
Simplified extruder process
Process innovation for the environment
Applying the in-depth process expertise From the very beginning, Sulzer has from a decade of EPS process develop- focused its process development on enviment, Sulzer Chemtech has developed ronmentally friendly solutions for EPS a second-generation EPS process suited, S0(5!- C$!)/!c$ !1!(+,. a* +""!-. in particular, to small/!c$*+(+#4 "+- /$! -!c4c(%*# +" EPS. scale production 3. production. This designation encompassUsing a combination of a twin-screw es two major areas: recycling capabilities extruderin which PS or EPS, blowing agent, and all required additives are com- and the use of alternative blowing agents. Because EPS is a lightweight, single-use poundedand Sulzers proprietary melt product with a decomposition time of coolers, the engineers have designed a several thousand years in nature, the simplified manufacturing unit that is end-of-life debate has always had a negattractive for smaller capacities of about ative imprint on the product image. At 5003000 kg per hour. This extruder the same time, the commonly used blowprocess, the result of a joint cooperation
ing agent pentane for foaming EPS has a critical global warming potential and falls under strict regulations in many countries and legislations. While suspension polymerization is rather inflexible in view of addressing these aspects, melt impregnation offers a lot of room for process innovation. Sulzer Chemtech develops and offers technology for the recycling of both unfoamed, impregnated EPS from production (e.g., off-spec material, unsold material from stock, etc.) and compressed foam from consumer recycling or production internal sources (cutoff, blocks, etc.). Those materials can be used as feed stream and be 100 % reutilized for production of virgin EPS resin. By using alternative blowing agents, which do not fall under the regulations of volatile organic compounds (VOC) yet have similar properties to those of pentane, converters can save significant money on pentane abatement systems and VOC taxes that may apply in some countries. Development of these process innovations is currently ongoing within Sulzer Chemtech.
P01317 N1:15/ Sulzer Chemtech Ltd Sulzer-Allee 48 8404 Winterthur Switzerland Phone +41 52 262 50 22 philip.nising@sulzer.com
POLYMERS
Flexible and durable high-efficiency pumps for the chemical process industry
Sustainable pumping solutions for polymer manufacturing

In the polymer-manufacturing industry, raw materials undergo chemical conversion during their processing into finished products. These conversion processes very often require conveying fluids with a wide range of characteristics. The liquids can be very hot or cold, they may be chemically aggressive, or they can contain solids or fibers. With the AHLSTAR process pump series, Sulzer meets the requirements of chemical process industries.
he wide range of processes in the polymer-manufacturing industries leads to an extensive scope of pumping necessities. It is essential to the operation of polymer plants that the process pumps fulfill a variety of requirements. In most polymer plants, pumps generate the majority of energy cost. Therefore, efficiencyof both hydraulics and electrical driveis important. Another, even more crucial, criterion is the reliability
of the pumps, because unplanned interruptions of the often-complex chemical processes can cause significant cost increases and environmental impact.
Pumping various fluids

With many installed units operating globally, Sulzers AHLSTAR series is the worlds largest process pump series for demanding industrial processes including polymer processes. The capability to
work with all types of liquids makes this pump range particularly suitable for the challenging pumping operations required in chemical processes. Whereas the basics of pumping are the same in all applicationsmoving a liquid and increasing its pressurethe specific parameters of the liquids to be processed can differ dramatically. The fluids can vary in viscosity or they can contain fibers or solids.
AHLSTAR pumps are designed for safe operation and easy maintenance and service.
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POLYMERS
40
66
73 79 84 88 91
35
2
over 93% efficiency

93
1 The performance of the AHLSTAR pumps exceeds standard requirements.
30
25 H-), H (4)
20
15
1 530 mm 2 505 mm
79 73
10
3 485 mm 4 465 mm
5 440 mm
0 0 200 400 600 800 C)7)+1;@ Q (3/:) 1000 1200 1400
Sulzer engineers had to consider all European standard EN 733 for light those and more boundary conditions industrial processes when they designed the over ten different The metric standard ISO 5199, for impellers that make the AHLSTAR range example, covers the requirements for suited for almost every hydraulic require- pumps of back pullout construction as ment. Whether closed or open, dedicated used primarily in the chemical and petrofor low discharge, or wear-resistant, chemical industries. It includes design impellers make it possible for the features relating to installation, mainteAHLSTAR pumps to work with slurries, nance, and safety. Other codes define clear, or contaminated liquids or fluids main dimensions and operating ranges containing solids of various sizes. These of the pumps. process pumps can work at temperatures The pumps of the AHLSTAR series of up to 260 C and pressures of up to fulfill ISO 5199 and ISO 2858 interna2.5 MPa, which is roughly equivalent to tional standards relating, e.g., to dimenthe pressure 250 m below water. With W%/$ /$! -%#$/ c$+%c! +" )a/!-%a(., the right choice /$! AHLSTAR ,0),. +,!-a/! c+--+.%+* "-!!. of materials, these pumps operate corrosion free even sions of flanges and base plates and, when handling liquids with extreme therefore, do not require special effort pH values from 0 up to 14. to install or maintain within existing pipework. When it comes to performance Exceeding international standards and quality, the pumps of the AHLSTAR International standards define sets of range have extra features exceeding minimum criteria that clients can expect the basic requirements and even surto be fulfilled by standard pumps. pass the international standards Depending on the specification, the governing technical performance and following standards are applied to quality 1. centrifugal pumps: Solutions for liquids with high gas load API 610 (ISO 13709) standard for Conventional centrifugal pumps can handemanding processes in the oil and dle liquids with gas content below 4 %, gas and hydrocarbon industries but gas bubbles collected in the impeller ISO 5199 and ISO 2858 (as well as eye do impair pumping and will reduce American standards ASME73.1) for capacity and head. At a gas content of industrial processes
Typical fluid properties in polymer manufacturing

Viscosity is an important fluid property that is relevant for pumping technology. The viscosity describes a fluids resistance to shear stress. Fluids like water have constant viscosities and are called Newtonian fluids. Molten polymers and salt solutions show non-Newtonian fluid behavior. Their viscosity depends on the rate of shear and can even be time dependent.
Newtonian fluids $1:+6:1;@
Shear thinning (pseudoplastic) fluids !0-)9 9);-
The shear-thinning behavior of polymers (also known as pseudoplastic behavior) means that the viscosity becomes smaller if the rate of shearing increases. Such changing viscosity coefficients have to be considered in the pump design for polymer manufacturing.
Martin Eager / Dreamstime
Non-Newtonian fluid behavior.
POLYMERS
What are the challenges of high gas loads?

Gases can be present in liquids in three different states: Dissolved in the liquid Bound on the particles contained in the liquid As free gas in the form of bubbles Gas in the form of bubbles disturbs pumping. Gas bubbles collected in the impeller eye reduce the pump capacity and head. Pumping becomes very unstable, varies heavily, and requires excessive overdimensioning of the pump. Sulzer Pumps has developed pump types, like the AHLSTAR pumps, which, through their operating principle, remove disturbing gas or air contained in the liquid so as to maintain proper pumping.
In conventional centrifugal pumps, the free gas accumulates in front of the impeller.
above 4 %, pumping is very unstable, and, without special measures, it requires excessive overdimensioning of the pump. Sulzer has found a solution to this customer requirement by offering degassing and self-priming units in the AHLSTAR series, which will stabilize centrifugalpump operation with liquids containing
up to 40 % weakly bonded gases or up to 70 % strongly bonded gases. The AHLSTAR pumps can be fitted with selfpriming or degassing units to start the pump with the inlet pipe empty or to help the pump operate with liquid containing high gas content, where conventional centrifugal pumps would lose suction compatibility.
ation, customers benefit from longer pump life, fewer unexpected shutdowns, and lower maintenance costs.
Superior reliability
Centrifugal pumps in industrial applications usually operate over a period of several decades. The design of the AHLSTAR pumps 2 aims to minimize the life cycle costs during the long expected lifetime. Whereas energy comprises the most significant direct cost of the pump, high reliability and easy maintenance help to bring down the indirect cost. The failure of one pump can stop the whole chemical processleading to increased costs and environmental impact
High efficiency, low energy cost

