Automatic extruder for processing recycled polymers with ultrasound and temperature control system

Melt viscosity is one of the main factors affecting product quality in extrusion processes particularly with regard to recycled polymers. However, due to wide variability in the physical properties of recycled feedstock, it is difficult to maintain the melt viscosity during extrusion of polymer blends and obtain good quality product without generating scrap. This research investigates the application of ultrasound and temperature control in an automatic extruder controller, which has ability to maintain constant melt viscosity from variable recycled polymer feedstock during extrusion processing. An ultrasonic modulation system has been developed and fitted to the extruder prior to the die to convey ultrasonic energy from a high power ultrasonic generator to the polymer melt. Two separate control loops have been developed to run simultaneously in one controller: the first loop controls the ultrasonic energy or temperature to maintain constant die pressure, the second loop is used to control extruder screw speed to maintain constant throughput at the extruder die. Time response and energy consumption of the control methods in real-time experiments are also investigated and reported this paper.

Viscosity Control for Extrusion Processes Using Recycled Polymers

The aim of this paper is to develop a new extruder control system for recycled materials which has ability to automatically maintain constant a polymer melt viscosity of mixed recycled polymers during extrusion, regardless of variations in the Melt Flow Index (MFI) of recycled mixed grade high density polyethylene (HDPE) feedstock. A closed-loop controller is developed to automatically regulate screw speed and barrel temperature profile to achieve constant viscosity and enable consistent processing of variable grade recycled HDPE materials. The experimental results of real time viscosity measurement and control using a 38mm single screw extruder with different recycled HDPEs with widely different MFIs are reported in this work

Recycled carbon fiber filled polyethylene composites

Composites of recycled carbon fiber (CF) with up to 30 wt % loading with polyethylene (PE) were prepared via melt compounding. The morphology of the composites and the degree of dispersion of the CF in the PE matrix was examined using scanning electron microscopy, and revealed the CF to be highly dispersed at all loadings and strong interfacial adhesion to exist between the CF and PE. Raman and FTIR spectroscopy were used to characterize the surface chemistry and potential bonding sites of recycled CF. Both the Young's modulus and ultimate tensile stress increased with increasing CF loading, but the percentage stress at break was unchanged up to 5 wt % loading, then decreased with further successive addition of CF. The effect of CF on the elastic modulus of PE was examined using the Halpin-Tsai and modified Cox models, the former giving a better fit with the values determined experimentally. The electrical conductivity of the PE matrix was enhanced by about 11 orders of magnitude on addition of recycled CF with a percolation threshold of 7 and 15 wt % for 500-mu m and 3-mm thick samples. (c) 2007 Wiley Periodicals, Inc.

Real time measurement and control of viscosity for extrusion processes using recycled materials

The aim of this paper is to develop a new generation of extruder control system for recycled materials which has ability to automatically maintain constant a polymer melt viscosity of mixed recycled polymers during extrusion, regardless of variations in the Melt Flow Index (MFI) of recycled mixed grade high density polyethylene (HDPE) feedstock. The variations in MFI are due to differences in the source of the recycled material used. The work describes how melt viscosity for specific extruder/die system is calculated in real time using the rheological properties of the materials, the pressure drop through the extruder die and the actual throughput measurements using a gravimetric loss-in-weight hopper feeder. A closed-loop controller is also developed to automatically regulate screw speed and barrel temperature profile to achieve constant viscosity and enable consistent processing of variable grade recycled HDPE materials. Such a system will improve processability of mixed MFI polymers may also reduce the risk of polymer melt degradation, reduce producing large volumes of scrap/waste and lead to improvement in product quality. The experimental results of real time viscosity measurement and control using a 38 mm single screw extruder with different recycled HDPEs with widely different MFIs are reported in this work.