Parametric study of a 2-d model of the nip region in a counter-rotating,non-intermeshing twin screw extruder

Within the polymer processing industry, the demand for more efficient mixing within the existing mixer geometries and keeping a tighter control over increasingly difficult applications calls for a quantitative understanding of the role of the mixer geometry on the mixing performance. An important extruder geometry to consider is the Counter-Rotating, Non-Intermeshing Twin Screw Extruder (CRTSE). Recent studies suggest that the greater than linear mixing performance in this geometry may be attributed to the flow in the nip region. Solution of the fluid dynamic equations for a 2-D model of the nip region was found in order to quantify mixing using a FEM software called FIDAP which was available to us on the CRAY X-MP supercomputer at San Diego Supercomputer Center. In order to study the effects of design parameters in the nip region, an arbitrary interface was placed in the entrance of the region. A program called “LINE” tracks the path and growth of the interface through the region. Measures of mixing are computed and compared. Effect of several design parameters on mixing performance are studied. Conclusions are presented as to the relative effect of various design parameters. Discussions regarding the measures of mixing and mixing efficiency are presented.     

Determination of the degree of fill in a counter-rotating twin screw extruder

Current residence time distribution models for counter-rotating extruders are mainly developed for fully filled machines. However, in practical situations, these extruders operate under starved conditions. To overcome this missing link in the current models, this paper describes the average degree of fill in the situation of starvation. This degree of fill is determined by the length over which the extruder is fully filled and the degree of fill in the partially filled zone. The comparison of the experiments with the theory shows that the existing theory underestimates the length of the fully filled zone by about 30%. The degree of fill in the partially filled zone is well predicted by taking into account all non-pressure driven leakage flows.     

Numerical nonisothermal flow analysis of non-Newtonian fluid in a nonintermeshing counter-rotating twin screw extruder

A simulation technique for nonisothermal flow analysis of non-Newtonian fluid in a nonintermeshing counter-rotating twin screw extruder was developed by modifying the flow analysis network (FAN) method. The local shear viscosity in the flow field was calculated by an iteration method combing the three types of mean shear rate functions. The modified Cross model and an Arrhenius-type function for temperature dependence were also introduced. Streamlines in the flow field are represented by computing the movements of fluid particles based on the flux fields. The computed residence time from the streamlines led us to solve the energy equation by replacing the coordinate system. The profiles of pressure, shear rate, shear viscosity, temperature, and residence time were simulated. The influence of operating and geometrical parameters on the screw characteristics are discussed. Further, residence time distribution (RTD), strain distribution function (SDF), and interfacial area growth are predicted from the computation of streamlines to analyze the mixing capabilities of the extruder.     

同向平行双螺杆挤出机螺纹元件的齿形计算探讨

螺纹元件是同向双螺杆挤出机积木式螺杆的主要组成部分，直接影响}齐出机的性能和产量，本文介绍了螺纹元件的断面轮廓及轴向齿形的计算方法。     

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.     

聚甲基丙烯酸甲酯双螺杆挤出机设计

介绍了一种聚甲基丙烯酸甲酯的新型脱挥设备.详细介绍了双螺杆挤出机组的结构,并对该机组的设计关键技术进行了阐述和分析.该设备经过实际生产运行考核,产出了高品质产品,获得了用户的高度认可.     

Residence time distribution in a twin screw extruder

The residence time distribution (RTD) in a fully intermeshing, corotating twin screw extruder was determined with a stimulus-response technique. In addition to varying three process parameters (i.e. throughput, screw rotational speed, and barrel temperature), two screw configurations were also studied: one containing four kneading block mixing sections, and the other consisting only of regular screw bushings. Although screw configuration was an important variable, it was found that for both configurations the throughput had the largest effect on RTD. The screw rotational speed was second in importance, and the barrel temperature change produced no effect. A fluid mechanical model based on the fluid flow in a partially-filled rectangular channel was used to explain the experimentally observed dependence of RTD on the process parameters. Reaction engineering approaches were adopted to compare the RTD results of two screw configurations with two idealized flows.     

同向双螺杆挤出机的共混技术

本文论述了聚合物共混须用同向双螺杆挤出机的原理、特征及不同物料的共混技术。     

Scale-up rules for mixing in a non-intermeshing twin-screw extruder

Various scale-up rules and theories have been presented for extrusion, including both single- and twin-screw extruders. Until now, however, most of these theories have concerned fully-filled channels, not only for twin screw extruders of the co-rotating fully intermeshing type (COTSE) or non-intermeshing counter-rotating type (NITSE), but single screw extruders as well. As the demand for distributive mixing and devolatilization devices increases, more and more nonintermeshing twin screw extruders with regions of partially-filled channels are being used. Therefore, developing scale-up rules for such screw extruders is imperative. In this paper, scale-up rules are developed, theoretically and experimentally, by examining the relationship between distributive mixing and important flow parameters. Two partially-filled NITSE's, with screw diameters of 0.8 and 2 inches, have been studied by using a flow visualization technique entailing a dye tracer to study the effects of distributive mixing by varying such parameters as: percentage of drag flow, screw stagger, and screw velocity. Qualitative evaluation of the spread of the dye with the number of screw revolutions was obtained from videotape of the experiments. Factorial experimental design method has been applied for evaluating these results. Finally, new scale-up rules were developed and compared with rules in the literature.     

Compatibilization of a polystyrene-polyethylene blend through reactive processing in a twin screw extruder

Direct grafting of polystyrene onto polyethylene has been carried out in a twin screw extruder with an organic peroxide and a crosslinking co-agent. The reaction extruded blends exhibited enhancement in impact properties at an optimum level of peroxide and co-agent. Further improvement was achieved by introducing styrene monomer into the system during reactive extrusion. The structure and morphology of the blends were studied using differential scanning calorimetry, scanning electron microscopy, infrared spectroscopy, and size exclusion chromatography.     

