MEΡΟ VI ΔΚΒΟΛΖ ΠΟΛΤΜΔΡΧΝ (POLYMER EXTRUSION)
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- Ἀπόλλωνιος Δάβης
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1 MEΡΟ VI ΔΚΒΟΛΖ ΠΟΛΤΜΔΡΧΝ (POLYMER EXTRUSION) Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
2 ΣΗ ΔΗΝΑΗ Ζ ΔΚΒΟΛΖ? ΜΗΑ ΑΠΌ ΣΗ ΚΤΡΗΔ ΓΗΔΡΓΑΗΔ ΣΖΝ ΒΗΟΜΖΥΑΝΗΑ ΠΟΛΤΜΔΡΧΝ ΤΝΔΥΖ ΓΗΔΡΓΑΗΑ ΜΔ ΜΔΓΑΛΖ ΔΤΔΛΗΞΗΑ ΟΟΝ ΑΦΟΡΑ ΣΟ ΣΔΛΗΚΟ ΠΡΟΗΟΝ ΤΥΝΑ ΔΊΝΑΗ ΣΟ ΠΡΧΣΟ ΣΑΓΗΟ Δ ΜΗΑ ΔΗΡΑ ΓΗΔΡΓΑΗΧΝ ΜΟΡΦΟΠΟΗΖΖ Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
3 Δ ΠΟΗΑ ΠΟΛΤΜΔΡΖ ΔΦΑΡΜΟΕΔΣΑΗ Primary Uses are Thermoplastics: LDPE, LLDPE, HDPE, ABS, PC, PS, Nylon, PVC, PP Melt Index and Density should be matched to application Some uses for Elastomers and Thermosets Important to watch age of material and processing conditions Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
4 ΔΗΓΖ ΔΚΒΟΛΖ ΠΟΛΤΜΔΡΧΝ Compounding Pellets for future use Blown Film Bags, film. Cast Film Sheet Plastic Food Packaging Foam Trays, packaging via thermoforming Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
5 ΔΗΓΖ ΔΚΒΟΛΖ ΠΟΛΤΜΔΡΧΝ Compounding Pellets for future use Blown Film Bags, film. Cast Film Plastic Food Packaging Sheet Foam Trays, packaging via thermoforming 5/15/2017
6 ΔΗΓΖ ΔΚΒΟΛΖ ΠΟΛΤΜΔΡΧΝ Pipe and Tubing PVC Pipe; Garden Hoses Extrusion Coating Paper Milk Cartons with Plastic Coating Wire and Cable Coating Underground Cables Monofilament Fishing Line, Ropes Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
7 ΤΝ-ΔΚΒΟΛΖ Allows Opportunity for Several Layers with Different Properties All Extruders for Each Material Goes into Common Die Die Design Determines Division of Layers Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
8 The history of extrusion goes back to Archimedes and before BUT modern developments based on understanding of the physical phenomena are less than 50 years old. 5/15/2017
9 Ο ΒΑΗΚΟ ΜΟΝΟΚΟΥΛΗΟ ΔΚΒΟΛΔΑ 9 5/15/2017
10 Advantages of Single Screw: Low Cost Straightforward Design Reliability Disadvantages of Single Screw: Mixing is not very good (for some applications) 5/15/2017
11 ΘΔΡΜΑΝΖ ΚΑΗ ΦΤΞΖ Heating Bring to startup temperature Maintain desired temperatures Cooling Water or Air Cooled To shutdown an extruder quickly To cool down when the polymer overheats To keep from bridging in the feed throat To keep from melting in the grooved feed Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
12 ΔΝΓΟ-ΚΟΥΛΗΑ ΘΔΡΜΑΝΖ ΚΑΗ ΦΤΞΖ Cartridge Heaters to heat from both sides Fluid Heating and Cooling to control melt temperature to prevent melting in the feed zone to increase pressure generation in feed Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
13 ΔΠΗΠΛΔΟΝ ΔΞΟΠΛΗΜΟ ΤΣΖΜΑΣΑ ΣΡΟΦΟΓΟΗΑ Gravimetric versus RPM-based Type of hopper ΠΗΝΑΚΑ ΔΛΔΓΥΟΤ ΠΑΡΑΚΟΛΟΤΘΖΖ ΛΔΗΣΟΤΡΓΗΑ ΑΝΣΛΗΔ (GEAR PUMPS) ΤΣΖΜΑΣΑ ΜΔΣΑΓΟΖ ΚΗΝΖΖ Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
14 Extruder Heads and Adapters Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
15 ΔΠΗΠΔΓΔ ΚΔΦΑΛΔ ΔΚΒΟΛΖ (FLAT EXTRUSION DIES) 5/15/2017
16 Tubular Dies Schematic of a spider leg tuning die Schematic of a spiral die Schematic of a cross-head tubing die used in film blowing Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
17 ΠΗΡΑΛ ΚΔΦΑΛΔ ΔΚΒΟΛΖ (SPIRAL EXTRUSION DIES) 5/15/2017
18 ΠΑΡΑΜΔΣΡΟΗ ΠΟΤ ΔΛΔΓΥΟΝΣΑΗ ΚΑΣΑ ΣΖΝ ΛΔΗΣΟΤΡΓΗΑ Entered By Operator Set-Point temperatures along barrel and die Rotational speed of screw Output from Process Melt pressure before & after screenpack Temperature of the polymer melt at die Actual temperatures along barrel and die Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