2 Design of the Sulzer AHLSTAR process pump.
Energy costs make up about 80 % of the life cycle cost of a process pump. Sulzer's engineers have considered this fact when designing the AHLSTAR pump series. Traditionally, pumps are operated with a constant-speed drive motor and a flow control valve to adjust the discharge. AHLSTAR ,0),. +,!-a/! 2%/$ 1a-%ab(! .,!! This operating mode -%1! )a'! !*!-#4 .a1%*#. 0, /+ 60% ,+..%b(!. can be compared to that easily outweigh the lifetime energy always driving a car at full throttle engine cost of the pump. speed and only using the brakes to A design with the goal of achieving control the velocity. If the pump motor low outage costs for the pump has to is operated using an electronic frequency take into consideration two main aspects. converter, it is possible to vary the rotating speed of the impeller and, thus, First, a reliable pump design minimizes the lifetime maintenance costs and to run the pump at high efficiency in a reduces the risk of unscheduled process broad operating range, making energy savings of up to 60 % possible. Further- interruption. Second, the units must be designed to be service friendly to shorten more, when operated with variable downtime whenever maintenance is speed, the pump runs smoothly without required. One example of this approach recirculation and with lower vibration is the innovative impeller mounting, and noise due to the low internal hydraulic loads. With this smoother oper- which allows for easy and quick instal-
10 | Sulzer Technical Review 2/2012
POLYMERS
ronment. The Sulzer process pumps sup- leaking. The shaft seals of AHLSTAR port these efforts with various features. require little or no water lubrication and Reliable shaft seals of the pump specifO1!- 90% +" /$! )!/a((%c )a/!-%a( 0.! "+ically selected for )a*0"ac/0-%*# /$! ,0), ca* b! -!c4c(! . pumped liquids and related applications prevent the pumped thus help to further reduce the environMinimal environmental impact liquids from leaking, and reliable shaft mental impact and operation costs. All industries must consider the ecological seals of the bearing unit prevent both Recycled metallic materials, reliable consequences of their processes and the contaminants from coming into con- operation, high energy efficiency, as well reduce the impact of those on the envi- tact with lubricant and lubricants from as few leaks from shaft sealing and bearing additionally minimize the enviSulzer Pumps has a full-scale laboratory in Kotka, Finland, ronmental impact of the units. Furtherand can test the final design options in real operational conditions. more, over 90 % of the metallic material used for manufacturing the pump can be recycled at the end of the pumps lifetime. lation and dismounting of the impeller. The highly standardized modular design of the AHLSTAR range facilitates spare parts service for the large number of pumps installed all around the world in different industrial segments.
Innovative and patented pump design

Pumping critical liquids in demanding applications requires innovative designs. Various characteristics of the AHLSTAR pump range are so advanced that Sulzer has decided to protect them by patent. Unusual for a mature product such as a pump, the AHLSTAR features several patented designs for hydraulics, shaft sealing, and bearing unit. These patents ensure reliable and highly efficient operation for challenging pumping applications and help to reduce the number process shutdowns, limit maintenance needs, and lower energy consumption, thereby minimizing total life cycle costs. The excellent flexibility, durability, and efficiency make the AHLSTAR pumps a perfect choice for the chemical process industryand especially for polymer manufacturing. Several key polymer producers have turned to Sulzer for the outstanding pumping performance and extensive experience.
H-1221 M)5515-5 Sulzer Pumps Finland Oy P.O. Box 66 48601 Kotka Finland Phone +358 500 259 737 heikki.manninen@sulzer.com
INTERVIEW
Lorenzo Ghelfi: Jolanda is the masterpiece of our biopolymer team.

The new Sulzer Chemtech pilot plant for bioplastics went into operation in Switzerland in June. In this interview, the Operational Manager Lorenzo Ghelfi gives us an insight into the development and importance of this facility.
Lorenzo Ghelfi presents polymer samples from the new pilot plant.
You and your team call the new pilot plant Jolanda. What can Jolanda do? With this facility, we can produce the bioplastic polylactic acid (PLA) on an industrial scale. Jolanda can produce up to 1000 tons of PLA a year. The starting materials for our innovative processes are dimers of lactic acid, which are extracted from natural raw materials such as sugar, starch, or cellulose. What is so innovative about this process? Our polymerization process is characterized by the unique mixing technology. With our static mixer technology and the SMRplus mixing reactor, we can considerably shorten reaction time and nevertheless have very good control over the entire process. Our competitors are using processes in which the polymer is retained in large reactors over much longer time periods. With the increase
in viscosity during the reaction, the dwell time in such reactors cannot be controlled across the complete volume of the tank. Our facility, on the other hand, is equipped with numerous, very efficient heating and cooling zones. As a result, we can precisely control temperature, viscosity, and pressure at every stage of the polymerization process, and we can thereby achieve the desired product properties. How did the idea for the new PLA process arise? Sulzer has already accumulated more than twenty years of experience with lactic acid and derivatives for the production of PLA. At the beginning, our interest was in the preparation and cleaning of lactic acid products through rectification. We then developed the crystallization technique for lactides. Sulzer Chemtech strengthened its expertise in the systems area with the acquisition of the Khni company in 2009. Cooperation with Puracthe world leader in lactic acid and lactide productionand Synbra as our end customer then led to our PLA activities. We thereby used our well-tested mixing and reaction technology as the basis, and we continued to develop the process
specifically for the production of PLA. A first, continuous pilot plant in Winterthur with this new PLA technology delivered such convincing results that a contract to build a large installation at Synbra in Holland came about within a very short time. With the new process, our customer can produce bioplastics with higher quality and tailor-made propertiesand that at a price that can increasingly compete with conventional petrochemical plastics. The new pilot plant now opens up entirely new possibilities. What are the major benefits for the customers? The new PLA facility in Pfffikon is larger and more efficient than the existing pilot system in our test center in Winterthur. We can now also ensure continuous operation with the operational concept of the new plant. We employ nine operators in three shifts in Pfffikon. In addition, we work closely with our development laboratory in Winterthur, where our analysis team is based. The new plant has a variety of functions. It serves as a demonstration plant for future customers and makes it possible to train their employees. It is also used for productionboth for larger
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INTERVIEW
product samples for customers and for the development of our own formulations and new PLA products. Why do customers want a demonstration of the technology? Customers invest millions in large-scale production plants, and want to take on as little risk as possible on the technical side. It is therefore understandable that the customers would like to see our polymerization process one-on-one before they make their investment. With our new plant, the customers can precisely check the energy consumption and efficiency of the process, as well as the quality of the product, well in advance.
plants or even complete PLA systems therein the immediate vicinity of the cultivation areasis particularly attractive. More and more companies around the world are becoming interested in PLA. What is the reason for this? Companies increasingly see a strategic advantage in producing products from alternative raw materials instead of mineral oil. At the moment, almost all the products in the plastics market are based on mineral oil and natural gas. The desire to become independent of rising prices and the limited availability of fossil fuels is a major trend.
How would you differentiate this project from the earlier ones that you carried out for Sulzer all over the world? I have worked for Sulzer all around the globe: in Brazil, Argentina, Russia, and the USA. This time, in the new project in Switzerland, there are no difficulties with regard to cultural and language differences. However, the official regulations and specifications for work and environmental protection are dealt with much more strictly here. Why has Sulzer Chemtech decided on the location in Pfffikon? Can production be cost effective in the high-wage country of Switzerland? Customers from all over the world visit us and appreciate the proximity to the sales department of Sulzer Chemtech as well as the easy accessibility via the nearby Zurich International Airport. Switzerland offers an ideal environment for high-tech industry. Furthermore, we also benefit from the proximity to our development department, which supports us in the operation and optimization of the plant. This would not be possible at other locations. And, as we work efficiently following LEAN principles, we are also competitive at the location Switzerland. What is planned for the future? We are planning to operate Jolanda for some years in order to establish the new PLA technology on the market. The significant investment in this polymer system should act as a trigger and lead to the breakthrough of the technology.
Interview: Tnde Kirstein
The production of samples is also an Is the PLA business also a growth important issue for the customers. market for Sulzer? Yes, because the customers carry out Yes, we have ambitious goals. The new their market development in the time PLA technology and our demonstration period from the purchase to the compleW%/$ J+(a* a 2! 2a*/ /+ !./ab(%.$ +0- *!2 PLA tion of a PLA plant /!c$*+(+#4 +* /$! )a-'!/. and there are many plant should considerably increase our risks in marketing. Before you produce the corresponding amounts in the kilo- business with polymers. Thecurrently still smallproportion of polymer ton scale in a large plant, there is always processing technology in the total sales the question of whether the right of Sulzer Chemtech should increase products have been selected, whether significantly in the next few years. the quality meets the requirements of specific applications and whether enough end consumers can be found. You, yourself, have been with Sulzer for more than 30 years. What experiOur customers therefore require PLA ence do you bring to this project? samples to be produced in advance, in What were the greatest challenges? order to be able to manufacture and test I bring experience in engineering and end products such as foils or fibers. With management. Managing a purely chemour facility, we can deliver PLA samples ical production is a new challenge for with various formulations in quantities me. But thanks to my life and professional from 20 to 200 tons and thereby ensure experience, I can comfortably deal with that the later production and sale runs unexpected situations. smoothly for the customers. It has been particularly challenging Who are your customers? to coordinate the teams from three We have received inquiries from major locations and to thereby keep to time plastics producers as well as many and cost schedules. Our colleagues in smaller companies who have cost-effec- Allschwil built the plant. The departtive access to the natural raw materials. ment in Winterthur is responsible for the In many countries in Asia and South engineering, while we in Pfffikon carry America, plants such as sugar cane or out the assembly. Thanks to the great cassava roots are cultivated in large quan- dedication of all our employees, we have tities, so that sugar and starch are easily been able to overcome all these difficulaccessible. The construction of processing ties.
L69-5A6 G0-3.1 studied mechanical engineering at the ZHAW (Zurich University of Applied Sciences), Winterthur, Switzerland. He worked as a project engineer in the field of industrial combustion technology for metallurgy and power plant construction. He has been working for Sulzer Chemtech for more than 30 years in the fields of international sales, project management, and engineering, as well as the production of process equipment for the international construction of chemical plants and oil refineries. During his foreign deployments in managing positions in Argentina, Brazil, Russia, and in the USA, he built up new business units for Sulzer and expanded the global market presence of Sulzer Chemtech. He recently returned to Switzerland following his deployment of several years in Russia and is now managing the buildup and the operation of the polymer pilot plant in Pfffikon.
POLYMERS
Efficient processing of plastics
More effective manufacturing through coated tools

