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

Estrada, Omar; Ortiz, J.; Hernández, Alexander Báez; López, Iván; Janna, Farid Chejne; Noriega, María del Pilar

doi:10.1016/j.energy.2019.116879

Cited by 6 publications

(9 citation statements)

References 23 publications

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“…[17,18,24] In comparison with GFE and SFE, melt temperature, residence time, and specific energy consumption are lower in this technology, while specific mass flow rate and melting capacity are significantly higher. This is shown in the Gruenschloss technology performance presentation papers [27,28] as well as in the work of Estrada et al, [29] who compared the energetic and productive behavior between GFE and GPE. Commercial diameters range from 50 mm approx.…”

Section: Introductionmentioning

confidence: 83%

A novel melting model for polymer extrusion: Mechanically induced transition layer removal

Estrada

Janna

2022

Polymer Engineering & Sci

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A novel polymer melting mechanism and model named mechanically induced transition layer removal is introduced as the most probable hypothesis to explain the enhanced behavior in terms of melting capacity, output, and energy efficiency of single screw Grooved Plasticating Extruders (GPE). This model considers a domain conformed by three phases: solid, molten or plasticized, and transition layers; the latter has never been considered in the state of the art before. To validate this hypothesis as the first approach, we present a simplified thermodynamic polymer melting model in drag and pressureinduced flow between parallel plates. The model is solved using the Finite Difference Method (FDM). The results obtained show that the proposed model enables a considerable improvement in the plasticizing speed. In addition, this mechanism describes the phenomenology of the plasticization process in the GPE presented in the state of the art. In future works, the mechanically induced transition layer removal, extended to the geometry and operating conditions in GPE, has the potential to accurately describe how this type of technology operates and help the improvement and design of new plasticizing units.

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Section: Introductionmentioning

confidence: 83%

A novel melting model for polymer extrusion: Mechanically induced transition layer removal

Estrada

Janna

2022

Polymer Engineering & Sci

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“…The foremost vital parameters considered in the extrusion machines are the speed of the extruder screw rotation, the temperature in all the heaters, and the pressure developed by the extruder. However, the drive motor of the extruder is the main examination for energy efficiency in the extrusion process [24]. The SEC is reduced in polymer extrusion as screw speed increases in a single screw machine, despite the difference in the screw geometry design [22,24,25].…”

Section: Introductionmentioning

confidence: 99%

“…However, the drive motor of the extruder is the main examination for energy efficiency in the extrusion process [24]. The SEC is reduced in polymer extrusion as screw speed increases in a single screw machine, despite the difference in the screw geometry design [22,24,25]. This reduction is due to the viscous shear or melt viscosity generation, which is excellent at medium or higher screw speeds.…”

Section: Introductionmentioning

confidence: 99%

“…Therefore, intrinsic properties such as viscosity or frictional characteristics would lead to an effect on drag flow or thermal conductivity, leading to differences in MT or SEC [28]. In [24], it was demonstrated that SEC depends on two critical conditions such as screw speed and die restriction. For these reasons, energy efficiency is linked to the screw geometry, polymer properties, processing temperatures, or screws speed [23,28].…”

Section: Introductionmentioning

confidence: 99%

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Effect of the Intercalation and Dispersion of Organoclays on Energy Demand in the Extrusion of Recycled HDPE/PP Nanocomposites

Rigail-Cedeño

Vera-Sorroche²,

García-Mejía

et al. 2022

Energies

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Few studies have drawn on any systematic research into the energy demand to produce polymer-based nanocomposites. Regarding the problem, it is well-known that single screw extrusion is an energy-intensive process, so the incorporation of energy meters must be considered to examine the energy efficiency of the process. In this study, the effect of a nanoclay addition on the energy demand of the extrusion process was examined by extruding recycled high-density polyethylene (rHDPE) and recycled polypropylene (rPP) with a gradual compression screw with both dispersive and distributive mixers. The rHDPE/rPP was modified by adding commercial organoclay (OMMT) (3 wt%) and olefin block copolymer (OBC) (5 wt%) as compatibilizers. The energy consumption was measured on the total energy of the extruder machine. Mass throughput (MT) and specific energy consumption (SEC) were obtained at different screw speeds (10, 20, 30, 40, 50 RPM). The SEC of OMMT and OMMT/OBC nanocomposites was 25–50% lower than rHDPE/rPP, especially at higher throughputs. X-ray diffraction (XRD) and scanning electron microscope (SEM) illustrated the degree of intercalation and dispersion of the organoclay at different screw speeds. Better organoclay intercalation and dispersion were found at lower temperatures. Rheological curves showed a decrease in the viscosity at extrusion rates of nanocomposite mixtures. Melt temperature measured at die exit was reduced in the presence of organoclay over the screw speeds studied. This work suggests that the processing of rHDPE/rPP based nanocomposites can result in minor costs when processing conditions are carefully selected.

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“…Their results show that the Nusselt number improves with an increasing flow rate. Estrada et al [13] evaluated the energy efficiency and melt temperature with different plasticization processes and screw geometries, allowing a better understanding of the effect of plasticization on energy loss.…”

Section: Introductionmentioning

confidence: 99%

Enhancing Mixing and Thermal Management of Recycled Carbon Composite Systems by Torsion-Induced Phase-to-Phase Thermal and Molecular Mobility

et al. 2020

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A novel torsion screw has been proposed to resolve the inadequate control of mass transfer and the thermal management of two component polymer blends and their carbon fiber composites. The novel torsional screw distinctly introduced radial flow in the torsion screw channel, which is a significant improvement over the flow pattern developed by the conventional screw. The heat transfer and mixing behavior of melt mixtures are enhanced by adapting screws with torsion elements compared with the traditional screw elements. Heat transfer efficacy in the polypropylene–polystyrene bi-phasic extrusion process improved with the increase in torsion element numbers. An increased number of newly designed torsional elements also improved the dispersion of minor phase in bi-phase polypropylene–polystyrene composition and their carbon fiber composites. The unique flow pattern induced by the torsion elements shows a synergistic effect on the melt-phase mass flow and the thermal flow field facilitating phase-to-phase thermal and molecular mobility and enhanced fiber orientation, crystallinity and mechanical properties of composite made from recycled carbon fiber/polypropylene. Microtomographs of recycled carbon fiber demonstrated the extraordinary ability of a torsion screw element to orient carbon fiber in both axial and radial directions.

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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

Cited by 6 publications

References 23 publications

A novel melting model for polymer extrusion: Mechanically induced transition layer removal

A novel melting model for polymer extrusion: Mechanically induced transition layer removal

Effect of the Intercalation and Dispersion of Organoclays on Energy Demand in the Extrusion of Recycled HDPE/PP Nanocomposites

Enhancing Mixing and Thermal Management of Recycled Carbon Composite Systems by Torsion-Induced Phase-to-Phase Thermal and Molecular Mobility

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