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.

Process efficiency in polymer extrusion: Correlation between the energy demand and melt thermal stability

Thermal stability is of major importance in polymer extrusion, where product quality is dependent upon the level of melt homogeneity achieved by the extruder screw. Extrusion is an energy intensive process and optimisation of process energy usage while maintaining melt stability is necessary in order to produce good quality product at low unit cost. Optimisation of process energy usage is timely as world energy prices have increased rapidly over the last few years. In the first part of this study, a general discussion was made on the efficiency of an extruder. Then, an attempt was made to explore correlations between melt thermal stability and energy demand in polymer extrusion under different process settings and screw geometries. A commodity grade of polystyrene was extruded using a highly instrumented single screw extruder, equipped with energy consumption and melt temperature field measurement. Moreover, the melt viscosity of the experimental material was observed by using an off-line rheometer. Results showed that specific energy demand of the extruder (i.e. energy for processing of unit mass of polymer) decreased with increasing throughput whilst fluctuation in energy demand also reduced. However, the relationship between melt temperature and extruder throughput was found to be complex, with temperature varying with radial position across the melt flow. Moreover, the melt thermal stability deteriorated as throughput was increased, meaning that a greater efficiency was achieved at the detriment of melt consistency. Extruder screw design also had a significant effect on the relationship between energy consumption and melt consistency. Overall, the relationship between the process energy demand and thermal stability seemed to be negatively correlated and also it was shown to be highly complex in nature. Moreover, the level of process understanding achieved here can help to inform selection of equipment and setting of operating conditions to optimise both energy and thermal efficiencies in parallel. 

Investigation of the process energy demand in polymer extrusion: a brief review and an experimental study

Extrusion is one of the fundamental production methods in the polymer processing industry and is used in the production of a large number of commodities in a diverse industrial sector. 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 reducing operating costs. Usually, extruders consume energy through the drive motor, barrel heaters, cooling fans, cooling water pumps, gear pumps, etc. Typically the drive motor is the largest energy consuming device in an extruder while barrel/die heaters are responsible for the second largest energy demand. This study is focused on investigating the total energy demand of an extrusion plant under various processing conditions while identifying ways to optimise the energy efficiency. Initially, a review was carried out on the monitoring and modelling of the energy consumption in polymer extrusion. Also, the power factor, energy demand and losses of a typical extrusion plant were discussed in detail. The mass throughput, total energy consumption and power factor of an extruder were experimentally observed over different processing conditions and the total extruder energy demand was modelled empirically and also using a commercially available extrusion simulation software. The experimental results show that extruder energy demand is heavily coupled between the machine, material and process parameters. The total power predicted by the simulation software exhibits a lagging offset compared with the experimental measurements. Empirical models are in good agreement with the experimental measurements and hence these can be used in studying process energy behaviour in detail and to identify ways to optimise the process energy efficiency.

Synthesis by extrusion: continuous, large-scale preparation of MOFs using little or no solvent

Grinding solid reagents under solvent-free or low-solvent conditions (mechanochemistry) is emerging as a general synthetic technique which is an alternative to conventional solvent-intensive methods. However, it is essential to find ways to scale-up this type of synthesis if its promise of cleaner manufacturing is to be realised. Here, we demonstrate the use of twin screw and single screw extruders for the continuous synthesis of various metal complexes, including Ni(salen), Ni(NCS)(2)(PPh3)(2) as well as the commercially important metal organic frameworks (MOFs) Cu-3(BTC)(2) (HKUST-1), Zn(2-methylimidazolate)(2) (ZIF-8, MAF-4) and Al(fumarate)(OH). Notably, Al(fumarate)(OH) has not previously been synthesised mechanochemically. Quantitative conversions occur to give products at kg h(-1) rates which, after activation, exhibit surface areas and pore volumes equivalent to those of materials produced by conventional solvent-based methods. Some reactions can be performed either under completely solvent-free conditions whereas others require the addition of small amounts of solvent (typically 3-4 mol equivalents). Continuous neat melt phase synthesis is also successfully demonstrated by both twin screw and single screw extrusion for ZIF-8. The latter technique provided ZIF-8 at 4 kg h(-1). The space time yields (STYs) for these methods of up to 144 x 10(3) kg per m(3) per day are orders of magnitude greater than STYs for other methods of making MOFs. Extrusion methods clearly enable scaling of mechanochemical and melt phase synthesis under solvent-free or low-solvent conditions, and may also be applied in synthesis more generally.

Drift:for tape

nominated for Prix Leonce Petitot, NOROIT, Arras, France

Frame:for soprano sax, bass clarinet and tape

written for and first performed by Julian Siegel (sax) and Simon Atkinson (bass clarinet)

Inside/out:for tape

commissioned by ORF (Austrian Radio) Wien (Heidi Grundmann) for project 'Entree/Sortie' Broadcast 10 January 1991

Plateau:for tape

commissioned by Adventures in Motion Pictures (Matthew Bourne) for Dance Umbrella Festival< London

Suspended Animation 2:for tape

commissioned by Ballet Rambert for the ballet 'Raw', choreographer Mary Evelyn

Interiors:for tape

commissioned by Adrian Jack for ICA Music series, ICA. London

Dangerous Liaisons:for tape

honourable mention, Bourges Festival France 1983
choreographed by Richard Alston for Ballet Rambert 1984
revived by Scottish Ballet (20th Century Classics) Festival Theatre Edinburgh 25/09/04

Wastes:for percussion and tape

commissioned by Cwmni Dawns Gwylan with funds from the Welsh Arts Council, for Chapter Arts Centre, Cardiff. Choreographer Lucy Fawcett. (Nick Parkin, percussion)

Passages:for tape

London premiere performance as part of the Society for the Promotion of New Music Festival, Morley College/St John's Smith Square, London 10-13 September 1981. World premiere at University of East Anglia 2 March 1981. Second performance Nottingham University 9 June 1981.