A NFM/WE extruder replaces a full array of equipment-typically, three large tanks for coagulation and washing, a mechanical dewatering stage, and an evaporative drying stage, and may eliminate the need for a thermal dryer.

Extruder screws transfer material from one process stage to another, thus eliminating slurry pumps and preventing fouling from non-wiped surfaces.

The complete line can be started up or shut down in one half hour. Product can be changed in one half hour compared to conventional systems that can require several hours.

All waste streams are fully contained. A short fluid bed conveyor can replace large apron dryers.

A small amount of solid latex particles are removed in the effluent water. These particles can easily be screened out and recycled back to the extruder resulting in reduced solids loss.

The amount of water required to wash the polymer is significantly reduced due to the small wash stage volume of the extruder and high water flow rate. Reduced waste water volume lowers waste treatment requirements and fewer potential emissions.

An optional Turbulator cutter can be incorporated to cut rubber crumb and airvey the crumb to an optional apron dryer. The airveying technique allows easy transport of the crumb between the extruder and the apron dryer.

The airveying technique is also resistant to the accumulation of fines, resulting from all surfaces of the tube being exposed to the high velocity air. This effect makes it possible to airvey material directly from the Turbulator for distances of as much as 75 meters to an apron dryer without contamination problems.

The NFM/WE process converts polymers from emulsion to crumb in less than two minutes. Wash water temperature and flow rates are used to control temperature, this technique has proven to be extremely reliable.

Hot air drying stages that can degrade the product are eliminated. Sticky, low molecular weight materials that cause contamination and dryer fires are easily dried in this process.

Coagulation tanks, wash tanks, transfer piping, and most hot air dryers tend to accumulate material which leads to product yield loss. The surface area of the extruder is frequently wiped by the screws, which allows rapid purge times and reduced chance of contamination.

20-80 Mooney Viscosity.

10% and higher.

Temperature of the material is controlled by steam and water injection rate to achieve desired devolatilization without degrading the polymer. Material temperature can be controlled between 130° and 200°C. depending on screw speed, throughput rate, wash rates, and temperatures.