Title of Invention

A METHOD AND AN APPARATUS FOR THE PELLETIZATION OF PLASTICS AND/OR POLYMERS

Abstract A method for the pelletization of plastics and/or polymers, wherein a melt coming from a melt generator (26, 27) is supplied via a diverter valve (1) having different operating positions to a plurality of pelletizing heads (24, 25, 34) through which the melt is pelletized, characterized in that pelletizing heads (24, 25, 34) having different throughput capacities are used sequentially for the start-up of the pelletizing process, wherein the melt is first supplied to a first pelletizing head (24) having a smaller throughput capacity and then the melt volume flow is increased, the diverter valve (1) is switched over and the melt is diverted by the diverter valve (1) to the second pelletizing head (25) having a larger throughput capacity.
Full Text A method and an apparatus for the pelletization of plastics and/or polymers
The present invention relates to a method for the pelletization of plastics and/or
polymers, wherein a melt coming from a melt generator is supplied via a diverter
valve having different operating positions to a plurality of pelletizing heads through
which the melt is pelletized. The invention furthermore relates to a pelletizing
apparatus for the pelletization of plastics and/or polymers having a diverter valve
which has at least one melt generator connection, at least two pelletizer
connections as well as a switching gate for selectively connecting the melt
generator connection to at least one of the pelletizer connections, with a respective
pelletizing head being connected to the at least two pelletizer connections and a
melt generator having a variable melt volume flow being connected to the melt
generator connection. Finally, the invention also relates to a diverter valve for such
a pelletizing apparatus having a melt generator connection, a pelletizer connection
as well as a melt passage for the connection of the melt generator connection to the
pelletizer connection.
As a rule, diverter valves via which the pelletizer is connected to the melt generator
are used for the start-up of pelletizer devices. This in particular applies to complex

production processes whose start-up procedure is difficult as well as to applications
in which uniform pellets should be generated as rapidly as possible. Diverter valves
of this type are described, for example, in DE 102 34 228 A1; DE 38 15 897 C2 or
EP 0 698 461 B1. These diverter valves comprise, in the melt passage which
connects the inlet opening of the valve at the melt generator connection to the
outlet opening at the pelletizer connection, a diverter gate which interconnects the
connection of the melt generator connection to the pelletizer connection in the
production position, whereas it keeps the melt flow away from the outlet opening at
the pelletizer connection in its start-up position, i.e. it blocks it and diverts the melt
loss so that the melt flow entering at the melt generator connection does not move
to the pelletizer connection, but instead exits at a bypass opening of the valve and
as a rule simply flows onto the floor. If the pelletizer device has started up so that all
the units are working with the desired operating parameters and the melt flow has
reached the desired quality, the diverter gate is switched over to its production
position so that the melt flow in the diverter valve flows to its pelletizer connection
and is then processed to pellets by the pelletizer connected there.
The start-up phase of a production process can admittedly be effected per se in a
satisfactory manner using such known diverter valves; however, problems occur on
the changing from one production process to a second production process, for
example on a change of the polymer/filler mixture, on a change of the pellet
geometry, on a changeover to changed throughput demands, on a change in the
color of the pellets or also on scheduled or unscheduled production interruptions
e.g. for repairs to the nozzle plate. The problem which results in this process is that
the total diverter valve, including the melt passage in the interior of the valve, has to
be cleaned completely before the plant can be started up again. Without such a
cleaning, contaminations of long duration would occur, for example on the
changeover from colored pellets to white pellets. Conventional diverter valves have
to be dismantled for cleaning as a rule, whereby the production process is
interrupted for a longer duration. Moreover, subsequent to the cleaning, the fitting
time has to be taken into account which is needed, for example, for the heating of
the diverter gate to operating temperature.

The possible alternative of having two separate diverter valves available for such
changes between two production processes is not acceptable for a number of
operators of such plant. On the one hand, the costs for two complete diverter valves
are incurred. Apart from this, time delays also occur on the use of two separate
diverter valves, e.g. due to the ramping up of the new diverter valve to operating
temperature.
Furthermore, DE 696 21 101 T2 describes the possibility of viscosity change within
a compounding process with subsequent pelletization in a corresponding large-
production plant having a performance of at least 1000 kg/h. Two pelletizer heads
are connected to the valve connected downstream of the melt generator so that
highly viscose material can be given to the one pelletizing head and low-viscose
material can be given to the other pelletizing head by switching over the valve. The
problems of the start-up losses are, however, not solved in this process; it is rather
the case that material not yet pelletizable should be discharged via a bypass
opening in a manner known per se up to the reaching of the respective operating
point. Furthermore, a pelletizing apparatus is described in DE 197 54 863 C2 in
which two pelletizing heads are connected to a 1/3 valve so that, on a color change
from black material to white material or vice versa, the one or the other pelletizing
head can selectively be selected. To so-to-say flush out color contaminations on a
color change in this process, a central bypass outlet is provided in the valve via
which material of the new color is discharged for so long after a change of color in
the melt generator until even the last contaminants have been taken along. This is
more counter-productive than helpful with respect to the aforesaid objective of
reducing start-up losses and of decreasing expensive material waste. Finally, a
multiway rotary valve for pelletizing plant is known from DE 100 30 584 with whose
help its high molecular plastic melts can be distributed or split up. The problems of
the start-up losses are, however, also not addressed in this reference.
With a customary design of an underwater pelletizing plant, the start-up losses
which occur and the corresponding material loss are definitely cost intensive. In

particular with polymers or plastics sensitive to freezing, e.g. products with a high
crystallite melting point, it is necessary to start and to operate at a minimal
throughput of more than 10 kg/h per nozzle bore. After the actual starting process,
the subsequent throughput increase is unproblematic as a rule. However, material
losses arise due to the starting process itself due to start-up product in block form
on the floor which can easily amount to several kilograms. This is not only
uneconomical because the expensive raw materials are transferred in a non-
sellable form, but is also unpleasant for the operator of a corresponding production
plant since the blocks can turn out relatively large and have to be reduced to small
particles in an expensive process and finally have to be disposed of. Such a hot
melting block having temperatures of, optionally, more than 250°C, and discharged
via the bypass outlet of the diverter valve not least also represents a potential
safety risk. The problems of the discharge of plastic melt via the bypass outlet does
not only occur in the actual start-up of a corresponding production plant for a new
production job, but also when, for whatever different reasons, the plant has to be
operated out of the throughput window of the pelletizing head, in particular when
the melt volume flow has to be operated below the lower capacity limit of the
respective pelletizer head. Here, too, the diverter valve sometimes has to be
switched into the bypass position so that corresponding material waste arises.
It is therefore the underlying object of the present invention to provide an improved
pelletizing method as well as a diverter valve of the named kind which avoids
disadvantages of the prior art and further develops it in an advantageous manner.
Preferably, a ramping up of the pelletizing should be achieved with start-up losses
which are as low as possible and also an operation should be achieved which is as
continuous as possible without intermediate interruptions of the process and restart-
up losses.
This object is solved in accordance with the invention by a method in accordance
with claim 1 as well as an apparatus in accordance with claim 10 and a diverter
valve in accordance with claim 30. Preferred configurations of the invention are the
subject of the dependent claims.

