The effects of kneading block design and operating conditions on distributive mixing in twin screw extruders

A mixing limited interfacial reaction between polymer tracers was used to directly measure the distributive mixing performance of a co‐rotating twin screw extruder during melt‐melt blending of polypropylene. The reaction between the polymer tracers, which are low molecular weight succinic anhydride and primary amine terminally functionalized polymer chains, was followed using Fourier‐Transform Infrared Spectroscopy (FT‐IR). Experiments were completed to determine the effects of flow rate, screw speed, and kneading block design on the distributive mixing performance and the residence time distribution (RTD). The only RTD variable that was significantly affected by the experimental factors was the average residence time. Distributive mixing with neutral and reverse kneading blocks was controlled by the average residence time, the fully filled volume, and the shear rate. Conversely, the mixing performance of a forward kneading block did not follow the same trends.     

Simulation of screw pumping characteristics for intermeshing counter‐rotating twin screw extruders

Intermeshing counter‐rotating twin screw extruders play an important role in polymer processing, especially for the extrusion of profiles and pipe, largely from polyvinyl chloride. There has been little effort on flow modeling of these machines and most of this has involved representing the machine as a “leaky” positive displacement pump and estimating leakages. In recent years, M.H. Hong and the authors have developed more general methods of simulation of flow in this machine and both applied and experimentally verified it for a few designs. Here we extend these efforts to a broader range of screw designs, especially with deeper screw channels where transverse shearing induced by the flights is important. Calculations are done for isothermal power law fluids. The results are compared with experiment. POLYM. ENG. SCI., 2011. © 2010 Society of Plastics Engineers     

Mixing efficiency in a pin mixing section for single‐screw extruders

Non‐Newtonian, non‐isothermal, 3D finite‐element simulation of mixing performance in a pin mixing section with different axial gaps in the pins has been carried out according to their realistic configurations. The quantitative evaluation of mixing ability was based on the theory of kinematics of fluid mixing. To learn and to compare the local mixing performance in a standard screw and a pin mixing section, the local mixing efficiency distribution proposed by Ottino was calculated. Also, the RTDs of these mixers were calculated in an attemt to measure mixing. The integration of the two, namely, the integrating local mixing efficiency along a number of particle pathlines from entrance to exit, together with statistical treatment, which was referred as integral mixing efficiency, then gives a quantitative judgment of the total mixing ability of a continuous mixer. The calculated results showed a nonlinear dependence of the mixing ability of a pin mixing section on the axial gap of the pins. Finally, the calculation results were compared with the experimental ones obtained in our previous study.     

The operating characteristics of twin screw extruders

The operation of a twin screw extruder processing a powder or granular solid is reviewed. The operating variables of screw speed and barrel temperature profile interact with a number of design parameters— screw design, die geometry, feed zone geometry and with the material properties, in determining machine performance. The factors that determine output and pressure development are specified in a sequence of block diagrams. The dynamic response of an operating machine to disturbances in the steady state conditions is explained in the light of the established relationships and interpreted in conventional control theory terms. Attention is drawn to the importance of mixing in the chambers formed by the screw channels and of the residence time distribution in determining the quality of the final product.     

Theoretical model for non-intermeshing twin screw extruders

A simple theoretical model for flow in nonintermeshing twin screw extruders has been derived. The assumptions which in single screw extruders result in the “two parallel plates” model, in twin screw extruders result in the “three parallel plates” model. The flow rate equation can be expressed, for Newtonian fluids, in terms of drag and pressure flow terms, as in single screw extrusion theory, but each term is multiplied by a geometrical factor. This factor incorporates the effect of one screw on the drag and pressure flow terms of the other. The theoretical model was experimentally verified on a 1 inch diameter Bausano twin screw extruder.     

Continuous screenchanger introduced for twin screw extruders

US company Key Filters has modified the design of its model KCN screenchanger specifically to match the discharge geometry of the twin screw extruder.This is a short news story only. Visit www.addcomp.com for the latest additives and compounding industry news.     

3‐D numerical simulations of nonisothermal flow in co‐rotating twin screw extruders

Three‐dimensional nonisothermal flow simulations in the kneading disc regions of co‐rotating twin screw extruders were performed using a finite element method. The standard Galerkin method and penalty function scheme were applied to the flow field. The streamline‐upwind/Petrov‐Galerkin scheme was used in the temperature field to reduce numerical oscillation. The simulations were carried out under the operational conditions of The Japan Steel Works TEX30 machine for various rotational speeds. The configuration was ten 2‐lobe kneading discs with a 90° stagger angle. Experimental observations were also performed to validate the numerical simulations under the same operational conditions. The pressure in front of the tip in the rotation direction was higher than behind the tip, and the region behind the tip sometimes had a negative value. Since variation of the pressure gradient in the axial direction causes forward and backward flows in the disc gap regions, the disc gap regions play an important role for mixing. The temperature becomes higher with increasing rotation speed due to high viscous dissipation. A high temperature was observed on the disc surface, in the disc gap, and in the intermeshing regions. The numerical results of pressure profiles with the rotation and the temperature in the axial direction were in good agreement with the experimental observations.     

