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Energy efficiency in extrusion-related polymer processing: A review of state of the art and potential efficiency improvements

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  • Abeykoon, Chamil
  • McMillan, Alison
  • Nguyen, Bao Kha

Abstract

Energy saving and industrial pollution have become increasingly important issues, therefore the identification and adoption of more energy efficient machines and industrial processes are now industrial priorities, and worthy topics for further development through academic research. Polymeric materials are a major raw material, finding widespread application to a range of current industrial machine components as well as multiple products and packaging found in our daily life. Polymer extrusion serves as a particular example of polymer processing techniques, representative of others in as much as there are analogous intermediate stages in the processing. Processing techniques which require such intermediate stages include the manufacture of blown film, blow moulding, thermo-forming, and injection moulding. Hence, the study of polymer extrusion is a representative paradigm for a wider range of processing techniques. Since polymer processing is an energy intensive process and accounts for a huge share (maybe more than 1/3) of the materials processing sector, any improvement to the process would contribute significantly to global energy savings. This work presents a review of studies, which focus on, or appertain to, the energy consumption of extrusion related polymer processing applications. Typical energy demand and losses during processing are considered, and possible approaches for improving the process energy efficiency while maintaining the required end product quality are considered. Overall, this work provides a detailed discussion about how and where energy is utilised; how, where and why energy losses occur; and sets out approaches for optimising the process energy efficiency.

Suggested Citation

  • 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).
    • Handle: RePEc:eee:rensus:v:147:y:2021:i:c:s1364032121005062
    DOI: 10.1016/j.rser.2021.111219
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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. Joo Hock Ang & Cindy Goh & Alfredo Alan Flores Saldivar & Yun Li, 2017. "Energy-Efficient Through-Life Smart Design, Manufacturing and Operation of Ships in an Industry 4.0 Environment," Energies, MDPI, vol. 10(5), pages 1-13, April.
    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 & 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.
    5. 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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