Characteristic parameters and process maps for fully-filled twin-screw extruder elements

Bauer, Hannes; Matić, Josip; Khinast, Johannes

doi:10.1016/j.ces.2020.116202

Cited by 18 publications

(21 citation statements)

References 32 publications

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“…The used solver is a weekly compressible SPH solver described in more detail in ( Monaghan, 2000 , Monaghan, 1994 , Monaghan, 1992 ; Monaghan and Kajtar, 2009 ), and implemented in our in house developed particle solved XPS (eXtenden Particle System) ( Jajcevic et al, 2013 ; Kureck et al, 2019 ; Siegmann et al, 2017 ; Toson et al, 2018 ). This approach was applied before in our previous work ( Bauer et al, 2020 ; Eitzlmayr et al, 2017 , Eitzlmayr et al, 2014a ; Eitzlmayr and Khinast, 2015a , Eitzlmayr and Khinast, 2015b ; Matić et al, 2019 ) and used to characterize the dimensionless pressure and power characteristics of the investigated screw element pairs. The dimensionless pressure characteristics is defined as the relation between the dimensionless throughput and dimensionless pressure build-up capacity of the screw element pair.…”

Section: Methodsmentioning

confidence: 99%

“…In the past, we have worked on the development of rapid formulation screening tools via vacuum compression molding ( Eder et al, 2017 ; Treffer et al, 2015 ), high-fidelity simulations based on Smoothed Particle Hydrodynamics (SPH) ( Bauer et al, 2020 ; Eitzlmayr et al, 2014a , Eitzlmayr et al, 2017 ; Eitzlmayr and Khinast, 2015b ; Ellero and Tanner, 2005 ; Gingold and Monaghan, 1977 , Gingold and Monaghan, 1982 ; Monaghan, 2005 , Monaghan, 2012 ; Morris et al, 1997 ) and 1D HME mechanistic models ( Eitzlmayr et al, 2014b , Eitzlmayr et al, 2013 ) for HME process analysis, design and scale-up ( Baumgartner et al, 2016 ; Matić et al, 2020b , Matić et al, 2020a , Matić et al, 2019 ). The current study is a follow up of the experiments, simulations and analyses that were earlier performed using the Leistritz 12 mm ZSE12 HP-PH extruder ( Matić et al, 2020a ).…”

Section: Introductionmentioning

confidence: 99%

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Towards predicting the product quality in hot-melt extrusion: Pilot plant scale extrusion

Matić

Alva

Eder

et al. 2021

International Journal of Pharmaceutics: X

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Following our study on the impact of hot melt extrusion (HME) process conditions on the product quality, we expanded our investigation to assessing the effect of scale-up on the product quality. To this end, we studied the influence of process settings and different scale-up variants on the active pharmaceutical ingredient (API) degradation in a pilot plant scale extruder. Six scale-up variants were investigated and none of them could replicate the product quality from the original process setup on a lab-scale extruder. By analyzing several process-dependent and -independent variables and cross referencing them to the experiments in the lab-scale extruder, we identified certain patterns. The results of the reduced order mechanistic 1D HME simulation of various process states made it possible to establish a correlation between the achieved API degradation and the local melt temperature and the exposure time in specific zones along the screw configuration. Since the same melt temperature and exposure time correlations were also valid for the lab scale-extruder, such an approach could be used in the future to predict the product quality as a function of processing conditions fully in silico prior to the first extrusion trials.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Towards predicting the product quality in hot-melt extrusion: Pilot plant scale extrusion

Matić

Alva

Eder

et al. 2021

International Journal of Pharmaceutics: X

Self Cite

View full text Add to dashboard Cite

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“…This novel conveying parameter called element conductance is similar to a die conductance, and is defined in Equation (58). To address problems related to the power consumption behavior of neutral elements, the dimensionless turbine point B 1 was replaced with a novel parameter B 3 , named turbine parameter, and defined by Equation (59). For conveying kneading blocks, the novel parameters can be calculated as functions of the classical parameters according to Equations ( 60) and (61).…”

