WO2012121391A1 - 混練装置 - Google Patents
混練装置 Download PDFInfo
- Publication number
- WO2012121391A1 WO2012121391A1 PCT/JP2012/056180 JP2012056180W WO2012121391A1 WO 2012121391 A1 WO2012121391 A1 WO 2012121391A1 JP 2012056180 W JP2012056180 W JP 2012056180W WO 2012121391 A1 WO2012121391 A1 WO 2012121391A1
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- WIPO (PCT)
- Prior art keywords
- kneading
- oxygen concentration
- purge
- kneading chamber
- unit
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/801—Valves
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/06—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices
- B29B7/10—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary
- B29B7/18—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with more than one shaft
- B29B7/183—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type with movable mixing or kneading devices rotary with more than one shaft having a casing closely surrounding the rotors, e.g. of Banbury type
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/24—Component parts, details or accessories; Auxiliary operations for feeding
- B29B7/242—Component parts, details or accessories; Auxiliary operations for feeding in measured doses
- B29B7/244—Component parts, details or accessories; Auxiliary operations for feeding in measured doses of several materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/02—Mixing; Kneading non-continuous, with mechanical mixing or kneading devices, i.e. batch type
- B29B7/22—Component parts, details or accessories; Auxiliary operations
- B29B7/28—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control
- B29B7/286—Component parts, details or accessories; Auxiliary operations for measuring, controlling or regulating, e.g. viscosity control measuring properties of the mixture, e.g. temperature, density
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
- B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
- B29B7/7495—Systems, i.e. flow charts or diagrams; Plants for mixing rubber
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/802—Constructions or methods for cleaning the mixing or kneading device
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B7/00—Mixing; Kneading
- B29B7/80—Component parts, details or accessories; Auxiliary operations
- B29B7/84—Venting or degassing ; Removing liquids, e.g. by evaporating components
- B29B7/845—Venting, degassing or removing evaporated components in devices with rotary stirrers
Definitions
- the present invention relates to a kneading apparatus used when kneading a material to be kneaded such as rubber or sulfur, which is a raw material for tires, for example.
- a kneading apparatus used when kneading a material to be kneaded such as rubber or sulfur, which is a raw material for tires, for example.
- additives and compounding agents such as sulfur, carbon black, oil, anti-aging agents, vulcanization accelerators, etc. are added to the raw rubber and kneaded.
- compounding agents such as sulfur, carbon black, oil, anti-aging agents, vulcanization accelerators, etc.
- kneading is performed in a heated and / or pressurized state.
- kneading machines such as Banbury mixers are widely used.
- the Banbury mixer puts a material to be kneaded into a kneading chamber having a closed structure, and then puts the material to be plasticized into a plasticized state while heating and / or pressurizing, and a large shear force is applied by a pair of rotors that are reversed in this state. It is a closed mixer that is fed and kneaded. Further, in the kneading operation by this Banbury mixer, the temperature of the kneading chamber, the current value of the motor driving the rotor, etc. are measured and the state of the material to be kneaded in this kneading chamber is grasped and its operation is managed. .
- inactive substances such as nitrogen and carbon dioxide are used so that dusts such as sulfur scattered in the kneading chamber during the kneading do not react with oxygen in the kneading chamber and ignite.
- a gas is introduced into the kneading chamber, and the oxygen concentration in the kneading chamber is set to the ignition limit or less (see, for example, Patent Documents 1 and 2).
- the oxygen concentration in the kneading chamber described above is constantly measured. Specifically, the atmospheric gas in the kneading chamber is always led to the oxygen concentration meter through a pipe connected to the kneading chamber. Further, in order to prevent the dust contained in the atmosphere gas in the kneading chamber from adversely affecting the oxygen concentration meter, the middle portion of the piping toward the oxygen concentration meter is included in the atmosphere gas flowing in the piping. A filter that collects dust and the like is generally provided.
- the dust collected by the filter is highly viscous and the diameter of the pipe is small (about 6 mm), so the pipe and the filter are likely to be clogged. Therefore, when the oxygen concentration is constantly measured during the kneading operation as in the conventional kneader, it is necessary to frequently perform troublesome operations such as cleaning of the pipes and replacement of the filters.
- a kneading step of the material to be kneaded that is, a combination of charging, kneading, and discharging of the material to be kneaded is set as one batch, For example, it may be repeated about 200 batches per production cycle. For this reason, it has become necessary to perform the above-described operations such as cleaning the pipe and replacing the filter once a day at the earliest.
- An object of the present invention is to provide a kneading apparatus capable of stably maintaining a target oxygen concentration in a kneading chamber even if the number of cleanings and replacements is reduced or eliminated.
- the apparatus is an apparatus represented by the following (1).
- the apparatus of the first aspect of the present application preferably has the following conditions.
- (2) The apparatus of (1) is a batch-type kneading apparatus that repeats the kneading process of the material to be kneaded twice or more batches, with the batch of the material to be kneaded, kneading and discharging as one batch.
- the calculation unit repeats the calculation for maintaining the target oxygen concentration for each batch, Based on the calculation result, the control unit controls the purge flow rate and purge time of the inert gas introduced into the kneading chamber by the gas introduction unit.
- control unit exposes the kneading chamber to the atmosphere before the start of each batch, seals the kneading chamber after the exposure to the atmosphere, and deactivates the kneading chamber by the gas introduction unit. Start introducing gas.
- the apparatus of (2) or (3) is exposed to the atmosphere in the kneading chamber before the start of the first batch, and then sealed, After the gas introduction unit introduces the inert gas into the kneading chamber until the concentration measuring unit measures the oxygen concentration in the sealed kneading chamber until the kneading chamber reaches a target oxygen concentration, While the concentration measurement unit measures the oxygen concentration in the kneading chamber for a certain period, the calculation unit obtains a purge flow rate of the inert gas that cancels out the increase in oxygen concentration within the period, by the calculation, The calculated value is used as a reference value for the arithmetic unit to maintain the target oxygen concentration in the kneading chamber during kneading in the first batch.
- the concentration measuring unit measures the oxygen concentration
- the flow rate of the inert gas that cancels the difference is calculated, The calculated value is used as a correction value for maintaining the target oxygen concentration in the kneading chamber during kneading in the next batch performed after the batch in which the oxygen concentration actual measurement is performed.
- the control unit controls the purge flow rate and purge time of the inert gas introduced into the kneading chamber during kneading by the gas introduction unit.
- the device of (7) is Periodically measure the oxygen concentration in the kneading chamber by the concentration measuring unit, When the oxygen concentration in the kneading chamber is below the allowable range, This is notified and the measurement of the oxygen concentration in the kneading chamber by the concentration measuring unit is continued until the batch is completed.
- the apparatus of (1) to (8) includes a pipe for guiding the atmospheric gas in the kneading chamber to the concentration measuring unit; A filter that collects dust contained in the atmospheric gas flowing in the pipe; A second gas introduction unit that introduces a reverse purge gas from the concentration measurement unit side of the pipe toward the filter.
- the device of (9) is A first flow of the atmospheric gas in the kneading chamber through the pipe toward the concentration measuring unit; A second flow of reverse purge gas introduced from the second gas introduction part through the pipe toward the filter; A switching unit for switching between While the concentration measuring unit measures the oxygen concentration in the kneading chamber, the switching unit opens the first flow and cuts off the second flow, While the concentration measuring unit interrupts the measurement of the oxygen concentration in the kneading chamber, the switching unit interrupts the first flow and opens the second flow, whereby the concentration of the pipe is A reverse purge gas is introduced from the measurement unit side toward the filter.
- the apparatus of (10) includes a third gas introduction unit that introduces zero gas into the concentration measurement unit, While the concentration measuring unit measures the oxygen concentration in the kneading chamber, the switching unit causes a third flow of zero gas introduced from the third gas introducing unit through the pipe toward the concentration measuring unit. While blocking While the concentration measuring unit interrupts the measurement of the oxygen concentration in the kneading chamber, the switching unit is opened and the third flow is directed to the concentration measuring unit. (12) In the apparatuses (9) to (12), the reverse purge gas is an inert gas. (13) In the devices of (11) and (12), the zero gas is an inert gas.
- the kneading apparatus is the following apparatus (14).
- a kneading chamber for kneading the material to be kneaded;
- a first gas introduction part for introducing an inert gas into the kneading chamber;
- a concentration measuring unit for measuring the oxygen concentration in the kneading chamber;
- a pipe for guiding the atmospheric gas in the kneading chamber to the concentration measuring unit;
- a filter that collects dust contained in the atmospheric gas flowing in the pipe;
- a kneading apparatus comprising: a second gas introduction unit that introduces a reverse purge gas from the concentration measurement unit side of the pipe toward the filter.
- the device (14) preferably has the following characteristics.
- the device of (14) is A first flow of the atmospheric gas in the kneading chamber through the pipe toward the concentration measuring unit; A second flow of reverse purge gas introduced from the second gas introduction part through the pipe toward the filter; A switching unit for switching between While the concentration measuring unit measures the oxygen concentration in the kneading chamber, the switching unit opens the first flow and cuts off the second flow, While the concentration measuring unit interrupts the measurement of the oxygen concentration in the kneading chamber, the switching unit interrupts the first flow and opens the second flow, whereby the concentration of the pipe is A reverse purge gas is introduced from the measurement unit side toward the filter.
- the device of (15) is A third gas introduction unit for introducing zero gas into the concentration measurement unit; While the concentration measuring unit is measuring the oxygen concentration in the kneading chamber, the switching unit causes a third flow in which the zero gas introduced from the third gas introducing unit through the pipe is directed to the concentration measuring unit. While blocking While the concentration measuring unit interrupts the measurement of the oxygen concentration in the kneading chamber, the switching unit is opened and the third flow is directed to the concentration measuring unit.
- the devices of (14) to (16) are A dust collector for collecting dust in the kneading chamber; Piping connecting between the dust collector and the filter; An opening and closing valve for opening and closing the pipe, While the concentration measuring unit stops measuring the oxygen concentration, the on-off valve opens the pipe, and dust collected in the filter is removed through the pipe while being sucked by the dust collector.
- the reverse purge gas is an inert gas.
- the zero gas is an inert gas.
- the third aspect of the present invention is the following kneading method. (20) A method in which a material to be kneaded is charged into a kneading chamber, kneaded and discharged using the kneading apparatus of (1), (A) The calculation unit performs a calculation for setting the target oxygen concentration in the kneading chamber while comparing the actually measured oxygen concentration measured by the concentration measurement unit during kneading with a preset target oxygen concentration.
- the kneading method (20) preferably includes the following features.
- the combination of step (a) and step (b) includes substeps represented by the following (1) to (5): (1) Obtain an initial purge time for setting the target oxygen concentration in the kneading chamber sealed after exposure to the atmosphere based on a preset initial purge flow rate value, Introducing an inert gas at the initial purge flow rate into the kneading chamber and stopping the introduction of the inert gas after the initial purge time has elapsed, An initial purge step for measuring a change in oxygen concentration in the kneading chamber over a period of time; (2) an initial batch process including the following steps (2a) to (2c) in this order; (2a) A purge step before kneading, in which an object to be kneaded is sealed after being put into the kneading chamber, and an inert gas is introduced into the kneading chamber at a predetermined purge flow
- a purge step during kneading to measure the oxygen concentration change during the kneading (4c) A discharging step of discharging the material to be kneaded from the kneading chamber; (5) A batch process after operation stop, including the following steps (5a) to (5c) in this order: (5a) Purge step before kneading, in which the material to be kneaded is sealed in the kneading chamber after the batch of materials to be kneaded has been discharged, and an inert gas is introduced into the kneading chamber at a predetermined purge flow rate and purge time.
- step (3) After the purge time elapses, the kneading of the material to be kneaded is started, and the inert gas is introduced into the kneading chamber at the same purge flow rate as the purge process during kneading in the previous batch process; (5c) A discharging step of discharging the material to be kneaded from the kneading chamber; In the sub-step, after (i) step (4) is performed, or (ii) step (5) is repeated a predetermined number of times, and subsequently, the change in oxygen concentration during kneading is measured in the purge step during kneading. After performing the batch process that is performed, after this batch process is performed, Returning to step (3), confirmation is performed.
- the “part” may mean a member, an apparatus, a process, a means, a method, or the like.
- a calculation for setting the target oxygen concentration in the kneading chamber to a target oxygen concentration is performed while comparing the preset target oxygen concentration and the measured actual oxygen concentration, and based on the calculation result.
- the first aspect of the present invention it is not necessary to always measure the oxygen concentration in the kneading chamber. That is, the number of cleanings and replacements can be reduced or eliminated. For this reason, it is possible to suppress clogging of the piping and the filter described above.
- dust accumulated in the filter and the pipe can be blown off to the kneading chamber side by introducing the reverse purge gas from the concentration measuring unit side of the pipe toward the filter.
- clogging of piping and a filter is suppressed, and it becomes possible to stably measure the oxygen concentration in the kneading chamber without frequently performing operations such as piping cleaning and filter replacement.
- FIG. 1 is a schematic diagram of a Banbury mixer showing an example of a kneading apparatus to which the first aspect of the present invention is applied.
- FIG. 2 is a flowchart for explaining the operation control method of the kneading apparatus to which the present invention is applied.
- FIG. 3 is a graph showing the initial purge, which was measured by an oxygen concentration meter and the change in the purge flow rate of the inert gas introduced into the closed kneading chamber without introducing the material to be kneaded after exposure to the atmosphere. It is a graph which shows the result of having measured the change of the oxygen concentration in a kneading chamber.
- FIG. 1 is a schematic diagram of a Banbury mixer showing an example of a kneading apparatus to which the first aspect of the present invention is applied.
- FIG. 2 is a flowchart for explaining the operation control method of the kneading apparatus to which the present invention is applied.
- FIG. 4 is a graph showing an initial batch, in which the material to be kneaded is introduced after being exposed to the atmosphere and introduced into a sealed kneading chamber, and the change in the purge flow rate of the inert gas and the kneading measured by an oximeter It is a graph which shows the result of having measured indoor oxygen concentration change.