19 ΓΔΧΜΔΣΡΗΚΑ ΥΑΡΑΚΣΖΡΗΣΗΚΑ ΚΟΥΛΗΑ 5/15/2017
20 The standard screw L ~20-30D Feed section ~ 4-8D Metering section ~6-10D q =17.66 o (E=1D) W =1D H feed ~ D H f /H m ~2-4 Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
21 ΛΔΗΣΟΤΡΓΗΚΑ ΥΑΡΑΚΣΖΡΗΣΗΚΑ ΣΟΤ ΚΟΥΛΗΑ L/D Ratio Flighted Length Outer Diameter of Screw Compressio nratio Feed Depth Metering Depth Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
22 Diameter Effect L/D Effect Output, pph Typical Extruder Output Versus Diameter Diameter, inches Flighted Length L/D Ratio Outer Diameter of Screw Increasing L/D: More shear heat can be uniformly generated without degradation Better mixing opportunities Greater Residence Times Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
23 ΓΗΔΡΓΑΗΔ ΚΑΣΑ ΜΖΚΟ ΣΟΤ ΚΟΥΛΗΑ Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
24 Ζ ΕΧΝΖ ΜΔΣΑΦΟΡΑ ΣΔΡΔΧΝ (ΕΧΝΖ ΣΡΟΦΟΓΟΗΑ Solids Conveying Zone) PURPOSE: Feed Section Supply plastic at a uniform rate and pressure to the other sections of the screw Compress the solids into solid bed (by difference between barrel and screw friction) Allows air to be pressured back to hopper Be able to withstand high torque loadings Problems in feeding will manifest themselves as air entrapment in melt, melting inconsistencies and irregular extrudate rate Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
25 Η ΖΩΝΗ ΜΕΤΑΦΟΡΑΣ ΣΤΕΡΕΩΝ (ΖΩΝΗ ΤΡΟΦΟΔΟΣΙΑΣ Solids Conveying Zone) How the solid pellets convey???? Barrels: rough surface (sometimes intentionally grooved) Screws: smooth (polished) surface Rheology-Extrusion - Univ. Thessaly /15/2017
26 ΑΝΑΛΤΗ ΕΧΝΖ ΣΡΟΦΟΓΟΗΑ Solid region approximated by a rigid plug in contact with all sides of channel Channel depth is constant Neglect flight clearance Coefficient of friction (COF) function of temperature but not of pressure No gravity, no density differentials in plug F r =W*dz*P*f s Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
27 ΑΝΑΛΤΗ ΕΧΝΖ ΣΡΟΦΟΓΟΗΑ Darnell & Mol (1956): 1 1 s q arcsin 2 1 fs H P fs 2H k ln 1 f z P f W b o b M f k fsk s HWpv z b L sin sinq sin q 1 afs W 2H z Pz Po exp fb f s a W H tan( q ) Max (M) when f s is small and f b is large Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
28 Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
29 Ms[kg/hr] Mass Flow Rate of the solid bed as a function of the ratio f s /f b : fs/fb Ο ρυθμός μεταφοράς των στερεών σε σχέση με το λόγο fs/fb. Max (M) when f s is small and f b is large Rheology-Extrusion - Univ. Thessaly /15/2017
30 Solids Conveying: COF Dependency of COF COF Depends On: Temperature Pressure Velocity (Screw Speed) COF Measurement SPR-18 Term Model Place plastic in between metal for barrel and metal for screw and measure COF (via torque). Barrel COF Effect on Conveying Solids Conveying Rate, pph at 100 RPM Soilds Conveying Rate versus Coefficient of Friction on the Barrel for Soarnol EVOH Coefficient of Friction Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
31 600, ,000 Ms [kg/hr] 400, , , ,000 0, ,001 0,002 0,003 0,004 0,005 0,006 0,007 0,008 H [m] Ο ρυθμός μεταφοράς των στερεών σε σχέση με το βάθος του καναλιού. Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
32 Feed Section - Screw Length Length of feed section can be negligible to 1/2 the length of screw Industry Standard = 5 Diameters Feed Section - Channel Depth Solids Conveying Rate versus Channel Depth for Various Back Pressures INCREASING LENGTH: Increase output of the screw Decrease available mixing time downstream Solids Conveying Rate, in3/s Channel Depth, inches P1/P0 = 1 P1/P0 = 100 P1/P0 = 200 P1/P0 = 500 Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