The present invention therefore starts from the idea of using a plurality of pelletizing
heads with different passage capacities and of hereby enlarging the throughput
windows to be able to work largely continuously without intermediate interruptions
and to shorten unavoidable start-up processes by switching in pelletizing heads
having small throughput capacities or to minimize them with respect to the start-up
products which occur. In accordance with an aspect of the present invention, a
plurality of pelletizing heads having different throughput capacities are used
sequentially for the start-up of the pelletizing process, with the melt first being
supplied to a first pelletizing head having a smaller throughput capacity and then
the melt volume flow being increased and the diverter valve being switched over
such that the melt is diverted by the diverter valve to a second pelletizing head
having a larger throughput capacity. The time and thus the amount of the start-up
product until the melt generator reaches the lower throughput limit of the pelletizing
head and the pelletizing process can be started are cut by the use of initially one
pelletizing head having a throughput capacity which is as low as possible. No
further start-up product is incurred from the start onwards of the pelletizing process
at the lower throughput limit of the said first pelletizing head. The melt volume flow
is increased quantitatively for so long until the diverter valve can be switched to the
second pelletizing head having the larger throughput capacity with no start-up
product being incurred during this time period. Moreover, the throughput window is
enlarged in total so that the number of unavoidable start-up procedures with start-
up product arising therein is reduced since it is possible, on a ramping down of the
melting performance below the lower throughput limit of the larger pelletizing head
which may become necessary for various reasons, to switch back to the first
pelletizing head.
In a technical apparatus respect, it is proposed in accordance with an aspect of the
present invention that the pelletizing apparatus of the initially named kind has a
control apparatus for the control of the switching gate of the diverter valve in
dependence on the melt volume flow of the melt generator. The diverter valve can
be switched to the pelletizing head having the smaller passage capacity with a

small melt volume flow by means of this control apparatus, whereas the diverter
valve is switched to the second pelletizing head having the larger throughput
capacity with a larger melt volume flow. A considerable increase in efficiency can
already be achieved by such a control apparatus, independently of the aforesaid
start-up process, in that the throughput window of the apparatus is enlarged and it
is possible to work over a larger operating range without interruptions so that fewer
start-up processes become necessary. In this connection, the control apparatus can
generally realize different degrees of automation, for example, be configured semi-
automatically such that it emits an indication on the reaching of a melt volume flow
which permits an operation of the second pelletizing head having the larger
throughput capacity, said indication drawing the attention of a plant operator thereto
and such that, after a corresponding input by the plant operator, the diverter valve
then switching in the aforesaid manner to the second pelletizing head having the
larger throughput capacity so that the melt flow is diverted from the first pelletizing
head to the second pelletizing head. The control apparatus can also be configured
to be fully automatic in a particularly advantageous manner such that it
automatically switches the diverter valve to the respectively matching pelletizing
head on the determination of a corresponding melt volume flow.
In a further development of the invention, the control apparatus can in particular
have control means which switch the diverter valve to the first pelletizing head
having a smaller throughput capacity when the melt volume flow is below a lower
capacity limit of the second pelletizing head having a larger throughput capacity, but
above a lower capacity limit of the first pelletizing head and which switch the
diverter valve to the second pelletizing head when the melt volume flow is above
the lower capacity limit of the second pelletizing limit and still below a lower
capacity limit of an optionally present third pelletizing head having an even larger
throughput capacity.
The control apparatus can advantageously also have volume flow control means for
the control of the volume flow which is directed into the diverter valve by the melt
generator. Generally, in this process, different melt producers with variable volume

flow can be used; for example, the melt flow can then be generated via a
corresponding screw extruder and simultaneously be varied with respect to its
volume. Optionally, however, a gear pump can also be interposed between the melt
generator and the diverter valve to control the volume flow accordingly. To be able
to adapt the process in as variable a manner as possible to different conditions, the
control apparatus is advantageously configured such that it can vary, preferably
continuously vary, the volume flow, also within the capacity limits of a pelletizing
head.
The melt volume flow can in particular be continuously increased within the
throughput capacity limits of the first pelletizing head on the start-up of the
pelletizing process on the pelletizing with the first pelletizing head having a smaller
throughput capacity, i.e. still before the switching over of the diverter valve to the
second pelletizing head. Since pelletizing is already taking place with the first
pelletizing head, no start-up product is incurred, with the plant being moved
continuously to the pelletizing process having the second, larger pelletizing head
due to the increase of the melt volume flow.
The diverter valve is advantageously only switched over to the second pelletizer
head when the melt volume flow has been increased up to the lower capacity limit
of the second pelletizing head and/or the upper capacity limit of the first pelletizing
head.
Generally, the diverter valve can be switched to the first pelletizing head on the
start-up of the pelletizing plant from its bypass position in which start-up product is
directed to the floor or to a suitable storage container when the minimal conditions
for a successful start have been reached. The diverter valve can in particular be
switched from the start-up position to the first pelletizing head in a further
development of the invention in dependence on the melt viscosity, on the mass
temperature, on the mass pressure, the degassing state and/or the reaching of the
required minimal volume flow. Corresponding means for the determination can
advantageously be provided in a technical apparatus respect, preferably sensors

for the detection of the said parameters, so that the control apparatus can switch
the diverter valve accordingly in dependence on the corresponding signals. Instead
of corresponding sensors, the said parameters can also be estimated. In addition to
the said parameters, even further parameters such as the color, filler induction or
further melt parameters or pelletizing parameters can be taken into account for the
switching over of the diverter valve to the first pelletizing head.
In a similar manner, the switching over of the diverter valve from the first pelletizing
head to the second pelletizing head or from the nth pelletizing head to the n+1th
pelletizing head can also take place not only in dependence on the reaching of the
required minimal volume flow for the second or n+1th pelletizing head, but
alternatively or additionally thereto in dependence on further parameters. The
diverter valve can in particular be switched from the first pelletizing head to the
second pelletizing head in dependence on the pellet size, the melt mass pressure,
the mass temperature of the melt or further parameters such as the pellet shape,
surface tackiness, agglomeration, occurrence of double grains, crystallization
effects, etc. If, for example, no further upward latitude is given on the reaching of
the maximally possible pelletizer speed in the first pelletizing head, so that the
correct pellet size can only be maintained or can only be reached again by
switching over to the next pelletizer, the diverter valve can be switched over to the
larger pelletizing head. Alternatively or additionally, this switchover can be carried
out when the mass pressure of the melt rises above a corresponding limit value.
When throughput performances are increased, the head pressure usually also
increases, which can be restrictive with some products since damage due to
shearing based on the pressure can occur. As a consequence thereof, the mass
temperature of the melt can also increase too pronouncedly, whereby similar
consequences occur. A switchover can also be a remedy here. When the pellet
shape is taken into account, a critical deformation of the pellets which arises on the
increase of the volume flow per bore can e.g. be used as the criterion. A switchover
to the larger pelletizing head can also help here in dependence on the sensitivity of
the material produced and on the demands on the pellet quality. Other secondary
switchover necessities can moreover be derived from the pellet size which are,

however, ultimately correlated with the grain size of the pellets, namely the surface
tackiness, the agglomeration, double-grain, different crystallization effects based on
a different size and temperature of the pellets and the like.
To achieve a throughput window, and thus operating window, which is as wide as
possible with as few pelletizing heads as possible, but simultaneously to ensure a
switchover of the melt processing which is as free of problems as possible from the
one pelletizing head to the other pelletizing head, the pelletizing heads connected
to the diverter valve have mutually complementary throughput capacity ranges,
preferably throughput capacity ranges seamlessly adjoining one another.
Optionally, the capacity ranges could also overlap, with it, however, nevertheless
applying overall for the increase of the throughput window that the throughput
capacity region defined by both pelletizing heads is larger than that of only one
pelletizing head. A maximal utilization of each capacity range can be achieved by a
configuration of the pelletizing heads such that their capacity ranges seamlessly
adjoin one another. For example, when the pelletizing apparatus is configured for
the pelletizing for PET, a first pelletizing head having a throughput performance
span from 2500 kg/h up to 4500 kg/h, a second pelletizing head having a
throughput capacity of 4500 kg/h up to 7500 kg/h and a third pelletizing head
having a throughput capacity of 7500 kg/h up to 12,500 kg/h can be used. It is
understood that the capacity limits can be selected differently, with them
advantageously seamlessly complementing one another in a corresponding
manner, however.
Generally, the pelletizing heads can be configured for different pelletizing
processes. In accordance with an advantageous embodiment of the invention, the
pelletizing heads can form underwater pelletizing heads. Alternatively, the
pelletizing heads can also form extrusion pelletizing heads or water ring pelletizing
heads.
In an advantageous further development of the invention, all the pelletizing heads
are of the same type, for example underwater pelletizing heads.

