CN104892972B - 单螺杆挤出脱硫与后处理系统及制备再生胶的方法 - Google Patents

单螺杆挤出脱硫与后处理系统及制备再生胶的方法 Download PDF

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CN104892972B
CN104892972B CN201410080452.5A CN201410080452A CN104892972B CN 104892972 B CN104892972 B CN 104892972B CN 201410080452 A CN201410080452 A CN 201410080452A CN 104892972 B CN104892972 B CN 104892972B
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desulfurization
post
screw
treatment
feeding
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CN104892972A (zh
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吕柏源
吕晓龙
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Qingdao Gaoji Technology Co ltd
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Qingdao Gaoji Technology Co ltd
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Priority to CN201410080452.5A priority Critical patent/CN104892972B/zh
Priority to PCT/CN2014/090358 priority patent/WO2015131526A1/zh
Priority to US15/123,644 priority patent/US9969857B2/en
Priority to EP14884372.5A priority patent/EP3115402B1/en
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    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/10—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation
    • C08J11/12—Recovery or working-up of waste materials of polymers by chemically breaking down the molecular chains of polymers or breaking of crosslinks, e.g. devulcanisation by dry-heat treatment only
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Abstract

本发明涉及单螺杆挤出脱硫与后处理系统及制备再生胶的方法，单螺杆挤出脱硫与后处理系统，包括单螺杆脱硫设备、单螺杆后处理设备以及连接单螺杆脱硫设备和单螺杆后处理设备的密闭式连接装置，单螺杆后处理设备包括互相连接的后处理喂料装置和后处理装置，以及贯穿于后处理喂料装置和后处理装置内的后处理螺杆，后处理螺杆连接到第二减速箱主轴上。本发明实现了“绿色”的脱硫和后处理过程，结构与工艺简单、产品质量和稳定性好、生产效率高、运行成本低、设备能耗低、占地面积小，可实现自动化连续化生产。

Description

单螺杆挤出脱硫与后处理系统及制备再生胶的方法
技术领域
本发明涉及一种使用废旧橡胶脱硫制备再生胶与后处理的设备及工艺方法；具体来说，本发明涉及一种单螺杆挤出脱硫与后处理系统及制备再生胶的方法。
背景技术
废旧橡胶脱硫过程是将废旧橡胶经过粉碎、加热、机械处理等物理化学过程，从弹性状态变成有塑性和黏性的能够再硫化的橡胶，该过程中，利用物理、化学或其他方式打开S-S键、S-C键而尽可能不破坏C-C键，有选择的破坏三维交联网状结构，尽可能不使C-C主链断裂，从硫化的橡胶还原为未硫化的状态。
目前国内外对废旧橡胶脱硫主要采用2种方式：第一种方式是采用动态脱硫设备（一般为高压脱硫罐）进行脱硫，然后采用三台或四台开炼机压片设备进行后处理，即一机三线或一机四线的生产工艺方法；第二种方式是采用螺旋连续脱硫设备进行脱硫，然后采用三台或四台开炼机压片设备进行后处理，亦即是新一机三线或新一机四线的生产工艺方法。
第一种方式污染严重、能耗高、劳动强度大，质量不稳定，效率低，高压脱硫罐存在安全隐患，动态脱硫设备和开炼机结构复杂、运行成本高，占地面积大；第二种方式实现了连续脱硫生产，污染程度也较低，但因脱硫过程是螺旋自由输送过程，脱硫过程中螺旋结构只是将物料向前输送，物理方面无法将S-S键、S-C键打断，只有热化学反应作用，没有强力剪切作用，导致脱硫效率低；螺旋脱硫设备庞大，结构复杂，维护保养困难，工作可靠性欠缺，运行成本高，能耗也很高；物料在机筒中物料呈现层流状态，物料加热不均匀，物料容易黏在叶片上，导致质量不稳定，物料在叶片上积累多了以后还会容易产生燃爆问题，安全性能欠可靠。
两种方式中均采用采用了三台开炼机或四台开炼机对脱硫胶进行后处理，不但工艺方法繁琐，劳动强度大，消耗功率高，同时在开炼机压片过程中，释放出大量带PM2.5的尾气，污染大气。
中国专利申请CN201210422570.0公开了一种采用双阶双螺杆挤出机连续制备再生胶的设备，该设备包括用于脱硫的异向双螺杆挤出机和用于后处理的同向双螺杆挤出机，利用异向双螺杆挤出机输送能力强、剪切弱的优势，代替动态脱硫与多螺旋脱硫，利用同向双螺杆挤出机剪切力强的优势，在低温下施加高剪切的作用，取代精炼机，最后由机头挤出即得再生胶。该技术中脱硫采用异向双螺杆挤出装置，废旧橡胶在输送过程中受到两个螺杆的啮合，不仅将S-S键、S-C键打断，还易将主链的C-C键打断，造成脱硫后的再生胶强度差，限制 了后续再生胶的使用范围和性能；后处理采用同向双螺杆挤出装置，结构复杂，制造困难，造价高，维护保养困难，同时物料不容易冷却，为了使物料从脱硫的高温降下来，需要另外增加冷却装置。
中国专利申请CN201310005753.7公开了一种废旧橡胶脱硫设备及其脱硫方法，该设备喂料段机筒和脱硫段机筒内安装一带有强力剪切作用的螺杆，采用二阶或多阶单螺杆脱硫装置代替了动态脱硫与多螺旋脱硫，脱硫时，热化学和剪切同时作用，并且克服了双螺杆不易控制剪切作用、结构复杂的缺点，提高工作稳定性与可靠性、减少占地面积、降低能耗、降低运行成本，实现绿色脱硫过程。该技术中采用单螺杆挤出装置实现了废旧橡胶的脱硫，但没有相配套的后处理设备，仍然需要采用一机三线或新一机四线的方式，采用传统三台开炼机或四台开炼机对脱硫胶进行后处理，后处理的方式的缺点和问题仍然存在。
发明内容