Beverage caps and disposable medical syringes have something in common: They are produced with tools whose modified surfaces are particularly resistant. Sulzer Metco has many years of experience in the development of tailor-made surface coatings and treatments for every kind of loading.
he use of surface coatings or treatments has gained acceptance as a way to improve tools in the production of plastics. Depending on the application, different thin-film technologies are used for wear and corrosion protection and for the minimization of friction. Sulzer Metco is a market leader for coating services, and it works together with well-known customers in the plastics industry. For example, the CocaCola Company in China produces all its caps with tools that have been coated by Sulzer Metco. More than 25 % of all beverage caps in the world are produced
with tools that have been coated by Sulzer Metco 1. Surface solutions from Sulzer Metco not only fulfill the high requirements of the food industry, they are also used in the demanding production of medical engineering products. Tools that have been coated by Sulzer Metco produce around 15 % of all medicinal disposable syringes worldwide.
Wide range of stresses

The surfaces of plastic molds or tools are subject to many different stresses in the production process. The major wear mechanisms in the production of plastics are:
Corrosion, above all, in the form of surface and pitting corrosion Fouling by the smallest particles or coatings on the tools Abrasive wear as a result of particles embedded in the plastic Cavitation (tool-damaging bubbles in the plastic material) through local vapor pressure differences in the flowing medium Adhesive interactions Surface damage when cleaning the tools Additives enhance the wear mechanisms. The additives that are important for plastics can be dyes, plasticizers, or other
More than 25 % of all beverage caps worldwide, including those for Coca-Cola in China, are produced using tools that have been coated by Sulzer Metco.
Liz Van Steenburgh / Dreamstime
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POLYMERS
Types of heat treatments

The generic term nitriding stands for processes in which the edge regions of ferrous materials are enriched with nitrogen. If carbon is also supplied at the same time, this is referred to as nitrocarburation. This process improves the resistance to wear, the hardness, and the friction and sliding properties of the material. Two subcategories are differentiated in nitriding: G): 51;96+)9*<9);165 is carried out in a reactive gas mixture (e. g., ammonia and carbon dioxide). In 73):4) 51;9);165, atomic and/or ionized (reactive) nitrogen is generated in a low-energy plasma from molecular (non-reactive) nitrogen that has accumulated in the surface. This has the advantage that the ionization of the nitrogen is independent from the temperature in the plasma. Nitration can thereby be carried out at temperatures well below those needed for other nitride processes. The process also functions without a white layer (also bonding or compound layer). It is possible to optimize the component strength and toughness regardless of the respective surface hardness and the surface chemistry of the base material.
Resistance to wear and friction and sliding properties can be improved with the IONIT procedure, which can also be used for high-alloy steels, super alloys, and light metals such as titanium and titanium alloys. Cost savings are possible in both procedures, above all, through the replacement of expensive materials. For example, tempered steels, which are considerably cheaper, can be used in place of stainless steels.
fillings, such as glass fibers or chalk. They are used to influence component properties such as strength, elasticity, and hardness. At the same time, however, these modified plastics place more load on the tools during the production process and increase wear. A coating or heat treatment of the tools can reduce the abovementioned wear, which increases their service life and reduces the maintenance outlay. At the
Improving the surface with heat

Surfaces can be improved with thermochemical heat treatment. The thin-film division of Sulzer Metco offers its customers two process variants of heat treatment: The patented IONIT OX procedure gives treated materials excellent resistance to corrosion and wear, and it has proven to be an environmentally friendly alternative to hard-chrome plating. It is frequently usedeven in the sensitive food industryand is a combination of gas nitrocarburization, plasma-nitrocarburization, and subsequent oxidation.
Proven coatings for the plastics industry

In coating processes, a distinction is made between physical vapor deposition (PVD) and chemical vapor deposition (CVD). Coatings with thicknesses in the micrometer range are applied in both procedures. The following PVD hard coatings have proved effective in the area of the plastic and elastomer processing industry: Titanium nitride (TiN) Aluminum titanium nitride (AlTiN) Chrome nitride (CrN) Multilayer chrome nitride Modified chrome nitride layer (CrNmod) 2.
C+a/%*#. a* $!a/ /-!a/)!*/. +" /$! /++(. -! 0c! /$! 2!a)!c$a*%.)..

same time, a modified tool surface can significantly reduce production costs by saving on separators or lubricants.
The right solution for every demand

The thin-film technology division of Sulzer Metco offers individual solutions for many different requirements. These include plasma heat treatments and coatings as well as a combination of the two. The selection of the appropriate surface treatment depends on the plastics and elastomers to be processed and the specific parameters of the production processes.
1 Tools with diamond-like carbon coatings are used in the production of beverage caps.
POLYMERS
What is PVD and CVD?

PVD and CVD are well-proven coating processes: In 70@:1+)3 =)769 ,-76:1;165 (PVD), the initial material is transferred into the gas phase with physical processes and is condensed onto the component to be coated. Commonly used variants are vacuum arc evaporation and magnetron sputtering. In +0-41+)3 =)769 ,-76:1;165 (CVD), material is deposited onto a component from the gas phase by means of a chemical reaction.
P$D 796+-::
1 Vacuum measurement and 1 5 6
control system
2 Circular evaporators 3 Power supplies 4 Coating chamber 5 Process gas 6 Vacuum pump set 7 Window 8 Infrared temperature 3 8 2 7
Versatile use of carbon coatings

Diamond-like carbon (DLC) coatings can be applied using the PVD process or the PACVD (plasma-assisted chemical vapor deposition) process. The PACVD process is a plasma-assisted variant of the CVD process, in which temperatures are considerably lower and do not exceed 200 C. DLC coatings of the type a-C:H (hydrogen-bearing amorphous carbon coatings) are used above all in the plastics industry. The particularly smooth, amorphous
measurement
9 Substrate holder 10 BIAS power supply (substrate) 10 4
Prevention of slip-stick effects (these arise from a reduced difference between sliding and adhesion friction) Elimination of burner streaking Improvement of the flow behavior of the polymer melt and, thereby, an increase in the transport capacity
Customers benefit from DLC coatings

Customer examples show how effective the coating of tools can be: cores for the manufacture of disposable syringes have to be cleaned every three to four hours if uncoated. After a DYLYN/DLC coating, no cleaning was necessary, even after one and a half years. Corrosion problems were also eliminated. Similar benefits were also seen in textured blow molds coated with DYLYN/DLC: instead of regular reworking in a two-week cycle, production without rework could be continued, even after eight weeks.
C$D 796+-::
In the thermal CVD process energy is supplied in form of heat; in the plasmaassisted CVD process, (see figure) a gas is excited in a plasma.
1 Vacuum pump 2 Substrate 3 Gas supply, e.g. CH4 4 Reactive plasma 5 Plasma generator 3 5 2 4
PVD c+a/%*#. %*c-!a.! /$! ,-+ 0c/%1%/4 .%#*%"%ca*/(4.