33 Solids Conveying - Feed properties: Bulk Density BULK DENSITY Bulk Density and Compressibility Density of the plastic including the air voids between the particles Typically lb/ft 3 < 10 lb/ft 3, then extrusion on conventional extruder is no longer possible Screw Design For Bulk Density Bulk Density Design Rules Bulk Density > 1/2 Solid Density Feed Channel = D 1/3 Solid < Bulk Density< 1/2 Solid Density Deeper feed Channel Required Bulk Density< 1/3 Solid Density Crammer Feeder Needed Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
34 Solids Conveying - Feed properties: Compressibility Bulk Density and Compressibility Bulk Density and Compressibility COMPRESSIBILITY Difference in percent between bulk density of loose particles and bulk density of packed particles > 20%, polymer is considered non-freeflowing Measure by Hand Clump Test Free flowing: No clump in hand squeeze test Angle of Repose < 45 Non-free flowing: Compressibility > 20% Easily broken clump in hand squeeze test Angle of Repose > 45 Bridge in Hopper: Compressibility > 40% Hard clump in hand squeeze test Difficult to feed a compressible powder Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
35 Feed Section Design Feed Section - Channel Depth Feed Section - Helix Angle SUMMARY OF COVNEYING SPEED VERSUS CHANNEL DEPTH: Parabolic Shape to curve - therefore, optimum depth can be chosen Pressure is a key variable - Increased pressure generation comes from a shallower depth Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
36 Feed Section Design Feed Section - # of Flights Solids C onveying Rate E ffe ct o f F ee d C h an n el D ep th o n S o lid s C o n ve yin g R a te D o u b le F lig h t C h a n n e l D e p th, in ch e s S in g le F lig h t *Increasing # of Flights, decreases Solids Conveying Torsion Factor Feed Section produces the most pressure, and greatest possibility of breaking screw TORSION Measurement: Where: H max 0.5D Hmax = maximum feed depth, inches D = Diameter, inches P motor = Power rating of the motor, horsepower N = screw speed, rpm zul = allowable shear stress of metal, psi P N motor 4140 Tensile 237,500 psi Yield 182,000 psi zul 1 3 Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
37 Ζ ΕΧΝΖ ΣΖΞΔΧ (Melting Zone) Solids bed in an unwrapped screw channel Screw channel cross section Predicted (Tadmor Model) and experimental solids bed profile Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
38 5/15/2017
39 Barrier Screw Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
40 Basic Extruder Analysis 1D Isothermal Newtonian flow between parallel plates One plate moving (screw surface) Other plate stationary (barrel inner surface) DP caused by constriction near the die Conclusion: The flowrate is the sum of the drag flow and of the pressure-driven flow Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
41 Now, let s (conceptually) unwind the channel, and turn it into.a CHANNEL between two flat plates (assume the screw is stationary and THE BARREL ROTATES): The barrel moves with V b =πdn where N rotational speed of screw (e.g. RPM) and z the downchannel direction. The down channel velocity component is: V bz =V b cosθ=πdncosθ and: L=z cosθ Recall the FLAT PLATE EQUATIONS for drag flow with an opposing pressure flow: Q VHW 2 3 H dp 12 dz 41 5/15/2017
