A new scale-up approach for dispersive mixing in twin-screw compounding

Fukuda, Graeme; Bigio, David I.; Andersen, Paul G.; Wetzel, Mark D.

doi:10.1063/1.4918474

Cited by 6 publications

(6 citation statements)

References 2 publications

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“…The authors found that the percent drag flow scaling resulted in significantly different coefficients and response surfaces compared to the volumetric scaling. In addition, the narrow KB %DF scaling more accurately recreated the stress behavior of the 18 mm extruder .…”

Section: Resultsmentioning

confidence: 98%

Comparison of scale‐up methods for dispersive mixing in twin‐screw extruders

Dryer

Fukuda

Webb

et al. 2016

Polymer Engineering & Sci

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Twin‐screw extrusion processes are commonly refined on laboratory‐scale extruders then scaled‐up to manufacturing systems. When using twin‐screw extrusion to compound filler into a polymer, the dispersion of the filler must be considered during scale‐up. In this work, two scale‐up methods are evaluated for how accurately they scale dispersion as measured by the Residence Stress Distribution, an experimental method that quantifies stress developed in a twin‐screw extruder. The first scale‐up method evaluated is the industry‐standard scaling based on maintaining equivalent volumetric flow rate across extruder sizes. Volumetric scaling is compared to a second, novel scale‐up method, the percent drag flow rule, which maintains the same degree of fill in the strongest dispersive screw elements on all extruder sizes. Both scale‐up rules have been used to scale between three extruder sizes and have been evaluated for how accurately the larger extruders recreate the dispersive mixing of the smallest machine. Results indicate that the percent drag flow scale‐up more accurately maintains dispersive mixing behavior than the volumetric scaling. Furthermore, percent drag flow scale‐up resulted in all three extruder sizes behaving similarly to changes in operating conditions. These results indicate that percent drag flow scale‐up is a valid technique to scale real industrial processes. POLYM. ENG. SCI., 57:345–354, 2017. © 2016 Society of Plastics Engineers

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Section: Resultsmentioning

confidence: 98%

Comparison of scale‐up methods for dispersive mixing in twin‐screw extruders

Dryer

Fukuda

Webb

et al. 2016

Polymer Engineering & Sci

Self Cite

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“…Alternatively, it can be aimed at keeping constant operating conditions such as shear rates, general screw configuration, discharge pressures, specific heating or residence times as reported in Ref. 32 In the past, also power law expressions were suggested which originate from single‐screw extrusion, such as 33,34 :

\frac{X_{1}}{X_{2}} = {((), \frac{D_{1}}{D_{2}})}^{x}

where

X_{1}

and

X_{2}

indicate a quantity of interest (e.g., residence time, pressure, shear rate) for the current and the scaled‐up extruder. The drawback of the similarity‐based approach is that its performance depends on the choice of the relationship that is used for scale‐up.…”

Section: Methodsmentioning

confidence: 99%

Optimal design and operation of reactive extrusion processes: Application to the production and scale‐up of polyurethane rheology modifiers for paints

Cegla,

Fage,

Kemmerling

et al. 2023

Polymer Engineering & Sci

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In this work, the methodology for the optimal design, operation and scale‐up of reactive extrusion processes in twin‐screw extruders previously presented in Reference (Cegla and Engell, 2023). is applied to the production of hydrophobically ethoxylated urethanes (HEURs). The new process is a promising alternative to the current batch technology in large reactors with long residence times. We demonstrate the use of model‐based design and scale‐up for this case. A novel mechanistic finite volume twin‐screw extruder model is used as the process model, which is adapted to the process at hand by embedding a detailed description of the HEUR chemistry and rheology. An economic cost function is used to examine the scale‐up process from an 18 mm extruder to a 27 and 75 mm extruders, considering a selected range of products. The comparison between the optimization results obtained for the individual products with the optimization results for the production of multiple material grades using the same screw setup shows the high flexibility of the extruder‐based process. Significant energy savings compared with the conventional batch process can be achieved using reactive extrusion. To quantify the effort for the transition to a purely continuous production in terms of flexibility and process logistics, product changeovers are investigated.Highlights Intensification of the HEUR production by reactive extrusion. Detailed model for the twin‐screw extruder and the chemistry. Optimization of extruder, screw design, and operating conditions. Model‐based scale‐up from laboratory to industrial scale. Investigation of flexible industrial production of different HEURs.

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“…Second-order interaction effects existed, making this process difficult to control with such a simple optimization methodology. Fukuda et al [ 73 ] used a DOE to analyse separately two different scale-up rules, one based on the volumetric flow rate, the other related to dispersive mixing, with the aim of optimizing the operating conditions of the target extruder.…”

Section: Optimization Algorithms In Polymer Processingmentioning

confidence: 99%

Optimization of Polymer Processing: A Review (Part I—Extrusion)

2022

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Given the global economic and societal importance of the polymer industry, the continuous search for improvements in the various processing techniques is of practical primordial importance. This review evaluates the application of optimization methodologies to the main polymer processing operations. The most important characteristics related to the usage of optimization techniques, such as the nature of the objective function, the type of optimization algorithm, the modelling approach used to evaluate the solutions, and the parameters to optimize, are discussed. The aim is to identify the most important features of an optimization system for polymer processing problems and define the best procedure for each particular practical situation. For this purpose, the state of the art of the optimization methodologies usually employed is first presented, followed by an extensive review of the literature dealing with the major processing techniques, the discussion being completed by considering both the characteristics identified and the available optimization methodologies. This first part of the review focuses on extrusion, namely single and twin-screw extruders, extrusion dies, and calibrators. It is concluded that there is a set of methodologies that can be confidently applied in polymer processing with a very good performance and without the need of demanding computation requirements.

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A new scale-up approach for dispersive mixing in twin-screw compounding

Cited by 6 publications

References 2 publications

Comparison of scale‐up methods for dispersive mixing in twin‐screw extruders

Comparison of scale‐up methods for dispersive mixing in twin‐screw extruders

Optimal design and operation of reactive extrusion processes: Application to the production and scale‐up of polyurethane rheology modifiers for paints

Optimization of Polymer Processing: A Review (Part I—Extrusion)

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