Solids conveying in screw extruders part I: A modified isothermal model

An improved theoretical model was derived for the solids conveying zone of a plasticating extruder. The model makes possible calculations in variable channel depth section. It also allows for a bulk density which is a function of pressure and for the non-isotropic pressure distribution in the solid plug. An expression for maximum flow rate was also derived. Results simulated by the model on a computer indicate the effect of variables on extruder performance. The power consumption terms in the solids conveying zone of a plasticating extruder were also derived. Total power consumption is the sum of power consumptions on the barrel surface, screw surfaces and those due to pressure rise. Their relative importance was analyzed by computations. The effect of operating conditions and coefficients of friction on the various power terms was also analyzed.     

单螺杆挤出固体输送段非塞流的三层模型法

依据单螺杆挤出机固体输送段的非塞流现象，把固体塞分成上、中、下三层，通过应力—速度方程，推导出产量与压力降的三次方程；详细讨论了摩擦系数对最大产量的影响，并深入地分析了单螺杆挤出机固体输送段产量与末端压力的关系，通过这些分析计算，三层模型法能很好地预示单螺杆挤出机固体输送段的压力与产量，该方法不仅简单明晰而且精度高，是一个可使用的方法     

IKV挤出机新型固体输送理论研究

从弧板物理模型出发,提出一种新的固体输送理论—双螺棱推动理论(或称TGL理论),其核心思想是避免固体塞发生周向剪切,实现单螺杆挤出机由拖曳输送向正位移输送转化。通过对IKV单螺杆挤出机固体塞的运动分析和受力分析可知,螺杆螺棱与加料套螺棱推进面的推动力是固体塞前进的原因,无论是固体塞与机筒表面的摩擦力,还是固体塞与螺杆表面的摩擦力,均是固体塞前进的阻力。通过判定系数k可求解避免固体塞发生周向剪切的边界条件。     

新型螺杆挤出机固体输送理论的研究

介绍了一种嵌套式新型螺杆挤出机。在固体输送段对内螺杆的两种等效情况下固体塞的运动和受力作了深入分析。理论上证明了这两种情况下的固体输送机理与外螺杆的情况相同,均建立在固体摩擦输送机理基础之上;讨论了牵引角、摩擦因数和螺纹升角对上述三种情况固体输送流率的影响。结果表明,螺杆旋转机筒静止和螺杆静止机筒旋转两种情况下固体输送流率相差不大,而螺杆机筒同时旋转情况下的固体输送流率远大于其他两种情况。增大牵引角、降低螺杆表面粗糙度和提高机筒内表面的摩擦因数均有助于提高固体输送流率。螺杆旋转机筒静止和螺杆静止机筒旋转这两种情况下最佳螺旋角均为17°左右,而螺杆机筒同时旋转情况下最佳螺旋角为15°左右。     

Solids conveying in screw extruders part III: The delay zone

A theoretical model was developed for the newly-defined delay zone of the plasticating screw extruder. The delay zone starts at the end of the solids conveying zone, i.e. at the point where the solid plug surface contacting the barrel melts and forms a film of melt up to where the steady state melting mechanism starts to operate. The model permits the film thickness and pressure profiles in this zone to be calculated. Published results were used to support the validity of the model. The results indicate that the film thickness at the end of the delay zone is several times the flight clearance. Finally, a criteria, based on the final value of the film thickness, is suggested to calculate the length of the delay zone.     

Experimental study of the influences of the pellet shape on the bulk density and the frictional behavior of polypropylene

Bulk solids are the raw material for almost every polymeric thermoplastic product. Their properties determine the quality of solids conveying and also influence the melting behavior of the material in processing units. This study investigates the influence of pressure and temperature on the bulk density of two thermoplastic polypropylene pellets of different shapes. Furthermore, the external friction dependent on temperature and pressure of those materials is examined at conditions usually occurring in the solids conveying zone of smooth barrel plasticating units. The experiments are carried out using a tribometer for polymer pellets which was adapted for these tests by making the sample chamber, the piston, and the cylindrical roll heatable. The tests show that long cylindrical pellets exhibit low bulk densities at low pressure and temperature, which can be increased dramatically—even above the values of spheroidal pellets—as those parameters increase. Moreover, the external coefficient of friction is always higher for the long cylinders and strongly dependent on the temperature. Those facts add up and can cause a higher output of single‐screw extruders. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015 , 132, 42197.     