In an alternative configuration of the invention, however, the pelletizing heads can
also realize different pelletizing types; for example, the pelletizing head having a
smaller throughput capacity can be an underwater pelletizing head, whereas the
pelletizing head having a larger throughput performance is an extrusion pelletizing
head.
The diverter valve is advantageously configured such that a diversion of the melt
flow from one pelletizing head to the next pelletizing head is made possible which is
as rapid and as free of interruption as possible.
The bidirectionally operable diverter valve for different process stages preferably
has different flow paths for the melt so that the diverter valve for a first process
stage can be operated with a first flow path and can selectively be operated for a
second process stage via a second flow path. It can selectively output the melt via a
first or a second pelletizer connection. The respective other, not operated, flow path
or pelletizer connection can simultaneously be cleaned for production via the flow
path in operation so that down times occurring hereby are omitted. The flow path or
pelletizer connection not in operation nevertheless remains at temperature since
the heat introduced by the melt naturally also heats up the non-operated part of the
diverter valve.
In accordance with an advantageous embodiment of the present invention, the
diverter valve can largely realize the plurality of production paths starting from only
one melt generator connection. In accordance with this embodiment of the
invention, the diverter valve has, in addition to the first pelletizer connection, a
second pelletizer connection which can be connected to the same melt producer
connection as the first pelletizer connection. To be able to allow the melt flow to be
discharged selectively via the first pelletizer connection or the second pelletizer
connection, the diverter valve has a switching gate which connects the melt
generator connection to the first pelletizer connection in a first production position

and connects the said melt generator connection to the second pelletizer
connection in a second production position.
The polymer melt can hereby quickly be diverted to one of the two nozzle
geometries installed at the pelletizer connections. The respective other nozzle
geometry is so-to-say in stand-by and is not used. A switchover between the two
possible production devices can be carried out in seconds by actuation of the
switching gate.
In a further development of the invention, a diverter gate can be provided in the
melt passage selectively connecting the melt producer connection to one of the two
pelletizer connections, said diverter gate switching the melt passage through to the
respective pelletizer connection in its production position, whereas it diverts the
melt flow in its start-up position and gives it to a bypass opening.
The aforesaid switching gate for the switchover between the production directions
and the diverter gate for the start-up process can generally be made separate from
one another. In a further development of the invention, however, they are coupled
to one another, are in particular formed by a common valve body and are actuable
by a common valve actuator.
In a further development of the invention, the diverter valve can also have a third or
a further pelletizer connection, which can be connected to the melt passage, in
addition to the first and second pelletizer connections. In this connection, the
switching gate is preferably configured such that it connects the third pelletizer
connection to the melt generator connection in a third production position.
Accordingly, the diverter valve can even switch over between more than two
production directions.
In accordance with an aspect of the present invention, the diverter valve has a
second production path made completely separate from the first production path. In
addition to the first melt generator connection, to the first pelletizer connection and

to the first melt passage for the connection of the said first melt generator
connection and the pelletizer connection, the valve in accordance with this
embodiment has a second pelletizer connection as well as a second melt generator
connection which can be connected to one another by a second melt passage. In
this option, the change from a first production process to a second production
process can advantageously take place particularly fast in that the initially used melt
connection and pelletizer connection are released by means of quick-closing
couplings and the diverter valve with the second melt connection and pelletizer
connection and corresponding quick-couplings is again installed between the melt
generator and the pelletizer after a minimal mechanical conversion and a
corresponding rotation of the diverter valve itself. The second melt passage is in the
cleaned state, on the one hand, and is already pre-heated by the preceding
production process, on the other hand, so that the new production process can be
started quickly.
In this connection, a diverter gate is provided in the said first melt passage and in
the said second melt passage and switches through the respective melt passage in
a production position so that the melt flow can flow from the inlet opening of the
respective melt generator connection to the outlet opening of the associated
pelletizer connection and diverts the melt flow in a start-up position, i.e. blocks the
respective pelletizer connection and directs the melt flow to a bypass opening so
that the start-up procedure can take place in a manner known per se for the new
production process.
In this connection, the diverter gate of the first melt passage and the diverter gate of
the second melt passage are advantageously realized in a common valve member
and can be actuated by a common valve actuator. Only a control mimicry is hereby
required for the switchover from the start-up position to the production position of
both production paths. The corresponding components such as the valve actuator,
the control electronics, etc. can be dispensed with with respect to the use of two
separate diverter valves so that this solution is characterized by its cost efficiency.

Switch-through passages both for the first melt passage and for the second melt
passage and corresponding bypass passages are provided in the valve member for
the diversion of the melt flow of the first melt passage and of the melt flow of the
second melt passage to a bypass opening in each case.
The diverter gates formed by the valve member are advantageously configured
such that both diverter gates are simultaneously in their production position and
simultaneously in their start-up position. When both production paths of the diverter
valve are used simultaneously, the corresponding production processes can hereby
be started up simultaneously. If only one of the two production paths of the diverter
valve is used, the non-used production path is open in a throughgoing manner so
that it can be cleaned completely while the other production path is being used.
The invention will be explained in more detail in the following with reference to
preferred embodiments and to associated drawings. There are shown in the
drawings:
Figure 1: a perspective overall view of a diverter valve having two melt generator
connections with corresponding inlet openings and two pelletizer
connections with corresponding outlet openings;
Figure 2: a side view of the diverter valve of Fig. 1 which shows a plan view of one
of the melt generator connections;
Figure 3: a side view of the diverter valve of Fig. 1 which shows a plan view of one
of the pelletizer connections;
Figure 4: a section along the line C-C in Figure 3;
Figure 5: a section along the line D-D in Figure 2;
Figure 6: a section along the line B-B in Figure 2;

Figure 7: a section along the line A-A in Figure 3;
Figures 8 to
Figure 13; side views and sectional views of the diverter valve of Figure 1
corresponding to the Figures 2 to 7, with the diverter valve in Figures 8 to
13 not being shown with its diverter gate in the production position, but is
shown in the bypass position or start-up position in which the melt is not
yet being directed to the pelletizer connections, but to the floor;
Figure 14: a side view of a diverter valve having two pelletizer connections, but only
one melt generator connection, with the side view showing a plan view of
one of the two pelletizer connections;
Figure 15: a section along the line A-A in Figure 14 which shows the diverter gate
and switching gate of the valve in its bypass position in which the melt
generator connection is connected to neither of the two pelletizer
connections, but to a bypass opening;
Figure 16: a section of the diverter valve of Figure 14 similar to Figure 15, but with
the switching gate and diverter gate being shown in a first production
position in which the melt generator connection is connected to a first
pelletizer connection;
Figure 17: a section of the diverter valve of Figure 14 similar to the Figures 15 and
16, but with the switching gate and diverter gate being shown in a
second production position in which the melt generator connection is in
communication with the second pelletizer connection;
Figure 18: a schematic representation of an underwater pelletizing apparatus
having a diverter valve in accordance with Figures 14 to 17 to which two
pelletizing heads having different throughput capacities are connected;

