Flow field analysis of the kneading disc region in a co-rotating twin screw extruder

Co-rotating, intermeshing twin screw extruders are widely used in polymer compounding and blending. Among the different modules of the co-rotating twin screw extruder, the kneading discs are the dominant ones in determining mixing efficiency. The major difficulty in solving the flow problem in the kneading disc region arises from the complex geometry and the time-dependent flow boundaries as the discs rotate. In this work, a fluid dynamics analysis package—FIDAP—using the finite element method was employed to simulate the flow patterns in the kneading disc region of a Werner & Pfleiderer ZSK-30 co-rotating twin screw extruder. The problem of time dependent flow boundaries was solved by selecting a number of sequential geometries to represent a complete mixing cycle. The flow field was characterized in terms of velocity profiles, pressure distributions, shear stresses generated and a parameter λ quantifying the elongational flow components. The last two parameters are the most important ones in analyzing mixing efficiency. The influence of design variables (stagger angle, right or left handed configuration) and processing conditions (rpm, axial pressure gradient) on the flow characteristics was analyzed.     

Numerical simulation and experimental validation of mixing performance of kneading discs in a twin screw extruder

This work aims at simulation by particle tracking the local residence time distributions (RTDs) of a co‐rotating twin‐screw extruder using computational fluid dynamics. Simulated results follow reasonably well the trend of experimental results obtained by an in‐line measuring instrument for different screw configurations and feed rates. To analyze the distributive mixing performance and overall efficiency of different types of kneading discs (KDs), mixing parameters such as area stretch ratio, instantaneous efficiency, and time‐average efficiency are calculated. Among KDs with stagger angles 45°, 60°, and 90°, the 90/10/64 with disc gaps is most efficient in terms of distributive mixing. The effects of the disc width and disc gap on the local RTD and distributive mixing are also discussed. This provides a numerical tool for assessing point‐by‐point information on the local RTD, flow, and mixing along the screw extruder. POLYM. ENG. SCI., 2009. © 2009 Society of Plastics Engineers     

串联式磨盘螺杆挤出机磨盘混炼段分布混合性能的研究

采用计算流体力学软件POLYFLOW 对串联式磨盘螺杆挤出机的磨盘研磨混炼段进行三维等温流动的数值模拟,并从统计学和动力学角度,采用分离尺度和时间平均混合效率,对磨盘区域的分布混合性能进行分析,研究磨盘构型和磨盘间隙对分布混合性能的影响.结果表明,臼目形磨盘的分布混合性能较好;磨盘间隙增大在一定程度上有利于提高分布混合性能.     

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.     

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.     

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.     

Granulation rate processes in the kneading elements of a twin screw granulator

To characterize the granulation rate processes in the kneading section of the twin screw granulator, separate experiments were conducted using exclusively conveying elements as the baseline in addition to different configurations of kneading elements. The configuration parameters examined were the length of the kneading section, the advance angle, and the angle direction. Granule size, shape and liquid distribution were measured. Two main rate processes were observed (1) breakage and layering, and (2) Shear elongation and layering. Breakage was dominant in the 90° configuration while shear elongation dominated in the 30° reverse configurations, with other configurations giving some combination of the two rate processes. The distinct three‐dimensional (3‐D) shape characteristics of granules obtained from each configuration were crucial in elucidating the dominant granulation rate process in each case. The proposed granulation mechanisms explain the events leading to particular granule attributes, but more importantly provide insight into future optimization of twin screw granulation process. © 2013 American Institute of Chemical Engineers AIChE J, 59: 4100–4115, 2013     

Polymer blend mixing and dispersion in the kneading section of a twin-screw extruder