a-C:H coatings are utilized for optically high-quality surfaces, for example, in CD and DVD production. DLC coatings are also used with great success on tools in the cosmetics industry 4, as well as for ejector pins, cores, and sliders in injection molding. The benefits are: Reduction of scale formation Excellent wear and corrosion protection, even at the standard film thickness of 24 microns
Thermoplastic synthetics, such as polyetheretherketone (PEEK), and elastomers, such as natural rubber, can be successfully processed. PVD coatings are also successfully used in the extrusion of polyethylene (PE) or polypropylene (PP), among other applications, as well as on polyethylene terephthalate (PET) molding tools.
Pioneering Psolid diffusion coating for high-gloss mirror surfaces

The new Psolid diffusion layer represents one of the most innovative approaches to tool surfaces in plastic injection
2 CrNmod-coated molds are used in the automobile industry.
Customer successes demonstrate the advantages

PVD coatings contribute significantly to increasing performance and productivity: In the case of coil distributors coated with CrNmod for the production of films from polyvinylchloride (PVC) or polypropylene (PP), customers have reported increases in service life of a factor of 10. The sliding properties of wide-slit nozzles coated in this way were also improved by 30 % 3.
POLYMERS
3 Nitrided wide-slot nozzles are coated in
4 DLC-coated components are used in the manufacture of cosmetic pencils.
the Sulzer installation.
molding and extrusion molding. Using Advantages of combined treatment dustry, polishing companies, and tool this method, a scratch-free passive layer manufacturers profit from the consider- The combination of plasma nitration that has a high resistance to corrosion able advantages of a Psolid coating 5. with subsequent coating using PVD or The time savings reduce production and PACVD combines the advantages of both and pitting is formed on the surface of types of surface treatment. Steels that the tools and molds. contain proportions of special alloying The use of a Psolid W%/$ P.+(% c+a/%*#. /$! ,(a./%c. ,-+c!..%*# elements (chrome, aluminum, vanadium, coating on corrosion%* 0./-4 ,-+"%/. "-+) c+*.% !-ab(! /%)! .a1%*#.. molybdenum) can achieve high surface resistant steels or repair costs dramatically, while simulta- hardness and represent an excellent basis cold-working steels with high chromium neously providing a considerable for the subsequent coating. The mechancontent provides hardening without any improvement in the uptime of the tools. ical properties of the material core, such loss in corrosion protection. In the coating of hot- and cold-working steels 5 Matrix blocks for the manufacture of disposable syringes have in particular, the diffusion layer creates cavitation holes on the inside. These cannot be coated with traditional tool surfaces with values up to 1600 HV. coatings with P.+(% , it is unproblematic. With a diffusion depth of 1050 m, coated components nevertheless remain constant in size and shape.
Time savings in the production of high-gloss surfaces

Due to the large outlay in time and the enormous cost factors when machining high-gloss or polished mold surfaces, savings are urgently sought in the plastics processing industry. A time saving for converting a polished surface to a high-gloss surface is possible thanks to Psolid. The wear-resistant coating protects against adhesion, considerably reduces deposits, and facilitates mold cleaning. Visible defects in the plastic parts can be excluded, as the layer neither flakes nor becomes brittle. Users in the plastics-processing in-
POLYMERS
What is the eggshell effect?

When hard coatings flake off from comparatively softer base materials, one speaks of the eggshell effect. Due to the difference in hardness between the coating and the base material, point or linear loadings can damage the applied coating and similar to a broken eggshell can separate. The plasma nitration hardens the base material and counteracts the eggshell effect.
as toughness and crack resistance, remain unchanged. With the combined treatment, the loadbearing capacity of the surface is decisively improved, so that the infamous eggshell effect does not occur (see infobox). In the processing of glass-fiber-reinforced polymer materials, these kinds of hardened tool surfaces prevent the added hard additives from being pressed into the tool surface at high process pressures. In plastics processing, the tools have to be cleaned at the latest during a production change. Polymer residues are thereby usually removed using scrapers and spatulas made from steel, which
can easily lead to damage to the surface. This damage can be avoided through the supportive effect of nitriding.
Sulzer Metcoa strong partner for coating solutions
6 A 4.5m-long extrusion screw is coated in the Sulzer system for large and long parts.
In the field of thin-film technology, Sulzer Metco has service centers worldwide for the contract treatment of tools and components. In addition to services for surface improvement for various T$! .!-1%c! /!a). +" S0(5!- M!/c+ $a1! )a*4 industrial and appli4!a-. +" !3,!-%!*c! %* !a(%*# 2%/$ ,(a./%c /++(.. cation areas, its own system construction division delivers and 3.18 m3 total volume. Furthermore, extruder screws or wide-slot nozzles up innovative new developments and to lengths of 4500 mm, diameters up to further developments through its own 600 mm, and volumes of 1.27 m3 can be treated 6.
research and development work. The service teams have many years of experience in dealing with plastic tools. The members of staff make use of their extensive experience in the industry to provide the clients with targeted consultation. A special feature is the contract treatment of long and large parts. The maximum dimensions for large-volume parts are: 1800 mm long, 1500 mm diameter,
"064): )<. ,-4 B9152Sulzer Metaplas GmbH Am Bttcherberg 3038 51427 Bergisch-Gladbach Germany Phone +49 2204 299 293 thomas.aufdembrinke@sulzer.com A55-;;- N6915 Am Bttcherberg 3038 51427 Bergisch-Gladbach Germany Phone +49 2204 299 262 annette.norin@sulzer.com
SULZER ANALOGY
Spider silk as a superpolymer

Macromolecules are formed by the polymerization of base molecules and form the basis of life. For example, proteins consist of thousands of amino acids, and nucleic acids build up the genetic code from millions of nucleotides. Spiders have an amazing technique for building complex spatial structures from protein chains.
he most highly developed examples of the natural silk technique are the webs of cross spiders and other orbweaving spiders. They construct a vertical, two-dimensional web between two anchor points that are relatively far apart. Starting from a first, bridging
can thereby cushion the impact of the collision. If the stretched thread were to then spring back to its original position like a rubber rope, the insect would be catapulted back into freedom as if from a trampoline. But because the web returns only gently after the rapid expansion, the prey remains caught. The trick lies in the sticky water drops. The silk thread is rolled up on the drops through the surface tension of the liquid. The resulting numerous loops cause, like a cable reel, both the rapid extension and the braked rerolling of the thread.
tensile strength of spider silk is around 2500 kg/cm2. Relative to its weight, it is, therefore, five times stronger than steel.
Medical and musical applications

In order to be able to make use of spider silk technology, the genes involved have been isolated recently and have been introduced into bacteria for silk production. Possible product applications are artificial tendons and ligaments, bandages, or fabrics for bulletproof vests. There is a great deal of interest now in the development being done by the Japanese professor for polymer chemistry Shigeyoshi Osaki. Thousands of threads from the spider species Nephila maculata have been woven into compact strands that can now be used as violin strings. After the first trials, violinists highly praised the soft and full tones of the silk strings.
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A targeted mix of amino acids

The silk technique of the cross spider is also amazing because, in its abdomen, the animal carries a selection of seven different silk glands, which lead into a complete battery of spinnerets. Depending on the function of the thread, it is produced with a special mixture of amino acids for a specific thickness and elasticity. For example, there are different silk materials for the frame and the spokes, for the auxiliary spiral, the catching spiral, or the glue for linking and attaching the threads. The thread itself also has a sophisticated design. Although still a liquid made up of keratin molecules in the silk glands, the protein mass transforms itself within milliseconds when squeezed through the narrow valve of the silk gland. Strong shear forces compel the keratin to take on a specific structure: A part of the protein folds like the bellows of an accordion to form solid crystals, while the rest encases the crystals as disordered molecule chains, like a ball of spaghetti. A thread that is both elastic and extremely tough results from this procedure. The
Keystone / Science Photo Library / Steve Gschmeissner
With their silk glands, spiders produce a silk material with exceptional properties.
thread, the spider constructs the basic framework of the orb web with edge threads and spokes and, finally, the catching spiral by means of an auxiliary spiral. Any insect that hits the web will become caught on this catching spiral through a chain of extremely sticky pearl-like drops made up of water and glycol proteins.
Gently catching a bomber

The web that catches the insects has to cope with an enormously challenging task. If, for example, a large fly hits one of the one-thousandth-of-a-millimeterthick threads, it is like a bomber, and the impact should actually break the web. However, the silk threads can stretch to up to five times their original length and
Spider silk is a wonder of nature and can even improve the sound of violins.
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POLYMERS
Polymer analysisbetween measurement and interpretation
Following the trail of polymeric evidence

Plastics are being used more and more frequently in modern machinery and equipment design because they are light, resistant to corrosion, and cost effective. In order to obtain optimal plastic properties, technological analyses are essential. Due to the many influencing factors and complex issues, however, the interpretation of results requires extensive knowledge and, in many cases, detective-like instincts.
ulzer Innotec supports the Sulzer divisions and external clients in polymer analyses with its modern laboratory and its many years of expertise in plastics. The following project examples from Sulzer Innotec show that many factors (such as material composition, component manufacturing, and operating conditions) have to be taken into account in polymer analysis
in order to uncover the causes of shortcomings and to find adequate solutions for them.
Case 1: What kind of constituents are in the plastic?