Figure 19: a sectionally enlarged representation of the diverter valve of the
pelletizer apparatus of Figure 18, with the start-up position of the valve
being shown in the view a) and one of the two production positions of the
diverter valve being showing in the representation b);
Figure 20: a schematic representation of the melt flows and pelletization capacities
settable by the diverter valve from the preceding Figures; and
Figure 21: a schematic representation of a diverter valve in accordance with an
alternative embodiment of the invention in which three pelletizing heads
having respectively different throughput capacities are connected so that
the melt entering into the inlet of the diverter valve can be selectively
directed to one of the three pelletizing heads or to a bypass line.
The diverter valve 1 shown in Figure 1 has a valve housing 2 at whose outer side a
first melt generator connection 3 as well as a second melt generator connection 4
as well as furthermore a first pelletizer connection 5 and a second pelletizer
connection 6 are provided. As Figure 1 shows, the connections 3 to 6 are
distributed over the periphery of the valve housing 4 and are arranged on
respective oppositely disposed sides. The first melt generator connection 3 is
disposed opposite the first pelletizer connection 5, whereas the second melt
generator connection 4 is disposed opposite the second pelletizer connection 6.
The melt generator connection and the pelletizer connection can be brought into
flow communication with one another. For this purpose, a first melt passage 7 (cf.
Figures 1 and 5) is provided in the interior of the valve housing 2 through which the
first melt generator connection 3 can be connected to the first pelletizer connection
5 and a second melt passage 8 (cf. Figures 4 and 6) is provided through which the
second melt generator connection 4 can be connected to the second pelletizer
connection 6. The melt passages 7 and 8 communicate in this connection with
corresponding inlet openings 10 and 11 at the two melt generator connections 3

and 4 and to corresponding outlet openings 12 and 13 at the pelletizer connections
5 and 6.
The two melt passages 7 and 8 having the respective associated first melt
generator connection and pelletizer connection 3 and 5 or the second melt
generator connection and pelletizer connection 4 and 6 form mutually independent
and separately operable production directions. The flow path for the melt through
the one melt passage has no overlap with the flow path through the second melt
passage. The two melt passages are only linked to one another to the extent that a
common diverter valve is provided for both melt passages, as will still be explained.
As Figures 1, 2 and 3 show, the matching first melt generator connection and
pelletizer connection 3 and 5 together with the first melt passage 7 connecting them
vertically offset with respect to the likewise matching second melt generator
connection and pelletizer connection 4 and 6 and the associated second melt
passage 8. The first melt passage 7 between the first melt generator connection
and pelletizer connection 3 and 5 extends above the second melt passage 8
between the second melt generator connection and pelletizer connection 4 and 6
and beyond them. It is understood that other arrangements are also possible here,
e.g. the four connections 3 - 6 could generally be arranged at the same vertical
level and the melt passages could, for example, extend beyond one another by an
arcuate extension. The embodiments shown in the Figures are, however,
characterized by their simple manufacturing capability based on the straight extent
of the melt passages 7 and 8.
In the interior of the valve housing or valve body 2, a diverter gate 14 is provided
which is associated with the two melt passages 7 and 8 and can divert the melt flow
in each of the melt passages 7 and 8 to a bypass opening for the start-up process.
The diverter gate 14 in the drawn embodiment comprises a substantially cylindrical
valve gate 15 which is longitudinally displaceably received in a valve bore which
extends vertically in the drawn embodiment and which extends transversely to the
longitudinal axes of the melt passages 7 and 8. It is understood that the valve gate
15 could optionally also be configured as a rotary slide which is not actuated by

axial longitudinal displacement, but by rotation around its longitudinal axis. Further
valve principles are possible.
As Figures 1 to 5 show, the valve gate 15 is actuated by a valve actuator 16 which
is arranged on the upper side of the valve housing 2 and is controlled by an
electronic control unit 17. The valve actuator 16 can realize different operative
principles, e.g. work electromagnetically or hydraulically or pneumatically. It effects
the adjustment of the valve gate 15 between its production position and its start-up
position or bypass position.
In the production position shown in Figures 5 to 7 of the valve gate 15, it switches
through the two melt passages 7 and 8, i.e. the melt flow entering at the respective
inlet openings 10 and 11 at the melt generator connections 3 and 4 is directed
through the melt passages 7 and 8 beyond the valve gate 15 to the associated
outlet openings 12 and 13 of the pelletizer connections 5 and 6. As Figures 4 to 7
show, the melt passages 7 and 8 each open onto the valve bore into which the
valve gate 15 is inserted. Two production passages 18 and 19 are provided in the
valve gate 15 and continue the melt passages 7 and 8 so-to-say in the position of
the valve gate 16 shown in Figures 5 to 7.
If the valve gate 15 is moved with the help of the valve actuator 16 from the
production position shown in Figures 5 to 7 into the start-up position shown in
Figures 8 to 13, the valve gate 15 blocks the communication of the inlet openings
10 and 11 at the melt generator connections 3 and 4 with the outlet openings 12
and 13 at the pelletizer connections 5 and 6. The valve gate 15 diverts the melt flow
entering at the inlet opening 10 and/or at the inlet opening 11 to a bypass opening
so that the melt flow is directed to the floor on start-up. For this purpose, the valve
gate 15 has to bypass passages 20 and 21 which are in flow communication with
the melt passages 7 and 8, more precisely with their sections originating from the
inlet openings 10 and 11 in the start-up position of the valve gate 15 shown in
Figures 9 to 14 and so-to-say pick up the melt flow coming from there. At the other
end, the two bypass passages 20 and 21 open into bypass outlet openings in the

end face of the valve gage 15 whose lower end face is in communication with the
outer side of the valve housing 2.
In particular two use possibilities present themselves for the diverter valve 1 shown
in Figures 1 to 13. On the one hand, the diverter valve 1 can be used with in each
case only one of the melt generator connections 3 and 4 and with only one of the
pelletizer connections 5 and 6 at a defined point in time. That is, only one of the two
production directions is used, whereas the other production direction, i.e. the other
pair of melt generator and pelletizer connections remains unused and is kept so-to-
say on stand-by. If the correspondingly running production process should be
interrupted and a new production process started, the diverter valve is released
from the respective melt generator and pelletizer via quick-closing couplings. The
valve is rotated through 90° and then installed at the melt generator and at the
pelletizer for the production process to be started using the previously unused melt
generator connection and pelletizer connection. This new production process can
be started in a manner known per se in that first the diverter gate 14 is moved to its
start-up position in accordance with Figures 8 to 13 so that the melt drops to the
floor during the start-up procedure. Once the plant has been started up, the diverter
gate 14 is moved into its production position in accordance with Figures 2 to 7 so
that the new melt flow is guided from the pelletizer beyond the diverter gate to the
connected pelletizer. The changeover times are hereby minimized. Time is above
all saved for the cleaning of the diverter valve. The cleaning of the previously used
production passage can take place after the valve with the fresh production
passage has been connected and the new production process is already running. It
is moreover advantageous that the diverter valve is already at least approximately
at operating temperature since it was still heated from the previously interrupted
production process.
On the other hand, the diverter valve 1 described above also provides the option of
using both production passages simultaneously, i.e. of connecting both melt
generator connections 3 and 4 to one or more melt generators and equally to
connect the two pelletizer connections 5 and 6 to two pelletizers simultaneously.

The previously described configuration of the diverter gate 14 ensures in this
process that initially both production passages are switched to the start-up position,
i.e. both processes can be started up. A soon as both processes have started up,
the diverter gate 14 can be switched over to start both production processes.
Independently of whether the production processes are operated sequentially or
simultaneously, the diverter gate 1 advantageously provides the opportunity of
operating two production processes which are the same or also which are
completely different. For instance, pelletizing processes which are the same in each
case such as extrusion pelletizing or underwater pelletization can be operated via
the first melt generator connection and pelletizer connection 3 and 5 and via the
second melt generator connection and pelletizer connection 4 and 6, but also
different pelletizing processes can be operated, i.e. extrusion processing on the one
and underwater pelletization on the other. In this respect, the respectively required
nozzle plates can be used which can either have the same section geometry and
number of bores, the same section geometry and a different number of bores, a
different section geometry and the same number of bores or both a different section
geometry and a different number of bores or which can also realize one of these
possible combinations in different constructional sizes.
The second embodiment of the diverter valve 1 in accordance with Figures 14 to 17
substantially differs from the previously described first embodiment in that the
diverter valve has, instead of two melt generator connections, only one melt
generator connection 3 which can be selectively connected to the first pelletizer
connection 5 or the second pelletizer connection 6 or which can be connected to
the bypass opening in the start-up position of the valve. To the extent that the
diverter valve 1 in accordance with Figures 14 to 17 agrees with the previously
described embodiment, the same components are provided with the same
reference numerals and reference is made to this extent to the previous description.
As Figures 14 and 15 show, in this embodiment, the melt generator connection 3
and the two pelletizer connections 5 and 6 are arranged at the same level (cf.