- FIG. 5 shows that in the second batch and subsequent batches, the concentration change deviated from the allowable value in the previous batch, so the calculation was repeated and the inert gas introduced into the kneading chamber at the flow rate corrected by the calculation.
- FIG. 6 is a graph showing the results of measuring the change in the purge flow rate of the inert gas introduced into the kneading chamber and the change in the oxygen concentration (zero gas measurement) using an oximeter in the batch after the operation was stopped.
- FIG. 7 is a graph showing the results of measuring the change in the purge flow rate of the inert gas introduced into the kneading chamber and the change in the oxygen concentration with an oximeter in batch processing performed continuously in the example. .
- FIG. 6 is a graph showing the results of measuring the change in the purge flow rate of the inert gas introduced into the kneading chamber and the change in the oxygen concentration (zero gas measurement) using an oximeter in the batch after the operation was stopped.
- FIG. 7 is a graph showing the results of measuring the change in the purge flow rate of the inert gas introduced into the kneading chamber and the change in the oxygen concentration with an oximeter in batch processing performed continuously in the example. .
- FIG. 8 is a schematic diagram of a Banbury mixer showing an example of a kneading apparatus to which the second aspect of the present invention is applied.
- FIG. 9 is a schematic diagram showing a modification of the Banbury mixer shown in FIG. 8 and using a two-way valve instead of a four-way valve.
- FIG. 10 shows a modification of the Banbury mixer shown in FIG. 8 and is a schematic diagram showing a case where a three-way valve is used instead of the four-way valve.
- FIG. 11 is a schematic diagram illustrating a modification of the Banbury mixer illustrated in FIG. 8, in which a dust collector and a filter are connected to remove dust.
- the kneading apparatus to which the first aspect of the present invention is applied is a Banbury mixer 1 that is suitably used when manufacturing rubber products such as tires as shown in FIG.
- a material obtained by adding an additive or a compounding agent such as sulfur, carbon black, oil, an antioxidant, a vulcanization accelerator, or the like to a raw material rubber is heated and kneaded. Or kneaded under pressure.
- the Banbury mixer 1 includes a kneading chamber 2 for kneading the material to be kneaded G, and a first gas introduction line for introducing an inert gas into the kneading chamber 2, that is, a first Gas introducing section (first gas introducing means) 3, an oxygen concentration meter for measuring the oxygen concentration in the kneading chamber 2, that is, a concentration measuring section (concentration measuring means) 4, and the atmosphere gas in the kneading chamber is changed to an oxygen concentration meter 4, pipes 5 a and 5 b leading to 4, a filter 6 that collects dust and the like contained in the atmospheric gas flowing in the inlet (one) pipe 5 a, and an oxygen concentration meter 4 in the outlet (other) pipe 5 b
- a second gas introduction line (second gas introduction means) 7 for introducing a reverse purge gas from the side toward the filter 6, and a third gas introduction line for introducing zero gas containing no contaminants into the oximeter 4
- the kneading chamber 2 has a hermetically sealed structure, and a kneading operation is performed by applying a large shearing force to the material to be kneaded G while rotating the pair of rotors 9a and 9b provided in the opposite directions to each other. ing.
- a charging door 11a for charging the material to be kneaded G before being kneaded conveyed by the belt conveyor 10 or the like is provided in an openable and closable manner.
- a discharge door 11b for discharging the kneaded material G after mixing to the outside is provided below the kneading chamber 2 so as to be openable and closable. Furthermore, a dust collector 12 for collecting dust and the like in the kneading chamber 2 is provided at the upper portion of the kneading chamber 2.
- the first gas introduction line 3 is a line through which an inert gas such as nitrogen or carbon dioxide is introduced into the kneading chamber 2 through the first introduction pipe 13 connected to the kneading chamber 2.
- This line is a pressure regulating valve (reduced pressure) for regulating the pressure of the inert gas flowing through the first introduction pipe 13 between the gas supply source (not shown) for supplying the inert gas and the kneading chamber 2.
- Valve 14 a shut-off valve (electromagnetic valve) 15 for opening and closing the first introduction pipe 13, a flow meter (FT) 16 for measuring the flow rate of the inert gas flowing through the first introduction pipe 13, and a first
- the flow rate adjustment valve (FCV) 17 that adjusts the flow rate of the inert gas flowing through the introduction pipe 13 and the flow rate adjustment valve 17 based on the measurement result of the flow meter 16 are used to adjust the flow rate of the first introduction pipe 13. It has a flow rate control device (FIC) 18 that controls the flow rate of the flowing inert gas, and a check valve 19 that prevents the atmosphere in the kneading chamber 2 from flowing into the first introduction pipe 13.
- FIC flow rate control device
- the oxygen concentration meter 4 measures the concentration of oxygen contained in the atmosphere gas while sucking the atmosphere gas in the kneading chamber 2 with the pump 4a through the pipes 5a and 5b connected to the kneading chamber 2.
- the pipes 5 a and 5 b constitute a measurement line that guides the atmospheric gas from which dust and the like have been removed by the filter 6 to the oximeter 4.
- the filter 6 is connected to these pipes 5a and 5b and is provided so as to be replaceable.
- the filter 6 to be used if it can collect dust, such as sulfur contained in the atmospheric gas in the kneading chamber 2, it will not specifically limit, A conventionally well-known thing can be used. .
- a four-way valve (switching means) 20 is arranged between the inlet side pipe 5a and the outlet side pipe 5b.
- the four-way valve 20 includes a first flow F1 in which the atmospheric gas in the kneading chamber 2 is directed to the oximeter 4 through the inlet-side pipe 5a, and a reverse purge gas introduced from the second gas introduction line 7 on the inlet side.
- the second gas introduction line 7 is a reverse purge line for introducing the reverse purge gas toward the inlet side pipe 5a through the second introduction pipe 21 connected to the four-way valve 20. Between the gas supply source (not shown) for supplying an inert gas such as nitrogen or carbon dioxide as the reverse purge gas and the four-way valve 20, the flow rate of the reverse purge gas flowing through the second introduction pipe 21 is adjusted.
- the gas introduction line 7 has a flow rate adjusting valve 22.
- the third gas introduction line 8 is a zero gas introduction line that introduces zero gas toward the outlet pipe 5b through the third introduction pipe 23 connected to the four-way valve 20.
- the gas introduction line 8 has a flow rate adjusting valve 24 for adjusting the flow rate of the gas.
- the material G to be kneaded conveyed on the belt conveyor 10 is put into the kneading chamber 2.
- the charging door 11a is preferably opened immediately before the material to be kneaded G is charged into the kneading chamber 2 and immediately shut off after the charging.
- an inert gas is introduced into the kneading chamber 2 through the first gas introduction line 3, and the oxygen concentration in the kneading chamber 2 is set to the ignition limit.
- the material to be kneaded G may be fed into the kneading chamber 2 while continuing to introduce the inert gas next.
- the material to be kneaded G is put into the kneading chamber 2, the material to be kneaded G is plasticized while being heated and / or pressurized, and a large shearing force is applied to the pair of rotors 9a and 9b that are reversed in this state. Knead.
- the discharge door 11b is open
- the temperature of the kneading chamber 2 and the current value of the motor that drives the rotors 9a and 9b are measured, and the state of the material G to be kneaded in the kneading chamber 2 is grasped. The operation of the mixer is managed.
- an inert gas is introduced into the kneading chamber 2 through the first gas introduction line 3 with the input door 11 a and the discharge door 11 b of the kneading chamber 2 closed.
- a target oxygen concentration is set.
- the oxygen concentration in the kneading chamber 2 is preferably set to 10% by volume or less, which is below the ignition limit.
- the lower limit value of the concentration is preferably set to a value that does not cause such a problem (for example, 4% by volume or more).
- the atmospheric gas in the kneading chamber 2 is sucked by the pump 4 a through the pipe 5 a connected to the kneading chamber 2, and the atmospheric gas from which dust or the like has been removed by the filter 6 through the pipe 5 b is oxygenated.
- the oxygen concentration in the introduced atmospheric gas is measured by the oxygen concentration meter 4. Based on the measured value, the introduction of the inert gas from the first gas introduction line 3 into the kneading chamber 2 is controlled so that the inside of the kneading chamber 2 has the target oxygen concentration.
- the Banbury mixer 1 includes a calculation unit (calculation unit) 30 that performs a calculation for setting the inside of the kneading chamber 2 to a target oxygen concentration, and a first gas based on a calculation result by the calculation unit 30. And a control unit (control means) 31 for controlling the introduction line 3.
- a calculation unit (calculation unit) 30 that performs a calculation for setting the inside of the kneading chamber 2 to a target oxygen concentration, and a first gas based on a calculation result by the calculation unit 30.
- a control unit (control means) 31 for controlling the introduction line 3.
- the arithmetic unit 30 is composed of a process computer such as a PLC (Programmable Logic Controller), and is electrically connected to the oxygen concentration meter 4.
- the control unit 31 includes a mass flow controller such as FIC (Flow Indication Controller), and in the present embodiment, the flow rate control device (FIC) 18 is electrically connected to the calculation unit 30 as the control unit 31. ing.
- the calculation unit 30 sets the kneading chamber 2 to the target oxygen concentration while comparing the actually measured oxygen concentration measured by the oximeter 4 with a preset target oxygen concentration.
- the control unit 31 controls the purge flow rate and purge time of the inert gas introduced into the kneading chamber 2 through the first gas introduction line 3 based on the calculation result.
- the Banbury mixer 1 employs a batch system in which the material to be kneaded G is charged, kneaded, and discharged as one batch and the kneading process of the material to be kneaded G is repeated a plurality of batches.
- the plurality of batches is 2 batches or more, preferably 3 batches or more, and the upper limit is not particularly set and can be arbitrarily selected.
- the calculation unit 30 repeats the calculation for each batch, and the control unit 31 controls the purge flow rate and purge time of the inert gas introduced into the kneading chamber 2 by the first gas introduction line 3 based on the calculation result. .
- Step S1 In the Banbury mixer 1 to which the present invention is applied, first, the process proceeds to step S1 (initial purge step) shown in FIG.
- the initial purge is performed to obtain a reference value for setting the inside of the kneading chamber 2 to the target oxygen concentration without performing the batch process. That is, in the initial purge, the material to be kneaded G is not charged. Specifically, for example, as shown in the graph of FIG. 3, before the material to be kneaded G is put into the kneading chamber 2, the charging door 11a is opened to expose the kneading chamber 2 to the atmosphere.
- the oxygen concentration in the kneading chamber 2 is set to the oxygen concentration in the atmosphere (about 20.9%).
- the oxygen concentration measurement is continuously performed except for the calculation stop step described later unless otherwise noted, but the measurement may be interrupted when it is not necessary to perform the oxygen concentration measurement if necessary.
- . 3 indicates the purge flow rate of the inert gas introduced into the kneading chamber 2, and the broken line in FIG. 3 indicates the oxygen concentration in the kneading chamber 2 measured every second.
- the inside of the kneading chamber 2 is hermetically sealed without introducing the material to be kneaded G, and the oxygen concentration meter 4 measures the oxygen concentration in the room.
- the control unit 31 is introduced for a period of time until the oxygen concentration in the kneading chamber 2 reaches a target value (for example, the ignition limit or less) (referred to as an initial purge time; a value obtained from the equation (2) below).
- the inert gas is introduced from the first gas introduction line 3 into the kneading chamber 2 while keeping the flow rate of the inert gas (referred to as initial purge flow rate) at a predetermined constant value.
- initial purge flow rate the flow rate of the inert gas
- the initial purge time Ta is obtained.
- the target oxygen concentration in the kneading chamber 2 is assumed to be completely mixed with the atmosphere gas in the kneading chamber 2 after exposure to the atmosphere and the inert gas introduced into the kneading chamber 2, the following formula (1) Can be expressed as
- Xa X0 * exp- (Qa / V0) * Ta (1)
- Qa is the initial purge flow rate [NL / min]
- Ta is the initial purge time [seconds]
- Xa is the (target) oxygen after introducing the inert gas in the kneading chamber 2.
- X0 represents the oxygen concentration [volume%] before introduction of the inert gas in the kneading chamber 2 (in the atmosphere)
- V0 represents the internal volume [L] of the kneading chamber 2.
- N described above for NL / min may represent Normal, and NL / min may simply be expressed as L / min.
- the initial purge time Ta can be obtained by the following equation (2).
- Ta ⁇ V0 / Qa * In (Xa / X0) (2)
- Step S2 the Banbury mixer 1 proceeds to step S2 (initial purge measurement process) shown in FIG.
- step S2 initial purge measurement process
- the introduction of the inert gas into the kneading chamber 2 by the initial purge is stopped, and the change in oxygen concentration (referred to as initial purge measurement) by the oxygen concentration meter 4 is measured for a certain period (initial purge measurement time).
- the oxygen concentration in the kneading chamber 2 gradually increases after the introduction of the inert gas is stopped, as shown in the graph of FIG.
- the reason why the oxygen concentration increases is that a negative pressure is generated in the kneading chamber 2 by the operation of the dust collector 12, and outside air is introduced from the gap of the kneading chamber 2.
- the calculation unit 30 determines the lowest point (actual value a in FIG. 3) and the highest point (actual measurement in FIG. 3) within the initial purge measurement time. A value b) is obtained, and an increase in oxygen concentration (ba or Xc-Xb) within the initial purge measurement time is obtained by calculation. In addition, the calculation unit 30 calculates the flow rate of the inert gas (referred to as an initial purge predicted flow rate Qc) that cancels out the increase in the oxygen concentration within the initial purge measurement time from the above data.
- an initial purge predicted flow rate Qc the flow rate of the inert gas
- the initial purge predicted flow rate Qc [NL / min] can be obtained by the following equation (3).