As a result of globalization, polymer materials and, in particular, high-performance plastics that supposedly have the same composition are available from
various manufacturers. The price of the material plays a central role in the choice of the supplier. The selection is still not easy, however, because the quality differences are often not recognizable at first glance. In order to ensure that the component quality remains the same, even following a change of supplier, it is recommended that buyers carry out a detailed analysis of the
Micrographs clearly illustrate how plastics are composed of different constituents (thin section under polarized light).
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POLYMERS
Plasticsa mix of individual components

As a rule, polymer materials are available in the form of feedstock pellets, which are processed further using extrusion or injection-molding processes. Polymeric base materials include, for example, polyethylene (PE), polyamide (PA), and polyetheretherketone (PEEK). In order to meet the detailed performance requirements for the finished parts, various additives are mixed together with the base material in a compounding process. The finished feedstock is therefore the mix of: The base polymer Processing aids Reinforcing agents Aging and flame retardants Dyes and other materials The composition of the feedstock material is part of the know-how of the respective material manufacturer and is a closely guarded secret due to the development work that went into it.
replacement material in advance. Deficiencies occurring in operation can thereby be avoided from the very start.
Comparing suppliers
For an external client, Sulzer Innotec compared carbon-fiber-reinforced modified PEEK materials from two different suppliers. For the end product, which is subjected to high mechanical and tribological loads, the client wanted to replace the feedstock pellets from supplier A with the cheaper pellets from supplier B. Sulzer Innotec was asked to determine whether or not the main components of the two materials were qualitatively and quantitatively the same. To start with, standard laboratory test methods were applied to the problem: Fourier transform infrared spectrometry (FTIR) Thermoanalysis: Differential scanning calorimetry (DSC) Thermogravimetric analysis (TGA) Dynamic mechanical analysis (DMA) Optical microscopy
The results of the FTIR analyses showed an optimal match with the database spectrum of PEEK for both feedstock pellets A and B. No indication of the supposed PTFE lubricant (Teflon) was found in either feedstock by means of FTIR. The results of the thermoanalytical investigations also revealed no obvious differences between the pellets from the although the qualitative and quantitative two suppliers. The two temperature composition of the two materials was peaks at approx. 21 C and 330 C for shown to be the same and although the the two materials clearly indicated the presence of PTFE, however. With addi- fabrication of the end products was carried out using the same processing tional investigations (thermogravimetry and optical microscopy), the relative pro- parameters, the resulting products made portions of PEEK, PTFE, carbon fiber, D!.,%/! a)b%#0+0. /!./ -!.0(/., S0(5!- 2a. and graphite could ab(! /+ /-ac! /$! ca0.!. +" /$! %*.0""%c%!*/ be determined. The )a/!-%a( b!$a1%+-. comparison between using feedstock B exhibited suboptimal the two feedstocks also showed no properties: These parts exhibited sliding differences here. behavior deemed insufficient for the The same, but not the same intended application. According to the analyses, the pellets The material analysts from Sulzer from the two suppliers should have been Innotec were able to discover the cause able to be processed into end products of this discrepancy. Thanks to scanning with equivalent properties. However, electron microscopy (SEM) of the two
1 Only in the scanning electron micrographs can a difference be seen between the pellets: The PTFE filler (light color) in material A (left) has a different distribution from that in material B (right).
10 m
10 m
POLYMERS
A change in the processing parameters has many consequences

As the market for the plastics-processing industry is very competitive, many manufactures try to save costs in the processing of polymer materials. As a result of variations in the processing parameters (pressure, temperature, speed), it is possible to make plastic components with very different properties from the same materials on the same production line. However, changes in the processing parameters and/or reductions in the cycle times can affect the quality of the end products. It is not uncommon for problems to arise with plastic parts that are subjected to high stress. This can have consequences for the part, particularly during long-term operation.
pellet types, they were able to detect significant microscale differences between the two materials. While in feedstock A, the PTFE phase (light-colored in Fig. 1) was relatively evenly distributed and took on a spherical form, in feedstock B, the PTFE component appeared as locally concentrated agglomerates looking something like popcorn. The difference concerning the appearance of the PTFE can be traced back to the use of different types of PTFE in the two feedstocks. With this knowledge, the poorer sliding properties could be conclusively explained, and consequently the client decided against a change of supplier.
free of damage
defective
20 mm
3 Two identically manufactured oil scrapers made of PPS behave completely differently in operation.
Case 2: How is the plastic processed?

A change in the process parameters can save manufacturing costs, but can also negatively affect the component quality. In order to detect deficiencies in quality, material analysts use test methods that react sensitively to changes in the processing parameters. Using modern simulation programs programs to model the filling behavior or temperature and stress distributions, the manufacture of plastic components can be visualized and the processing can be effectively optimized. With some components, such as transparent plastics, it is easy to reveal unfavorable processing parameters 2. It is
M+ !-* .%)0(a/%+* ,-+#-a). $!(, /+ +,/%)%5! /$! )a*0"ac/0-! +" ,(a./%c..

more difficult to analyze the processing parameters of long-life components of high-performance plastics, as the following case shows.
2 The images of the polystyrene lid taken under polarized light reveal residual stresses in the material, which stem from the manufacturing process.
Injection point
A smaller temperature peak provides the first clue

Sulzer Innotec investigated two oil scraper rings that behaved completely differently under the same operating conditions 3. While one worked flawlessly, massive breakout was found on the scraper edges of the other after only a short operating time. The measurement results for both components yielded almost identical melting curves. Only a small peak between 200 C and 230 C, which occurred at a higher temperature in the thermogram of the defective component, indicated a small difference between the thermoanalytical results of the analyses of the two components. For the materials analyst, this inconspicuous
Discoloration resulting from residual stress.
POLYMERS
Analysis of damage caused in operation

A number of factors can lead to the failure of plastic parts in operation: Mechanical stresses (time- and temperature-dependent creep and relaxation processes) Thermal stresses Chemical stresses As these three factors are interdependent, it is not enough to assess their operational impact individually. The analysis is made more difficult by the complex and secret compositions of the plastic compounds. In particular when installing offthe-shelf plastic components, it is not possible to judge whether or not both the material and the processing were correct. It is therefore challenging to interpret the analysis results correctly and to attribute them to the operating conditions where necessary.
difference was a first clue answering the question as to whether the breakout was due to the composition of the material, the processing, or the operating conditions.
Inadequate predrying led to brittleness

In the case of the scraper, the detected anomaly could be definitively assigned to the processing procedure. Further investigations showed that the starting material of the brittle scraper did, indeed, have the same composition, but that the material had been insufficiently predried before it was processed. Due to the residual moisture that was present, the manufacturer had to change the processing parameters in order to produce scrapers that were optically perfect. This change resulted in the detected, higher peak temperature of the brittle, failed scraper. As this example shows, the processing of the components must also be taken into account when explaining deficiencies in end products.
Specialists from Sulzer Innotec on-site assessment of the situation is difassessed the seal geometry and the ficult, because the causal factors influence O-ring groove on site and found each other and are not obvious. them to be in order, but detected massive Sulzer Innotec investigated defects in damage to the O-rings themselves 5. the seals of water-cooled engines, for which silicone O-rings were used. The deformation of the O-rings and According to the data sheet from the I* ca.! +" a)a#! ca0.! %* +,!-a/%+*, S0(5!material manufactura*a(45!. *+/ +*(4 #!+)!/-%ca( a* )!c$a*%ca( er, the silicone used ,-+,!-/%!., b0/ a(.+ /$!-)+c$!)%ca( ,-+c!..!.. is resistant to water the numerous cracks along the entire and steam at operating temperatures circumference indicated the occurrence below 130 C. However, leaks in the seals of a thermal degradation process. Labowere detected after an operational period ratory tests on unused O-rings were able of only six months 4.
4 First on-site inspections provide only few indications of the causes of defects (e.g., at these O-ring seals in a water-cooled engine).
Case 3: What happens to the plastic in the operation?