为了解决现有技术中后处理设备采用同向双螺杆挤出机时，结构复杂，制造困难，造价高，维护保养困难，同时物料不容易冷却，需要另外增加冷却装置的问题，本发明提供了一种单螺杆挤出连续脱硫与后处理系统。
本发明的技术方案为：
单螺杆挤出脱硫与后处理系统，包括单螺杆脱硫设备，单螺杆脱硫设备包括互相连接的脱硫喂料装置和脱硫装置，以及贯穿于脱硫喂料装置和脱硫装置内的脱硫螺杆，脱硫螺杆连接到第一减速箱主轴上，脱硫喂料装置、脱硫装置和脱硫螺杆内均设置有加热结构；与现有技术相比，单螺杆挤出脱硫与后处理系统还包括单螺杆后处理设备以及连接单螺杆脱硫设备和单螺杆后处理设备的密闭式连接装置，单螺杆后处理设备包括互相连接的后处理喂料装置和后处理装置，以及贯穿于后处理喂料装置和后处理装置内的后处理螺杆，后处理螺杆连接到第二减速箱主轴上。
本发明在脱硫方面，沿用中国专利申请CN201310005753.7的技术方案，采用单螺杆脱硫装置进行脱硫处理，克服了动态脱硫和螺旋脱硫方式中以热化学反应为主而脱硫效率低、影响脱硫效果的缺点，脱硫过程中热化学反应和剪切力同时作用，提高了脱硫效果；单螺杆挤出脱硫设备相对于双螺杆结构和多螺旋结构，体积显著减小、结构简单、制造容易、运行成本低以及节能降耗，而且更为关键的是，单螺杆脱硫时，物料均匀经过螺纹表面，且每个粒子都会与机筒进行热传递，剪切强度适宜，可以保证将S-S键、S-C键打断，而不会破坏C-C主链，保证了脱硫的有效进行，且减小了再生胶强度的下降。
在后处理方面，本发明采用单螺杆挤出后处理设备，实现废旧橡胶的低温剪切后处理，可以与传统的高温脱硫设备、螺旋脱硫及双螺杆脱硫设备连用，颠覆了传统技术中三台开炼 机或四台开炼机对脱硫胶进行后处理的方式，改变了传统的间歇式后处理过程，实现了脱硫过程和后处理过程的连续进行；并且不同于现有技术中的双螺杆挤出后处理装置，物料在机筒中的流动方式不仅包括轴向的层流，还包括径向的运动，物料充分与机筒接触，接触面积大，加快了物料的降温过程，从而使得本发明中无需使用额外增加冷却装置，只需要将物料通过后处理装置，即可实现降温冷却的过程。
优选的是，脱硫装置包括一脱硫喂料机筒、至少一阶脱硫机筒，脱硫喂料机筒与第一阶脱硫机筒连接，脱硫螺杆贯穿于脱硫喂料机筒和脱硫机筒内。脱硫螺杆为全销钉螺杆、全主副螺纹螺杆、销钉/主副螺纹螺杆和销钉/主副螺纹相间螺杆的其中一种，每一根脱硫螺杆上的销钉排数、主副螺纹段数以及销钉/主副螺纹阶数均可根据工艺要求进行变化，脱硫螺杆长径比大于16。全销钉螺杆中，脱硫机筒销钉插入脱硫螺杆的螺杆切槽内。本发明采用了具有特殊结构的脱硫单螺杆，采用主副螺纹间隙和/或销钉结构增大了物料在机筒内的剪切力，改善了单螺杆挤出装置的混合剪切功能，提高了废旧橡胶脱硫效率，由于不存在两个螺杆的啮合，因此自洁性提高，且强度不至于打断C-C主链，可以保证脱硫后再生胶的强度。
优选的是，脱硫喂料装置包括设置在脱硫喂料机筒内的脱硫喂料螺旋辊，脱硫喂料螺旋辊可设计为圆柱型或锥型，脱硫螺杆相应与其进行配合，脱硫喂料螺旋辊与脱硫螺杆啮合，脱硫喂料螺旋辊螺纹与脱硫螺杆螺纹导程或螺距相对应，脱硫喂料螺旋辊螺纹方向与脱硫螺杆螺纹方向相反。本发明采用螺旋啮合喂料装置，改变了传统单螺杆挤出喂料效果差，生产效率低的问题，保证了喂料过程的顺利，结合具有优良自洁性能的单螺杆结构，保证了脱硫过程强制输送功能，不但提高了脱硫过程的生产效率，还实现了脱硫过程的自洁功能，避免具有高温的物料停滞在螺旋叶片上或螺杆的螺棱上面，导致物料的焦烧和粘结而影响设备使用的可靠性以及带来维护保养的困难。