- Qc V0 / Tc * In (Xc / Xb) (3)
- ⁇ Xc Xb * exp ⁇ (Qc / V0) * Tc )
- Tc is the initial purge measurement time [second]
- Xb is the lowest point of the oxygen concentration [volume%] within the initial purge measurement time
- Xc is within the initial purge measurement time. This represents the highest rise point [volume%] of the oxygen concentration.
- initial purge flow rate Qa set to a constant value
- initial purge time Ta initial purge time Ta
- Estimated initial purge flow rate Qc the flow rate of the inert gas which is predicted by the measurement and calculation in the initial purge and offsets the increase in oxygen concentration
- the initial purge measurement time Tc set to a constant value
- Step S3 the Banbury mixer 1 proceeds to the initial batch shown in FIG. That is, the process proceeds to step S3 (pre-kneading purge step) shown in FIG.
- a pre-kneading purge is performed to set the inside of the kneading chamber 2 to the target oxygen concentration Xa.
- the inside of the kneading chamber 2 is exposed to the atmosphere by opening the charging door 11a.
- the oxygen concentration in the kneading chamber 2 is set to the atmospheric oxygen concentration (about 20.9%).
- the solid line in FIG. 4 indicates the purge flow rate of the inert gas introduced into the kneading chamber 2, and the broken line in FIG. 4 indicates the oxygen concentration in the kneading chamber 2.
- the inside of the kneading chamber 2 before introducing the inert gas in each batch is always the same.
- the reference oxygen concentration (the oxygen concentration in the atmosphere) can be set.
- the material to be kneaded G is charged from the opened charging door 11a. After the material to be kneaded G is charged, the inside of the kneading chamber 2 is sealed. Thereafter, purging before kneading is performed by introducing an inert gas into the kneading chamber 2 through the first gas introduction line 3 while continuing to measure the oxygen concentration by the oxygen concentration meter 4.
- the control unit 31 keeps the flow rate of the inert gas introduced (kneading) until the inside of the kneading chamber 2 reaches the target oxygen concentration Xa (set target value) (referred to as purge time Tb before kneading).
- the inert gas is introduced into the kneading chamber 2 from the first gas introduction line 3 while keeping the pre-purge flow rate Qb) constant.
- the purge time Tb before kneading can be determined by the following equation (5), and a constant value is selected as the purge flow rate Qb before kneading.
- the flow rate Qb is preferably the same value as the flow rate Qa.
- V [L] after charging the kneading chamber 2 into which the material to be kneaded G is charged can be expressed by the following formula (4).
- V V0-kg * Vg (4)
- Vg represents the volume [L] of the material to be kneaded G
- kg represents the void coefficient of the material to be kneaded G.
- Tb ⁇ V / Qb * In (Xa / X0) (5)
- the calculation unit 30 performs a calculation for obtaining the purge time Tb before kneading before introducing the inert gas in the purge before kneading. Then, based on the calculation result, the control unit 31 controls the purge flow and purge time of the inert gas introduced into the kneading chamber 2 through the first gas introduction line 3 while purging before the kneading (inert gas). Introduction).
- the control unit 31 performs the flow of the inert gas to be introduced (pre-kneading purge flow rate Qb) until the inside of the kneading chamber 2 reaches the target oxygen concentration Xa (pre-kneading purge time Tb).
- the inert gas is introduced from the first gas introduction line 3 into the kneading chamber 2 while keeping the pressure constant. Thereby, before the kneading
- Step S4 purge process during kneading
- step S4 purge process during kneading
- kneading of the material to be kneaded G is started, and an increase in oxygen concentration in the kneading chamber 2 is suppressed during kneading. Purge during kneading. Specifically, as shown in the graph of FIG.
- the kneading chamber 2 is passed through the first gas introduction line 3.
- An amount of inert gas determined by calculation is introduced.
- the kneading time an arbitrary time can be selected, and this may be used for the calculation.
- the controller 31 sets the time during which the material to be kneaded K is kneaded (referred to as purge time Tc ′ during kneading) and the flow rate of the introduced inert gas (referred to as purge flow Qc ′ during kneading).
- the inert gas is introduced into the kneading chamber 2 from the first gas introduction line 3 while keeping it constant.
- the volume ratio ⁇ of the kneading chamber 2 before and after feeding the material to be kneaded G can be expressed by the following formula (6).
- ⁇ V / V0 (6)
- the purge flow rate Qc ′ [NL / min] during kneading is calculated from the initial purge predicted flow rate Qc obtained as a guide value from the above equation (3), the above equation (6), and the purge time Tc ′ during kneading. It can obtain
- Qc ′ Qc * ⁇ (7)
- Qc in the above formula (7) is a value obtained by converting Tc in the above formula (3) by Tc ′.
- the calculation unit 30 performs a calculation to obtain the purge flow rate Qc ′ during kneading before introducing the inert gas in the purge step during kneading. Based on the calculation result, the control unit 31 controls the purge flow during the kneading (inactive) while controlling the purge flow rate and purge time of the inert gas introduced into the kneading chamber 2 by the first gas introduction line 3. Gas introduction).
- control unit 31 controls the first gas introduction line 3 while keeping the flow rate of the inert gas (purge flow rate Qc ′ during kneading) constant during kneading (purge time Tc ′ during kneading).
- An inert gas is introduced into the kneading chamber 2.
- the Banbury mixer 1 performs step S5 (purge measurement process during kneading) shown in FIG. 2 during the purge during kneading. That is, as shown on the right side of FIG. 4, the purge is performed during the kneading, and from the time when the oxygen concentration meter 4 confirms that the oxygen concentration in the kneading chamber 2 has reached the lowest point during the kneading, step S5 is performed.
- the oxygen concentration change measurement by the oxygen concentration meter 4 (referred to as purge measurement during kneading) is performed.
- the time from when the oxygen concentration reaches the lowest point until it starts to rise again and reaches the highest point is defined as a purge measurement time Te during kneading.
- Step S6 allowable range confirmation step
- the actual oxygen concentration measured by the oximeter 4 in step S5 is compared with a predetermined concentration range (preset) including the target oxygen concentration Xa, and the predetermined concentration width is determined. It is determined whether or not the actually measured oxygen concentration falls within the range, that is, whether or not the actually measured oxygen concentration is within the allowable range.
- An allowable range that is, a predetermined concentration range including the target oxygen concentration Xa can be arbitrarily set as necessary.
- the computing unit 30 compares the highest and lowest points of the oxygen concentration within the purge time Tc ′ during kneading with a predetermined concentration range including the target oxygen concentration Xa, and calculates the oxygen concentration. It is determined whether or not the highest rising point and the lowest point are within a predetermined concentration range. If the highest and lowest points of the oxygen concentration are out of the predetermined concentration range, the process proceeds to step S7 (correction value calculation step) in FIG. 2, while if within the range, the process proceeds to FIG. Proceed to step S8 (the second batch or subsequent batches and the purge step before kneading after the calculation is stopped).
- Step S7 correction value calculation step shown in FIG. 2, the actual oxygen concentration measured by the oxygen concentration meter 4 obtained in steps S5 and S6 and the preset target oxygen concentration obtained before starting the next batch. Based on the comparison, the flow rate of the inert gas that offsets the difference is obtained. The obtained value is used as a correction value for maintaining the target oxygen concentration Xa in the kneading chamber 2 during kneading in the next batch.
- the calculation unit 30 determines the lowest point of the oxygen concentration within the kneading purge time (Tc ′) from the measurement result of the oxygen concentration of the first batch by the oxygen concentration meter 4 (see FIG. 4 and the highest rise point (actual value b in FIG. 4), and the oxygen concentration rise (ba) within the purge measurement time during kneading is obtained by calculation.
- step S ⁇ b> 7 the calculation unit 30 calculates a flow rate of the inert gas (referred to as a purge correction flow rate q during kneading) that cancels out the increase in the oxygen concentration within the purge measurement time during kneading.
- the purge correction flow rate q [NL / min] during kneading can be obtained by the following equation (8).
- q ⁇ V / Te * In (Xe / Xd)
- ⁇ Xe Xd * exp- (q / V) * Te
- Te is the purge measurement time [seconds] during kneading
- Xd is the lowest point of oxygen concentration (measured value a) [volume%] within the purge time Tc ′ during kneading
- Xe represents the highest rise point (actual value b) [volume%] of the oxygen concentration within the purge time Tc ′ during kneading.
- the batch after the first batch exceeds the allowable range, it is used as a correction value for maintaining the target oxygen concentration in the kneading chamber 2 during kneading in the next batch kneading purge.
- the purge correction flow rate q during kneading can be obtained.
- the calculation of the purge correction flow rate q during kneading (step S7) may be performed before the step of confirming whether the oxygen concentration is within the allowable range (step S6).
- Step S9 the Banbury mixer 1 proceeds to the second and subsequent batches shown in FIG. That is, the process proceeds to step S9 (purging step before kneading after the change in oxygen concentration in the previous batch exceeds the allowable range) shown in FIG.
- step S9 purging step before kneading after the change in oxygen concentration in the previous batch exceeds the allowable range
- a purge before kneading is performed to set the above-described kneading chamber 2 to the target oxygen concentration Xa.
- the charging door 11 a is used before the material to be kneaded G is newly charged into the kneading chamber 2, the charging door 11 a is used. Is opened, the inside of the kneading chamber 2 is exposed to the atmosphere, and the oxygen concentration in the kneading chamber 2 is made approximately the oxygen concentration in the atmosphere (about 20.9%).
- 5 indicates the purge flow rate of the inert gas introduced into the kneading chamber 2
- the broken line in FIG. 5 indicates the oxygen concentration in the kneading chamber 2.
- the inside of the kneading chamber 2 is sealed. Then, while measuring the oxygen concentration with the oxygen concentration meter 4, an inert gas is introduced into the kneading chamber 2 through the first gas introduction line 3, and a purge before kneading is performed.
- the control part 31 can perform the same control as step S3. Specifically, while maintaining the flow rate of the introduced inert gas (pre-kneading purge flow rate Qb) until the inside of the kneading chamber 2 reaches the target oxygen concentration Xa (pre-kneading purge time Tb), the first An inert gas is introduced from the gas introduction line 3 into the kneading chamber 2. That is, in the pre-kneading purge of the second and subsequent batches, the control unit 31 performs the first based on the calculation result for the pre-kneading purge performed by the calculation unit 30 for the initial batch in step S3.
- Purge before kneading is performed in the same manner while controlling the purge flow rate and purge time of the inert gas introduced into the kneading chamber 2 by the gas introduction line 3. Thereby, before the kneading
- Step S10 and Step S13 the Banbury mixer 1 of this aspect proceeds to step S10 shown in FIG. 2 (purge process during kneading of the batch after the oxygen concentration change of the previous batch exceeds the allowable range). While the kneading of the material to be kneaded G is started, purging during kneading is performed to suppress an increase in oxygen concentration in the kneading chamber 2 during kneading. Specifically, in the second batch and subsequent batches, after purging before kneading, for example, as shown in the center and right side of the graph of FIG.
- the oxygen concentration in the kneading chamber 2 by the oxygen concentration meter 4 during kneading is introduced into the kneading chamber 2 through the first gas introduction line 3 while performing the measurement.
- the control unit 31 refers to the flow rate of the introduced inert gas (referred to as purge flow rate Qe during the next batch kneading. Oxygen concentration in the previous batch.
- the inert gas is introduced into the kneading chamber 2 from the first gas introduction line 3 while maintaining a constant purge flow rate during kneading of the batch after the change exceeds the allowable range.
- the purge time Tc ′ during kneading is the same as the purge time Tc ′ during kneading in the previous batch.
- the purge flow rate Qe [NL / min] during the next batch kneading can be obtained by the following equation (9) from the purge correction flow rate q during kneading obtained as the correction value and the above equation (7).
- Qe Qc ′ (or Qe ′) ⁇ q (9)
- Qe ′ shown in the above formula (9) represents a purge flow rate during kneading in the previous batch. That is, Qe ′ is used to obtain the purge flow Qe during kneading in the next batch as the purge flow of the previous batch after the third batch. That is, in the third batch and thereafter, the purge flow rate Qe ′ during the previous batch kneading is used to obtain the purge flow rate Qe during the next batch kneading.
- the calculation unit 30 performs the above equation (2) before introducing the inert gas in the purge during kneading.
- the calculation for obtaining the purge flow rate Qe during the next batch kneading shown in 9) is performed.
- the control unit 31 performs purging during kneading while controlling the purge flow rate and purge time of the inert gas introduced into the kneading chamber 2 by the first gas introduction line 3. Do.
- control unit 31 controls the first gas introduction line 3 while keeping the flow rate of the inert gas (purge flow rate Qe during the next batch kneading) constant during kneading (purge time Tc ′ during kneading).
- An inert gas is introduced into the kneading chamber 2.
- the inside of the kneading chamber 2 can be maintained at the target oxygen concentration Xa during kneading.
- step S13 purge measurement process during kneading shown in FIG. 2 is performed during the purge during kneading.
- step S13 The measurement of the highest and lowest points of the oxygen concentration by the oxygen concentration meter 4 in step S13 and the calculation of the purge measurement time Te during kneading can be performed in the same manner as in step S5 described above. Thereafter, the process returns to step S6 shown in FIG. That is, it is determined whether or not the oxygen concentration change in step S13 is within an allowable range.
- Step S8 purge step before kneading after stopping the calculation
- the oxygen concentration need not be measured.
- purging before kneading is performed to set the inside of the kneading chamber 2 to the target oxygen concentration Xa before starting kneading of the batch under the conditions determined and used in the previous batch. .
- the oxygen measurement in the kneading chamber by the oxygen concentration meter 4 is not performed.
- the inside of the kneading chamber 2 is exposed to the atmosphere by opening the charging door 11a, so that the oxygen concentration in the atmosphere (about 20.9%) is obtained.
- the solid line in FIG. 6 indicates the purge flow rate of the inert gas introduced into the kneading chamber 2
- the broken line in FIG. 6 indicates the oxygen concentration in the atmospheric gas led to the oxygen concentration meter 4.