The analysis of damage caused in operation is challenging because of the many influencing factors which need to be considered. Seals and O-rings in heavy-duty applications represent typical examples of this kind of question. Component performance is not only a question of the seal geometry and the temperaturedependent mechanical properties of the material, but also of the thermochemical processes that occur in operation. A quick
POLYMERS
10 mm
5 The numerous cracks in the silicone O-rings indicated a thermochemical cause of the failure.
6 The degradation process could be recreated in the laboratory:
Left, a new silicone seal and, right, a silicone seal aged and embrittled by exposure to water vapor at 140 C.
to show that both material and manufacturing quality could be excluded as causes of the failure.
Moisture and heat decompose the plastic
More-detailed analyses finally led the analysts at Sulzer Innotec onto the right track: The damage to the O-rings was Ba.! +* S0(5!-7. /!./ -!.0(/., a )a&+- )a/!-%a( due to a chemical c$a*#! 2a. %*%/%a/! . decomposition of the silicone as a result of the conditions expe- the operating temperature in the area of the O-rings to below 130 C, or replace rienced in operation. The cause was a damp environment (hydrolysis) at a tem- the silicone with a more suitable elastomer material. Using aging trials perature that was too high (significantly above 130 C). Consequently, the macro- developed and performed out in-house, Sulzer Innotec was able to narrow molecules of the O-ring material were being split chemically, resulting in short- down the choices and recommend the
7 Aging trials for the selection of a suitable sealing material were carried out in the laboratory.
ened molecular chains and the consequent embrittlement of the material. The degeneration process could be reproduced in laboratory trials, since degradation also occured without the mechanical loading typically experienced in operation 6. The client had two options available based on this result: Either reduce
best-possible sealing material 7. Followup checks on the seals in use confirmed the good results from the laboratory. Based on the results from Sulzer Innotec, a major material change to a special fluoroelastomer was initiated.
It is the right interpretation that matters

As the above examples show, it is not simply performing the measurements themselves that is difficult in plastics analyses; the interpretation of the measurements requires almost detective-like instincts. It is particularly challenging when it is not possible to precisely analyze all the required parameters. In order to be able to draw the right conclusions in complex issues, interdisciplinary expertise in the area of plastics technology, in addition to close and open-minded cooperation with the client and extensive experience in polymer analysis, is decisive for success.
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GC5;-9 DB95-9 Sulzer Innotec Sulzer-Allee 25 8404 Winterthur Switzerland Phone +41 52 262 69 41 guenter.doerner@sulzer.com
SULZER WORLD
Welcome to Sulzer Metco in Limoges

Sulzer Metco has a modern and growing location for diamond-like carbon coatings (DLC) in Limoges, France. These coatings are particularly suited for use in automotive applications and motor sports.
hrough the acquisition of Bekaerts DLC division in 2010, Sulzer Metco expanded its technology portfolio in the area of thin-film surface coating. The location in Limoges that is involved in this field has a long history of success with DLC coatings. The first engines were coated with DLC here as long ago as 1995, and the location has experienced active growth in the meantime. This is especially evident from the numerous expansion activities in the production halls in the last few years. Clients can be sure that the 65 employees at the location will guarantee the very best quality at all times.
ticularly suitable for use in motor sport, where every millisecond is crucial. Formula 1 teams worldwide are equipped with DLC coatings. At the Limoges site, the majority of the business is generated in motor sport. Significant and steady growth can, however, also be seen in the fields of plastics, automobiles, engineering, and metalworking. Surface solutions for the semiconductor industry are also being offered in increasing numbers.
Center of excellence and cooperation with universities

In order to be able to guarantee stateof-the-art coating solutions for clients, the site also operates an R&D system. Coatings that have been modified and further developed can be tested
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under realistic production conditions, which makes the rapid transition to a sustainable production process particularly easy. In addition, Limoges is currently working together with the University of Limoges and leading partners from the automobile industry on a research project that will set new standards with its DYLYN coatings. The proximity of the location to the university, which is only 500 meters away, facilitates the continuous cooperation with qualified students and institutes. Sulzer Metco in Limoges stands out through its impressive diversity. In addition to modern coating installations and high-tech equipment, the expert knowledge of the employees is just as important as the wide competence network with industry and research. Through the experience and the broad-based expertise of the employees in Limoges, Sulzer can continue to grow internationally and expand its position as a technology expert.
The highest standards for equipment and control

Limoges has a modern, fully automated cleaning line that meets all customer requirements. Eleven coating installations are currently in continuous operation. These include DLC coating installations and a PVD (physical vapor deposition) system. In particular, Limoges is able to guarantee a high quality of production through its cleanroom. A special feature of the Limoges site is the final inspection at the end of the coating process: visual inspections as well as additional mechanical and computer-supported analyses in some cases with equipment developed inhouse for large componentsensure the highest quality of the end products.
Established in motor sport growing in new markets

DLC coatings such as CAVIDUR and DYLYN are characterized by their especially smooth textures. At the same time, they display low coefficients of friction and a very high resistance to wear. It is for exactly this reason that they are par-
The location in Limoges is world-famous in motor sports for diamond-like carbon coatings.
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PANORAMA
Thermographic inspection of industrial gas turbine components
Insightful hot spots

Lock-in thermography is a versatile inspection method capable of identifying defects in gas turbine parts. Sulzer Turbo Services Venlo uses this advanced method not only to examine turbine components, but also as an R&D instrument to improve turbine design and repair to the benefit of the customers.
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inding defects in turbine blades is one important task of the lock-in thermography setup at Sulzer Turbo Services 1. An ultrasound transducer introduces elastic waves (propagating elastic deformations) into the turbine component. In homogeneous material, the reflected waves are evenly distributed. However, at locations where the alloy is
damaged, some of the wave energy is absorbed, and heat is generated. This heat has a different infrared (IR) radiation than its surrounding area and is detected by the IR camera 2 (see infobox).
Infrared images reveal defects

Modulation of the ultrasonic wave improves the heat contrast and provides
an amplitude image and a phase image of the turbine component. The amplitude image is a measure for the temperature and is related to the thermal diffusivity. The phase image reveals the size and depth of the defect. The phase is a result of a shift in the output signal with respect to the input signal and is related to the propagation time or depth.
1 Sulzer Turbo Services Venlo uses ultrasonic thermography for turbine inspection and research.
IR camera Turbine part Ultrasonic transducer
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PANORAMA
Thermographic inspection
In thermographic inspection, an infrared (IR) camera measures and visualizes the heat distribution within an object. There are two approaches: In 7)::1=- ;0-946/9)70@, the existing thermal radiation of an object is measured. Common applications are the detection of insulation faults in housing, detection of overheating in power supply stations, and level detection in storage tanks. A+;1=- ;0-946/9)70@ introduces energy into the object and measures the objects response. One method is lock-in thermography, which uses a transducer to introduce ultrasonic waves into the object.
FFT
IR camera
Phase image
2 The detection principle of lockin thermography is based on ultrasonic waves that generate heat at damaged locations inside the turbine part.
Amplitude image Elastic wave Thermal wave
Turbine blade with defect
Ultrasonic excitation
Lock-in frequency
The bright spots in the phase image need to be inspected in more detail in order to determine whether the hot spot is a real defect. For this reason, the sequence profilewhich is the amount of radiation measured on one spot in time is analyzed. The sequence profile of a defect is different from the profile of other surrounding heat sources, for example, the reflection of a lamp. A defect shows a response curve similar to the modulation frequency of the excitation.
approaches. For instance, fluorescent penetrant inspection cannot detect internal defects and borescopic inspection is time consuming.
Evaluating coatings with thermography

