Numerical Modeling of the Mixing of Highly Viscous Polymer Suspensions in Partially Filled Sigma Blade Mixers

This paper presents a non-isothermal, non-Newtonian Computational Fluid Dynamics (CFD) model for the mixing of a highly viscous polymer suspension in a partially filled sigma blade mixer. The model accounts for viscous heating and the free surface of the suspension. The rheological model is found by calibration with experimental temperature measurements. Subsequently, the model is exploited to study the effect of applying heat both before and during mixing on the suspension's mixing quality. Two mixing indexes are used to evaluate the mixing condition, namely, the Ica Manas-Zlaczower dispersive index and Kramer's distributive index. Some fluctuations are observed in the predictions of the dispersive mixing index, which could be associated with the free surface of the suspension, thus indicating that this index might not be ideal for partially filled mixers. The Kramer index results are stable and indicate that the particles in the suspension can be well distributed. Interestingly, the results highlight that the speed at which the suspension becomes well distributed is almost independent of applying heat both before and during the process.

Dispersion of Graphite Nanoplates in Polypropylene by Melt Mixing: The Effects of Hydrodynamic Stresses and Residence Time

This work combines experimental and numerical (computational fluid dynamics) data to better understand the kinetics of the dispersion of graphite nanoplates in a polypropylene melt, using a mixing device that consists of a series of stacked rings with an equal outer diameter and alternating larger and smaller inner diameters, thereby creating a series of converging/diverging flows. Numerical simulation of the flow assuming both inelastic and viscoelastic responses predicted the velocity, streamlines, flow type and shear and normal stress fields for the mixer. Experimental and computed data were combined to determine the trade-off between the local degree of dispersion of the PP/GnP nanocomposite, measured as area ratio, and the absolute average value of the hydrodynamic stresses multiplied by the local cumulative residence time. A strong quasi-linear relationship between the evolution of dispersion measured experimentally and the computational data was obtained. Theory was used to interpret experimental data, and the results obtained confirmed the hypotheses previously put forward by various authors that the dispersion of solid agglomerates requires not only sufficiently high hydrodynamic stresses, but also that these act during sufficient time. Based on these considerations, it was estimated that the cohesive strength of the GnP agglomerates is in the range of 5–50 kPa.

Erosion as a possible mechanism for the decrease of size of plastic pieces floating in oceans

A sea water wave tank fitted in an artificial UV light weathering chamber was built to study the behaviour of polypropylene (PP) injected pieces in close ocean-like conditions. In air, the same pieces sees a degradation in the bulk with a decrease of mechanical properties, a little change of crystal properties and nearly no change of surface chemistry. Weathering in the sea water wave tank shows only a surface changes, with no effect on crystals or mechanical properties with loss of small pieces of matter in the sub-micron range and a change of surface chemistry. This suggests an erosion dispersion mechanism. Such mechanism could explain why no particle smaller than about one millimeter is found when collecting plastic debris at sea: there are much smaller, eroded from plastic surfaces by a mechano-chemical process similar to the erosion mechanism found in the dispersion of agglomerate under flow.

Model for the hydrodynamic dispersion of agglomerates incorporating thermoresponsive additives

A phenomenological model for the hydrodynamic dispersion of silica agglomerates modified with a thermoresponsive hydrogel (poly-N-isopropylacrylamide, PNIPAM) is presented. The model well describes experimental observations of the dependence of the dispersion behavior on the presence of additives (water and PNIPAM hydrogels) and applied hydrodynamic stress. Most importantly, the thermosensitivity of the dispersion process is captured by characterizing the agglomerate structure and cohesive force at two different temperatures (above and below the hydrogel transition temperature). The transition in dispersion mechanism between rupture-like and erosion-like regimes with system temperature can also be accommodated within the model.