- the four-way valve 20 can be switched so as to shut off the first flow F1 and open the third flow F3.
- the zero gas introduced into the pipe 5 b from the third gas introduction line 8 (third introduction pipe 23) via the four-way valve 20 flows into the oximeter 4.
- the oxygen concentration indicated by the broken line in FIG. 6 always indicates 0 [volume%].
- the inside of the kneading chamber 2 is hermetically sealed, and the oxygen concentration meter 4 measures the oxygen concentration of the zero gas flowing from the third introduction pipe 23 while the first kneading chamber 2 is filled with the first kneading chamber G.
- a pre-kneading purge in which an inert gas is introduced through the gas introduction line 3 is performed.
- the pre-kneading purge is performed under the same conditions as the previous batch. Specifically, in the batch after the calculation is stopped, as shown in the graph of FIG. 6, for example, based on the calculation result used in the previous batch when the allowable range is reached, in other words, step S3 or step
- the controller 31 performs the pre-kneading purge while controlling the flow rate and time of the inert gas introduced into the kneading chamber 2 by the first gas introduction line 3 using the values used in S9.
- the control unit 31 performs the flow of the inert gas to be introduced (pre-kneading purge flow rate Qb) until the inside of the kneading chamber 2 reaches the target oxygen concentration Xa (pre-kneading purge time Tb).
- the inert gas is introduced into the kneading chamber 2 from the first gas introduction line 3 while maintaining a constant value.
- Step S11 Next, in the Banbury mixer 1, the process proceeds to step S11 (purge process during kneading after the calculation is stopped) shown in FIG.
- step S11 purge process during kneading after the calculation is stopped
- kneading of the material to be kneaded G is started and purge during kneading is performed to suppress an increase in oxygen concentration in the kneading chamber 2 during kneading.
- the purge flow rate in the graph of FIG.
- control unit 31 performs purge during kneading while controlling the flow rate and time of the inert gas introduced into the kneading chamber 2 by the first gas introduction line 3.
- control unit 31 controls the flow rate of the inert gas to be introduced (purge flow rate Qc ′ during kneading or purge flow rate Qe during pre-batch kneading) while the material G is being kneaded (purge time Tc ′ during kneading).
- the inert gas is introduced into the kneading chamber 2 from the first gas introduction line 3 while keeping ') constant. Thereby, the inside of the kneading chamber 2 can be maintained at the target oxygen concentration Xa during kneading.
- Step S12 When the batch processing by the combination of step S8 and step S11 is completed, the Banbury mixer 1 proceeds to step S12 (batch number confirmation step) in FIG. 2, and the number of batches after the computation stops reaches a predetermined number. Confirm whether or not. If the number of batches after the calculation has not stopped has reached the predetermined number, the process returns to step S8 again, and a new batch process is repeated a predetermined number of times. On the other hand, when the number of batches after the calculation stops reaches a predetermined number, the oxygen concentration is measured in the next batch, and it is determined whether or not it is within the allowable range.
- the pre-kneading purge S9 and the in-kneading purge S10 are performed using the values used in the previous batch, and the process proceeds to the step S6 again, where the kneading chamber 2 It is confirmed whether or not the oxygen concentration is within the allowable range. If the measured oxygen concentration is within the allowable range, the process proceeds to step S8 again. On the other hand, if the measured oxygen concentration is outside the allowable range, the process proceeds to step S7, and the calculation by the calculation unit 30 is resumed. If it is confirmed in step S12 that the predetermined number of final batches has been reached, the operation of the Banbury mixer 1 is stopped after the end of the final batch.
- step S6 if the oxygen concentration in the kneading chamber 2 does not fall within the allowable range, the fact may be notified, for example, by issuing an alarm or the like with light or sound. In that case, the oxygen concentration in the kneading chamber 2 is forcibly continuously measured by the oxygen concentration meter 4 until the batch is completed. This is in order to maintain the quality of the product. By switching to constantly measuring the oxygen concentration in the kneading chamber 2, the oxygen concentration in the kneading chamber 2 does not exceed the allowable range. The amount of inert gas introduced into the is adjusted.
- the operation control of the Banbury mixer 1 is performed according to the flowchart shown in FIG. 2, so that the inside of the kneading chamber 2 is within an allowable range value centered on the target oxygen concentration Xa for each batch. In addition, it is possible to keep it stable.
- the measurement of the oxygen concentration in the kneading chamber 2 by the oximeter 4 can be stopped after the calculation by the calculation unit 30 is stopped. Therefore, in the Banbury mixer 1, when the calculation is stopped, for example, the oxygen concentration in the kneading chamber 2 is not measured by the oxygen concentration meter 4 during the kneading (purge measurement during kneading), and the purge during the kneading is performed. Is possible. In this case, since it is not necessary to always measure the oxygen concentration in the kneading chamber 2, it is possible to suppress the clogging of the pipe 5a and the filter 6 described above.
- the four-way valve 20 opens the first flow F1.
- the second flow F2 is cut off and the third flow F3 is cut off.
- the atmospheric gas in the kneading chamber 2 is purified by the filter 6 through the pipes 5 a and 5 b and then flows into the oximeter 4.
- the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2 in step S8 and step S11
- the first flow F1 is interrupted by switching the four-way valve 20, and the third flow Open F3.
- the zero gas introduced into the pipe 5 b from the third gas introduction line 8 (third introduction pipe 23) via the four-way valve 20 flows into the oximeter 4.
- the measurable state (standby state) of the oximeter 4 can be maintained while the oximeter 4 is interrupting the measurement of the oxygen concentration in the kneading chamber 2. Therefore, it is possible to immediately start measuring the oxygen concentration in the kneading chamber 2 by the oximeter 4 by switching the four-way valve 20 without recalibrating the oximeter 4 at the time of re-measurement. is there.
- the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2, that is, during steps S8 and S11, by switching the four-way valve 20, Two streams F2 can be opened.
- the reverse purge gas introduced into the pipe 5 a from the second gas introduction line 7 (second introduction pipe 21) via the four-way valve 20 flows toward the filter 6.
- the second introduction pipe is configured so that dust or the like accumulated in the pipe 5 a or the filter 6 is blown off to the kneading chamber 2 side by the momentum of the reverse purge gas introduced into the pipe 5 a.
- the pressure and flow rate of the reverse purge gas flowing through 21 are adjusted in advance. Then, reverse purge is performed by switching the four-way valve 20 to remove dust and the like accumulated in the pipe 5a and the filter 6.
- a method of introducing the reverse purge gas a method of continuously introducing the reverse purge gas (referred to as continuous purge) can be used. In this case, after the reverse purge gas is introduced for a certain period, the second flow F2 is shut off by switching the four-way valve 20.
- a method of intermittently introducing a reverse purge gas intermittent purge
- the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2 while switching the four-way valve 20 a plurality of times.
- the reverse purge gas can be introduced at a high pressure.
- the reverse purge gas used for the reverse purge is introduced into the kneading chamber 2 through the pipe 5a. Therefore, it is preferable to use an inert gas, but in some cases, air or the like can be used.
- the Banbury mixer 1 shown in FIG. 8 showing a preferred example of the second aspect of the present invention unlike the first aspect, does not include the arithmetic unit 30, and the arithmetic unit 30, the flow rate control device and the flow rate adjustment valve. Are not connected, and the flow rate control by the calculation unit 30 is not performed. Except for these conditions, it is almost the same as the Banbury mixer 1 described with reference to FIG. Therefore, the same members as those in the Banbury mixer 1 shown in FIG.
- the oxygen concentration can be measured at an arbitrary stage and timing, and the measurement of the oxygen concentration can be interrupted at an arbitrary stage and timing.
- reverse purge is performed in which reverse purge gas is introduced from the second gas introduction line 7 toward the filter 6.
- reverse purge gas is introduced from the second gas introduction line 7 toward the filter 6.
- the four-way valve 20 opens the first flow F1, and the second flow The flow F2 is cut off and the third flow F3 is cut off.
- the atmospheric gas in the kneading chamber 2 is purified by the filter 6 through the pipes 5a and 5b, and then flows into the oxygen concentration meter 4.
- the four-way valve 20 is switched to block the first flow F1 and open the third flow F3.
- the zero gas introduced into the pipe 5 b from the third gas introduction line 8 (third introduction pipe 23) via the four-way valve 20 flows into the oximeter 4.
- the oxygen concentration meter 4 can be maintained in a measurable state (standby state). It is possible to immediately start the measurement of the oxygen concentration in the kneading chamber 2 by the oximeter 4 by switching the four-way valve 20 without re-calibrating.
- the second flow F2 can be opened by switching the four-way valve 20 while the oxygen concentration meter 4 is interrupting the measurement of the oxygen concentration in the kneading chamber 2.
- the reverse purge gas introduced into the pipe 5 a from the second gas introduction line 7 (second introduction pipe 21) via the four-way valve 20 flows toward the filter 6.
- the second purge gas is introduced into the pipe 5 a so that the dust accumulated in the pipe 5 a and the filter 6 can be blown off to the kneading chamber 2 side by the momentum of the reverse purge gas.
- the pressure and flow rate of the reverse purge gas flowing through the inlet pipe 21 are adjusted in advance. Then, reverse purge is performed by switching the four-way valve 20 to remove dust and the like accumulated in the pipe 5a and the filter 6.
- a method of introducing the reverse purge gas a method of continuously introducing the reverse purge gas (referred to as continuous purge) can be used. In this case, after the reverse purge gas is introduced for a certain period, the second flow F2 is shut off by switching the four-way valve 20.
- a method of intermittently introducing a reverse purge gas intermittent purge
- the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2 while switching the four-way valve 20 a plurality of times.
- the reverse purge gas can be introduced at a high pressure.
- the reverse purge gas used for the reverse purge is introduced into the kneading chamber 2 through the pipe 5a. Therefore, it is preferable to use an inert gas, but in some cases, air or the like can be used.
- the kneading apparatus according to the second aspect of the present invention is not necessarily limited to the embodiment described above, and various modifications can be made without departing from the spirit of the present invention.
- the four-way valve 20 as shown in FIG. 8 is used as the switching means for switching between the first flow F1 and the second flow F2 described above.
- the present invention is not necessarily limited to such a configuration using a four-way valve, and a configuration using a two-way valve 20A as shown in FIG. 9 or a three-way valve 20B as shown in FIG. A configuration is also possible.
- the first two-way valve 20 ⁇ / b> A is disposed between the inlet-side pipe 5 a and the outlet-side pipe 5 b.
- the second gas introduction line 7 (second introduction pipe 21) is connected to the inlet side pipe 5a
- the third gas introduction line 8 (third introduction pipe 23) is connected to the outlet side pipe 5b. It is connected to the.
- a second two-way valve 20B is disposed between the flow rate adjusting valve 22 and the inlet side pipe 5a, and a third two-way is provided between the flow rate adjusting valve 24 and the outlet side pipe 5b.
- a valve 2C is arranged.
- the first two-way valve 20A opens the first flow F1, and the second two-way valve.
- the valve 20B shuts off the second flow F2
- the third two-way valve 20C shuts off the third flow F3.
- the atmospheric gas in the kneading chamber 2 is purified by the filter 6 through the pipes 5 a and 5 b and then flows into the oximeter 4.
- the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2
- the first two-way valve 20A shuts off the first flow F1
- the third two-way valve 20C 3 flow F3 is released.
- the zero gas introduced from the third gas introduction line 8 (third introduction pipe 23) to the outlet side pipe 5 b flows toward the oximeter 4.
- the second two-way valve 20B opens the second flow F2, whereby the reverse purge can be performed.
- the reverse purge gas introduced from the second gas introduction line 7 (second introduction pipe 21) into the inlet side pipe 5a flows toward the filter 6, and dust and the like accumulated in the pipe 5a and the filter 6 are removed. It is possible to remove.
- a three-way valve 20D is disposed between the inlet side pipe 5a and the outlet side pipe 5b, and the second gas introduction line 7 (second introduction pipe 21) is connected to the three-way valve 20D. It is connected. Note that the third gas introduction line 8 (the third introduction pipe 23 and the flow rate adjusting valve 24) is not included because zero gas does not flow into the oximeter 4.
- the three-way valve 20D opens the first flow F1 and shuts off the second flow F2. To do. Thereby, after the atmospheric gas in the kneading chamber 2 is purified by the filter 6 through the pipes 5a and 5b, it flows into the oxygen concentration meter 4 and the oxygen concentration is measured.
- the three-way valve 20D blocks the first flow F1.
- the oximeter 4 is brought into a stopped state by stopping the pump 4a.
- the flow rate adjustment valve 22 is opened to perform reverse purging.
- the reverse purge gas introduced from the second gas introduction line 7 (second introduction pipe 21) into the inlet side pipe 5 a through the three-way valve 20 ⁇ / b> D flows toward the filter 6. Therefore, it is possible to remove dust and the like accumulated in the pipe 5a and the filter 6.
- dust removal using suction by the dust collector 12 will be described.
- dust such as dust P accumulated in the filter 6 as shown in FIG. 11 is removed while being suctioned by a dust collector 12 (not shown in FIG. 11) as shown in FIG. A configuration is also possible.
- the dust collector 12 and the filter 6 are connected by a pipe 25.
- An opening / closing valve 26 for opening and closing the pipe 25 is provided between the dust collector 12 and the filter 6.
- the filter 6 generally has a structure in which an element 6a that collects dust P is disposed in a collection container 6b.
- the open / close valve 26 opens the pipe 25 while the oxygen concentration meter 4 interrupts the measurement of the oxygen concentration in the kneading chamber 2, so that the gas flows from the pipe 5 a side into the collection container 6 b.
- the dust P accumulated in the element 6a in the collection container 6b can be desorbed and removed while being sucked by the dust collector 12. Therefore, when this configuration is adopted, the replacement life of the filter 6 can be further extended.