A Computer Model for Single-Screw Plasticating Extrusion

A fully predictive computer model has been developed for a single-screw plasticating extrusion (with conventional screws). The model takes into account five zones of the extruder (hopper, solids conveying, delay zone, melting zone, melt conveying) and the die, and describes an operation of the extruder-die system, making it possible to predict a mass flow rate of the polymer, pressure and temperature profiles along the screw channel and in the die, solid bed profile, and power consumption. Moreover, mixing degree, temperature fluctuation and viscoelastic properties of the polymer are estimated. The simulation parameters are the material and rheological properties of the polymer, the screw, hopper and die geometry, and the operating conditions (screw speed and barrel temperature profile). Such a comprehensive approach to the modeling of extrusion creates the possibility of optimizing the process, for example, from the point of view of the quality of extrusion. The model has been verified experimentally for a low-density polyethylene on a 45 mm diameter single-screw extruder.     

Solids conveying in the solids compaction zone of vane extruder

On the basis of the forces on the differential element in the solids bed, a function between bulk density and pressure, and the nonisotropic pressure distribution in the element, an expression of pressure in the circumferential direction is derived. And the total power introduced through the positive conveying and the friction dragging conveying is also deduced. Experimental data are obtained using a self‐developed and simplified vane extruder with an adjustable rotor eccentricity. The solids conveying mechanism in the solids compaction zone of a vane extruder is theoretically and semiempirically confirmed. Besides, the various portions of total power consumption including the power dissipated on the surfaces of the stator and baffles, the power used to build pressure and the power converted into rotational kinetic energy are derived. The effects of the eccentricity on the solids conveying are also discussed theoretically and semiempirically. POLYM. ENG. SCI., 55:719–728, 2015. © 2014 Society of Plastics Engineers     

注塑机螺杆的固体流变分析

分析了注塑机螺杆工作时加料段塑料颗粒的流动特性，介绍了塞流固体输送理论及非塞流固体输送理论的基本计算方法，并引入压力的计算公式，从而使塞流固体输送流率可直接计算求解。     

Vertical pneumatic conveying of particle plugs

Dense-phase pneumatic conveying of solids offers many advantages over dilute-phase conveying. The lower air velocities, and, consequently, lower particle velocities, result in lower pipe wear and lower particle attrition. This paper describes an experimental program that has been undertaken to study the flow pattern of cohesionless solids in vertical transport and to measure the parameters influencing the pressure drop required to move a single plug of solids. Highspeed photographic techniques have been used to observe the flow pattern of polyethylene particles (diameter ? 3 mm) in the vertical riser section of a circulating unit constructed from pipes with an internal diameter of 50.8 mm. The flow pattern resembles that of square-nosed slugging in a fluidized bed. The solids move up as “plugs” of bulk solids that occupy the entire cross-section of the pipe. Particles are seen to “rain” down from the back of one plug and then to be collected by the front of the next plug. Collecting these particles causes a stress on the plug front which is transmitted by powder mechanics forces axially through the plug and radially to the wall. The pressure drop required to move a single plug of cohesionless solids through the transport pipeline was measured as a function of the plug length, particle properties, pipe diameter, and the frontal stress. The results of these experiments are compared with a theoretical model.     

Coefficients of dynamic friction for low density polyethylene

The coefficient of dynamic friction is often the controlling factor for solids conveying, pressure generation, and thermal decomposition of a resin in the feed section of a single-screw plasticating extruder. The coefficients of friction are, however, very poorly understood, and the interpretation of the measurements are complicated by the dissipation of frictional energy at the sliding interface. A new instrument was recently built to help understand dynamic friction, and a numerical technique was developed to estimate the interface temperature. The coefficients of dynamic friction for a low-density polyethylene resin are presented in this paper as a function of the surface temperature, pressure, and velocity.     

Resistance Properties of a Bend in Dense‐Phase Pneumatic Conveying of Pulverized Coal under High Pressure

Experiments of high‐pressure dense‐phase pneumatic conveying of pulverized coal with different mean particle sizes using nitrogen were carried out in an experimental test facility with a conveying pressure of up to 4 MPa. The effects of three representative operating parameters (solids‐to‐gas mass flow ratio, conveying pressure, mean particle size) on the total pressure drop were examined. The pressure drops across the horizontal and vertical bends were analyzed by experimental and analytical calculation. The results show that the pressure drop due to gas friction is of much less significance, while the pressure drop due to the solids friction component of the total pressure drop dominates. There exists a relationship between the pressure drop due to solids kinetic energy loss and mass flux of solids.     