Figure 14) and are in communication with one respective melt passage 7, 7a and
7b which extend in each case radially inwardly from the inlet opening 10 or the
outlet openings 12 and 13 and all three open in the valve bore in which the valve
gate 15 is received. The valve gate 15 of the diverter gate 14 is axially adjustable in
the previously described manner. It includes two production passages 18 and 19
(cf. Figures 16 and 17). In the first production position of the valve gate 15, which
Figure 16 shows, the diverter gate 14 switches the inlet opening 10 of the melt
generator connection 3 through to the outlet opening 12 of the first pelletizer
connection 5. The first production passage 18 continues the melt passage 7 coming
from the melt generator connection 3 to the section 7a of the melt passage in
communication with the first pelletizer connection 5 so that the melt flow entering
via the inlet opening 10 moves to the pelletizer installed at the first pelletizer
connection 5.
If the valve gate 15 moves into its second production position, which Figure 17
shows, the diverter gate 14 switches the first melt generator connection 3 to the
second pelletizer connection 6. The second production passage 19 in the valve
gate 15 continues the melt passage 7 coming from the inlet opening 10 to the
section 7b of the melt passage in communication with the second pelletizer
connection 6 so that the melt flow entering via the inlet opening 10 can move to the
pelletizer which is connected to the second pelletizer connection 6.
Furthermore, the valve gate 15 can be moved into a start-up position or a bypass
position, which Figure 15 shows. In this position, the valve gate 15 blocks both
pelletizer connections 5 and 6 and directs the melt flow entering via the inlet
opening 10 via the bypass passage 20 formed in the valve gate 15 to a bypass
opening which is provided at the end face at the lower end of the valve gate 15. The
melt can be directed to the floor in the previously described manner via this bypass
opening on the start-up of the plant.
In this second embodiment of the diverter valve 1, in each case only one of the two
outlet openings 12 and 13 are therefore served via a common inlet at a defined

point in time. The polymer melt entering via the inlet opening 10 is diverted to one
of the pelletizer connections, whereas the respective other is in stand-by and is
therefore not used. The switchover can take place in a matter of seconds by
actuation of the diverter gate 14.
In simple processes, the diverter gate 14 could also only have its two production
positions and could dispense with the bypass position and the corresponding
bypass passage 20. In this process, the so-called start-up product could then be
reshaped to pellets on the then smaller pelletizer, whereby the otherwise usually
large start-up positions would be completely dispensed with.
In particular the second embodiment of the diverter valve 1 can be used where
complex plant should be operated with units which are as small as possible and in
very restricted space. The switchover possibility during operation makes it possible
to avoid interruptions to a very large extent or to realize a very wide throughput
processing window on one production machine by a clever selection of the two
pelletizer heads.
Two pelletizing processes which are the same, that is, for example, extrusion
pelletization at both pelletizer connections 5 and 6 or also underwater pelletization
processes at both connections, can also be operated in this embodiment of the
diverter gate 1 via the two pelletizer connections 5 and 6. However, different
pelletization processes can also be operated, e.g. extrusion pelletization at the one
pelletizer connection and an underwater pelletization at the other pelletizer
connection. In any case, nozzle plates can be used at the two pelletizer
connections 5 and 6 which have the same section geometry and number of bores,
the same section geometry with a different number of bores, a different section
geometry with the same number of bores or a different number of bores. It is
understood that nozzle plates in different construction sizes can also be used with
each of these possibilities.

Interesting use possibilities in particular result when different pelletizer construction
sizes are used at the two pelletizer connections 5 and 6. The volume flow window
achievable with a machine can thus e.g. be considerably increased by different
nozzle plates. The loss quantity per start-up process can moreover be considerably
reduced, whereby less material loss arises overall which then has to be disposed of
or treated, on the one hand, and a faster start is achieved, on the other hand, which
means less personnel and less handling overall.
The described diverter valve 1 in accordance with Figures 14 to 17 is used in a
particularly advantageous manner in an underwater apparatus 23 as is shown in
Figure 18, with pelletizer heads 24 and 25 having different throughput capacities
advantageously being connected to the two pelletizer connections 5 and 6. As
Figure 18 shows, the melt supplied horizontally via an extruder 26 and/or via a gear
pump 27 is pressed via the diverter valve 1 through the radially arranged bores of
the nozzle plate 28 of one of the two pelletizing heads 24 or 25. The strands are cut
directly to pellets on discharge from the said nozzle plate 28 in the completely
flooded cutting chamber and are transported away by the water flow 29, with the
melt solidifying abruptly due to the high temperature difference to the process water
so that the spherical shape of the pellets characteristic for underwater pelletization
arises in dependence on the viscosity. As Figure 18 illustrates, the pellet/water
mixture exiting the cutting chamber of the respective pelletizing head 24 or 25 is
supplied by means of a transport line 30 to an agglomerate collector 31 which is
positioned upstream of a centrifugal drier 32.
When the plant is started up, the diverter gate 1, as first shown in Figure 19a, is
moved into its bypass position so that the melt flow is diverted to the floor. The melt
volume flow is continuously increased by a central control apparatus 33 by a
corresponding control of the extruder 26 and/or of the gear pump 28 until a lower
capacity limit of the first pelletizing head 24 having the smaller throughput capacity
is reached. As already mentioned, it is in particular necessary with polymers
sensitive to freezing, e.g. with products having a high crystallite melting point, to
start and to operate at a minimum throughput of, for example, more than 10 kg/h

per nozzle bore. It is also necessary to ramp up apparatus components, including
the diverter valve 1, to a predetermined minimum temperature which can be
material dependent.
As soon as the lower capacity limit of the named first pelletizing head 24 has been
reached and/or further operating parameters characteristic for the plant or
characteristic for the material have been reached, the control apparatus 33 controls
the diverter valve 1 such that the valve gate 15 is moved into its first production
position in which the melt is directed to the first pelletizing head 24. Figure 20
illustrates this smaller melt volume flow on the first pelletizing head 24 by the arrow
A.
As soon as the pelletization through the first pelletizing head 24 has started up, the
melt volume flow is further increased until the lower capacity limit of the second
pelletizing head 25 has been reached which is above the lower capacity limit of the
first pelletizing head 24 and is advantageously approximately in the range of the
upper capacity limit of the said first pelletizing head 24. The capacity ranges of the
named two pelletizing heads 24 and 25 preferably adjoin one another seamlessly or
a slight overlap can be provided. Once the melt volume flow has been ramped up to
the said lower capacity limit of the second pelletizing head 25, the control apparatus
33 controls the valve gate 15 into its second production position so that the volume
flow is diverted from the first pelletizing head 24 to the second pelletizing head 25 in
a matter of seconds.
Substantial increases in efficiency can be achieved and start-up losses can be
avoided by the start-up of the pelletization process of the second, larger pelletizing
head 25 with interposition of the pelletizing process via the first, smaller pelletizing
head 24.
The economic advantage should be illustrated by the following examples:
Example 1:

A pelletization for PP compounds starting from a double screw extruder having e.g.
150 bores in the nozzle plate and an assumed volume flow window of 10 kg/h and
bore up to 35 kg/h and bore normally processes between 1,500 kg/h and up to
5,250 kg/h. In this process, the cutting speed of the pelletizer is necessarily
feedback tracked by the factor of 3.5; one starts at 1,500 kg/h and 1,030 l/min of a
given blade combination and increases the blade speed in linear fashion to 3,600
l/min for 5,250 kg/h. The pellets generated in this manner then each have the same
weight. If a 2nd pelletizing head were now installed at this given machine having,
for example, 45 bores and the resulting capacity from 450 - 1,575 kg/h, the
production window increases to approximately factor 12. The same machine could
thus generate from 450 - 5,250 kg/h of high-quality pellets.
When the worst-case scenario is taken into account (approximately 3 minutes start-
up requirement up to the actual start with a minimum required throughput
performance), this means for the above case:
With a standard diverter valve:
3 minutes x 1,500 kg/h = 75 kg material losses, per start-up process.
With a bidirectional diverter valve, this would mean:
3 minutes x 450 kg/h = 22.5 kg material losses, per start-up process.
There is in addition the fact that the same production machine which requires 3
minutes for the manufacture of 1,500 kg, will reach the 450 kg/h substantially faster.
This can in turn reduce the start-up time to a third, which then means in sum:
54 seconds x 450 kg/h = 6.75 kg material losses, per start-up process
As documented in this example, this option of the invention therefore opens up a
reduction of the loss quantity per start-up process by a factor 11.11. For the
production facility, this means that, on the one hand, less material loss arises which
then has to be disposed of or treated and, on the other hand, a faster start is
permitted, which means less personnel and less handling overall (plastics have to

be sucked up and cooled on discharge from the diverter valve to the bottom = floor,
which naturally directly influences the operating costs).
With only one product change per day and raw material prices of €1.20/kg, this
means that €81.90 can be saved per day; this is an annual savings potential of
€29,839.50 p.a.
Example 2:
A pelletization for PET starting from a reactor having e.g. 250 bores in the nozzle
plate and an assumed volume flow window of 30 kg/h and bore up to 50 kg/h and
bore normally processes between 7,500 kg/h and up to 12,500 kg/h. In this
process, the cutting speed of the pelletizer is necessarily feedback tracked by the
factor of 1.67; one starts at 7,500 kg/h and 1,796 l/min of a given blade combination
and increases the blade speed in linear fashion to 3,000 l/min for 12,500 kg/h. The
pellets generated in this manner then each have the same weight. If a 2nd
pelletizing head were now installed at this given machine having, for example, 150
bores and the resulting capacity from 4,500 - 7,500 kg/h, the production window
increases to approximately factor 2.78. The same machine could thus generate
from 4,500 -12,500 kg/h of high-quality pellets.
When the worst-case scenario is taken into account (approximately 2 minutes start-
up requirement up to the actual start with a minimum required throughput
performance), this means for the above case:
With a standard diverter valve:
2 minutes x 7,500 kg/h = 250 kg material losses, per start-up process.
With a bidirectional diverter valve, this would mean:
2 minutes x 4,500 kg/h = 150 kg material losses, per start-up process.

There is in addition the fact that the same production machine which requires 2
minutes for the manufacture of 7,500 kg, will reach the 4,500 kg/h substantially
faster. This can in turn reduce the start-up time, which then means in sum:
72 seconds x 4,500 kg/h = 90 kg material losses, per start-up process
As documented in this example, this option of the invention therefore opens up a
reduction of the loss quantity per start-up process by a factor 2.78. For the
production facility, this means that, on the one hand, less material loss arises which
then has to be disposed of or treated and, on the other hand, a faster start is
permitted, which means less personnel and less handling overall (plastics have to
be sucked up and cooled on discharge from the diverter valve to the bottom = floor,
which naturally directly influences the operating costs).
Example 3:
A pelletization for PET starting from a reactor having e.g. 250 bores in the nozzle
plate and an assumed volume flow window of 30 kg/h and bore up to 50 kg/h and
bore normally processes between 7,500 kg/h and up to 12,500 kg/h. In this
process, the cutting speed of the pelletizer is necessarily feedback tracked by the
factor of 1.67; one starts at 7,500 kg/h and 1,796 l/min of a given blade combination
and increases the blade speed in linear fashion to 3,000 l/min for 12,500 kg/h. The
pellets generated in this manner then each have the same weight. If a 2nd
pelletizing head were now installed at this given machine having, for example, 150
bores and the resulting capacity from 4,500 - 7,500 kg/h, the production window
increases to approximately factor 2.78. The same machine could thus generate
from 4,500 -12,500 kg/h of high-quality pellets. If one were now to use the option of
a multidirectional diverter valve and to install a further third nozzle plate/pelletizing
head combination, as shown in Figure 21, this has the consequence of a further
reduction of the minimum start-up performance. If one e.g. takes a third nozzle with
90 bores, a throughput performance range from 2,700 kg/h up to 4,500 kg/h is
obtained. The pelletizing device is thus ultimately available in the range from 2,700
-12,500 kg/h. The production window thus increases to approximately factor 4.63.

Analogously to the aforesaid, it applies to this case: when the worst-case scenario
is taken into account (approximately 2 minutes start-up requirement up to the actual
start with a minimum required throughput performance), this means for the above
case:
With a standard diverter valve:
2 minutes x 7,500 kg/h = 250 kg material losses, per start-up process.
With a bidirectional diverter valve, this would mean:
2 minutes x 2,700 kg/h = 90 kg material losses, per start-up process.
There is in addition the fact that the same production machine which requires 2
minutes for the manufacture of 7,500 kg, will reach the 2,700 kg/h substantially
faster. This can in turn reduce the start-up time by half, which then means in sum:
43.2 seconds x 2,700 kg/h = 32.4 kg material losses, per start-up process
As documented in this example, this option of the invention therefore opens up a
reduction of the loss quantity per start-up process by a factor 7.72. For the
production facility, this means that, on the one hand, less material loss arises which
then has to be disposed of or treated and, on the other hand, a faster start is
permitted, which means less personnel and less handling overall (plastics have to
be sucked up and cooled on discharge from the diverter valve to the bottom = floor,
which naturally directly influences the operating costs).
For a fully continuous pelletization, this means that a total of €216.12 per week can
be saved with one product change per week and raw material prices of €1.20/kg.
this is an annual savings potential of €13,578.24 p.a.
For a discontinuous pelletization, this means that with only one product change per
day (= 50 tonnes preparation with 20h reaction time and 4h pelletization discharge

time) and raw material prices of €1.20/kg, a total of €261.12/day can be saved, this
is an annual savings potential of €95,308.80 p.a.
Even if the use of the diverter valve 1 in an underwater pelletization apparatus is
described above, corresponding advantages can also be achieved with other
pelletizing processes, for instance e.g. with extrusion pelletization or water ring
pelletization, with optionally also the pelletizing heads with the different throughput
capacities being able to use such different pelletizing processes.
The product flows A and B (cf. Figure 20) can differ for the option in the following
application examples:
Both flows each use the same pelletization method (extrusion pelletization/extrusion
pelletization; water ring pelletization/water ring pelletization; underwater
pelletization/underwater pelletization) while using the respectively required nozzle
plates which are either of the same geometry in section and of the same number of
bores or are of the same geometry in section and of a different number of bores or
are of a different geometry in section and of the same number of bores, of are of
different geometry in section or of the same number of bores or have one of the
preceding options, but can be associated with a respectively different construction
size.
Both flows each use a different pelletization process (extrusion pelletization/water
ring pelletization or underwater pelletization; water ring pelletization/extrusion
pelletization or underwater pelletization; underwater pelletization/water ring
pelletization or extrusion pelletization) while using the respectively required nozzle
plates which are either of the same geometry in section and of the same number of
bores or are of the same geometry in section and of a different number of bores or
are of a different geometry in section and of the same number of bores, of are of
different geometry in section or of the same number of bores or have one of the
preceding options, but can be associated with a respectively different construction
size.