- the timing for opening the on-off valve 26 is not limited to the time when the reverse purge is performed even before the reverse purge using the four-way valve 20, the two-way valve 20A, the three-way valve 20D, or the like. Or after reverse purging.
- this invention is not necessarily limited to the thing of the said embodiment, A various change can be added in the range which does not deviate from the meaning of this invention.
- the kneading apparatus to which the present invention is applied is not necessarily limited to the Banbury mixer 1 shown in FIGS. 1 and 8, and may be a kneader mixer, for example.
- the kneading is performed by, for example, a method of measuring the concentration of the inert gas introduced into the kneading chamber 2. It is also possible to indirectly measure the oxygen concentration in the chamber 2.
- Steps S1 and S2 In the Banbury mixer 1, first, the calculation unit 30 performed a calculation for obtaining the initial purge time Ta.
- the conditions used for obtaining the initial purge time Ta are as follows.
- Target oxygen concentration Xa 5.0 [volume%]
- Initial purge flow rate Qa 4000 [NL / min]
- Internal volume of kneading chamber V0: 1000 [L] Therefore, the initial purge time Ta is 21.45 seconds based on the calculation result of the equation (2).
- an initial purge was performed. That is, first, before the material to be kneaded G is put into the kneading chamber 2, the kneading chamber 2 is exposed to the atmosphere by opening the charging door 11a without introducing an inert gas.
- the oxygen concentration in the chamber 2 was defined as the oxygen concentration in the atmosphere.
- the inside of the kneading chamber 2 is hermetically sealed, and the oxygen concentration is measured by the oxygen concentration meter 4, and is 21.45 seconds (initial purge flow rate Qa) at 4000 NL / min.
- an inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3.
- initial purge measurement was performed. That is, after stopping the introduction of the inert gas into the kneading chamber 2 and confirming that the oxygen concentration in the kneading chamber 2 has reached the lowest point, the introduction of the inert gas is stopped while the oxygen gas is stopped. Measurement of the oxygen concentration (initial purge measurement) by the densitometer 4 was performed for a certain period (initial purge measurement time Tc).
- the calculation unit 30 performs a calculation for obtaining an initial purge predicted flow rate Qc that is a flow rate of the inert gas that cancels out the increase in the oxygen concentration.
- the conditions used for obtaining the initial purge predicted flow rate Qc are as follows.
- the calculation unit 30 performed a calculation for obtaining the purge time Tb before kneading.
- the conditions used for obtaining the purge time Tb before kneading are as follows.
- the calculation part 30 performed the calculation for calculating
- the conditions used for obtaining the purge flow rate Qc ′ during kneading are as follows. Internal volume of kneading chamber V0: 1000 [L] Internal volume V after charging: 592.6 [L] Purge time Tc ′ during kneading: 90 [seconds] Therefore, from the calculation results of the above formulas (6) and (7), the volume ratio ⁇ was 0.5926, and the purge flow rate Qc ′ during kneading was 622 NL / min.
- Step S3 the first batch (first batch) was started and purged before kneading. That is, when the material to be kneaded G is put into the kneading chamber 2, the charging door 11a is opened to expose the kneading chamber 2 to the atmosphere, and the oxygen concentration in the kneading chamber 2 is determined as the oxygen concentration in the atmosphere. did. After the material to be kneaded G is charged, the inside of the kneading chamber 2 is hermetically sealed, and the oxygen concentration is measured by the oxygen concentration meter 4, and is 12.71 seconds (kneading at 4000 NL / min (purge flow rate Qb before kneading)). During the pre-purging time Tb), an inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3.
- Steps S4 and S5 Next, the introduction of the inert gas into the kneading chamber 2 by the purge before kneading was stopped, the kneading of the material to be kneaded G was started, and the purge during the kneading was performed. That is, an inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3 for 90 seconds (purge time Tc ′ during kneading) at 622 NL / min (purge flow rate Qc ′ during kneading).
- the purge measuring time Te during the kneading was obtained. That is, the introduction of the inert gas into the kneading chamber 2 by the purge before kneading is stopped, and the oxygen concentration meter 4 confirms that the oxygen concentration in the kneading chamber 2 has reached the lowest point. The time required to reach this was determined, and this was taken as the purge measurement time Te during kneading.
- Steps S6 and S7 As a result of measuring the oxygen concentration with the oxygen concentration meter 4, the lowest point of the oxygen concentration within the purge time Tc ′ during kneading was out of the allowable range (5.0 ⁇ 0.1% by volume). Since it was out of the allowable range, the calculation for determining the purge correction flow rate q during the kneading was performed.
- the conditions used for obtaining the purge correction flow rate q during kneading are as follows. Internal volume V after charging: 592.6 [L] Purge measurement time Te during kneading (actual value): 62 [seconds] The lowest point of oxygen concentration within the purge time Tc ′ during kneading (actual measured value) Xd: 5.0 [volume%] Maximum rising point of oxygen concentration within purge time Tc ′ during kneading (actual value) Xe: 5.2 [volume%] Therefore, from the calculation result of the above formula (8), the purge correction flow rate q during kneading was ⁇ 23 NL / min.
- the calculation unit 30 performed calculation for obtaining the purge flow rate Qe during the next batch kneading.
- the purge flow rate Qe during the next batch kneading was 645 NL / min.
- Step S9 the second batch was started, and the purge before kneading was performed. That is, when the material to be kneaded G is put into the kneading chamber 2, the introduction of the inert gas is stopped and the charging door 11a is opened to expose the inside of the kneading chamber 2 to the atmosphere.
- the oxygen concentration was defined as the oxygen concentration in the atmosphere.
- the inside of the kneading chamber 2 is hermetically sealed, and the oxygen concentration is measured by the oxygen concentration meter 4 for 12.71 seconds (kneading at 4000 NL / min (purge flow rate Qb before kneading)).
- an inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3.
- Step S10 Next, after introducing the inert gas into the kneading chamber 2 by the purge before kneading, the kneading of the material to be kneaded G was started and the purge during the kneading was performed. Inactive through the first gas introduction line 3 in the kneading chamber 2 for the value obtained in step S6, that is, 645 NL / min (purge flow rate Qe during the next batch kneading) for 90 seconds (purge time Tc ′ during kneading). Gas was introduced.
- Step S13 the purge measuring time Te during the kneading was obtained. That is, the purge during the kneading is performed, and after the oxygen concentration meter 4 confirms that the oxygen concentration in the kneading chamber 2 has reached the lowest point during the kneading, the time to reach the highest point is obtained.
- the purge measurement time Te during kneading was obtained.
- Step S6 of the second batch And the oxygen concentration measurement result by the oxygen concentration meter 4 within the purge time Tc ′ during kneading was within the allowable range (5.0 ⁇ 0.1 vol%). From this result, the calculation for obtaining the purge correction flow rate q during kneading was stopped. The measurement of oxygen concentration was also stopped.
- Step S8 the third batch was started and purge before kneading was performed. That is, when the material to be kneaded G is put into the kneading chamber 2, the introduction of the inert gas is stopped and the charging door 11a is opened to expose the inside of the kneading chamber 2 to the atmosphere.
- the oxygen concentration was defined as the oxygen concentration in the atmosphere. After the material to be kneaded G is charged, the inside of the kneading chamber 2 is closed, and the oxygen concentration in the kneading chamber 2 is not measured, but the oxygen concentration of the zero gas is measured by the oxygen concentration meter 4 and 4000 NL / min.
- the inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3 for 12.71 seconds (pre-kneading purge flow rate Qb) (pre-kneading purge time Tb).
- the four-way valve 20 is switched so as to shut off the first flow F1 and open the third flow F3.
- the zero gas (oxygen concentration [0% by volume]) introduced from the third gas introduction line 8 (third introduction pipe 23) into the pipe 5b through the four-way valve 20 flows into the oximeter 4. .
- the oxygen concentration indicated by the broken line in FIG. 7 always indicates 0 [volume%].
- Step S11 Next, the introduction of the inert gas into the kneading chamber 2 by the purge before kneading was stopped, the kneading of the material to be kneaded G was started, and the purge during the kneading was performed. That is, the inert gas was introduced into the kneading chamber 2 through the first gas introduction line 3 for 90 seconds (purging time Tc ′ during kneading) at 645 NL / min (purge flow rate Qe during the next batch kneading).
- Step S12 Then, after the calculation is stopped, step S8 and step S11 are repeated until the predetermined number of times is reached.
- Step S6 In the next batch that has reached the 20th batch (the 22nd batch from the start of kneading) after stopping the calculation and measuring the oxygen concentration in the kneading chamber 2, a purge before kneading (step S9), a purge during kneading (step S10), and Purge measurement during kneading (step S13) was performed to check whether the oxygen concentration was within the allowable range.
- the purge flow rate Qe during kneading in the batch is the same as the purge flow rate Qe during kneading in the previous batch. If the measurement result is within the allowable range, the process proceeds to step S8 for the second time, and if it is out of the range, the process proceeds to step S7 for the second time. In this experiment, these steps were repeated up to 200 batches. However, it was not out of tolerance until the last measurement. That is, after stopping the calculation, it was confirmed whether or not the oxygen concentration in the kneading chamber 2 was within the allowable range every 20 batches. As a result, the oxygen concentration in the kneading chamber 2 was within the allowable range up to the final batch (200th batch), and no extreme increase or decrease in the oxygen concentration was observed.
- the inside of the kneading chamber 2 can be stably maintained at the target oxygen concentration Xa for each batch. Further, in the process after the stop of the calculation, the measurement of the oxygen concentration in the kneading chamber 2 by the oximeter 4 is stopped, and by switching the four-way valve 20, the flow is reversed toward the filter 6 in the pipe 5 a through the introduction pipe 21. A reverse purge was performed by flowing a purge gas. As a result, it was confirmed that dust and the like accumulated in the filter 6 and the pipe 5a can be removed.
- the present invention can provide a kneading apparatus capable of stably maintaining a kneading chamber at a target oxygen concentration. Also, a kneading device that can stably measure the oxygen concentration in the atmosphere of the kneading chamber, without clogging the piping and filter, and without frequently performing operations such as piping cleaning and filter replacement Can provide.