优选的是，后处理装置包括后处理喂料机筒、后处理冷却机筒，后处理螺杆贯穿于后处理喂料机筒和后处理冷却机筒内。后处理螺杆为全销钉螺杆、全主副螺纹螺杆、销钉/主副螺纹螺杆和销钉/主副螺纹相间螺杆的其中一种，每一根后处理螺杆上的销钉排数、主副螺纹段数以及销钉/主副螺纹阶数均可根据工艺要求进行变化，后处理螺杆长径比小于42。全销钉螺杆中，后处理机筒销钉插入后处理螺杆的螺杆切槽内。本发明中采用了具有特殊结构的后处理单螺杆，物料进入主副螺纹间隙中，相比较双螺杆挤出后处理装置，增大了轴向剪切和接触面积，加快了物料的冷却，不需要外加冷却装置即可实现后处理效果；销钉的使用可增加热量散出渠道，并且带来了径向的剪切，实现物料搅拌的作用，冷却效果和后处理效果同时提高。由于采用上述结构的单螺杆，使得后处理装置中形成多段捏炼，物料与机筒、主副螺纹和/或销钉充分接触，提高了捏炼和冷却效果，提高了后处理和冷却效果。
优选的是，后处理喂料装置包括设置在后处理喂料机筒内的后处理喂料螺旋辊，后处理喂料螺旋辊可设计为圆柱型或锥型，后处理螺杆相应与其进行配合，后处理喂料螺旋辊与后处理螺杆啮合，后处理喂料螺旋辊螺纹与后处理螺杆螺纹导程或螺距相对应，后处理喂料螺旋辊螺纹方向与后处理螺杆螺纹方向相反。与本发明脱硫的啮合喂料装置相同，后处理装置同样采用啮合喂料方式，保证了脱硫设备和后处理设备的有效衔接，提高了后处理的生产效率。
优选的是，密闭式连接装置包括与脱硫装置出口连接的接盘、与后处理装置喂料口连接的密闭箱以及设置在接盘和密闭箱之间的输送管道。本发明的系统可以根据生产场地或工艺布置需要将脱硫设备与后处理设备以直线连接方式或其他任何方式连接，相应的，接盘与密闭箱的形状和连接方式根据实际需要进行调整。
本发明还提供了使用上述单螺杆挤出脱硫与后处理系统制备再生胶的方法，脱硫装置加热到再生胶脱硫工艺所需温度，脱硫螺杆转动，废旧橡胶经脱硫喂料装置加入，经过脱硫螺杆的热化学作用和强力剪切输送至后处理喂料装置，经过后处理螺杆捏炼并降温冷却，从后处理装置中排出系统外。
本发明的有益效果为：
1）本发明克服了传统技术的高污染问题，本发明没有蒸汽和水参与热化学脱硫，其脱硫过程与后处理过程都是在全封闭系统进行，且后处理后的再生胶温度低，不产生废气，克服了废气、废水的二次污染，实现了“绿色”脱硫和后处理过程。
2）本发明只使用一台单螺杆挤出连续后处理设备，克服了三台或四台开炼机的后处理技术所造成的能耗高，占地面积大，尾气污染严重，劳动强度大，生产效率低和运行成本高等问题，大大简化了脱硫及后处理工艺过程，能耗低，占地面积小，可实现自动化连续生产，工作稳定可靠，有效的提高了脱硫和后处理的生产效率，降低设备运行成本。
3）本发明克服了现有脱硫技术中脱硫过程只产生热化学反应而影响脱硫效果的缺点。本发明的脱硫过程除保证热化学反应功能外，还采用了具有特殊剪切功能的单螺杆，对脱硫的物料进行强制高剪切作用，能有效地破坏硫化胶粉中的S—S键和S—C键以及扩展强化物料热化学反应的脱硫效果，进而有效地提高脱硫再生胶的质量和保证脱硫胶再生胶批量与批量之间质量的稳定性，脱硫胶再生胶性能不会反弹。
4）本发明采用螺旋啮合喂料装置和方法以及具有优良自洁性能的单螺杆结构，保证了脱硫过程和后处理过程强制输送功能，不但提高了脱硫过程和后处理过程的生产效率，还实现了脱硫过程和后处理过程的自洁功能，避免传统技术具有高温的物料停滞在螺旋叶片上或螺旋的螺棱上面，导致物料的焦烧和粘结而影响设备使用的可靠性以及带来维护保养的困难。
5）本发明采用结构简单的单螺杆结构，不但实现了连续脱硫和连续后处理功能，同时比其现有的双螺杆结构和多螺旋结构的脱硫设备，其体积显著减小，结构简单、工作可靠、制造容易、运行成本低以及节能降耗等优异性能。
附图说明：
图1为单螺杆挤出脱硫与后处理系统结构示意图
图2为图1的俯视图
图3为全销钉螺杆结构示意图