WE CLAIM:
1. A method for the pelletization of plastics and/or polymers, wherein a melt
coming from a melt generator (26, 27) is supplied via a diverter valve (1)
having different operating positions to a plurality of pelletizing heads (24,
25, 34) through which the melt is pelletized, characterized in that
pelletizing heads (24, 25, 34) having different throughput capacities are
used sequentially for the start-up of the pelletizing process, wherein the
melt is first supplied to a first pelletizing head (24) having a smaller
throughput capacity and then the melt volume flow is increased, the
diverter valve (1) is switched over and the melt is diverted by the diverter
valve (1) to the second pelletizing head (25) having a larger throughput
capacity.
2. The method as claimed in the preceding claim, wherein the volume flow is
increased within the throughput capacity limits of the first pelletizing head
(24) before the switchover of the diverter valve (1) to the second
pelletizing head (25).
3. The method as claimed in one of the preceding claims, wherein the melt
volume flow is first maintained in the range of a lower capacity limit of the
first pelletizing head (24) and is then increased up to the upper capacity

limit of the first pelletizing head (24) and/or up to the lower capacity limit of
the second pelletizing head (25).
4. The method as claimed in one of the preceding claims, wherein the
diverter valve (1) is only switched over to the second pelletizing head (25)
when the melt volume flow has been increased up to the lower capacity
limit of the second pelletizing head (25) and/or the upper capacity limit of
the first pelletizing head (24).
5. The method as claimed in one of the preceding claims, wherein pelletizing
heads (24, 25, 34) having mutually complementary and/or overlapping
throughput capacity ranges are used.
6. The method as claimed in one of the preceding claims, wherein the melt is
diverted past the pelletizing heads (24, 25, 34) by the diverter valve (1) in
its bypass position before the supply of the melt to the first pelletizing head
(24), wherein the melt volume flow is increased until it has reached the
lower capacity limit of the first pelletizing head (24) having the smallest
throughput capacity, and wherein the diverter valve (1). is then switched
from its bypass position to the first pelletizing head (24) and the melt is
diverted to the first pelletizing head.

7. The method as claimed in one of the preceding claims, wherein the
diverter valve (1) is switched from its bypass position to the first pelletizing
head (24) in dependence on at least one parameter from the group of melt
viscosity, mass temperature of the melt and mass pressure of the melt.
8. The method as claimed in one of the preceding claims, wherein the
diverter valve (1) is switched from its bypass position to the first pelletizing
head (24) in dependence on at least one parameter from the group of
color of the melt, filler induction and degassing state.
9. The method as claimed in one of the preceding claims wherein the
diverter gate (1) is switched from the first pelletizing head (24) to the
second pelletizing head (25) and/or from the second pelletizing head (25)
to a further pelletizing head (34) in dependence on at least one parameter
from the group of pellet size, mass pressure of the melt, mass
temperature of the melt and pellet shape.
10.A pelletizing apparatus for the pelletizing of plastics and/or polymers
comprising a diverter valve (1) having at least one melt generator
connection (3), at least two pelletizer connections (5, 6) as well as a
switching gate (15) for the connection of the melt generator connection (3)
selectively to at least one of the pelletizer connections (5, 6), with a

respective pelletizing head (24, 25, 34) being connected to the at least two
pelletizer connections (5, 6) and a melt generator (26, 27) having a variable
melt volume flow being connected to the melt generator connection (3),
wherein at least two pelletizing heads (24, 25, 34) having different throughput
capacities and a control apparatus (33) is provided for the switchover of the
connection of the melt generator connection (3) of the diverter valve (1) from
one of the pelletizing heads (24) to another of the pelletizing heads (25) in
dependence on the melt volume flow of the melt generator (26, 27).
11.A pelletizer apparatus as claimed in the preceding claim, wherein the
control apparatus (33) has control means which switches the diverter
valve (1) to a first pelletizing head (24) having a smaller throughput
capacity when the melt volume flow is below a lower capacity limit of a
second pelletizing head (25) having a larger throughput capacity and/or
above a lower capacity limit of the first pelletizing head and the diverter
valve switches to the second pelletizing head (25) when the melt volume
flow is above the lower capacity limit of the second pelletizing head (25)
and/or below a lower capacity limit of a third pelletizing head (34) having
an even larger throughput capacity.

12.The pelletizer apparatus as claimed in one of the preceding claims,
wherein the control apparatus (33) has start-up control means which, in a
first step, move the switching gate (15) of the diverter valve (1) into a first
operating position in which the melt is directed to a first pelletizing head
(24) having a minimum throughput capacity and operates the melt
generator (26, 27) to a volume flow which is in the range of the lower
capacity limit of the first pelletizing head (24) which then, in a second step,
increase the volume flow of the melt generator (26, 27) up to an upper
capacity limit of the first pelletizing head (24) and/or to a lower capacity
limit of the second pelletizing head (25) having a larger throughput
capacity, and which finally, in a third step, operate the switching gate (15)
of the diverter valve (1) into a second operating position, in which the melt
is directed to the second pelletizing head (25).
13. The pelletizer apparatus as claimed in the preceding claim, wherein the
start-up control means are configured such that the switching gate (15) is
kept before the said first step in a bypass position in which the melt
directed into the diverter valve (1) is directed past all pelletizing heads (25,
25, 34) until the melt volume flow is operated in the range of the lower
capacity limit of the first pelletizing head having a minimum throughput
capacity.

14. The pelletizer apparatus as claimed in one of the preceding claims,
wherein the at least two pelletizing heads (24, 25, 34) have mutually
complementary throughput capacity ranges.
15.The pelletizer apparatus as claimed in the preceding claim, wherein the at
least two pelletizing heads (24, 25, 34) have throughput capacity ranges
adjoining one another seamlessly.
16. The pelletizer apparatus as claimed in one of the preceding claims,
wherein detection means are provided for the detection of the melt volume
flow directed into the diverter valve (1) and the control apparatus (33)
automatically switches over the diverter valve (1) in dependence on a
signal of the detection means.
17. The pelletizer apparatus as claimed in one of the preceding claims,
wherein at least one of the pelletizing heads (24, 25, 34) forms an
underwater pelletizing head.
18. The pelletizer apparatus as claimed in the preceding claim, wherein all the
pelletizing heads (24, 25, 34) form underwater pelletizing heads.

19. The pelletizer apparatus as claimed in one of the preceding claims,
wherein at least one of the pelletizing heads (24, 25, 34) forms an
extrusion pelletizing head and/or a water ring pelletizing head.
20. The pelletizer apparatus as claimed in one of the preceding claims,
wherein at least one of the pelletizing heads (24, 25, 34) forms an
underwater pelletizing head and at least one other of the pelletizing heads
(24, 25, 34) forms an extrusion pelletizing head and/or a water ring
pelletizing head.
21.The pelletizer apparatus as claimed in one of the preceding claims,
wherein the diverter valve (1) is provided with a melt generator
connection (3), a first pelletizer connection (5), a melt passage (7, 8) for
the communication of the melt generator connection (3) with the first
pelletizer connection (5) as well as a second pelletizer connection (6)
which can likewise be connected to the melt passage (7), with a switching
gate (14) being provided in the melt passage (7) which, in a first
production position, connects the melt generator connection (3) to the first
pelletizer connection (5) and, in a second production position, connects
the melt generator connection (3) to the second pelletizer connection (6).