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Abstract
Description
本願は、2011年3月10日に日本に出願された、特願2011-052887号、及び、特願2011-052888号に基づき優先権を主張し、その内容をここに援用する。
また、酸素濃度の測定を常時行う必要が無いようにする為には、バッチ毎に混練室内を目標とする酸素濃度(例えば、発火限界以下)に安定して保つ必要があること、そのためには、混練室内の酸素濃度を安定させるのに必要な、混練室内に導入される不活性ガスの流量等をバッチ開始前に予め正確に予測しておく必要があること、を見出した。
(1)被混練物を混練する混練室と、
前記混練室に不活性ガスを導入するガス導入部と、
前記混練室内の酸素濃度を測定する濃度測定部と、
前記混練室内を目標の酸素濃度とするための演算を行う演算部と、
前記演算部による演算結果に基づいて前記ガス導入部を制御する制御部とを備え、
前記濃度測定部が混練時に測定した実測の酸素濃度と、予め設定した目標酸素濃度と、を比較しながら、前記演算部が前記混練室内を目標の酸素濃度とするための演算を行い、
前記演算を行った後の混練において、得られた演算結果に基づき、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御することを特徴とする、混練装置である。
(2) (1)の装置が、前記被混練物の投入、混練、及び排出を1バッチとして、前記被混練物の混練工程を2回バッチ以上繰り返すバッチ式の混練装置であって、
前記演算部が、バッチ毎に目標の酸素濃度を維持する為の演算を繰り返し、
この演算結果に基づいて、前記制御部が、前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御する。
(3) (2)の装置が、前記制御部が、各バッチの開始前に前記混練室内を大気暴露し、前記大気曝露後に混練室を密閉し、前記ガス導入部による混練室内への不活性ガスの導入を開始する。
前記濃度測定部が前記密閉した混練室内の酸素濃度を測定しながら、前記混練室内が目標の酸素濃度となるまで、前記ガス導入部が混練室内に不活性ガスを導入した後、
前記濃度測定部が混練室内の酸素濃度を一定の期間測定しながら、その期間内での酸素濃度の上昇分を相殺する不活性ガスのパージ流量を、前記演算部が演算により求め、
この求めた値を、前記演算部が、初回バッチにおいて混練中に前記混練室内を目標の酸素濃度のまま維持するための、目安値として用いる。
(5) (2)~(4)の装置が、初回バッチ又はそれ以降のバッチにおいて、前記濃度測定部が酸素濃度を実測し、
前記演算部が前記濃度測定部が測定した実測の酸素濃度と、あらかじめ設定した目標酸素濃度との比較により、その差を相殺する不活性ガスの流量を演算により求め、
この求めた値を、前記演算部が、前記酸素濃度実測が行われたバッチの後に行われる、次回バッチにおいて、混練中に前記混練室内を目標の酸素濃度のまま維持するための、補正値として用いる。
次回バッチ及びそれ以降のバッチでの前記演算部による演算を停止し、
前記許容範囲となったときの演算結果に基づいて、
次回バッチ及びそれ以降のバッチで、前記制御部が前記ガス導入部により混練中に前記混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御する。
(7) (6)の装置が、前記演算部による演算を停止した後は、
定期的に前記濃度測定部による混練室内の酸素濃度の測定を行い、
この測定した酸素濃度が前記許容範囲を超えた場合には、
前記演算部による演算を再開し、この演算結果に基づいて、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御する。
定期的に前記濃度測定部による混練室内の酸素濃度の測定を行い、
前記混練室内の酸素濃度が前記許容範囲を下回った場合には、
その旨を告知して、当該バッチが終了するまで、前記濃度測定部による混練室内の酸素濃度の測定を継続する。
(9) (1)~(8)の装置が、前記混練室内の雰囲気ガスを前記濃度測定部へと導く配管と、
前記配管内を流れる雰囲気ガス中に含まれる粉塵を捕集するフィルタと、
前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する第2のガス導入部とを備える。
(10) (9)の装置が、
前記配管を通して前記混練室内の雰囲気ガスが前記濃度測定部に向かう第1の流れと、
前記配管を通して前記第2のガス導入部から導入された逆パージガスが前記フィルタに向かう第2の流れと、
を切り替える切替部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記切替部が前記第1の流れを開放し、前記第2の流れを遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が前記第1の流れを遮断し、前記第2の流れを開放することによって、前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する。
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記配管を通して前記第3のガス導入部から導入されたゼロガスが前記濃度測定部に向かう第3の流れを前記切替部が遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が開放され、第3の流れが濃度測定部に向かう。
(12) (9)~(12)の装置において、逆パージガスが、不活性ガスである。
(13) (11)及び(12)の装置において、前記ゼロガスが、不活性ガスである。
(14)被混練物を混練する混練室と、
前記混練室に不活性ガスを導入する第1のガス導入部と、
前記混練室内の酸素濃度を測定する濃度測定部と、
前記混練室内の雰囲気ガスを前記濃度測定部へと導く配管と、
前記配管内を流れる雰囲気ガス中に含まれる粉塵を捕集するフィルタと、
前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する第2のガス導入部とを備える混練装置。
上記(14)の装置は以下の特徴を有することが好ましい。
(15) (14)の装置が、
前記配管を通して前記混練室内の雰囲気ガスが前記濃度測定部に向かう第1の流れと、
前記配管を通して前記第2のガス導入部から導入された逆パージガスが前記フィルタに向う第2の流れと、
を切り替える切替部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記切替部が前記第1の流れを開放し、前記第2の流れを遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が前記第1の流れを遮断し、前記第2の流れを開放することによって、前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する。
前記濃度測定部にゼロガスを導入する第3のガス導入部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記配管を通して前記第3のガス導入部から導入されたゼロガスが前記濃度測定部に向う第3の流れを前記切替部が遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が開放され、第3の流れが濃度測定部に向かう。
(17) (14)~(16)の装置が、
前記混練室内の粉塵を捕集する集塵機と、
前記集塵機と前記フィルタとの間を接続する配管と、
前記配管を開閉する開閉弁とを備え、
前記濃度測定部が酸素濃度の測定を休止している間に、前記開閉弁が前記配管を開放し、この配管を通して前記フィルタ内に溜まった粉塵を前記集塵機により吸引しながら除去する。
(18) (14)~(17)の装置において、逆パージガスが、不活性ガスである。
(19) (16)~(18)の装置において、ゼロガスが、不活性ガスである。
(20)(1)の混練装置を用いて、混練室に被混練物を投入し混練し排出する、方法であって、
(a)前記濃度測定部が混練時に測定した実測の酸素濃度と、予め設定した目標酸素濃度と、を比較しながら、前記演算部が前記混練室内を目標の酸素濃度とするための演算を行う工程と、
(b)前記演算を行った後の混練において、得られた演算結果に基づき、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御する工程、を含む、混練方法。
(21) 工程(a)と工程(b)の組み合わせが、以下の(1)~(5)で表されるサブ工程を含み、
(1) 大気曝露後密閉された混練室内を目標の酸素濃度とするための初期パージ時間を、予め設定した初期パージ流量の値に基づいて求め、
前記初期パージ流量で不活性ガスを前記混練室に導入するとともに前記初期パージ時間経過後に不活性ガスの導入を停止し、
一定期間における混練室内での酸素濃度変化の測定を行う初期パージ工程;、
(2)以下の工程(2a)~工程(2c)をこの順で含む、初回のバッチ工程、
(2a) 被混練物を前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(2b) 前記パージ時間経過後、被混練物の混練を開始するとともに、工程(1)での酸素濃度変化に基づいて求めたパージ流量で不活性ガスを前記混練室に導入しながら、当該混練中の酸素濃度変化の測定を行う混練中パージ工程、
(2c) 混練後、被混練物を混練室から排出する排出工程;
(3) 前回のバッチ工程における混練中パージでの酸素濃度変化が設定された許容範囲に収まっているかどうかの確認を行い、許容範囲を外れたと判断された場合工程(4)に進み、許容範囲に収まったと判断された場合工程(5)に進む工程;
(4)以下の工程(4a)~工程(4c)をこの順で含む、2回目以降のバッチ工程、
(4a) 被混練物を、前回バッチの被混練物が排出された前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(4b) 前記パージ時間経過後、被混練物の混練を開始するとともに、前回のバッチ工程での混練中パージ工程の酸素濃度変化を相殺するパージ流量で不活性ガスを前記混練室に導入しながら、当該混練中の酸素濃度変化の測定を行う混練中パージ工程、
(4c) 被混練物を混練室から排出する排出工程;
(5)以下の工程(5a)~工程(5c)をこの順で含む、演算停止以降のバッチ工程、
(5a) 被混練物を、前回バッチの被混練物が排出された前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(5b) 前記パージ時間経過後、被混練物の混練を開始するとともに、前回のバッチ工程における混練中パージ工程と同じパージ流量で不活性ガスを前記混練室に導入する混練中パージ工程;
(5c) 被混練物を混練室から排出する排出工程;
上記サブ工程において、(i)工程(4)を行った後に、又は、(ii)工程(5)を所定の回数繰り返し、更に続いて、混練中パージ工程において混練中の酸素濃度変化の測定が行われるバッチ工程を行い、このバッチ工程が行われた後に、
工程(3)へ戻り確認が行われる。
なお本発明において、上記“部”は部材、装置、工程、手段、及び方法などを意味してよい。
なお、以下の記載は、発明の趣旨をより良く理解させるために具体的に例を説明するものであり、特に指定のない限り、本発明を限定するものではない。本発明は趣旨を逸脱しない範囲において、位置や数や形状などについて、付加、省略、置換、およびその他の変更が可能である。本発明は後述する説明によって限定されることはなく、添付のクレームの範囲によってのみ限定される。また2つの態様間では、好ましい例や条件などを共有あるいは交換して良い。
(第一の態様の混練装置)
本発明の第一の態様を適用した混練装置は、例えば図1に示すような、タイヤなどのゴム製品を製造する際に好適に用いられるバンバリーミキサ1である。このようなミキサーでは、その原料となるゴムに、硫黄や、カーボンブラック、オイル、老化防止剤、加硫促進剤などの添加剤や配合剤を加えたものが、被混練物Gとして、加熱及び/または加圧状態で混練される。
また、混練室2の投入扉11aと排出扉11bを閉じた状態で、この混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入し、混練室2内の酸素濃度を発火限界以下としてから、次に不活性ガスを導入し続けながら、被混練物Gを混練室2へと投入しても良い。
なお図2においては、混練中パージ工程とそれに続く混練中パージ測定工程は順番に記載されているが、混練中パージ工程において混練中パージ測定も同時に行われていることが好ましい。
本発明を適用したバンバリーミキサ1では、先ず、図2に示すステップS1(初期パージ工程)に進む。このステップでは、バッチ処理を行う初期パージの開始前に、バッチ処理を行わずに、混練室2内を目標の酸素濃度にするための目安値を求めるための、初期パージを行う。すなわち初期パージでは、被混練物Gは投入しない。具体的には、例えば図3のグラフに示すように、混練室2内に被混練物Gを投入する前に、上記投入扉11aを開放し、混練室2内を大気曝露することによって、この混練室2内の酸素濃度を大気中の酸素濃度(約20.9%)とする。なお本例では、酸素濃度測定は、断りのない限り後述する演算停止工程を除き、継続して行われるが、必要に応じて酸素濃度測定を行う必要がない時点で測定を中断してもよい。
なお、図3中の実線は、混練室2内に導入される不活性ガスのパージ流量を示し、図3中の破線は、1秒毎に測定した混練室2内の酸素濃度を示す。
上記式(1)中において、Qaは、初期パージ流量[NL/分]を、Taは、初期パージ時間[秒]を、Xaは、混練室2内の不活性ガス導入後の(目標)酸素濃度[体積%]を、X0は、混練室2内の不活性ガス導入前(大気中)の酸素濃度[体積%]を、V0は、混練室2の内容積[L]を表す。
なお本発明において上記NL/分のNは、Normalを表し、NL/分は単にL/分と表しても良い。
Ta=-V0/Qa*In(Xa/X0)…(2)
次に、バンバリーミキサ1では、図2に示すステップS2(初期パージ測定工程)に進む。このステップでは、上記初期パージによる混練室2内への不活性ガスの導入を停止し、酸素濃度計4による酸素濃度の変化の測定(初期パージ測定という。)を一定の期間(初期パージ測定時間という。)行う。ここで、混練室2内の酸素濃度は、図3のグラフに示すように、不活性ガスの導入を停止した後に、徐々に上昇することになる。
酸素濃度が上昇する原因は、集塵機12の作動により混練室2内に負圧が発生し、この混練室2の隙間から外気が導入されるからである。
また、演算部30は、上記データから、この初期パージ測定時間内での酸素濃度の上昇分を相殺する不活性ガスの流量(初期パージ予測流量Qcという。)を演算により求める。
Qc=V0/Tc*In(Xc/Xb) …(3)
(∵ Xc=Xb*exp-(Qc/V0)*Tc)
なお、上記式(3)中において、Tcは、初期パージ測定時間[秒]、Xbは、初期パージ測定時間内での酸素濃度の最下点[体積%]、Xcは、初期パージ測定時間内での酸素濃度の最上昇点[体積%]を表す。
次に、バンバリーミキサ1では、図2に示す初回バッチに進む。すなわち、図2に示すステップS3(混練前パージ工程)に進む。この工程では、初回バッチの混練を開始する前に、混練室2内を目標の酸素濃度Xaとする混練前パージを行う。具体的には、例えば図4に示すグラフの左部に示されるように、混練室2内に被混練物Gを投入する時に、上記投入扉11aを開放することで混練室2内を大気曝露し、この混練室2内の酸素濃度を大気中の酸素濃度(約20.9%)とする。
なお、図4中の実線は、混練室2内に導入される不活性ガスのパージ流量を示し、図4中の破線は、混練室2内の酸素濃度を示す。
混練前パージ時間Tbは以下の式(5)によって決定でき、混練前パージ流量Qbとしては一定値が選択される。流量Qbは流量Qaと同じ値を用いることが好ましい。
V=V0-kg*Vg …(4)
なお、上記式(4)中において、Vgは、被混練物Gの体積[L]を、kgは、被混練物Gの空隙係数を表す。
Tb=-V/Qb*In(Xa/X0) …(5)