图4为全主副螺杆结构示意图
图5为销钉/主副螺纹螺杆结构示意图
图6为销钉/主副螺纹相间螺杆结构示意图
图7为脱硫设备和后处理设备的喂料装置结构示意图
图8为密闭式连接装置结构示意图
具体实施方案
下面给出本发明的优选实例，对本发明做进一步说明，并不是对本发明的限定。
如附图1、图2所示，单螺杆挤出脱硫与后处理系统，包括单螺杆脱硫设备3、单螺杆后处理设备1以及连接单螺杆脱硫设备3和单螺杆后处理设备1的密闭式连接装置2。
单螺杆脱硫设备3包括互相连接的脱硫喂料装置5和脱硫装置4，以及贯穿于脱硫喂料装置5和脱硫装置4内的脱硫螺杆6，脱硫螺杆6连接到第一减速箱主轴上，脱硫喂料装置5、脱硫装置4和脱硫螺杆6内均设置有加热结构。脱硫装置4包括一脱硫喂料机筒15、一阶脱硫机筒17、二阶脱硫机筒18，脱硫喂料机筒15与一阶脱硫机筒17连接，脱硫螺杆6贯穿于脱硫喂料机筒15和两阶脱硫机筒内。脱硫机筒包括脱硫筒体10和脱硫衬套11。
脱硫螺杆长径比大于16，可以为全销钉螺杆30，全主副螺纹螺杆32，销钉/主副螺纹螺杆35，销钉/主副螺纹相间螺杆38的其中一种。
如图3所示的全销钉螺杆30，它在螺杆上设置有多排销钉切槽31与脱硫机筒插入的销钉相匹配。销钉的排数，根据工艺要求设计时可以变动。
如图4所示的全主副螺纹螺杆32，它在螺杆上设置有主螺纹33和副螺纹34。主副螺纹的段数，根据工艺要求设计时可以变动。
如图5所示的销钉/主副螺纹螺杆35上设置有主副螺纹36和销钉切槽31，销钉切槽31与脱硫机筒插入的销钉相匹配。其销钉的排数与主副螺纹的段数，根据不同工艺要求，设计时可以变动。
如图6所示的销钉/主副螺纹相间螺杆38，它在螺杆上设置有一阶销钉/主副螺纹43、二 阶销钉/主副螺纹44，可以设多阶销钉/主副螺纹，每一阶的销钉排数可以变动，每一主副螺纹段数可以变动。
如图2所示，脱硫螺杆6上有销钉结构时，一阶脱硫机筒销钉12和二阶脱硫机筒销钉8分别插入脱硫螺杆6的一阶脱硫螺杆销钉切槽13和二阶脱硫螺杆销钉切槽9内。
如图7所示，脱硫喂料装置5包括固定在脱硫喂料机筒15上的支座53，支座53内装有脱硫喂料螺旋辊46，脱硫喂料螺旋辊46表面设有与脱硫喂料机筒内脱硫螺杆螺纹14导程或螺距相对应的螺旋辊螺纹54，螺旋辊螺纹54方向与脱硫喂料机筒内脱硫螺杆螺纹14方向相反；螺旋辊螺纹54与脱硫喂料机筒内脱硫螺杆螺纹14形成啮合。
脱硫喂料螺旋辊46的左端轴58上装有左轴承57，左轴承57安装在左轴承座56上，在左轴承座56的右端面安装有耐磨衬套55，耐磨衬套55右端面与脱硫喂料螺旋辊46左端面为微间隙配合，耐磨衬套55的内孔穿过脱硫喂料螺旋辊46左端并固定在左轴承座56上；在脱硫喂料螺旋辊46的右端轴49上装有右轴承52，右轴承52安装在右轴承座51上，在右轴承座51的右端部设有调节螺母48；在脱硫喂料螺旋辊46右端轴49末端安装有挤出机螺杆驱动齿轮47啮合的脱硫喂料螺旋辊驱动齿轮50。在喂料装置运转时，脱硫喂料螺旋辊46与脱硫螺杆6相向运动，由此实现螺旋啮合喂料的方法。
单螺杆后处理设备1包括互相连接的后处理喂料装置21和后处理装置23，以及贯穿于后处理喂料装置21和后处理装置23内的后处理螺杆19，后处理螺杆19连接到第二减速箱主轴上。后处理装置23包括后处理喂料机筒28、后处理冷却机筒20。后处理冷却机筒20包括后处理筒体23和后处理衬套22。后处理喂料机筒28包括喂料筒体26和喂料衬套27。
后处理螺杆19与脱硫螺杆6结构相同但长度短，螺杆长径比小于42，可以为全销钉螺杆30，全主副螺纹螺杆32，销钉/主副螺纹螺杆35，销钉/主副螺纹相间螺杆38的其中一种。
后处理喂料装置31与脱硫喂料装置5结构相同。
