On-Line Optical Monitoring of the Mixing Performance in Co-Rotating Twin-Screw Extruders

The use of real-time techniques to evaluate the global mixing performance of co-rotating twin-screw extruders is well consolidated, but much less is reported on the specific contribution of individual screw zones. This work uses on-line flow turbidity and birefringence to ascertain the mixing performance of kneading blocks with different geometries. For this purpose, one of the barrel segments of the extruder was modified in order to incorporate four sampling devices and slit dies containing optical windows were attached to them. The experiments consisted in reaching steady extrusion and then adding a small amount of tracer. Upon opening each sampling device, material was laterally detoured from the local screw channel, and its turbidity and birefringence were measured by the optical detector. Residence time distribution curves (RTD) were obtained at various axial positions along three different kneading blocks and under a range of screw speeds. It is hypothesized that K, a parameter related to the area under each RTD curve, is a good indicator of dispersive mixing, whereas variance can be used to assess distributive mixing. The experimental data confirmed that these mixing indices are sensitive to changes in processing conditions, and that they translate the expected behavior of each kneading block geometry.

Dynamics of Filler Size and Spatial Distribution in a Plasticating Single Screw Extruder – Modeling and Experimental Observations

A model of agglomerate break-up, incorporating both rupture and erosion, is employed to predict the dynamics of filler size distribution in a plasticating single screw extruder. Filler spatial distribution along the extruder length was also ascertained and direct comparison of experimental and computational data proved to be satisfactory. The method was also used to investigate the effect of material properties, operating conditions and extruder geometry on the dynamics of agglomerate dispersion along a single screw extruder. Generally, dispersion levels were primarily governed by the magnitude of the hydrodynamic stresses developed in the extruder and the residence time in the melt.

Modeling of Agglomerate Dispersion in Single Screw Extruders

A model for solid agglomerate dispersion in single screw extruders is proposed. The model combines numerical simulations of flow patterns in the metering section of a single screw extruder with a Monte Carlo method of clusters rupture and erosion mediated by a local fragmentation number. Particle size distributions and Shannon entropy are used for mixing characterization. The model is quite general and can be adapted for different polymer-additive systems as well as for different processing equipment.