次に、バンバリーミキサ1では、図2に示すステップS4(混練中パージ工程)に進む。この工程では、上記混練前パージによる混練室2内への不活性ガスの導入を行った後、被混練物Gの混練を開始すると共に、混練中に混練室2内の酸素濃度の上昇を抑える混練中パージを行う。具体的には、図4に示すグラフのように、混練中に酸素濃度計4による混練室2内の酸素濃度の測定を行いながら、この混練室2内に第1のガス導入ライン3を通じて、演算で決定された量の不活性ガスを導入する。混練時間としては、任意の時間を選択でき、これを演算に使用して良い。
λ=V/V0 …(6)
Qc’=Qc*λ …(7)
但し、上記式(7)中のQcは、上記式(3)中のTcをTc’で換算した値とする。
を酸素濃度計4により確認された時間から、ステップS5をスタートし、酸素濃度計4による酸素濃度の変化測定(混練中パージ測定という。)を行う。酸素濃度が最下点に到達してから再び上昇を始め最上昇点に到達するまでの時間を、混練中パージ測定時間Teとする。
そして、図2に示すステップS6(許容範囲の確認工程)に進む。このステップでは、ステップS5において酸素濃度計4が測定した実測の酸素濃度と、目標酸素濃度Xaを含んだ所定の濃度範囲(予め設定しておく)との比較を行い、前記所定の濃度幅の範囲内に実測の酸素濃度が入るか否か、すなわち実測酸素濃度が許容範囲に収まっているか否かを判断する。許容範囲すなわち目標酸素濃度Xaを含んだ所定の濃度範囲は必要に応じて任意で設定できる。
図2に示すステップS7(補正値演算工程)では、次回バッチの開始前に、ステップS5及び6で得られた、上記酸素濃度計4が測定した実測の酸素濃度と、予め設定した目標酸素濃度との比較に基づき、その差を相殺する不活性ガスの流量を求める。求めた値は、次回バッチにおいて、混練中に混練室2内を目標の酸素濃度Xaのまま維持するための補正値として用いられる。
q=-V/Te*In(Xe/Xd) …(8)
(∵ Xe=Xd*exp-(q/V)*Te)
なお、上記式(8)中において、Teは、混練中パージ測定時間[秒]を、Xdは、混練中パージ時間Tc’内での酸素濃度の最下点(実測値a)[体積%]を、Xeは、混練中パージ時間Tc’内での酸素濃度の最上昇点(実測値b)[体積%]を表す。
なお、混練中パージ補正流量qの算出(ステップS7)は、酸素濃度が許容範囲内に収まっているか確認する工程(ステップS6)の前に行ってもよい。
次に、バンバリーミキサ1では、図2に示す2回目以降のバッチに進む。すなわち、図2に示すステップS9(前回バッチの酸素濃度変化が許容範囲を超えた後の、混練前パージ工程)に進む。このステップでは、2バッチ目及びそれ以降のバッチにおいて、各バッチの混練開始前に、上述した混練室2内を、目標の酸素濃度Xaとする混練前パージを行う。
なお、図5中の実線は、混練室2内に導入される不活性ガスのパージ流量を示し、図5中の破線は、混練室2内の酸素濃度を示す。
これにより、2バッチ目及びそれ以降のバッチで、被混練物Gの混練を開始する前に、混練室2内を目標の酸素濃度Xaとすることができる。
次に、本態様のバンバリーミキサ1は、図2に示すステップS10(前回バッチの酸素濃度変化が許容範囲を超えた後のバッチの、混練中パージ工程)に進む。被混練物Gの混練を開始すると共に、混練中に混練室2内の酸素濃度の上昇を抑える混練中パージを行う。
具体的には、2バッチ目及びそれ以降のバッチでは、混練前パージの後に、例えば図5のグラフの中央及び右側に示すように、混練中に酸素濃度計4による混練室2内の酸素濃度の測定を行いながら、この混練室2内に第1のガス導入ライン3を通じて、ステップS7での演算に基づいて決定された量の不活性ガスを導入する。
Qe=Qc’(or Qe’)-q …(9)
なお、上記式(9)中に示すQe’は、前回バッチでの混練中パージ流量を表す。すなわちQe’は、3バッチ目以降において、前回バッチのパージ流量として、次回バッチでの混練中パージ流量Qeを得る為に使用される。すなわち、3バッチ目以降は、次バッチ混練中パージ流量Qeを得る為に、前バッチ混練中パージ流量Qe’を用いるものとする。
また、バンバリーミキサ1では、混練中パージの間に、図2に示すステップS13(混練中パージ測定工程)を行う。ステップS13における酸素濃度計4による酸素濃度の最上昇点及び最下点の測定、及び、混練中パージ測定時間Te算出は、上述のステップS5と同様に行うことができる。
その後、図2に示すステップS6へ再び戻る。すなわち、ステップS13での酸素濃度変化が許容範囲に収まっているか否かを判断する。
一方、ステップS6において酸素濃度が許容範囲となった場合、図2のステップS8に進む。ステップS8(演算停止後の混練前パージ工程)では、次回バッチ(2回目のバッチ)及びそれ以降のバッチについて、すなわち本工程で処理されるバッチ等について、上記混練中パージ補正流量qを求める演算を停止する。前記補正流量を求める演算を停止する間は、酸素濃度の測定を行わなくても良い。そして、演算停止した後のバッチにおいては、以前のバッチで決定され使用されていた条件で、バッチの混練開始前に、上述した混練室2内を目標の酸素濃度Xaとする混練前パージを行う。
なお、図6中の実線は、混練室2内に導入される不活性ガスのパージ流量を示し、図6中の破線は、酸素濃度計4へ導かれた雰囲気ガス中の酸素濃度を示す。
上記演算停止中のバッチ処理では、ステップS12に述べる特定の場合を除き、酸素濃度計4による混練室2内の測定を行う必要がない。このため、演算が停止されたバッチの処理中には、第1の流れF1を遮断し、第3の流れF3を開放するように四方弁20を切り替えることができる。これにより、第3のガス導入ライン8(第3の導入管23)から四方弁20を介して配管5bに導入されたゼロガスが酸素濃度計4に向かって流れ込む。このため、図6中の破線で示す酸素濃度は、常時0[体積%]を示している。
次に、バンバリーミキサ1では、図2に示すステップS11(演算停止後の混練中パージ工程)に進む。このステップでは、被混練物Gの混練を開始すると共に、混練中に混練室2内の酸素濃度の上昇を抑える混練中パージを行う。
具体的には、演算停止後のバッチでは、例えば図6のグラフのパージ流量で示されるように、上記許容範囲となったときの前回のバッチの演算結果に基づいて、言い換えればステップS4又はステップS10で使用した値を用いて、制御部31が第1のガス導入ライン3により混練室2内に導入される不活性ガスの流量及び時間を制御しながら混練中パージを行う。
ステップS8とステップS11の組み合わせによるバッチ処理が終了すると、次に、バンバリーミキサ1では、図2のステップS12(バッチ数の確認工程)へと進み、演算停止後のバッチ数が所定の数に到達したか否かの確認を行う。そして、演算停止後のバッチ数が所定数に到達していない場合には、再びステップS8に戻り、新たなバッチ処理を所定の回数まで繰り返す。
一方、演算停止後のバッチ数が所定数に到達した場合には、次バッチにおいて、酸素濃度測定を行い、許容範囲内か否かの判断を行う。すなわち、上記ステップS9に戻り、前バッチで使用した値を使用して混練前パージS9、混練中パージS10(混練中パージ測定S13を含む。)を行い、再び上記ステップS6に進み、混練室2内の酸素濃度が上記許容範囲にあるか否かの確認を行う。そして、この測定した酸素濃度が上記許容範囲にある場合は、再び上記ステップS8に進む。一方、この測定した酸素濃度が上記許容範囲を外れた場合には、上記ステップS7に進み、演算部30による演算を再開する。なおステップS12で所定の最終バッチの数まで達した事が確認された場合は、最終バッチの終了後に、上記バンバリーミキサ1の運転を停止する。
ところで、一般的なバンバリーミキサでは、混練中に混練室2内の酸素濃度の測定を常時行うと、上述した入側の配管5aの清掃やフィルタ6に溜まった粉塵等が目詰まりを起こす頻度が高くなる。これら問題を避けるために行われる配管5aの清掃やフィルタ6の交換等といった煩わしい作業を回避するために、逆パージを行っても良い。すなわち、本発明の第一の態様を適用したバンバリーミキサ1では、本願の第二の態様で採用されるような、第2のガス導入ライン7からフィルタ6に向かって逆パージガスを導入する、いわゆる逆パージを行うことで、これら配管5aやフィルタ6に溜まった粉塵等を除去することも可能である。
次に、本発明の第二の態様の混練装置の好ましい例について、図8を用いて説明する。
図8に示される、本発明の第二の態様の好ましい例を示すバンバリーミキサ1では、第一の態様とは異なり、演算部30が含まれず、また演算部30と流量制御装置や流量調整弁を結ぶラインが無く、演算部30による流量制御が行われない。これらの条件以外は、上記の図1を用いて説明されたバンバリーミキサ1とほぼ同じである。よって図1に示すバンバリーミキサ1と同じ部材については、同じ符号を付し、その説明を省略する。
本態様の混練装置では、任意の段階やタイミングで酸素濃度の測定ができ、また任意の段階やタイミングで酸素濃度の測定を中断できる。
例えば、上記実施形態では、上述した第1の流れF1と第2の流れF2とを切り替える切替手段として、上記図8に示すような四方弁20を用いた構成となっている。しかしながら、本発明はこのような四方弁を用いる構成に必ずしも限定されるものではなく、図9に示すような二方弁20Aを用いた構成や、図10に示すような三方弁20Bを用いた構成とすることも可能である。
二方弁を用いた構成の例について説明する。
具体的には、図9に示す構成では、入側の配管5aと出側の配管5bとの間に第1の二方弁20Aが配置される。上記第2のガス導入ライン7(第2の導入管21)が入側の配管5aに接続されると共に、上記第3のガス導入ライン8(第3の導入管23)が出側の配管5bに接続されている。また、上記流量調整弁22と入側の配管5aとの間に第2の二方弁20Bが配置され、また、上記流量調整弁24と出側の配管5bとの間に第3の二方弁2Cが配置されている。
三方弁を用いた構成の例について説明する。
図10に示す構成では、入側の配管5aと出側の配管5bとの間に三方弁20Dが配置され、上記第2のガス導入ライン7(第2の導入管21)が三方弁20Dに接続されている。なお、酸素濃度計4へのゼロガスの流れ込みを行わないため、上記第3のガス導入ライン8(第3の導入管23及び流量調整弁24)は含まれない。
次に、集塵機12による吸引を用いた粉塵除去を説明する。
本発明では、図11に示すようなフィルタ6内に溜まった粉塵Pなどの粉塵等を、図8に示されるような集塵機12(図11において図示せず。)により吸引を行いながら、除去する構成とすることも可能である。
図11を具体的に説明すると、上記集塵機12と上記フィルタ6との間は、配管25により接続されている。また、上記集塵機12と上記フィルタ6との間には、この配管25を開閉する開閉弁26が設けられている。フィルタ6は、一般に、粉塵Pを捕集するエレメント6aが捕集容器6b内に配置された構造を有している。
例えば本発明を適用した混練装置は、上記図1や8に示すバンバリーミキサ1に必ずしも限定されるものではなく、例えばニーダーミキサなどであってもよい。
上記バンバリーミキサ1では、先ず、演算部30が初期パージ時間Taを求めるための演算を行った。
ここで、初期パージ時間Taを求めるために使用する条件は、以下のとおりである。
目標の酸素濃度Xa:5.0[体積%]
大気中の酸素濃度X0:20.9[体積%]
初期パージ流量Qa:4000[NL/分]
混練室の内容積V0:1000[L]
したがって、上記式(2)の演算結果から、上記初期パージ時間Taは21.45秒となった。
ここで、上記初期パージ予測流量Qcを求めるために使用する条件は、以下のとおりである。
混練室の内容積V0:1000[L]
投入後の内容積V:[L]
初期パージ測定時間Tc:15[秒]
初期パージ測定時間(Tc)内での酸素濃度の最下点(実測値)Xb:5.0[体積%]
初期パージ測定時間(Tc)内での酸素濃度の最上昇点(実測値)Xc:6.5[体積%]
したがって、上記式(3)の演算結果から、初期パージ予測流量Qcは1050NL/分となった。
ここで、上記混練前パージ時間Tbを求めるために使用する条件は、以下のとおりである。
混練室の内容積V0:1000[L]
被混練物Gの体積Vg:420[L]
被混練物Gの空隙係数kg:0.97
混練前パージ流量Qb:4000NL/分
したがって、上記式(4),(5)の演算結果から、上記投入後の内容積Vは592.6L、上記混練前パージ時間Tbは12.71秒となった。
ここで、上記混練中パージ流量Qc’を求めるために使用する条件は、以下のとおりである。
混練室の内容積V0:1000[L]
投入後の内容積V:592.6[L]
混練中パージ時間Tc’:90[秒]
したがって、上記式(6),(7)の演算結果から、上記容積比λは0.5926、上記混練中パージ流量Qc’は622NL/分となった。
次に、初回バッチ(1バッチ目)の処理を開始し、混練前パージを行った。すなわち、混練室2内に被混練物Gを投入する際に上記投入扉11aを開放することで、混練室2内を大気曝露し、この混練室2内の酸素濃度を大気中の酸素濃度とした。そして、被混練物Gの投入後は、混練室2内を密閉状態とし、酸素濃度計4による酸素濃度の測定を行いながら、4000NL/分(混練前パージ流量Qb)で12.71秒(混練前パージ時間Tb)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
次に、上記混練前パージによる混練室2内への不活性ガスの導入を停止し、被混練物Gの混練を開始すると共に、上記混練中パージを行った。すなわち、622NL/分(混練中パージ流量Qc’)で90秒(混練中パージ時間Tc’)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
そして、酸素濃度計4による酸素濃度測定の結果、混練中パージ時間Tc’内での酸素濃度の最下点が許容範囲(5.0±0.1体積%)を外れた。許容範囲を外れたことから、上記混練中パージ補正流量qを求めるための演算を行った。
投入後の内容積V:592.6[L]
混練中パージ測定時間Te(実測値):62[秒]
混練中パージ時間Tc’内での酸素濃度の最下点(実測値)Xd:5.0[体積%]
混練中パージ時間Tc’内での酸素濃度の最上昇点(実測値)Xe:5.2[体積%]
したがって、上記式(8)の演算結果から、上記混練中パージ補正流量qは、-23NL/分となった。
次に、2バッチ目を開始し、上記混練前パージを行った。すなわち、混練室2内に被混練物Gを投入する際に、不活性ガスの導入を止め、上記投入扉11aを開放することで、混練室2内を大気曝露し、この混練室2内の酸素濃度を大気中の酸素濃度とした。そして、被混練物Gの投入後は、混練室2内を密閉状態とし、酸素濃度計4による酸素濃度の測定を行いながら、4000NL/分(混練前パージ流量Qb)で12.71秒(混練前パージ時間Tb)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
次に、上記混練前パージによる混練室2内への不活性ガスの導入を行った後、被混練物Gの混練を開始すると共に、上記混練中パージを行った。ステップS6で求めた値、すなわち、645NL/分(次バッチ混練中パージ流量Qe)で90秒(混練中パージ時間Tc’)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
また、混練中に、上記混練中パージ測定時間Teを求めた。すなわち、上記混練中パージを行い、混練中に混練室2内の酸素濃度が最下点に到達したことを酸素濃度計4で確認した後、最上昇点に到達するまでの時間を求め、これを混練中パージ測定時間Teとした。
そして、混練中パージ時間Tc’内での酸素濃度計4による酸素濃度測定結果が許容範囲内(5.0±0.1体積%)となった。この結果から、上記混練中パージ補正流量qを求めるための演算を停止した。また酸素濃度の測定もあわせて停止した。
次に、3バッチ目を開始し、混練前パージを行った。すなわち、混練室2内に被混練物Gを投入する際に、不活性ガスの導入を止め、上記投入扉11aを開放することで、混練室2内を大気曝露し、この混練室2内の酸素濃度を大気中の酸素濃度とした。そして、被混練物Gの投入後は、混練室2内を密閉状態とし、混練室2内の酸素濃度測定は行わず、酸素濃度計4によるゼロガスの酸素濃度の測定を行いながら、4000NL/分(混練前パージ流量Qb)で12.71秒(混練前パージ時間Tb)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
なお、演算停止後は、酸素濃度計4による混練室2内の測定が不要となるため、第1の流れF1を遮断し、第3の流れF3を開放するように四方弁20を切り替える。これにより、第3のガス導入ライン8(第3の導入管23)から四方弁20を介して配管5bに導入されたゼロガス(酸素濃度[0体積%])が酸素濃度計4に向かって流れ込む。このため、図7中の破線で示す酸素濃度は、常時0[体積%]を示している。
