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The effect of materials, process settings and screw geometry on energy consumption and melt temperature in single screw extrusion

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  • Abeykoon, Chamil
  • Kelly, Adrian L.
  • Brown, Elaine C.
  • Coates, Phil D.

Abstract

Polymer extrusion is an energy intensive production process and process energy efficiency has become a key concern in the current industry with the pressure of reducing the global carbon footprint. Here, knowledge of the pattern of energy usage and losses of each component in the plant is highly useful in the process energy optimization. Moreover, it is essential to maintain the melt quality while improving the energy efficiency in polymer processing. In this work, an investigation was made on the total energy consumption, drive motor energy consumption, power factor and the melt temperature profile across the die melt flow (as an indication of the melt thermal quality) of an industrial scale extruder with three different screw geometries, three polymer types and wide range of processing conditions (altogether 135 different processing situations were observed). This aims to widen the knowledge on process energy and thermal behaviors while exploring possible correlation/s between energy demand and melt quality (in terms of melt temperature fluctuations across the melt flow). The results showed that the level and fluctuations of the extruder’s power factor is particularly dependent upon the material being processed. Moreover, it seems that there is a relation between the level of energy demand of the heaters and the level of melt temperature fluctuations. While the extruder specific energy consumption decreases with increasing screw speed, specific energy consumption of the drive motor may have either increasing or decreasing behavior. Overall, this study provides new insights in a wide range on process energy demand and melt thermal quality in polymer extrusion. Moreover, further research is recommended to establish strong correlation/s between process energy consumption and melt thermal quality which should help to enhance process control and hence the product quality in single screw polymer extrusion.

Suggested Citation

  • 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.
    • Handle: RePEc:eee:appene:v:180:y:2016:i:c:p:880-894
    DOI: 10.1016/j.apenergy.2016.07.014
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    References listed on IDEAS

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    1. 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.
    2. 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.
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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. Delon Konan & Ekoun Koffi & Adama Ndao & Eric Charles Peterson & Denis Rodrigue & Kokou Adjallé, 2022. "An Overview of Extrusion as a Pretreatment Method of Lignocellulosic Biomass," Energies, MDPI, vol. 15(9), pages 1-25, April.
    3. 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).
    4. Canice C. Uzosike & Lachlan H. Yee & Ricardo Vasquez Padilla, 2023. "Small-Scale Mechanical Recycling of Solid Thermoplastic Wastes: A Review of PET, PEs, and PP," Energies, MDPI, vol. 16(3), pages 1-23, January.

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