如图8所示，密闭式连接装置2包括与脱硫装置出口连接的接盘62、与后处理装置喂料口66连接的密闭箱60以及设置在接盘62和密闭箱60之间的输送管道61。接盘62包括与脱硫设备3连接的盘体63。密闭箱60是一由底座64连接在后处理装置喂料口66的箱体67，其顶面上有可移动视窗59，在密闭箱60左侧开有圆孔65与接盘62相对应的输送管道61穿过圆孔65进入后处理装置喂料口66上方。
当脱硫及后处理过程处于初始状态时，脱硫设备加热到工艺所需温度时，脱硫螺杆开始转动，随后将配合好的硫化胶粉喂入脱硫喂料装置中，硫化胶粉在脱硫喂料装置的作用下，将物料源源不断地输入到脱硫设备中，物料在设备中不断获得热化学和强力剪切作用，促使物料中的S—S键和S—C键产生断裂，从而获得脱硫的再生胶。在脱硫再生胶接近挤出脱硫 系统出口时，启动后处理设备，后处理螺杆开始转动，脱硫的再生胶通过密闭式连接装置进入后处理喂料装置，脱硫再生胶源源不断地进入后处理设备，经过脱硫且具有高温的脱硫再生胶在后处理设备作用下，使脱硫再生胶得到捏炼的同时获得了充分的降温冷却，然后从后处理设备挤出机外，由此，完成了脱硫工艺和后处理工艺。以上工艺过程是连续的，可以循环往复连续操作。

Claims (8)

1.单螺杆挤出脱硫与后处理系统，包括单螺杆脱硫设备，单螺杆脱硫设备包括互相连接的脱硫喂料装置和脱硫装置，以及贯穿于脱硫喂料装置和脱硫装置内的脱硫螺杆，脱硫螺杆连接到第一减速箱主轴上，脱硫喂料装置、脱硫装置和脱硫螺杆内均设置有加热结构；
其特征在于：还包括单螺杆后处理设备以及连接单螺杆脱硫设备和单螺杆后处理设备的密闭式连接装置，单螺杆后处理设备包括互相连接的后处理喂料装置和后处理装置，以及贯穿于后处理喂料装置和后处理装置内的后处理螺杆，后处理螺杆连接到第二减速箱主轴上；
脱硫螺杆长径比大于16；后处理螺杆长径比小于42。
2.如权利要求1所述的单螺杆挤出脱硫与后处理系统，其特征在于：脱硫装置包括一脱硫喂料机筒、至少一阶脱硫机筒，脱硫喂料机筒与第一阶脱硫机筒连接，脱硫螺杆贯穿于脱硫喂料机筒和脱硫机筒内。
3.如权利要求1所述的单螺杆挤出脱硫与后处理系统，其特征在于：脱硫喂料装置包括设置在脱硫喂料机筒内的脱硫喂料螺旋辊，脱硫喂料螺旋辊与脱硫螺杆啮合，脱硫喂料螺旋辊螺纹与脱硫螺杆螺纹导程或螺距相对应，脱硫喂料螺旋辊螺纹方向与脱硫螺杆螺纹方向相反。
4.如权利要求1所述的单螺杆挤出脱硫与后处理系统，其特征在于：后处理装置包括后处理喂料机筒、后处理冷却机筒，后处理螺杆贯穿于后处理喂料机筒和后处理冷却机筒内。
5.如权利要求2或4所述的单螺杆挤出脱硫与后处理系统，其特征在于：脱硫螺杆和后处理螺杆为全销钉螺杆、全主副螺纹螺杆、销钉/主副螺纹螺杆和销钉/主副螺纹相间螺杆的其中一种。
6.如权利要求1所述的单螺杆挤出脱硫与后处理系统，其特征在于：后处理喂料装置包括设置在后处理喂料机筒内的后处理喂料螺旋辊，后处理喂料螺旋辊与后处理螺杆啮合，后处理喂料螺旋辊螺纹与后处理螺杆螺纹导程或螺距相对应，后处理喂料螺旋辊螺纹方向与后处理螺杆螺纹方向相反。
7.如权利要求1所述的单螺杆挤出脱硫与后处理系统，其特征在于：密闭式连接装置包括与脱硫装置出口连接的接盘、与后处理装置喂料口连接的密闭箱以及设置在接盘和密闭箱之间的输送管道。
8.使用如权利要求1-7所述的单螺杆挤出脱硫与后处理系统制备再生胶的方法，其特征在于：脱硫装置加热到再生胶脱硫工艺所需温度，脱硫螺杆转动，废旧橡胶经脱硫喂料装置加入，经过脱硫螺杆的热化学作用和强力剪切输送至后处理喂料装置，经过后处理螺杆捏炼并降温冷却，从后处理装置中排出系统外。
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