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

Author

Listed:
  • Abeykoon, Chamil
  • Kelly, Adrian L.
  • Vera-Sorroche, Javier
  • Brown, Elaine C.
  • Coates, Phil D.
  • Deng, Jing
  • Li, Kang
  • Harkin-Jones, Eileen
  • Price, Mark

Abstract

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.

Suggested Citation

  • Abeykoon, Chamil & Kelly, Adrian L. & Vera-Sorroche, Javier & Brown, Elaine C. & Coates, Phil D. & Deng, Jing & Li, Kang & Harkin-Jones, Eileen & Price, Mark, 2014. "Process efficiency in polymer extrusion: Correlation between the energy demand and melt thermal stability," Applied Energy, Elsevier, vol. 135(C), pages 560-571.
  • Handle: RePEc:eee:appene:v:135:y:2014:i:c:p:560-571
    DOI: 10.1016/j.apenergy.2014.08.086
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    Citations

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    Cited by:

    1. Estrada, Omar & Ortiz, Juan Carlos & Hernández, Alexander & López, Iván & Chejne, Farid & del Pilar Noriega, María, 2020. "Experimental study of energy performance of grooved feed and grooved plasticating single screw extrusion processes in terms of SEC, theoretical maximum energy efficiency and relative energy efficiency," Energy, Elsevier, vol. 194(C).
    2. Mkwananzi, Thobeka & Mandegari, Mohsen & Görgens, Johann F., 2019. "Disturbance modelling through steady-state value deviations: The determination of suitable energy indicators and parameters for energy consumption monitoring in a typical sugar mill," Energy, Elsevier, vol. 176(C), pages 211-223.
    3. Abeykoon, Chamil & Kelly, Adrian L. & Brown, Elaine C. & Coates, Phil D., 2016. "The effect of materials, process settings and screw geometry on energy consumption and melt temperature in single screw extrusion," Applied Energy, Elsevier, vol. 180(C), pages 880-894.
    4. Abeykoon, Chamil & McMillan, Alison & Nguyen, Bao Kha, 2021. "Energy efficiency in extrusion-related polymer processing: A review of state of the art and potential efficiency improvements," Renewable and Sustainable Energy Reviews, Elsevier, vol. 147(C).
    5. Zauner, Christoph & Windholz, Bernd & Lauermann, Michael & Drexler-Schmid, Gerwin & Leitgeb, Thomas, 2020. "Development of an Energy Efficient Extrusion Factory employing a latent heat storage and a high temperature heat pump," Applied Energy, Elsevier, vol. 259(C).

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