This paper examines the mechanisms by which a polymer is dispersed in a co-rotating twin-screw extruder. An experimental investigation of the morphological evolution has been carried out on a 45-mm co-rotating twin-screw extruder. Polyethylene/polystyrene (PE/PS) blends in the low concentration range (i.e., 5–15 wt% of PE) were used as a model system. The following general trends were observed. First, the minor phase right after melting is predominantly in a fibrillar form. Secondly, droplet and fiber diameter at this early stage of compounding are already in the micron or sub-micron range. Even though a wide variety of mixing section configurations were used, the fibers created in the early compounding stages were relatively stable throughout extrusion. Morphological evolution after melting must therefore be discussed in terms of variation in the fiber fraction (i.e., fiber to droplet transition) rather than in a change in particle diameter. A control volume model for the flow in kneading blocks is used to interpret the morphological results and to predict the deformation and breakup of dispersed phase fibers under shear and in absence of coalescence. Theoretical results indicate that fiber breakup under shear is not likely in the kneading block under the normal processing conditions, which is confirmed by morphological observations made at the mixing section exit. The influence of several geometrical parameters on mixing and pumping in kneading blocks is also discussed with the use of flow model results.     

Experimental investigation of the energy balance for the metering zone of a twin screw extruder

The object of this study is to investigate experimentally the mechanical power transported from the screws to the polymer melt, the heat dissipated in the polymer melt, and the heat transferred to the barrel of the metering zone of a co‐rotating twin screw extruder. For the experimental investigations, different screw elements, mixing elements, and kneading discs are used. The experimental results for the dissipation show good agreement with known calculation models. For the calculation of the heat transfer, a new equation is used to calculate the mean temperature difference under consideration of the dissipation. The Nusselt‐number can be calculated in good agreement with the experimental results as a function of the Brinkmann‐number.     

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。     

Color mixing in the metering zone of a single screw extruder: Numerical simulations and experimental validation

We present numerical simulations for an acrylonitrile‐butadiene‐styrene copolymer (ABS) resin extrusion in an industrial conventional single‐screw extruder. Based upon the flow field patterns obtained in the simulations, a particle tracking procedure was employed to obtain information about the spatial distribution of particle tracers of two colors. Results of the simulation were compared with experimental data obtained under similar extrusion conditions. To evaluate the degree of color mixing and color homogeneity for the system, we employ a specific index calculated based upon the Shannon entropy for two species populations. POLYM. ENG. SCI., 45:1011–1020, 2005. © 2005 Society of Plastics Engineers     

3‐D numerical simulations for polycondensation of poly(p‐phenylene terephthalamide) in twin screw extruder

Poly(p‐phenylene terephthalamide) (PPTA) is a typical high‐performance fiber and usually synthesized by low temperature solution polycondensation in twin screw extruder. During the reactive extrusion, flow behavior, rheokinetics, and temperature are highly coupled, which makes it difficult to ensure the quality of product. In the present work, the rheokinetics of the PPTA solution is established by experiments and its reactive extrusion is investigated via 3‐D numerical simulation. The flow pattern, molecular weight distribution and temperature have been investigated for the extruders with three different elements, i.e., full flight screw (FF), kneading block (KB), and screw mixing element (SME). The results indicate that the unique flow characteristic of different screw elements affects mixing experience of the reactants and further the PPTA qualities. By numerical simulation, it shows the temperature increase within the tested extrusion stage is 7 K and reaction heat is found the main energy source for extrusion stage. Furthermore, heat removal method is verified with consideration of industrial production process. The numerical simulation work also discusses the reaction and mixing process in the extruders with three combined screws. The results show the introduction of more reverse FF and KB elements can lead to higher quality of PPTA. POLYM. ENG. SCI., 57:1252–1261, 2017. © 2017 Society of Plastics Engineers     

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.     

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。     

Finite element modeling of a counter-rotating,non-intermeshing twin screw extruder

This paper is concerned with Newtonian flow in a counter-rotating non-intermeshing twin-screw extruder. Both the matched and the mismatched screw flight configurations are considered. A three-dimensional analysis of the pressure flow through the complete extruder cross-section is included. The model predictions agree well with the experimental data. Computed examples are given to illustrate the utility of this work.     

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.     

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.     

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.     

挤出机螺杆计量段的优化设计

讨论了挤出机螺杆计量段的优化设计问题。应用粘性流体动力学基本方程，分析了聚合物物料在螺槽中的流动。以单位产量能耗最小为优化目标，建立简化的挤出机计量段螺杆优化设计的数学模型，应用约束随机方向法求解。结果表明，螺槽深度、螺纹棱顶宽度、螺纹棱顶与机筒间隙和螺纹升角均位于或接近于献中所建议的最佳取值范围。