Improving mixing characteristics with a pitched tip in kneading elements in twin‐screw extrusion

In twin‐screw extrusion, the geometry of a mixing element mainly determines the basic flow pattern, which eventually affects the mixing ability as well as the dispersive ability of the mixing element. The effects of geometrical modification, with both forward and backward pitched tips, of a conventional forward kneading disks element (FKD) in the pitched‐tip kneading disks element on the flow pattern and mixing characteristics are discussed. Numerical simulations of fully filled, nonisothermal polymer melt flow in the melt‐mixing zone were performed, and the flow pattern structure and the tracer trajectories were investigated. The pitched tips largely affect the inter‐disk fluid transport, which is mainly responsible for mixing. These changes in the local flow pattern are analyzed by the distribution of the strain‐rate state. The distribution of the finite‐time Lyapunov exponent reveals a large inhomogeneity of the mixing in FKD is suppressed both by the forward and backward tips. By the forward tips on FKD, the mixing ability is relatively suppressed compared to FKD, whereas for the backward tips on FKD, the mixing ability is enhanced while maintaining the same level of dispersion efficiency as FKD. From these results, the pitched tips on the conventional KD turn out to be effective at reducing the inhomogeneity of the mixing and tuning the overall mixing performance. © 2017 American Institute of Chemical Engineers AIChE J, 64: 1424–1434, 2018     

Analysis and experimental evaluation of twin screw extruders

Twin screw extruders can he classified according to their geometrical configuration. The main distinction is made between intermeshing and nonintermeshing extruders. Another distinguishing characteristic is the sense of rotation. The most important characteristics of the various twin screw extruders are examined, with particular emphasis on the effect of screw geometry on the conveying characteristics. A brief review is given of the state of the art in theoretical analysis of twin screw extruders. Experiments with two lab scale, intermeshing twin screw extruders are described, one co- and one counterrotating. Results are presented on power consumption, residence time distribution, and mixing characteristics of the two extruders. The counterrotating extruder exhibits a narrower residence time distribution and better dispersive mixing capability. The corotating extruder showed a better distributive mixing capability. These results can be explained in terms of the conveying and mixing mechanisms in both extruders. The overall extruder performance seems to be dominated by the effect of the intenneshing region. Any realistic, theoretical analysis of twin screw extruders should be centered around the flow behavior and mixing characteristics of the intermeshing region. The corotating extruder appears to be best suited for melt blending operations, while the counterrotating extruder seems to be preferred in operations where solid fillers have to be dispersed in a polymer matrix.     

Morphology of polymer blends in the melting section of co‐rotating twin screw extruders

The properties of polymer blends are largely determined by the morphological structure of the polymer combinations that are involved. In terms of extruder design, this means it is necessary to have models available for estimating the development of the morphology over the length of the screws. Since significant morphological changes are observed in the melting section, in particular, is it necessary to analyze not only the plasticizing process for binary material combinations but also the initial formation and further development of the morphology in this section of the extruder. In the framework of this study, experimental investigations were conducted into polypropylene/polyamide 6 (PP/PA6) blends with small components (by weight) of the disperse PA phase. Apart from varying the process conditions of screw speed and throughput, the viscosity ratio was also varied through the use of two different PP grades. The degree of melting and the development of the morphology over the length of the screws were determined for the individual tests. The study of blend morphology in the melting section reveals key findings that must be taken into account for modeling the initial formation and further development of the morphology. It is very clear that, on the second component, which melts at higher temperatures, a kind of melt film removal occurs at the surface of the granules as they melt. The drops of second component in the melting section, which are directly adjacent to components that have not yet fully melted in some cases, have already assumed dimensions (in the μm range) similar to those that are seen at the end of the extrusion process. This means that, in the melting section of the twin‐screw extruder, no volumes become detached from or are worn off the already‐molten granule surfaces. An evaluation of scanning electron micrographs also shows that, in the melting section of co‐rotating twin‐screw extruders, virtually all the degradation mechanisms that can essentially be distinguished, such as quasi‐steady drop breakup, folding, end pinching and decomposition through capillary instabilities, take place in parallel.     

