Numerical simulation of energy consumption in the melt conveying section of eccentric rotor extruders

Abstract

The polymer melt flow field in the melt conveying section of the eccentric rotor extruder was performed by the Fluid Dynamics software POLYFLOW. The rotor torque and the melt volume flow rate at each time were obtained by simulation analysis, and the energy consumption and the output in one cycle were computed with the support of the simulated data. Eventually, the specific energy consumption of the eccentric rotor, which was regarded as energy consumption evaluation index in the melt conveying process, could be calculated. The results showed that for different parameters, the eccentricity had the greatest impact on the specific energy consumption. With the increase in eccentricity, the energy consumption per unit melt transported decreased, and the extrusion output increased. The same tendency occurred for changing the pitch of the eccentric rotor, but the effect on the specific energy consumption was slight. When increasing the rotor speed and the rotor radius, the specific energy consumption increased. Experimental and theoretical methods were applied to compare the error of the simulation data under the same conditions, and the numerical simulation results were verified.

A comprehensive review on flow field properties in polymer mixing processes: a focus on applications in energetic materials

“…When the rotor rotates, the space between the vanes and the stator is restricted, causing periodic volume changes that produce volume elongational mixing, plasticizing, and conveying. Qu [91][92][93] also invented the uniaxial eccentric rotor extruder (ERE), based on the principle of volumetric tensile deformation, as shown in figure 14. The rotation of the spiral-shaped eccentric rotor forces the materials in the space between the rotor and stator to undergo tensile deformation through multiple convergence-divergence zones.…”

Recent Advances in Elongational Flow Dominated Polymer Processing Technologies

“…Wen et al [ 25 ] analyzed the flow field in the melt conveying section based on fluid dynamics simulations. Varying technological parameters in the melt conveying section such as rotor speed, radius, and eccentricity in the numerical simulation model, the energy consumption and output efficiency of the ERE were studied.…”

“… Structure of the eccentric rotor extruder (ERE) with different rotating states. Reproduced with permission from [ 25 ]. Copyright 2018, John Wiley and Sons.…”

Rheological Properties of Wood–Plastic Composites by 3D Numerical Simulations: Different Components

“…Liu et al [20] used Polyflow to calculate the velocity, local shear rate, viscosity, and pressure distributions of materials during extrusion and the relationships among the rheological properties and flow field distribution of the materials were obtained. The effects of the die structure including expansion-die and dam-expansiondie on the extrusion flow field of short fiber and rubber composite during extrusion were also investigated using Polyflow [21]. The non-isothermal extrusion of hollowprofile viscoelastic fluids was simulated and the influence of processing conditions and die structure parameters on the polymer melt flow was studied [22].…”