FLAME TREATMENT FLAME TREATMENT TECHNOLOGY AND …€¦ · AIMCAL FALL CONFERENCE - MYRTLE BEACH - SC - USA - 19 October 2005 11/10/2005 1 FLAME TREATMENT FLAME TREATMENT TECHNOLOGY

11/10/2005AIMCAL FALL CONFERENCE - MYRTLE BEACH - SC - USA - 19 October 20051

FLAME TREATMENT FLAME TREATMENT TECHNOLOGY AND ITS TECHNOLOGY AND ITS

APPLICATIONSAPPLICATIONS

Stefano MancinelliesseCI SRL Process Engineer

esse CIflame treaters®

Via Flaminia Ternana no.386

05035 – Narni (TR) - ITALY

www.essecinet.com


SUMMARYSUMMARY

1. Laminar flame profile

2. Flame chemistry

3. PP surface flame oxidation mechanism

4. Flame treatment main process parameters

5. Flame treatment applications


1.1.11 LAMINAR FLAME LAMINAR FLAME PROFILEPROFILE

1) Preheating zone;

2) Luminous zone;

3) Recombination zone

Temp. profile

Radicals gradient

Unburned gases

convective flows

+

Radicals diffusion

REDUCING ZONENO TREATMENTEXCESS GAS

OXIDIZING ZONETREATMENT AREAEXCESS O2



FLAME SPEEDMallard-LeChatelier Theory

SL ~ (b ´ RR)1/2

b = Thermal Diffusivity = l/rcp

FLAME = Dynamic balance between flame speed and

mixture speed ÞMixt. Flow vs. Air Gap



Flame speed and mixture speed in premixed laminar flame



FLAMMABILITY LIMITS (FUEL VOL. %)

551022C3H8

611555CH4

79281515NH3

94741612CO

947544H2

O2AIRO2AIR

GAS RICHGAS LEAN


2.2.11 FLAME CHEMISTRYFLAME CHEMISTRY

Chain/Radical reactions:l M Þ R ; Initiating step – k1

l R+M Þ aR+M’ ; Chain Branching – k2

l R+M Þ R+P ; Propagating step – k3

l R+M Þ P’ ;Terminating/Production – k4

l R Þ P’’ ; Wall destruction – k5M = reactants; P,P’,P’’ = reaction products

Multiplication factor a = 1 + [(k4 + k5) / k2]


2.2.22 HH22 -- 0022

COMBUSTION SYSTEMCOMBUSTION SYSTEMChain Branching Þ RADICAL POOL

H+O2 Þ OH+O;

OH+H2 Þ H+H2O;

O+H2 Þ OH+H;

O+H2O Þ 2OH.


2.2.33 METHANE OXIDATIONMETHANE OXIDATION

CH4 + M Þ CH3 + H + MCH4 + X Þ CH3 + XHa) methyl radicals oxidation Þ CH3O;CH2O

b) C2H6 formation and its oxidation

Þ H2O and CO2 production (passing through CO).


3.3.11 PP PP surface flame oxidation surface flame oxidation

mechanismmechanism

l C-H link breaking vs. C-C link breaking;l OH > O > H >> HO2

RH+OH Þ R°+H2O; Initiating stepRH+H Þ R°+H2

R°+OH Þ ROH;

R°+HO2 Þ ROOH; Propagating stepR°+O2 Þ ROO;R°+H2O2 Þ ROO+OHR°+O Þ RO

R°+H Þ RH; Terminating step



mechanismmechanism

b-scission reaction:

-C-C-C- Þ -C=O + C

ô

O

O Þ alkoxy radicals RO° Þ LMWOM.



mechanismmechanism

l O/C RATIO

l IMWOM vs. LMWOM

INCREASED SURFACE ENERGY

l Chain Scission behaviour

l “Aging” behaviour

l Metallizing barrier effect & Improved surface properties



mechanismmechanism


TREATED


mechanismmechanism

UNTREATED


4.4.11 FLAME TREATMENT MAIN FLAME TREATMENT MAIN PROCESS PARAMETERSPROCESS PARAMETERS


4.4.2 2 FLAME TREATMENT MAIN FLAME TREATMENT MAIN PROCESS PARAMETERSPROCESS PARAMETERS

A) MIXTURE FLOW

Q1 Q2

MIXTURE FLOW (m3/h)


4.4.3 3 FLAME TREATMENT MAIN FLAME TREATMENT MAIN PROCESS PARAMETERSPROCESS PARAMETERSTREATMENT LEVEL vs. MIXTURE FLOW CURVES

(AT DIFFERENT LINE SPEEDS)

38

40

42

44

46

48

50

52

54

10 20 30 40 50 60 70 80 90 100

MIXTURE FLOW [Nmc/h per burner meter]

v 150m/min

v 200m/min

v 250m/min

v 300m/min



TREATMENT LEVEL vs. MIXTURE FLOW CURVES

(AT DIFFERENT LINE SPEEDS)

38

40

42

44

46

48

50

52

54

40 50 60 70 80 90 100 110 120 130 140

MIXTURE FLOW [Nmc/h per burner meter]

v 350m/min

v 400m/min

v 450m/min

v 500m/min



f = EQUIVALENCE

RATIO

B) MIXTURE COMPOSITION

l = LAMBDA =

= 1 / f





TREATMENT LEVEL vs. JONO TEMPERATURE CURVE (Qmix = 48m3/h*m; gap

4.0mm; s 160m/min; H2O roll = 27°C)

303540455055

810 820 830 840

Jono temperature [°C]

Tre

atm

en

t L

ev

el

[d

yn

es/c

m]



Lambda value vs. Room Temperature

at different relative humidity values.Natural Gas combustion (d=0.59).