Ultrasonic lock-in thermography can also detect a lack of proper bonding between the parts and their metallic coating. The elastic waves cause vibration in
the part. If the coating is bonded properly to the base material, no friction heat is observable. Friction between the part and the poorly bonded coating creates a bright thermal signature. Recently, thermographic inspection has been compared with conventional manual ultrasonic inspection with a probe, and a 100 % match of observed indications has been achieved.
3 The results of a thermography inspection show damage to a turbine blade.
The magnified image on the top shows an internal crack; the magnified image on the bottom shows a crack on the surface.
Distinguishing between internal and external defects

Sulzer Turbo Services Venlo applies lockin thermography to identify structural defects in turbine parts. Such defects include cracks along the grain boundary that have been caused by corrosion, oxidation, mechanical stresses, or casting defects. Because turbine parts are made of metal alloys, the heat signature generated is not just limited to the defect itself. The heat is conducted and creates a slightly weaker hot spot that is larger than the defect itself. The advantage of this thermal conduction is that the heat signature of internal defects is detectable as a diffuse heat source at the surface. Thus, ultrasonic lock-in thermography can detect both external as well as internal defects. Figure 3 shows the detection of cracks on the surface and inside of a blade. This method has significant advantages over other
PANORAMA
5 The thermographic measurement of a blade shows open and blocked cooling channels.
4 Cooling channels protect turbine blades from high temperatures.
National Aerospace Laboratory of the For turbine components, cooling is very Netherlands. This model describes the important to extend and protect compo- heat transfer between combustion gas, nent life 4. During the repair of vanes cooling air, and surface temperature of or blades with cooling channels, it must the part. In order to validate the model, be ensured that all cooling holes are open. Sulzer built a test rig that represents the An IR camera can show at a glance turbine situation, just with inverse whether cooling holes are blocked T$! -!.!a-c$ -!.0(/. 2%(( a((+2 /$! +,/%)%5a/%+* or open. This is +" /$! c++(%*# !""%c%!*c4. achieved by blowing warm air through the component. A ther- thermal conditions. Warm air is guided mal image of the part is recorded in through the cooling channels and cold order to visualize the heating of the com- air flows along the outer surface of the ponent. Figure 5 shows an example of part. The parameters have been scaled such a recording. Open cooling holes down to ensure proper flow regimes and appear in bright yellow because of the flow ratios. heating by the warm air. Blocked cooling Validation of heat transfer model channels are not heated; they appear as The test rig 6 is designed to achieve a a blue-black color. controlled flow of air along the airfoil. Research on the efficiency of cooling For the hot air that flows through the holes vane, a temperature and flow control is Sulzer has started a research project in used. The actual setup consists of a vane order to develop a method of evaluating surrounded by a heating element, cold the efficiency of cooling channels of tur- airflow section, and IR camera. It allows bine blades and vanes. The results of the measurement of the wall temperature this project will provide more information of the component. about how the cooling-hole geometry An example of a measurement is affects the cooling efficiency. shown in Figure 7. The homogeneity of the cooling-hole pattern of four rows of The research is based on a heat transfer ten holes is easily recognizable by the model that has been developed by the
Detection of blocked cooling channels
PANORAMA
Frequence regulator
Temperature probe
Pressure probe
Pressure probe
Camera
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Fan
Inhomogeneous air flow distribution
Uniform air velocity distribution
Vane
Stilling chamber
Camera gives a view of cooling holes
6 The test rig is designed to achieve a controlled flow of air along the airfoil.
peak temperatures. These results will be used as input for the model verification in the ongoing research project.
Versatile use of thermography

The projects of Sulzer show that the lockin thermography technique is able to detect: Cracks in turbine blades, both external and internal Grain boundary attack in turbine blades
Corrosion in turbine blades Apart from fault detection, ultrasonic Spallation in the coating lock-in thermography is very successful Blocked cooling holes as an R&D instrument that enables Due to the high sensitivity of the IR engineers to increase their knowledge camera, even minor hot spots can be of turbine parts, improve repairs, and detected. A careful analysis by experiW%/$ 0(/-a.+*%c (+c'-%* /$!-)+#-a,$4, !*#%*!!-. enced technicians is %*c-!a.! /$!%- '*+2(! #! +" /0-b%*! ,a-/.. important in order to decide whether small defects are develop new designs to the benefit within allowable limits or whether the of the customers. defects need to be repaired.
7 The thermographic analysis of the cooling holes delivers data to help verify the heat transfer model.
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J6: %133-4: Sulzer Turbo Services Venlo B.V. Spikweien 36 NL-5943 AD Lomm The Netherlands Phone +31 77 473 85 16 jos.willems@sulzer.com M)91<: =)5 ,-9 G<5 Sulzer Turbo Services Venlo B.V. Spikweien 36 NL-5943 AD Lomm The Netherlands Phone +31 77 473 86 43 marius.vandergun@sulzer.com
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EVENTS & NEWS

July 1720, 2012, Louisville, KY, USA H@,96 $1:165 I5;-95);165)3 www.hydroevent.com September 35, 2012, Brisbane, Australia 7;0 A55<)3 LNG %693, C65.-9-5+www.lngworld-lse.com September 1013, 2012, Karlsruhe, Germany P96+-::N-; A55<)3 M--;15/, DECHEMA-A55<)3 M--;15/ 6. B16;-+05636/1:;: www.processnet.org/jt2012 September 1014, 2012, Boksburg, South Africa E3-+;9) M1515/ 2012 www.electramining.co.za September 1015, 2012, Chicago, IL, USA I5;-95);165)3 M)5<.)+;<915/ "-+05636/@ !06> IM"! C01+)/6 www.imts.com September 1012, 2012, Shanghai, China C"I !@476:1<4 C015), A<;646;1=- "9)5:41::165:, H@*91, & E3-+;91+ D91=-: http://cn.transmission-symposium.com September 1620, 2012, San Diego, CA, USA F)33 C"O"F (C64*<:;165 "<9*15- O7-9);165: "-+051+)3 F69<4) www.ccj-online.com/2012-meetings September 1720, 2012, Rio de Janeiro, Brazil 16 O13 )5, G): !06> www.ibp.org.br September 1819, 2012, Riga, Latvia 7;0 G36*)3 I5:<3);165 C65.-9-5+- )5, E?01*1;165 www.globalinsulation.com September 1822, 2012, Stuttgart, Germany AMB !;<;;/)9;, I5;-95);165)3 E?01*1;165 .69 M-;)3 %69215/ www.messestuttgart.de/amb September 2327, 2012, London, United Kingdom E<964-4*9)5www.euromembrane2012.com September 2426, 2012, Las Vegas, NV, USA MINE&PO 2012 www.minexpo.com September 2427, 2012, Houston, TX, USA "<9*64)+015-9@ !@476:1<4 http://turbolab.tamu.edu September 2628, 2012, Beijing, China EPA 2012 www.epchinashow.com September 29October 3, 2012, New Orleans, LA, USA %EF"EC '12 www.weftec.org/exhibition October 35, 2012, Bangkok, Thailand P6>-9-G-5 A:1) www.powergenasia.com October 911, 2012, Sao Paolo, Brazil AB"CP 2012 P<37 )5, P)7-9 I5;-95);165)3 C65/9-:: )5, E?01*1;165 www.abtcp2012.org.br October 1620, 2012, Friedrichshafen, Germany FAK#MA 2012 I5;-95);165)3 "9),- F)19 .69 P3):;1+: P96+-::15/ www.fakuma-messe.de October 28November 2, 2012, Pittsburgh, PA, USA AIC0E A55<)3 M--;15/ www.aiche.org/Conferences More events: >>>.:<3A-9.+64/;-+051+)3-=-5;:
New Sulzer web presence

usability. With the new Sulzer website customers can: Find comprehensive information of all Sulzer products and services in six languages: English, Chinese, Portuguese, Spanish, German, and Russian Quickly identify the products and services applicable for their industry Use targeted search tools for specific information and resources including articles of the Sulzer Technical Review Get the specific contact at Sulzer in their country for specific products and services Get updated on the latest news and developments.
www.sulzer.com
Sulzer is launching a new website which provides comprehensive information about the full range of products and services. With new functionalities and many additional documents, the website strengthens Sulzers internet presence for all businesses. The customer-focused approach of the website ensures high
Outstanding safety performance

