Scale-up Effect in Internal Mixers

Abstract

In the development of a new polymer and a new compound, mixing equipment plays an important role. However, the properties of a compound tend to vary depending on the size and shape of the equipment used and a means to obtain the same compound by a small scale laboratory mixer as the one obtained by a large scale mixer has been longed for a long time.As a rubber compound is characterized by the physical properties, they are affected both by the dimensions and shape of the equipment and the mixing conditions. Recently, we developed a laboratory mixer generally following the designs of FH Banbury with exchangeable rotors and mixing chamber blocks which enable us to investigate the influences of the shape of equipment as well as the mixing conditions.In analysing rubber mixing, we found that the following factors should be taken into account, that is, unit-work which is the applied energy to the unit volume of the material during mixing, Mooney viscosity of the compound, bound rubber which is the amount of polymer unextractable from the compound by a solvent, and weight average molecular weight of polymer extractable by a solvent. If the values of the four factors are close enough for the two compounds obtained by different mixers of different size and shape, one may regard them as the same compounds. Furthermore, we experimentally measured the four factors for the compounds of typical formulations of three species of commercially available rubbers, that is, styrene butadiene rubber, ethylene propylene rubber and butadiene, and expressed the values of the factors as functions of mixing conditions and the parameters of rotor shapes by means of multiple regression analysis. Among the rotor parameters, the following showed significant effects: tip clearance, tip width, total bulkiness and wing overlap ratio. As for the mixing conditions, mixing time, rotor speed and mixing temperature were dominant.Using the functions obtained by the above mentioned method for the laboratory scale mixer, we tried to find the combinations of rotor shapes and mixing conditions that reproduced the compound mixed by large scale mixers. The optimum parameters of a laboratory mixer for the reproduction of the mixing of an industrial mixer were found to be larger rotor tip clearance, larger rotor tip width, larger wing overlap ratio, higher mixing temperature, and higher rotor speed than those of proportionally reduced dimensions and comparable conditions.

Simulation and visualization of flow in a new miniature mixer for multiphase polymer systems

“…3 Finally, with simulation, we can also conduct a comparison with industrial equipment or standard laboratory batch mixers so that we can better scale-up processing after the materials are initially processed in the APAM. 21,23 The main disadvantage of simulation is that the results rely on the accuracy of the input, that is, the accuracy of the geometry, polymer properties, flow conditions, and also, the level of meshing, proper choice of equations, and relevant approximations to reduce the complexity of the problem.…”