Friction measurement in dense phase plug flow analysis

Pneumatic conveying, employing the dense phase plug flow regimen, is largely used to transport bulk solids. This process permits the conveying of large amounts of material in economical manner with less particle and pipe degradation compared to dilute phase conveying. By using an experimental system with special measurement devices and different materials of construction and transport, the friction between the material being transported and the pipe wall, the actual motion of the particles was determined, and the degree of fluidization were estimated. This information permits more accurate modeling of dense phase plug flow providing basic parameters to insert in existing and developing models.     

Coefficients of dynamic friction as a function of temperature,pressure, and velocity for several polyethylene resins

The coefficient of dynamic friction is often the controlling factor for solids conveying, pressure generation, and thermal decomposition of a resin in the feed section of a single-screw plasticating extruder. The coefficients of friction are, however, very poorly understood, and the interpretation of the measurements are complicated by the dissipation of frictional energy at the sliding interface. A new instrument was recently built to help understand dynamic friction, and a numerical technique was developed to estimate the interface temperture. Coefficients of dynamic friction for several polyethylene resins are presented in this paper as a function of the surface temperature, pressure, and velocity. The relationship of the data with respect to the extrusion process is discussed.     

密相气力输送系统的比较

在建材、冶金、化工等行业中,现广泛应用的稀相气力输送技术,其气流速度高、固气比低,耗气量大,且不适用粒径大和相对体积质量大的物料输送。而低速、低压的密相栓流输送新技术,既可在输送过程中实施对物料的加热、冷却和烘干;且当物料速度减少或粉料流量增大时,具有较高的系统稳定性。目前,国内外已相继开发了多种密相栓流气力输送系统,其成栓方式包括有脉冲气刀式、挤压式和重管式等多种,均各具特点。其中,脉冲气刀栓流输送系统在运行时,输送固气比高、耗气量低,且成栓方式简单、有效,应成为密相气力输送设计时优先考虑的系统。     

Study of the pressure drop of dense phase gas-solid flow through nozzle

Pressure drops are measured on different nozzles of various pipe sizes in dense phase pulverized coal pneumatic conveying. From the experimental results, we conclude that the effect of the gas phase nozzle pressure drop is negligible when comparing with the solid phase pressure drop in the experimental range. The main influence factors contributing to the nozzle pressure drop are gas and solid mass flow rate, solids loading ratio, and the diameters of the nozzle inlet and outlet. A new model was developed to predict the nozzle pressure drop in dense phase pneumatic conveying of pulverized coal based on the Barth's pneumatic conveying theory. The pressure drop predictions from the model are in good agreement with the experimental values. The model quantified the important influence factors of the nozzle pressure drop.     

A numerical model for single screw extrusion with poly(vinyl chloride) (PVC) resins

A computer model has been developed to simulate the behavior of molten polymer in the melt conveying zone of extruders. This model, based on a hybrid finite difference/finite element resolution of the equations of change governing momentum and heat transfer, allows the prediction of the pressure profile while accounting for wall end effects as well as the solid bed velocity. Simulation results are compared with analytical and finite difference method results found in the literature. A fairly good agreement is obtained in the case of low density polyethylene. Numerical tests are also carried out with rigid poly(vinyl chloride) compound used for window profile extrusion. The good agreement found between the predictions and experimental measurements obtained on an industrial extruder confirms the performance of the proposed model.     

Low-Velocity Pneumatic Conveying Calculations for a High Concentration of the Particulate Material

The assumption that a moving solid–gas mixture is quasi- homogeneous and is characterized by some pseudoviscosity allows one to use conventional hydrodynamic methods and to generalize numerous experimental data on the low-velocity pneumatic conveying of various particulate materials. Formulas are derived for calculating the friction pressure drop criterion and the local flow-resistance coefficient in bent pipes. These formulas take into account the relative velocity, concentration, and properties of the solids. Basic principles are developed for the design of stepped-diameter pipelines of complicated configuration for long-distance pneumatic conveying.     

脉冲式密相气力输送水平管中的料栓行为

探讨了聚丙烯颗粒在脉冲式密相气力输送水平管中的料栓行为. 结果表明在一定操作气速下,料栓的长短变化有规律,料栓的运动速度随其长度而变;栓长为1 m左右的聚丙烯颗粒由栓状流向沙丘流型转变的料气速度之比为0.7~0.8,出现在操作气速5 m/s左右;单个料栓的压力梯度与其长度有关,沿单个料栓的压力梯度和截面固含量随气速而变;料栓压降与操作气速无关.