42 Use the helical geometry of the channel: N = revs per second (rpm/60) of screw Q 1 2 D 2 2 HN sinq cosq 3 DH 12 sin 2 DP q L 42 5/15/2017
43 If we take into account the leakage flow rate from the small clearance (δ) between the barrel and the screw: Q 1 2 D 2 2 Q L D 12e 3 DH HN sinq cosq 12 DP tanq L sin 2 DP q L in our analysis we neglect this term ~ D 12e DP tanq L NOTE: 1. If there is no pressure build-up (e.g. no constriction of flow at the end of the extruder), the output would be maximum, i.e. drag flow only: 1 2 D 2 Q max 2 HN sinq cosq μέγιςτη παροχή 2. If the end is closed, Q=0 and we may equate drag and pressure flow which gives the MAXIMUM POSSIBLE PRESSURE: μέγιςτη DH 2 DP 6DLN πτώςη D HN sinq cosq sin q P max 2 πίεςησ 2 12 L tanq Since μ is large for polymer melts, extremely large (AND VERY DANGEROUS!!!) pressures can develop. 5/15/2017
44 For the extruder: Q max D HN sinq cosq 2 P max 2 6DLN tanq Careful..!! L is the length of the METERING ZONE ONLY! L For the DIE (κεφαλή) the pressure drop vs flow rate can be obtained by the usual equations: DP mh ( 2n1 ) L F n Q W n 2H y x DP 2mR ( 3n1 ) 1 Q LC 3 n n r z 5/15/2017
45 2D Isothermal Analysis of Screw Extruders Parallel plate representation u l =u x *cos(q)+u z *sin(q) V=πDN (ι)=άμoλαο ηνπ θνριία, ζρεκαηίδεη γωλία (ζ) κε ηνλ άμoλα (ρ) (z)=helical axis Γηα ζεηηθή ξνή, u ι >0 Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
46 Melt Conveying simplified flow model - U z (y) (z) u z (H)=V z Flow in the y-z plane useful for flowrate predictions Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
47 Melt Conveying simplified flow model on x-y plane (x) (y) V x =Vsin(q) Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
48 Melt conveying simple flow theory u l =u x *cos(q)+u z *sin(q) The U l column shows the velocity perpendicular to the q-plane (shaded) in the direction of the screw axis u x u z u l Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
49 Melt conveying: fluid motion No net flow (circulation only) Pure drag flow Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
50 Melt conveying power calculations????? Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
51 Melt Conveying: geometrical corrections Effect of finite width of flow channel Shape factors Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
52 Melt Conveying: Effect of clearance () F pn =F p (1+f L ) And of course (H) is replaced by H- in the F D formula Pressure gradient in the presence of leackage flow Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
53 Parallel plate vs. annular flow vs. V=πDN (ι)=άμoλαο ηνπ θνριία, ζρεκαηίδεη γωλία (ζ) κε ηνλ άμoλα (ρ) (z)=helical axis Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
54 Error introduced due to flat-plate assumption Α.Γ. Παπαζαλαζίνπ, Αλνημε 2011
55 Melt conveying: non-newtonian fluids Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
56 ρεδηαζκόο θαη ιεηηνπξγία εθβνιέα θνριία The concept of combining die and screw characteristic curves to obtain operating points Screw and die characteristics for a grooved feed 45 mm diameter extruder with LDPE Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
57 Dimensionless screw characteristic curves for conventional and grooved feed extruders Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
58 ΑΛΛΔ ΓΗΟΡΘΧΔΗ Effect of channel nonuniformity in z- direction The operating curve becomes steeper Non-isothermal operation Α.Γ. Παπαζαλαζίνπ, Αλνημε 2017
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