Mean residence time analysis for twin screw extruders

This paper presents and experimentally validates a physically motivated model for predicting the mean residence time in twin screw extruders. Accurate estimation of the mean residence time and the propagation delay through a plasticating extruder is critical for implementing feedback control schemes employing sensors mounted along the extruder. Experiments were carried out on a 30 mm Krupp Werner and Pfleiderer co‐rotating twin screw extruder equipped with reflectance optical probes over the melting section and mixing section and at the die. The residence time distributions for twelve operating conditions and two screw geometries are compared. The mean residence times predicted by our model are in good agreement with the experimentally measured mean residence times.     

Mixing and residence time distribution in melt screw extruders

The residence time distribution (RTD) functions were derived for screw extruders, based on the “parallel plate” and curved channel flow models. The results indicate a relatively narrow distribution, and they explain several characteristics of screw extruders. The strain distribution in the fluid across the channel was also derived. With the aid of these two functions an average strain of the fluid leaving the extruder was defined. The resulting weighted-average total strain (WATS) provides a quantitative criterion to the “goodness of mixing” in extruders.     

Mechanisms of mixing in single and co-rotating twin screw extruders

Previous experimental studies have revealed that the mixing efficiencies of widely used continuous processors such as the single and twin screw extruders depend on the types of screw elements, which are utilized. It is generally recognized that the basic single screw extruder and the fully-fighted sections of the fully-intermeshing co-rotating twin screw extruders are not efficient mixers, in contrast to the specialized mixing elements such as the kneading discs used in co-rotating twin screw extruders. However, no simulation techniques were available to characterize quantitatively and rigorously the mixing efficiencies of continuous processors. In this study, we have solved the three-dimensional equations of conservation of mass and momentum, and utilized various tools of dynamics to analyze the mixing occurring in single and co-rotating twin screw extruders. It is shown that simulation methods can indeed capture the relative differences in the mixing mechanisms of continuous processors like the single and twin screw extruders. The ability to distinguish quantitatively between the distributive mixing capabilities of various continuous processors should facilitate numerical testing of new continuous mixer designs, optimization of operating conditions and geometries of existing mixers and the material-specific design of new mixers.     

Numerical simulation of pressure and velocity profiles in kneading elements of a co‐rotating twin screw extruder

The objective of this work is to validate, via comparison with available experimental data, the results obtained from the numerical simulation of polymer melt flow in the kneading disc section of an intermeshing co‐rotating twin screw extruder. A quasi‐steady state 3‐D solution of the conservation equations via the finite element method was obtained, and comparisons were made with experimental pressure profiles measured by McCullough and Hilton (1) on various kneading block elements. These measurements helped provide understanding of the flow patterns developed within the unit and provided a comprehensive approach of validating the numerical model. Results confirm the importance of a fully 3‐D model for this type of geometry, where the model predicts the development of flow patterns in the radial directions and within the intermeshing region. The influence of inlet and outlet boundary conditions was studied and it was determined that they play an important role in the physical significance of the model solution. Comparisons of the simulation results with experimental data by McCullough and Hilton (1) for two different configurations of kneading discs showed good agreement, with some differences in the peaks of pressure produced at the narrow clearances encountered in intermeshing co‐rotating twin screw extruders. Differences between simulation and experiments are attributed to a number of factors. It is difficult to measure the very steep pressure gradients generated over small lengths. The assumptions of isothermal flow and quasi‐steady state may cause an over‐prediction of the pressure peaks. Simulation results describe the general trends and produce good quantitative agreement in most of the kneading disc region.     

Melting model for modular self wiping co-rotating twin screw extruders

A model for the melting process in a self wiping co-rotating twin screw extruder is described. Self-wiping co-rotating twin screw extruders are modular and starve fed. This leads to melting mechanisms that are different from single screw extruders. The melting process in the modular screw configurations generally occurs in specialized sections such as kneading disk blocks. The model, based on our previous experimental observations, considers the formation of two stratified layers of melt in contact with the hot barrel and solid pellets in contact with the relatively colder screw. In the kneading disk blocks, a part of the solid bed is blocked because of the relative stagger between successive disks. The model predicts both the location of melting and melting lengths in a screw configuration. Calculations for individual screw elements and kneading disc elements are presented first. Melting in a modular configuration of these elements is then considered. The effect of operating variables such as mass flow rate and screw speed on melting is then studied. The model is put in a dimensionless form and the effect of various dimensionless groups is discussed. We make a comparison to the experiment and agreement is good.