Since July 2010, Sulzer Chemtech Tower Field Service Singapore has been working on the Exxon Parallel Train (SPT) project on Jurong Island, Singapore. The team recently received a safety award for carrying out more than 400 000 man-hours of safe work without any lost-time incidents. The client appreciates Sulzers outstanding safety commitment and thanked the team for contributing to the safety culture on the Olefins recovery site.
Sulzer Tower Field Service is the leading provider of specialized mechanical services to offshore platforms, natural gas plants, oil refineries, and petrochemical plants. Customers benefit from mass transfer equipment services, welding services, plant maintenance, and turnaround projects on a global basis.
Introduction of new thermal-spray gun

Sulzer Metco is expanding its product portfolio with the new SinplexPro plasma spray gun, which significantly increases productivity with little additional equipment investment. SinplexPro is a single-cathode gun with a fixed cascaded arc, enabling users to spray significantly more material in less timeoften with higher deposition efficiencies. The cascaded-arc design produces a much more consistent plume temperature and velocity profile compared with other single cathode models on the market. This results in an overall reduction in costs and processing times. Because the SinplexPro can be easily integrated into most existing plasma spray systems, it offers a low-risk investment that will not disrupt current production. Furthermore, when the SinplexPro is installed, companies will retain the ability to operate different guns in a single booth, allowing their technicians to continue using their existing plasma guns where necessary. The SinplexPro will be available in both 90 and 180 configurations so it can be used for a variety of applications and processing requirements. It also has thorium-free gun components, ensuring it meets regulations in global markets.
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IMPRINT
Online Sustainability Report 2011

Sulzer published its online Sustainability Report 2011 and received the highest transparency level A+ of the Global Reporting Initiative. Sulzer is committed to building its business success on responsible action, which allows it to grow sustainably and to generate value for current and future economic, social, and ecological stakeholders. For social responsibility, health and safety remained of highest importance for Sulzer. In 2011, the company further reduced the frequency of accidents from 4.4 to 3.7 accidents per million working hours. Creating jobs is an essential contribution to supporting the prosperity and quality of life in communities. Sulzer created 940 new jobs worldwide in 2011 (excluding acquisition effects). In the area of ecological sustainability, Sulzer aspires to be a leader in energy efficiency within its industries, both with regard to its own operations and the ecological performance of the companys solutions. In 2011, CO2 emissions per net value added were reduced by 5% compared to the prior year. In the same year, energy consumption per net value added remained stable. In order to highlight the superior environmental standards of Sulzer solutions, the company issues environmental product declarations and aims to cover all relevant main product www.sulzer.com/sustainability categories this year.
The S0(5!- T!c$*%ca( R!1%!2 (STR) is a customer magazine produced by Sulzer. It is published periodically in English and German and annually in Chinese. The articles are also available at: www.sulzer.com/str 2 /2012 94th year of the STR ISSN 1660-9042 Publisher Sulzer Management Ltd. P.O. Box 8401 Winterthur, Switzerland Editor-in-Chief Tnde Kirstein tuende.kirstein@sulzer.com Editorial Assistant Laura Gasperi sulzertechnicalreview@sulzer.com Advisory Board Mia Claselius Samuel Eckstein Ralf Gerdes Thomas Gerlach Hans-Michael Hhle Ernst Lutz Claudia Prger Heinz Schmid Daniel Schnyder Translations Interserv AG, Zrich Design Typografisches Atelier Felix Muntwyler, Winterthur Printer Mattenbach AG, Winterthur July 2012 Reprints of articles and illustrations are permitted subject to the prior approval of the editor. The S0(5!- T!c$*%ca( R!1%!2 (STR) has been compiled according to the best knowledge and belief of Sulzer Management Ltd. and the authors. However, Sulzer Management Ltd. and the authors cannot assume any responsibility for the quality of the information, and make no representations or warranties, explicit or implied, as to the accuracy or completeness of the information contained in this publication. Circulation: 16 000 copies. Magno Satin 135 g/m2 from sustainably managed forests.
Opening of service center in Russia

After last years opening of the first Russian service center in Khimki, Moscow, Sulzer Pumps now has opened a second service center in Russia. It is located in the city of Oktyabrsky, Republic of Bashkortostan, and offers its customers round-the-clock response. The state-of-the-art service center has an area of 1500 m2 and is fully equipped to overhaul and repair all types of rotating equipment. Its close proximity to Ufa, Samara, Orenburg, and other industrial cities in the area of oil production fields and refineries brings Sulzer Pumps closer to customers. The service center houses service technicians, engineering, contract administration, and sales staff providing services for a wide range of pumps used for different applications. Russia is a significant market for Sulzer Pumps, and the aim is to further expand its presence with more service centers in the years to come.
For readers in the United States of America only: The S0(5!- T!c$*%ca( R!1%!2 is published periodically by Sulzer Management Ltd., P.O. Box, 8401 Winterthur, Switzerland. Periodicals postage paid at Folcroft, PA, by US Mail Agent La Poste, 700 Carpenters Crossing, Folcroft PA 19032. Postmaster: Please send address changes to Sulzer Technical Review, P.O. Box 202, Folcroft PA 19032.
Generator rotor refurbishment
Improved generator efciency

Wi!h comple!e in-ho" e capabili!ie for !he !o!al o#erha"l, "pgrade, or repair of genera!or , S"l&er T"rbo Ser#ice can go be%ond eq"ipmen! er#ice !o reengineer replacemen! par! and remo#e defec! . O"r in-ho" e coil man"fac!"ring facili!% help !o minimi&e o"!age !ime . We are commi!!ed !o pro#iding reliable o#erha"l ol"!ion !ha! keep %o"r machine r"nning efficien!l% and afel%. We al o pro#ide a $ide range of er#ice for !hermal ro!a!ing eq"ipmen! !o impro#e !he performance of %o"r plan!.
!<3A-9 "<9*6 !-9=1+-: Z'rcher !ra e 12 8401 Win!er!h"r S$i!&erland "l&er! @ "l&er.com $$$. "l&er.com

STR 2012 2 e Complete

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2/2012

New benchmarks for polymer technology

Dear Technology Professionals, Customers, and Partners,

Klaus Stahlmann CEO Sulzer

| Sulzer Technical Review 2/2012

Sustainable pumping solutions for polymer manufacturing

New bioplastics pilot plant

More effective manufacturing through coated tools

Spider silk as a superpolymer

Following the trail of polymeric evidence

Insightful hot spots

Events & News

Sulzer Technical Review 2/2012 | 3

Customized manufacturing of expandable polystyrene

Flexible foam production

Melt impregnation allows customized production

| Sulzer Technical Review 2/2012

Environmental benefits and energy savings

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"0-94)3 +65,<+;1=1;@ (10 -3 %/'4DK()

(depending on density) (depending on density)

Sulzer Technical Review 2/2012 | 5

Meeting environmental requirements: alternative flame retardants

2 Prefoamed EPS beads from Sulzers EPS process show excellent

sphericity and cell size distribution.

| Sulzer Technical Review 2/2012

Gravimetric dosing systems

Small-scale, economical production

Twin-screw extruder (ZSK MEGA compounder)

SMR melt cooler

Simplified extruder process

Process innovation for the environment

Sulzer Technical Review 2/2012 | 7

Sustainable pumping solutions for polymer manufacturing

Pumping various fluids

| Sulzer Technical Review 2/2012

over 93% efficiency

1 The performance of the AHLSTAR pumps exceeds standard requirements.

0 0 200 400 600 800 C)7)+1;@ Q (3/:) 1000 1200 1400

Typical fluid properties in polymer manufacturing

Shear thinning (pseudoplastic) fluids !0-)9 9);-

Martin Eager / Dreamstime

Non-Newtonian fluid behavior.

Sulzer Technical Review 2/2012 | 9

What are the challenges of high gas loads?

High efficiency, low energy cost

10 | Sulzer Technical Review 2/2012

Innovative and patented pump design

Sulzer Technical Review 2/2012 | 11

Lorenzo Ghelfi: Jolanda is the masterpiece of our biopolymer team.

12 | Sulzer Technical Review 2/2012

Sulzer Technical Review 2/2012 | 13

Efficient processing of plastics

More effective manufacturing through coated tools

Wide range of stresses

Liz Van Steenburgh / Dreamstime

14 | Sulzer Technical Review 2/2012

Types of heat treatments

Improving the surface with heat

Proven coatings for the plastics industry

C+a/%*#. a* $!a/ /-!a/)!*/. +" /$! /++(. -! 0c! /$! 2!a)!c$a*%.)..

The right solution for every demand

Sulzer Technical Review 2/2012 | 15

What is PVD and CVD?

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PVD c+a/%#. %c-!a.! /$! ,-+ 0c/%1%/4 .%#%"%ca/(4.