Stoichiometric at 20°C; H% = 0

0,4

0,5

0,6

0,7

0,8

0,9

1

1,1

0 10 20 30 40 50 60 70 80 90 100

Room Temperature [°C]

RH 0%

RH 25%

RH 50%

RH 75%

RH 100%



C) AIR GAP

AIR GAP OPTIMIZATION CURVE (METHANE 2.5 GAS;

MIXTURE LAMBDA 1.028; GRID TYPE 0)

2,5

3

3,5

4

4,5

5

1000 1500 2000 2500 3000

OUTPUT MIXTURE SPEED [m/h]

AIR

GA

P [

mm

]



FLAME TEMPERATURE vs. AIR GAP at different mixture compositions

1290

1300

1310

1320

1330

1340

1350

2 3 4 5 6 7 8

AIR GAP [mm]

LAMBDA 1.000LAMBDA 1.050LAMBDA 0.950



D) TREATER ROLL TEMPERATURE

P =KA DT ; [W/m]

K [W/(m2/°C)]

A [m2] ; DT [°C]

1/K =S / (A´lm) + 1/h +Rd


5.5.11 FLAME TREATMENT APPLICATIONSFLAME TREATMENT APPLICATIONS

•

••

•••

••

•••

••

•••

•• • • •• • •• ••• • • •• • •• ••

• • • •• • •• ••• • • •• • •• ••

•

••

• • • •

• • • •

Anti-blocking particles (mineral or polymer)

Slip agents – Amides

Anti-static – Tertiary Ethoxilated Amines

Anti-static – GMS

Layer “C” – Heat Seal

Layer “A” – Heat Seal / Conversion

Layer “B” – PP Structural

•

BOPP Films for Printing and Lamination



Flame treated. Slow peeling.

Corona treated. Fast peeling. Flame treated. Fast peeling.

NO ADHESION PROMOTERCorona treated. Slow peeling.




CORONA TREATED




FLAME TREATED



5.5.55 FLAME TREATMENT APPLICATIONS FLAME TREATMENT APPLICATIONS

•• • •Anti-blocking particles

Layer “C” – Heat Seal

Layer “A” – Al deposition receptive

Layer “B” –PP Structural

Al layer (deposition under vacuum)

•

Metallized Coex films


5.5.6 6 FLAME TREATMENT APPLICATIONSFLAME TREATMENT APPLICATIONS







TargetsEffective treatment at high line speeds, with little impact in heat seal initiation temperature (SIT),

on optical properties and flatness

Results Treated film UT/UT sealing temp= Untreat UT/UT;UT/T and T/T sealing temp. max 10°C > UT/UT .

UT = untreated; T = treated .

Sealable Coex films



363.977.587.1147414.8454.8Seal Str.[N]

NYYv.littleNNCurling

NYYLightNNFilm aspect

(stripes)

424443424141Dynes/cm

192619261919Roll Temp.[°C]

325325325325325325Speed [m/min]

815825815815815815T Jono [°C]

2.532.82.52.52.5Gap [mm]

283936282725Mixt. [m3/h*m]

654321

Sealable Coex films



SEALING STRENGHT vs. FLAME TREATMENT PARAMETERS

454,8414,8

14787,1 77,5

363,9

0

50

100

150

200

250

300

350

400

450

500

45 48 50 65 70 50

Mixture flow values [Nm3/h]

Sealable Coex films



White Opaque films / Synthetic Paper

Targets

Effective treatment at high line speeds, with little on optical properties and flatness

ResultsTreatment level up to 44 dynes/cm at 450m/min without problems as stripes along film width and

curling effect



0/10/11/211/2Curling

10/121/22/3 Film aspect

(stripes)

44 42 46 4250Dynes/cm

1616202020Roll Temp.[°C]

280280280280280Speed [m/min]

820820815815815T Jono [°C]

2.82.52.82.53.3Gap [mm]

3530403550Mixt. [m3/h*m]

54321

White Opaque films / Synthetic Paper



esseCI SRL PILOT PLANT


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FLAME TREATMENT FLAME TREATMENT TECHNOLOGY AND …€¦ · AIMCAL FALL CONFERENCE - MYRTLE BEACH - SC - USA - 19 October 2005 11/10/2005 1 FLAME TREATMENT FLAME TREATMENT TECHNOLOGY