Flow field analysis of an intermeshing counterrotating twin screw extruder

The intermeshing counterrotating twin screw extruder is widely used for compounding, devolatilization, blending, and reactive extrusion. A fluid dynamics analysis package-FIDAP, using the finite element method, was implemented to simulate the 3-D flow patterns in the region of conveying elements and shearing discs of a Leistritz LSM30.34 twin screw extruder. The rheological behavior of the fluid was described by a power law model. The flow fields were characterized in terms of velocity profiles, pressure distributions, shear stresses generated, and a parameter λ quantifying the elongational flow components. The influence of screw rotational speed and axial pressure difference on the flow characteristics was also analyzed. A comparison between the flow characteristics in the shearing discs operated in a corotating or counterrotating mode was also presented.     

Modeling of peroxide initiated controlled degradation of polypropylene in a twin screw extruder

In this work, experimental and theoretical studies of the free‐radical initiated molecular weight degradation of polypropylene in a modular self‐wiping corotating twin screw extruder have been investigated. Our objective was to build a model that would be able to predict the evolution of the average molecular weight along the screws, in relation to the processing conditions and the geometry of the twin screw extruder. Modeling the process involves resolving interactions occurring between the various flow conditions encountered in the extruder, the kinetics of the reaction and the changes in viscosity with changes in molecular weight. We have studied the influence of operating parameters such as the initial peroxide concentration, the feed rate and the screw speed on the degradation reaction. Good agreement was found between theoretical results and experimental values obtained by size exclusion chromatography measurements.     

Functionalization of PVC by grafting of plasticizing group in a twin screw extruder

Substitution reactions are an appropriate way to attach chemical functions to polymer chains for improving properties and to diversify the application of polymer materials. The stereoselective substitution of chlorine atoms affords a useful way to plasticize polyvinychloride (PVC) by attaching appropriate plasticizing functions (ester group) such as isooctylthiosalicylate. Thus, the substitution of chlorine atoms of PVC by reactant bearing plasticizing groups was carried out in a continuous mixing apparatus such as a twin screw extruder. This continuous chemical engineering process taking place in the extruder is studied as the function of the residence time distribution (RTD) measured by a UV method. This function combined with the kinetics of the chemical reaction allows to define a new function G as the distribution of the extent of conversion by analogy with the RTD function.     

Distributive mixing in conveying elements of a ZSK-53 co-rotating twin screw extruder

A fluid dynamics analysis package (FIDAP), using the finite element method, was implemented to simulate the 3-D isothermal flow patterns in the conveying element of a ZSK-53 co-rotating twin screw extruder. The fluid was described by a power-law model. The dynamics of distributive mixing was studied numerically by tracking the motion of particles in the mixer. The extent of distributive mixing was characterized in terms of length and area stretch as well as strain distributions. The length stretch reflects the overall capability of the mixing device to spread minor component particles away from their neighbors originally present in the same cluster. The area stretch reflects the evolution of intermaterial area when mixing two fluids with a passive interface. We observed an oscillatory behavior for the average intermaterial area stretch, which was explained in terms of a stretching and folding mechanism. Folding occurs during material takeover from one screw to the other. Operating at higher rotational speeds enhances distributive mixing efficiency.     

Stereoselective modification of poly(vinyl chloride) in a twin screw extruder

Continuous chemical modification of poly(vinyl chloride) (PVC) with sodium benzene thiolate (NaBT) in a counter-rotating twin screw extruder has been studied. The course of the reaction is analyzed, taking into account the physical changes of the polymer along the length of the screw. From the results, it is concluded that the modification reaction is associated with the fusion–gelation process. The reaction kinetics are determined as a function of the mean residence time with the aid of a UV tracer. Temperature profile, flow rate, and premixing are some of the processing parameters influencing the reaction, kinetics. The continuous modified polymer is analyzed in terms of thermal behavior, molecular weight, and stereochemical structure, and the results are compared with those obtained by a discontinuous melt process (Haake–Rheocord). It is confirmed that the same stereoselective substitution mechanism occurs as that in discontinuous melt with no side reactions.     

新型螺杆元件对LDPE-g-MAH反应挤出的影响

改变同向双螺杆挤出机主反应区的螺杆元件,研究该螺杆元件对低密度聚乙烯(LDPE)熔融接枝马来酸酐(MAH)的接枝产物和接枝率的影响。傅里叶变换红外光谱分析证实,部分MAH成功接枝到LDPE分子链上。对挤出沿程4个在线取样位置的试样做了对比分析,结果表明具有高剪切性能的捏合盘元件的沿程试样接枝率最大,熔体流动速率最小;具有高分布混合性能的齿形盘元件的沿程试样接枝率较大,熔体流动速率较小;具有回混作用的非啮合多过程元件能够迅速提高该元件所在区域的接枝率。     

A study of foam granulation and wet granulation in a twin screw extruder

This research investigated a new technique known as foam granulation for the continuous manufacturing of pharmaceuticals by a twin screw extruder. Six grades of hypromellose were compared as binders in the trials, using two addition methods: foam injection by auxiliary side stuffer feeder and liquid injection directly into the extruder. The produced granules were tested for particle size, Carr compressibility index and characteristic fracture strength. It was found that granulation using foam injection improved powder lubrication inside the extruder and wetting uniformity of the lactose, as well as produced granules having lower Carr indices. © 2012 Canadian Society for Chemical Engineering