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

Author

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

Abstract

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.

Suggested Citation

  • Abeykoon, Chamil & Kelly, Adrian L. & Brown, Elaine C. & Vera-Sorroche, Javier & Coates, Phil D. & Harkin-Jones, Eileen & Howell, Ken B. & Deng, Jing & Li, Kang & Price, Mark, 2014. "Investigation of the process energy demand in polymer extrusion: A brief review and an experimental study," Applied Energy, Elsevier, vol. 136(C), pages 726-737.
    • Handle: RePEc:eee:appene:v:136:y:2014:i:c:p:726-737
    DOI: 10.1016/j.apenergy.2014.09.024
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    References listed on IDEAS

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    1. Deng, Jing & Li, Kang & Harkin-Jones, Eileen & Price, Mark & Karnachi, Nayeem & Kelly, Adrian & Vera-Sorroche, Javier & Coates, Phil & Brown, Elaine & Fei, Minrui, 2014. "Energy monitoring and quality control of a single screw extruder," Applied Energy, Elsevier, vol. 113(C), pages 1775-1785.
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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. Jessica Walther & Matthias Weigold, 2021. "A Systematic Review on Predicting and Forecasting the Electrical Energy Consumption in the Manufacturing Industry," Energies, MDPI, vol. 14(4), pages 1-24, February.
    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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    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. 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).

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