Monitoring and modelling of the energy consumption in polymer extrusion

Abstract

Extrusion is one of the fundamental methods in polymer processing and is involved in the production of various commodities in diverse industrial sectors. Being an energy intensive production method, process energy efficiency is one of the major concerns and the selection of the most energy efficient processing conditions is a key to reduce operating expenses. Usually, extruders consume energy through the drive motor, barrel heaters, cooling fans, cooling water pumps, gear pumps, etc. Typically the drive motor is the dominant energy consuming device in a polymer processing extruder while barrel/die heaters are responsible for the second largest energy demand. This study was focused on investigating the total energy demand of an extrusion plant while identifying ways to optimise the energy consumption. Total energy consumption of a single screw extruder was measured over different processing conditions and then modelled as a function of a number of major process variables. The results show that the extruder energy demand is heavily coupled with machine, material and process parameters. Also, the proposed models show excellent agreement with the experimental measurements and hence these should be useful in optimising process energy efficiency.

Powder‐Based Additive Manufacturing: A Critical Review of Materials, Methods, Opportunities, and Challenges

“…They mainly include three forms of polymer feed: wire, photosensitive resin, and polymer powder. Since the polymer powders require low sintering energy, simple sintering process, and ensures good prototype quality, it is widely used in AM [ 211–213 ] and particularly in PBF methods such as SLS. [ 214 ] AM moulding requires polymer powders with low powder agglomeration temperature, low shrinkage, low internal stress, high strength, and good fluidity.…”

Fused Deposition Modelling of Polymer Composite: A Progress

“…The material is fed into the barrel through the feed throat by gravity force, and in most single screw extruders, the speed of the screw controls the output rate. High pressure to transfer material from the feed system causes the plastic pellet or powder to condense into a solid bed [ 155 ]. Periodically, the mass flow rate is unaffected by the speed of the screw and is regulated directly from the feed system by using a starving fed mechanism, resulting in an output rate that is lower than the forwarding efficiency of the screw [ 156 , 157 ].…”