22.A pelletizer apparatus as claimed in the preceding claim, wherein a
diverter gate (14) is provided in the melt passage (7) which releases the
connection of the melt generator connection (3) to the first and/or second
pelletizer connections (5, 6) in a production position and blocks the first
and/or second pelletizer connections (5, 6) from communication with the
melt generator connection (3) and connects the melt generator connection
(3) to a bypass opening (22) in a start-up position.
23.The pelletizer apparatus as claimed in the preceding claim, wherein the
diverter gate (14) and the switching gate (14) are coupled to one another,
are in particular integrated in a common valve body (15) and can be
actuated by a common valve actuator (16).
24. The pelletizer apparatus as claimed in one of the claims 21 to 23, wherein
a third pelletizer connection (34) is provided which can be connected to
the melt passage (7) and the switching gate (14) is configured such that it
connects the melt generator connection (3) to the third pelletizer
connection (34) in a third production position.

25. The pelletizer apparatus as claimed in either of the preceding claims 23 or
24, wherein the diverter gate or switching gate (14) is formed by a
cylindrical valve body which has a plurality of separate production
passages (18, 19) and is longitudinally displaceably supported in a valve
recess, in particular a valve bore.
26. The pelletizer apparatus as claimed in the preceding claim, wherein the
valve body (15) has at least one bypass passage (20, 21).
27. The pelletizer apparatus as claimed in either of the two preceding claims,
wherein the valve body (15) is movably supported in a direction transverse
to the connections between the melt generator connection and the
pelletizer connection.
28. The pelletizer apparatus as claimed in one of the preceding claims,
wherein the melt generator connections and the pelletizer connections (3,
4, 5, 6) are configured such that they can be connected to the melt
generator or to the respective pelletizer head by quick-closing couplings.

29.The pelletizer apparatus as claimed in one of the preceding claims,
wherein means for determination, in particular sensors for the detection of
the melt viscosity, of the mass temperature of the melt, of the mass
pressure of the melt, of the volume flow of the melt, of the degassing
state, of the pellet size and/or of the pellet shape are provided, and
wherein the control apparatus (33) switches the diverter valve (1) in
dependence on at least one signal of the said detection means.
30.The diverter valve for a pelletizing apparatus comprising a first melt
generator connection (3), a first pelletizer connection (5) and a first melt
passage (7) for the connection of the melt generator connection to the
pelletizer connection, a second pelletizer connection (6), a second melt
generator connection (4) as well as a second melt passage (8) for the
connection of the second melt generator connection (4) to the second
pelletizer connection (6) as well as a valve body for the control of the
passage of at least one melt passage (7, 8), wherein the two melt
passages (7, 8) are configured separately from one another and free of
overlap; and in that the valve body (15) in a valve recess which is in
communication with both melt passages (7, 8) and with a bypass valve (7,
8) can be moved to and fro between a first operating position in which the
first melt generator connection (3) is switched through to the first pelletizer
connection (5) and the second melt generator connection (4) is switched

through to the second pelletizer connection (6) and a second operating
position in which the first melt generator connection (3) and/or the second
melt generator connection (4) is/are switched through to the bypass
passage.
31. The diverter valve as claimed in the preceding claim, wherein the valve
body (15) forms a valve gate which is axially displaceably seated in the
valve recess, with the valve recess extending transversely to the melt
passages (7,8).
32.The diverter valve as claimed in one of the preceding claims, wherein the
valve body (15) is movably supported in a direction transversely to the
connections between the melt generator connection and the pelletizer
connection.

33. The diverter valve as claimed in one of the preceding claims, wherein the
melt generator connections and the pelletizer connections (3, 4, 5, 6) are
configured such that they can be connected to the melt generator and/or
to the respective pelletizer head by quick-closing couplings.


ABSTRACT

Title: A method and an apparatus for the pelletization of plastics and/or polymers
A method for the pelletization of plastics and/or polymers, wherein a melt coming
from a melt generator (26, 27) is supplied via a diverter valve (1) having different
operating positions to a plurality of pelletizing heads (24, 25, 34) through which
the melt is pelletized, characterized in that pelletizing heads (24, 25, 34) having
different throughput capacities are used sequentially for the start-up of the
pelletizing process, wherein the melt is first supplied to a first pelletizing head
(24) having a smaller throughput capacity and then the melt volume flow is
increased, the diverter valve (1) is switched over and the melt is diverted by the
diverter valve (1) to the second pelletizing head (25) having a larger throughput
capacity.

Documents:

02623-kolnp-2007-abstract.pdf

02623-kolnp-2007-claims.pdf

02623-kolnp-2007-correspondence others.pdf

02623-kolnp-2007-description complete.pdf

02623-kolnp-2007-drawings.pdf

02623-kolnp-2007-form 1.pdf

02623-kolnp-2007-form 2.pdf

02623-kolnp-2007-form 3.pdf

02623-kolnp-2007-form 5.pdf

02623-kolnp-2007-international publication.pdf

02623-kolnp-2007-international search report.pdf

02623-kolnp-2007-pct request form.pdf

02623-kolnp-2007-priority document.pdf

2623-KOLNP-2007-(13-10-2011)-ABSTRACT.pdf

2623-KOLNP-2007-(13-10-2011)-AMANDED CLAIMS.pdf

2623-KOLNP-2007-(13-10-2011)-DESCRIPTION (COMPLETE).pdf

2623-KOLNP-2007-(13-10-2011)-DRAWINGS.pdf

2623-KOLNP-2007-(13-10-2011)-EXAMINATION REPORT REPLY RECEIVED.pdf

2623-KOLNP-2007-(13-10-2011)-FORM 1.pdf

2623-KOLNP-2007-(13-10-2011)-FORM 2.pdf

2623-KOLNP-2007-(13-10-2011)-FORM 3.pdf

2623-KOLNP-2007-(13-10-2011)-OTHERS.pdf

2623-KOLNP-2007-(13-10-2011)-PA.pdf

2623-KOLNP-2007-(13-10-2011)-PETION UNDER RULE 137.pdf

2623-KOLNP-2007-ASSIGNMENT.pdf

2623-KOLNP-2007-CORRESPONDENCE 1.1.pdf

2623-KOLNP-2007-CORRESPONDENCE-1.2.pdf

2623-KOLNP-2007-EXAMINATION REPORT.pdf

2623-KOLNP-2007-FORM 18-1.1.pdf

2623-kolnp-2007-form 18.pdf

2623-KOLNP-2007-FORM 26.pdf

2623-KOLNP-2007-FORM 3.pdf

2623-KOLNP-2007-FORM 5.pdf

2623-KOLNP-2007-GRANTED-ABSTRACT.pdf

2623-KOLNP-2007-GRANTED-CLAIMS.pdf

2623-KOLNP-2007-GRANTED-DESCRIPTION (COMPLETE).pdf

2623-KOLNP-2007-GRANTED-DRAWINGS.pdf

2623-KOLNP-2007-GRANTED-FORM 1.pdf

2623-KOLNP-2007-GRANTED-FORM 2.pdf

2623-KOLNP-2007-GRANTED-SPECIFICATION.pdf

2623-KOLNP-2007-OTHERS.pdf

2623-KOLNP-2007-PA.pdf

2623-KOLNP-2007-REPLY TO EXAMINATION REPORT.pdf


Patent Number 253100
Indian Patent Application Number 2623/KOLNP/2007
PG Journal Number 26/2012
Publication Date 29-Jun-2012
Grant Date 25-Jun-2012
Date of Filing 13-Jul-2007
Name of Patentee GALA INDUSTRIES, INC.
Applicant Address 181 PAULEY STREET, EAGLE ROCK, VIRGINIA
Inventors:
# Inventor's Name Inventor's Address
1 ELOO, MICHAEL PARDENDYCKWEG 4 D-46509 XANTEN
2 VELTEL, JURGEN ALTER STEEG 5 D-47626 KEVELAER
PCT International Classification Number B29B 9/06
PCT International Application Number PCT/EP06/001363
PCT International Filing date 2006-02-15
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 102005007102.3 2005-02-16 Germany