次に、上記混練前パージによる混練室2内への不活性ガスの導入を停止し、被混練物Gの混練を開始すると共に、上記混練中パージを行った。すなわち、645NL/分(次バッチ混練中パージ流量Qe)で90秒(混練中パージ時間Tc’)の間、混練室2内に第1のガス導入ライン3を通じて不活性ガスを導入した。
そして、演算停止後は、上記ステップS8とステップS11を所定の回数になるまで繰り返し行った。
(ステップS6)
演算停止及び混練室2内の酸素濃度測定を止めてから20バッチ目(混練スタートから22バッチ目)になった次のバッチにおいて、混練前パージ(ステップS9)、混練中パージ(ステップS10)及び混練中パージ測定(ステップS13)を行い、酸素濃度が許容範囲に入っているかの確認を行った。当該バッチでの混練中パージ流量Qeは、その前のバッチでの混練中パージ流量Qeと同じである。
なお上記測定の結果が許容範囲であれば2回目のステップS8に進み、範囲外であれば、2回目のステップS7に進む設定を行っていたが、本実験ではこれらステップを200バッチまで繰り返したが、最後の測定まで許容範囲を外れなかった。
すなわち、演算停止後、20バッチ毎に混練室2内の酸素濃度が上記許容範囲にあるか否かの確認を行った。その結果、最終バッチ(200バッチ目)まで混練室2内の酸素濃度は上記許容範囲となり、極端な酸素濃度の増加や低下は見られなかった。
また、演算停止後の工程で、酸素濃度計4による混練室2内の酸素濃度の測定を停止すると共に、上記四方弁20の切り替えによって、導入管21を通して配管5aにあるフィルタ6に向かって逆パージガスを流す、逆パージを行った。その結果、上記フィルタ6や配管5aに溜まった粉塵等が除去できることを確認した。
2 混練室
3 第1のガス導入ライン(第1のガス導入手段)
4 酸素濃度計(濃度測定手段)
4a ポンプ
5a 入側の配管
5b 出側の配管
6 フィルタ
6a エレメント
6b 捕集容器
7 第2のガス導入ライン(第2のガス導入手段)
8 第3のガス導入ライン(第3のガス導入手段)
9a,9b ロータ
10 ベルトコンベア
11a 投入扉
11b 排出扉
12 集塵機
13 第1の導入管
14 圧力調整弁
15 遮断弁
16 流量計
17 流量調整計
18 流量制御装置
19 逆止弁
20 四方弁(切替手段)
20A 第1の二方弁
20B 第2の二方弁
20C 第3の二方弁
20D 三方弁
21 第2の導入管
22 流量調整弁
23 第3の導入管
24 流量調整弁
25 配管
26 開閉弁
30 演算部(演算手段)
31 制御部(制御手段)
G 被混練物
F1 第1の流れ
F2 第2の流れ
F3 第3の流れ
Claims (21)
- 被混練物を混練する混練室と、
前記混練室に不活性ガスを導入するガス導入部と、
前記混練室内の酸素濃度を測定する濃度測定部と、
前記混練室内を目標の酸素濃度とするための演算を行う演算部と、
前記演算部による演算結果に基づいて前記ガス導入部を制御する制御部とを備え、
前記濃度測定部が混練時に測定した実測の酸素濃度と、予め設定した目標酸素濃度と、を比較しながら、前記演算部が前記混練室内を目標の酸素濃度とするための演算を行い、
前記演算を行った後の混練において、得られた演算結果に基づき、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御することを特徴とする、混練装置。 - 前記被混練物の投入、混練、及び排出を1バッチとして、前記被混練物の混練工程を2回バッチ以上繰り返すバッチ式の混練装置であって、
前記演算部が、バッチ毎に目標の酸素濃度を維持する為の演算を繰り返し、
この演算結果に基づいて、前記制御部が、前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御することを特徴とする請求項1に記載の混練装置。 - 前記制御部が、各バッチの開始前に前記混練室内を大気暴露し、前記大気曝露後に混練室を密閉し、前記ガス導入部による混練室内への不活性ガスの導入を開始することを特徴とする請求項2に記載の混練装置。
- 初回バッチの開始前に、混練室内を大気曝露しその後密閉し、
前記濃度測定部が前記密閉した混練室内の酸素濃度を測定しながら、前記混練室内が目標の酸素濃度となるまで、前記ガス導入部が混練室内に不活性ガスを導入した後、
前記濃度測定部が混練室内の酸素濃度を一定の期間測定しながら、その期間内での酸素濃度の上昇分を相殺する不活性ガスのパージ流量を、前記演算部が演算により求め、
この求めた値を、前記演算部が、初回バッチにおいて混練中に前記混練室内を目標の酸素濃度のまま維持するための、目安値として用いることを特徴とする請求項2に記載の混練装置。 - 初回バッチ又はそれ以降のバッチにおいて、前記濃度測定部が酸素濃度を実測し、
前記演算部が前記濃度測定部が測定した実測の酸素濃度と、あらかじめ設定した目標酸素濃度との比較により、その差を相殺する不活性ガスの流量を演算により求め、
この求めた値を、前記演算部が、前記酸素濃度実測が行われたバッチの後に行われる、次回バッチにおいて、混練中に前記混練室内を目標の酸素濃度のまま維持するための、補正値として用いることを特徴とする請求項2に記載の混練装置。 - 目標酸素濃度を含んだ所定の許容範囲に、前記濃度測定部が測定した実測の酸素濃度が収まった場合において、
次回バッチ及びそれ以降のバッチでの前記演算部による演算を停止し、
前記許容範囲となったときの演算結果に基づいて、
次回バッチ及びそれ以降のバッチで、前記制御部が前記ガス導入部により混練中に前記混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御することを特徴とする請求項5に記載の混練装置。 - 前記演算部による演算を停止した後は、
定期的に前記濃度測定部による混練室内の酸素濃度の測定を行い、
この測定した酸素濃度が前記許容範囲を超えた場合には、
前記演算部による演算を再開し、この演算結果に基づいて、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御することを特徴とする請求項6に記載の混練装置。 - 定期的に前記濃度測定部による混練室内の酸素濃度の測定を行い、
前記混練室内の酸素濃度が前記許容範囲を下回った場合には、
その旨を告知して、当該バッチが終了するまで、前記濃度測定部による混練室内の酸素濃度の測定を継続することを特徴とする請求項7に記載の混練装置。 - 前記混練室内の雰囲気ガスを前記濃度測定部へと導く配管と、
前記配管内を流れる雰囲気ガス中に含まれる粉塵を捕集するフィルタと、
前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する第2のガス導入部とを備える請求項1に記載の混練装置。 - 前記配管を通して前記混練室内の雰囲気ガスが前記濃度測定部に向かう第1の流れと、
前記配管を通して前記第2のガス導入部から導入された逆パージガスが前記フィルタに向かう第2の流れと、
を切り替える切替部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記切替部が前記第1の流れを開放し、前記第2の流れを遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が前記第1の流れを遮断し、前記第2の流れを開放することによって、前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入することを特徴とする請求項9に記載の混練装置。 - 前記濃度測定部にゼロガスを導入する第3のガス導入部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記配管を通して前記第3のガス導入部から導入されたゼロガスが前記濃度測定部に向かう第3の流れを前記切替部が遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が開放され、第3の流れが濃度測定部に向かうことを特徴とする請求項10に記載の混練装置。 - 前記逆パージガスが、不活性ガスであることを特徴とする請求項9に記載の混練装置。
- 前記ゼロガスが、不活性ガスであることを特徴とする請求項11に記載の混練装置。
- 被混練物を混練する混練室と、
前記混練室に不活性ガスを導入する第1のガス導入部と、
前記混練室内の酸素濃度を測定する濃度測定部と、
前記混練室内の雰囲気ガスを前記濃度測定部へと導く配管と、
前記配管内を流れる雰囲気ガス中に含まれる粉塵を捕集するフィルタと、
前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入する第2のガス導入部とを備える混練装置。 - 前記配管を通して前記混練室内の雰囲気ガスが前記濃度測定部に向かう第1の流れと、
前記配管を通して前記第2のガス導入部から導入された逆パージガスが前記フィルタに向う第2の流れと、
を切り替える切替部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記切替部が前記第1の流れを開放し、前記第2の流れを遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が前記第1の流れを遮断し、前記第2の流れを開放することによって、前記配管の前記濃度測定部側から前記フィルタに向かって逆パージガスを導入することを特徴とする請求項14に記載の混練装置。 - 前記濃度測定部にゼロガスを導入する第3のガス導入部を備え、
前記濃度測定部が前記混練室内の酸素濃度を測定している間は、前記配管を通して前記第3のガス導入部から導入されたゼロガスが前記濃度測定部に向う第3の流れを前記切替部が遮断する一方、
前記濃度測定部が前記混練室内の酸素濃度の測定を中断している間は、前記切替部が開放され、第3の流れが濃度測定部に向かうこと、を特徴とする請求項15に記載の混練装置。 - 前記混練室内の粉塵を捕集する集塵機と、
前記集塵機と前記フィルタとの間を接続する配管と、
前記配管を開閉する開閉弁とを備え、
前記濃度測定部が酸素濃度の測定を休止している間に、前記開閉弁が前記配管を開放し、この配管を通して前記フィルタ内に溜まった粉塵を前記集塵機により吸引しながら除去することを特徴とする請求項14に記載の混練装置。 - 前記逆パージガスが、不活性ガスであることを特徴とする請求項14に記載の混練装置。
- 前記ゼロガスが、不活性ガスであることを特徴とする請求項14に記載の混練装置。
- 被混練物を混練する混練室と、
前記混練室に不活性ガスを導入するガス導入部と、
前記混練室内の酸素濃度を測定する濃度測定部と、
前記混練室内を目標の酸素濃度とするための演算を行う演算部と、
前記演算部による演算結果に基づいて前記ガス導入部を制御する制御部とを備える混練装置を用いて、混練室に被混練物を投入し混練し排出する、方法であって、
(a)前記濃度測定部が混練時に測定した実測の酸素濃度と、予め設定した目標酸素濃度と、を比較しながら、前記演算部が前記混練室内を目標の酸素濃度とするための演算を行う工程と、
(b)前記演算を行った後の混練において、得られた演算結果に基づき、前記制御部が前記ガス導入部により混練室内に導入される不活性ガスのパージ流量及びパージ時間を制御する工程、を含む、混練方法。 - 工程(a)と工程(b)の組み合わせが、以下の(1)~(5)で表されるサブ工程を含み、
(1) 大気曝露後密閉された混練室内を目標の酸素濃度とするための初期パージ時間を、予め設定した初期パージ流量の値に基づいて求め、
前記初期パージ流量で不活性ガスを前記混練室に導入するとともに前記初期パージ時間経過後に不活性ガスの導入を停止し、
一定期間における混練室内での酸素濃度変化の測定を行う初期パージ工程;
(2) 以下の工程(2a)~工程(2c)をこの順で含む初回のバッチ工程、
(2a) 被混練物を前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(2b) 前記パージ時間経過後、被混練物の混練を開始するとともに、工程(1)での酸素濃度変化に基づいて求めたパージ流量で不活性ガスを前記混練室に導入しながら、当該混練中の酸素濃度変化の測定を行う混練中パージ工程、
(2c) 混練後、被混練物を混練室から排出する排出工程;
(3) 前回のバッチ工程における混練中パージでの酸素濃度変化が設定された許容範囲に収まっているかどうかの確認を行い、許容範囲を外れたと判断された場合工程(4)に進み、許容範囲に収まったと判断された場合工程(5)に進む工程;
(4) 以下の工程(4a)~工程(4c)をこの順で含む2回目以降のバッチ工程、
(4a) 被混練物を、前回バッチの被混練物が排出された前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(4b) 前記パージ時間経過後、被混練物の混練を開始するとともに、前回のバッチ工程での混練中パージ工程での酸素濃度変化を相殺するパージ流量で不活性ガスを前記混練室に導入しながら、当該混練中の酸素濃度変化の測定を行う混練中パージ工程、
(4c) 混練後、被混練物を混練室から排出する排出工程;及び
(5) 以下の工程(5a)~工程(5c)をこの順で含む演算停止以降のバッチ工程、
(5a) 被混練物を、前回バッチの被混練物が排出された前記混練室に投入した後密閉し、所定のパージ流量及びパージ時間で不活性ガスを前記混練室に導入する混練前パージ工程、
(5b) 前記パージ時間経過後、被混練物の混練を開始するとともに、前回のバッチ工程における混練中パージ工程と同じパージ流量で不活性ガスを前記混練室に導入する混練中パージ工程、
(5c) 混練後、被混練物を混練室から排出する排出工程;
上記サブ工程において、
(i)工程(4)を行った後に、又は、(ii)工程(5)を所定の回数繰り返し、更に続いて、混練中パージ工程において混練中の酸素濃度変化の測定が行われるバッチ工程を行い、このバッチ工程が行われた後に、
工程(3)へ戻り確認が行われる、請求項20に記載の混練方法。
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CN2012800060694A CN103328087A (zh) | 2011-03-10 | 2012-03-09 | 混炼装置 |
US14/003,875 US20140016428A1 (en) | 2011-03-10 | 2012-03-09 | Kneading apparatus |
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JP2014214051A (ja) * | 2013-04-25 | 2014-11-17 | 三菱マテリアルテクノ株式会社 | 粉塵除去装置及び粉塵除去方法 |
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US9259856B2 (en) * | 2011-07-12 | 2016-02-16 | Toyo Tire & Rubber Co., Ltd. | Methods for controlling the mixing process of processing rubber |
CN107079276B (zh) * | 2014-10-21 | 2021-06-22 | Lg电子株式会社 | 在无线通信系统中发送/接收d2d信号的方法及其设备 |
CN106256421B (zh) * | 2016-08-24 | 2019-02-22 | 佛山慧谷科技股份有限公司 | 一种制造板片或块体形式的产品的生产设备及其方法 |
DE102017212387A1 (de) * | 2017-07-19 | 2019-01-24 | Continental Reifen Deutschland Gmbh | Verfahren zur Herstellung einer Kautschukmischung |
CN108828154B (zh) * | 2018-06-25 | 2024-02-23 | 山东恒量测试科技有限公司 | 一种氧气检测仪检定装置与方法 |
CN111702978A (zh) * | 2020-06-28 | 2020-09-25 | 安徽立信橡胶科技有限公司 | 啮合型密闭式炼胶机及其工作方法 |
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