Numerical analysis of mixing in block‐head mixing screws

The research reported here used 3D non‐Newtonian flow simulations to investigate the pumping and mixing capability of block‐head mixers. Block‐head mixers are distributive mixing screws that are widely used to homogenize the polymer melt and eliminate thermal gradients. The polymer‐processing industry employs a variety of block‐head mixers, with little consensus on design and distribution of screw flights and mixing blocks. This analysis addresses this issue based on a computational design study in which the influence of three geometrical parameters was examined: (1) the number of flights at a mixing block, (2) the number of blocks along the screw, and (3) the stagger angle between the blocks. To examine the flow behavior of the mixing screws, the pressure consumption and energy dissipation is evaluated. Distributive mixing is analyzed using residence time distribution functions, kinematic stretching parameters, and the scale of segregation. Dispersive mixing is assessed by means of the mixing index and the shear stress. The results of this design study increase the understanding of block‐head mixers and contribute to the design and optimization of such geometries. The findings can further be applied to mixing screws of similar geometry, including pin‐type and knob mixers. POLYM. ENG. SCI., 59:E88–E104, 2019. © 2018 The Authors. Polymer Engineering & Science published by Wiley Periodicals, Inc. on behalf of Society of Plastics Engineers.