Tools to Simulate Distributive Mixing in Twin‐Screw Extruders

Fard, A Arash Sarhangi; Hulsen, MA Martien; Meijer, Heh Han; Famili, N.; Anderson, Patrick Patrick

doi:10.1002/mats.201100077

Cited by 35 publications

(22 citation statements)

References 30 publications

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“…For first principles simulations of the flow in co-rotating twinscrew extruders, mainly mesh-based CFD (computational fluid dynamics) methods, such as the FEM (finite element method) and FVM (finite volume method), have been used (e.g., Ishikawa, 2001;Bertrand et al, 2003;Malik and Kalyon, 2005;Ficarella et al, 2006a;Ficarella et al, 2006b;Kalyon and Malik, 2007;Barrera et al, 2008;Bierdel, 2008;Conzen, 2008;Rodríguez, 2009;Haghayeghi et al, 2010;Vyakaranam et al, 2012;Sarhangi Fard et al, 2012a;Sarhangi Fard et al, 2012b;Sarhangi Fard and Anderson, 2013;Hétu and Ilinca, 2013;Rathod and Kokini, 2013;Sobhani et al, 2013;Durin et al, 2014). FEM was also used to simulate complex fluids in extruders including wall slip phenomena, (e.g., Kalyon et al, 1999;Lawal et al, 1999;Malik et al, 2014).…”

Section: Introductionmentioning

confidence: 99%

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

Eitzlmayr

Khinast

2015

Chemical Engineering Science

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We applied SPH to study the flow in a co-rotating twin-screw extruder. A new model which accounts for the flow in unresolved clearances was presented. We showed detailed results for pressure drop, flow rate and power consumption. We achieved excellent agreement with CFD data for the completely filled state. Detailed results for the partially filled state are included. a b s t r a c tDue to the complex geometry of the rotating screws and, typically, free surface flows in partially filled screw sections, first principles simulations of the flow in co-rotating intermeshing twin-screw extruders using the well-established, mesh-based CFD (computational fluid dynamics) approaches are highly challenging. These issues can be resolved via the smoothed particle hydrodynamics (SPH) method thanks to its meshless nature and the inherent capability to simulate free surface flows. In our previous work, we developed a novel method for modeling the boundary conditions with complex wall geometries, under which SPH could be efficiently applied to complex surfaces of typical screw geometries of extruders. In this work, we employed SPH and our boundary method to study the flow in a conveying element in detail. To address unresolved clearances, we developed a new model that is coupled to SPH and can correctly account for the flow through unresolved clearances. A validation of our approach using CFD data from the literature for a completely filled conveying element indicated excellent agreement. Consequently, we studied the flow in a partially filled conveying element and obtained results for the flow rate, the power input and the axial force with variable filling ratio. A detailed analysis of the corresponding mixing phenomena is presented in Part 2. Our results show that the proposed method is a comprehensive approach to study the flow in different types of screw elements in detail, providing an excellent basis for further development of simplified models of entire extrusion processes.

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Section: Introductionmentioning

confidence: 99%

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

Eitzlmayr

Khinast

2015

Chemical Engineering Science

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“…This new implementation is easy applicable to 3D flows and represents therefore a major improvement, allowing the use of the method even in complex geometries like those of the Sulzer mixer, but also in dynamic mixers like co-rotating twin screw extruders, see e.g. [83][84][85].…”

Section: Flow and Mixing In Different Designsmentioning

confidence: 99%

On the performance of static mixers: A quantitative comparison

Meijer

Singh

Anderson

2012

Progress in Polymer Science

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113

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This article appeared in a journal published by Elsevier. The attached copy is furnished to the author for internal non-commercial research and education use, including for instruction at the authors institution and sharing with colleagues.Other uses, including reproduction and distribution, or selling or licensing copies, or posting to personal, institutional or third party websites are prohibited. b s t r a c tThe performance of industrially relevant static mixers that work via chaotic advection in the Stokes regime for highly viscous fluids, flowing at low Reynolds numbers, like the Kenics, the Ross Low-Pressure Drop (LPD) and Low-Low-Pressure Drop (LLPD), the standard Sulzer SMX, and the recently developed new design series of the SMX, denoted as SMX(n) (n, N p , N x ) = (n, 2n − 1, 3n), is compared using as criteria both energy consumption, measured in terms of the dimensionless pressure drop, and compactness, measured as the dimensionless length. Results are generally according to expectations: open mixers are most energy efficient, giving the lowest pressure drop, but this goes at the cost of length, while the most compact mixers require large pressure gradients to drive the flow. In compactness, the new series SMX(n), like the SMX(n = 3) (3, 5, 9) design, outperform all other devices with at least a factor 2. An interesting result is that in terms of energy efficiency the simple SMX (1, 1, 4, Â = 135 • ) outperforms the Kenics RL 180• , which was the standard in low pressure drop mixing, and gives results identical to the optimized Kenics RL 140• . This makes the versatile "X"-designs, based on crossing bars, superior in all respects.

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“…First principle simulations of the flow in corotating twin‐screw extruders were mainly conducted via mesh‐based CFD (computational fluid dynamics) methods, such as the finite element method (FEM) and the finite volume method (FVM) . These methods require sophisticated remeshing techniques to manage the rotation of the complex, intermeshing screw geometry.…”

Section: Introductionmentioning

confidence: 99%

Analysis of flow and mixing in screw elements of corotating twin‐screw extruders via SPH

2017

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Due to its meshless nature, the smoothed particle hydrodynamics method (SPH) provides high potential for the simulation of free‐surface flows and mixing in complex geometries. We used SPH to analyze the flow inside five typical screw elements of corotating twin‐screw extruders, two conveying elements, two kneading elements and a mixing element. Our results show conveying capabilities, pressure generation and power input for various operation states, completely and partially filled. We conducted a detailed mixing analysis based on tracer particles, which yielded the time evolution of the intensity of segregation for different tracers. From that, we determined exponential mixing rates, which describe the relative decrease of the intensity of segregation per screw revolution and characterize the mixing performance in different operation states. This provides valuable input information for simplified models of extruders, which are relevant to industrial applications and can significantly contribute to the efficient design, optimization and scale‐up of extruders. © 2017 American Institute of Chemical Engineers AIChE J, 63: 2451–2463, 2017

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Tools to Simulate Distributive Mixing in Twin‐Screw Extruders

Cited by 35 publications

References 30 publications

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics

On the performance of static mixers: A quantitative comparison

Analysis of flow and mixing in screw elements of corotating twin‐screw extruders via SPH

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