Section: Dimensionless Characteristic Curvesmentioning

confidence: 99%

“…Over the years, an extensive catalog of such simulation studies has accumulated. [41][42][43][44][45][46][47][48][49][50][51][52][53][54] Khinast et al [55][56][57][58][59] proposed a particle-hydrodynamics method for twin-screw extrusion modeling that, due to its meshless nature, does not require any complicated remeshing techniques. Dong [60] simulated partially filled conveying elements by applying such a smoothed particle hydrodynamics method.…”

mentioning

confidence: 99%

Modeling melt conveying and power consumption of co‐rotating twin‐screw extruder kneading blocks: Part A. Data generation

Stritzinger

Roland

Berger‐Weber

et al. 2022

Polymer Engineering & Sci

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Mathematical models of polymer melt flow in co‐rotating twin‐screw extruders are crucial to screw design and predict processing characteristics, such as pressure distribution, back‐pressure lengths, degree of filling, melt‐temperature increase, and drive power. Twin‐screw modeling focuses predominantly on conveying elements, and kneading blocks are commonly represented with fictitious continuous flights, which significantly simplifies geometry and ignores considerable leakage flow. This work (Part A) presents a comprehensive analysis of the conveying characteristics and power demands of fully intermeshing co‐rotating twin‐screw extruder kneading blocks that considers the complex three‐dimensional geometry without geometrical simplifications. This analysis comprises the following steps: (1) dimensionless description of the geometry, (2) simplification of the governing equations, (3) formulation of novel dimensionless conveying and power parameters, and (4) a parametric design study with the novel approach of using the characteristic angular screw position, which avoids complex numerical algorithms and drastically reduces the computation required. Our comprehensive parametric design study included 1536 independent design points—a vast amount of data that revealed various effects that are highlighted in this work, including new findings on the interactions between geometry and conveying and power parameters. The obtained results serve, for example, as the basis for screw design, optimizations, scale‐up, and soft sensors.

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“…22 Compared with the traditional solution-based conditions, reactive extrusion can mix the reactants under solvent-free condition and induce the reaction and assembly under high pressure and shearing force as well. 23 Different from ball milling, twin-screw extrusion can exactly control the temperature of the whole process and can satisfy the continuous production, proportionally to kgh -1 on the lab scale. 24,25 What's more, the related chemical law models of reactive extrusion are well developed.…”

Section: Introductionmentioning

confidence: 99%

Cyclic Extrusion Synthesis of Mesoporous Carbon-Supported Metal Catalysts for Selective Hydrogenation

Zhang

Hou

et al. 2022

Preprint

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The mesoporous carbon-supported metal catalysts are important materials in heterogeneous catalysis. From the standpoint of process intensification, the current synthesis methods still suffer from several issues, such as the excessive use of toxic solvents, the time-consuming self-assembly process, and the difficulty of continuous production. Herein, we report a solvent-free and continuous route to synthesize mesoporous carbon-supported metal catalysts. Interestingly, the use of cyclic extrusion could promote the mixing, coordination, and assembly of catalyst precursors (tannin-metal salts-additives) by shearing and squeeze force. The as-made mesoporous carbon-supported nickel showed high surface areas (up to 512m2g-1), narrow pore size distribution (~10 nm), and good performance in the selective hydrogenation of nitrobenzene to aniline (Conv.>99%; Sel.>99%). In addition, the fluid property of catalyst precursors and the geometry of the twin-screw extrusion channel were studied, and the essence of this cyclic extrusion process is also discussed.

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Characteristic parameters and process maps for fully-filled twin-screw extruder elements

Cited by 18 publications

References 32 publications

Towards predicting the product quality in hot-melt extrusion: Pilot plant scale extrusion

Towards predicting the product quality in hot-melt extrusion: Pilot plant scale extrusion

Modeling melt conveying and power consumption of co‐rotating twin‐screw extruder kneading blocks: Part A. Data generation

Cyclic Extrusion Synthesis of Mesoporous Carbon-Supported Metal Catalysts for Selective Hydrogenation

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