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Artigo - Thermal Optimisation of Polymer Extrusion Using In-Process Monitoring Techniques
Artigo - Thermal Optimisation of Polymer Extrusion Using In-Process Monitoring Techniques
a r t i c l e i n f o a b s t r a c t
Article history: Polymer extrusion is an energy intensive process, which is often run at less than optimal conditions. The
Received 12 December 2011 extrusion process consists of gradual melting of solid polymer by thermal conduction and viscous
Accepted 4 April 2012 shearing between a rotating screw and a barrel; as such it is highly dependent upon the frictional,
Available online 24 April 2012
thermal and rheological properties of the polymer. Extruder screw geometry and extrusion variables
should ideally be tailored to suit the properties of individual polymers, but in practice this is rarely
Keywords:
achieved due to the lack of understanding of the process. Here, in-process monitoring techniques have
Polymer extrusion
been used to characterise the thermal dynamics of the extrusion process. Novel thermocouple grid
Melt temperature
Energy
sensors have been used to measure melt temperature fields within flowing polymer melts at the
Optimisation entrance to an extruder die in conjunction with infra-red thermometers and real-time quantification of
energy consumption. A commercial grade of polyethylene has been examined using three extruder screw
geometries at different extrusion operating conditions to understand the process efficiency. Extruder
screw geometry, screw rotation speed and set temperature were found to have a significant effect on the
thermal homogeneity of the melt and process energy consumed.
Ó 2012 Elsevier Ltd. Open access under CC BY license.
energy consumption in mind, so the effects of processing condi- measured temperature at that point. Using such techniques the
tions on energy consumption are not well understood and gener- effect of extruder screw speed, polymer type and screw geometry
ally extruders are not equipped with energy monitoring have been measured [12]. The fragility of such sensors restrict their
equipment. Often extruders are operated with extruder screw use to research rather than production environments.
geometries, which are not suited to the polymer being used, either Infra-red (IR) sensors offer a non-intrusive, fast response method
through lack of understanding or financial restrictions. of polymer melt temperature measurement. Typical response times
The quality of extruded polymer is highly dependent upon the of infra-red sensors are around 10 ms and several studies have re-
homogeneity of the molten polymer being fed into the die, which ported their use in polymer extrusion, mainly using sensors flush
should ideally be supplied at a constant pressure, temperature and mounted to the surface of the extruder die [13e15]. Measurements
throughput. Another difficulty faced by the industry is that the from infra-red sensors can provide some information about melt
temperature of flowing polymer melt is inherently difficult to temperature within a flowing melt, however the effective penetra-
quantify without adversely affecting the flow. To address this tion depth of this technique is difficult to quantify and has been
measurement need, a number of real-time melt temperature shown to depend heavily on the emissivity of the polymer melt under
measurement techniques have been developed, primarily more measurement [13]. Such sensors can be used in production envi-
suited to research rather than a production environment. These are ronments although the cost of the devices and the fragility of optical
discussed in more detail in the following section. The aims of this fibres and electronics limit their use. Measurement techniques based
work were to relate thermal energy consumption of the single on alternative physical principles have also been developed to
screw extrusion process to operating conditions and screw geom- measure polymer melt temperatures, such as ultrasound [16] or
etry. The reported study forms part of a wider research project to fluorescence spectroscopy [17], but the cost of the systems and
provide the polymer industry with tools to optimise energy effi- complexity of calibration and analysis has limited their use. A
ciency using a whole systems approach. summary of these measurement techniques is shown in Table 1:
The work reported in this study utilises the thermocouple grid
2. Polymer melt temperature measurement technique and infra-red temperature measurement combined with
real-time quantification of energy consumption to investigate
Single screw extruders are controlled by setting barrel and die thermal optimisation of the extrusion process.
temperatures and screw rotation speed. Melt temperature is widely
acknowledged as being one of the key variables in polymer extru-
sion which directly influences process stability and product quality 3. Experimental
[4]. However, most extruders are supplied with only wall temper-
ature measurement capability, usually through a thermocouple All measurements were carried out on a 63.5 mm diameter
flush mounted at the extruder die wall. Such sensors have been single screw extruder (Davis Standard BC60). A linear high density
shown to be heavily dependent upon the temperature of the metal polyethylene (Ineos HD5050EA) was used throughout the studies
wall rather than the flowing melt [6], although slight improvements which has a quoted melt flow index (MFI) of 4.0 g/10 min (2.16 kg,
can be obtained by using thermocouples embedded in an insulating 190 C). A comparison of shear viscosity measured using capillary
medium, such as a ceramic. Protruding thermocouples have also rheometer is shown in Fig. 1 to highlight the importance of the
been used in an attempt to measure the melt temperature profile, temperature dependence. Viscosity decreased with increasing
but these have the disadvantage of disturbing the process flow and temperature as could be expected.
hence risking weld lines in the extruded product [7]. Traversing Three extruder screws were used throughout the experiments
thermocouples are also subject to conduction errors along the with a length to diameter ratio of 24:1. These polyolefin screw
length of the sensor and shear heating around the tip. Several designs were selected to provide a comparison of melting condi-
techniques have been reported whereby a number of thermocou- tions with screws typically used in the polymer industry but had
ples have been mounted on a supporting structure to measure not been specifically designed for this study.
temperature radially across the melt flow but these also suffer from Schematic representations of the screw designs are shown in
disturbance of the melt streamlines and slow response times [8,9]. Fig. 2, and details are provided below:
Sensors based on grids of thermocouple wires placed within the
melt flow have been used to generate detailed information con- (a) 3:1 compression ratio, with gradual compression and % free
cerning melt temperature profiles and temperature variation volume (FV) ¼ 31.64
[10,12]. These thermocouple meshes use unsheathed thermocouple (b) 3:1 compression ratio, with rapid compression and % free
wires with small diameters to minimise the flow disturbance and volume (FV) ¼ 26.99
reduce response time. Wires of opposing polarity are fused (c) 2.5:1 compression ratio, barrier flighted with Maddock mixer
together to form thermocouple junctions whose e.m.f. is related to and % free volume (FV) ¼ 36.05
Table 1
Summary of temperature measurement methods.
Fig. 2. Extruder screw geometries used a) Single flighted, tapered compression. b) Single flighted, stepped compression, c) Barrier flighted with spiral mixer.
408 J. Vera-Sorroche et al. / Applied Thermal Engineering 53 (2013) 405e413
Fig. 3. Instrumented extruder die showing location of thermocouple grid at die entrance.
of the screw is flood fed and the screw channels operate full of The total energy consumption for each screw is compared in
polymer. Therefore, the set screw rotation speed has a direct Fig. 6. This was found to be heavily dependent upon screw rotation
influence on the throughput. For both single flighted screws there speed and ranged from 850 to 2600 J/g. This minimum value of
was a linear relationship between screw speed and throughput, and energy consumption required in the process is much higher than
in both cases the set temperature had a negligible effect on the enthalpy of PE between ambient and process temperatures
throughput. The barrier flighted screw with spiral mixer was (202 J/g) [19], and it is therefore clear that significant process
influenced more by set temperature. At 180 C the throughput from energy losses occur. At low screw speeds the barrier flighted screw
this screw was lower than the two single flighted screws and dis- consumed less energy per unit mass than both of the single flighted
played a non-linear behaviour. The throughput is heavily depen- screws, although at higher screw speeds the single flighted screws
dent upon the polymer’s thermal and frictional properties and due compared more favourably. Brinkman numbers [20] were calcu-
to their design, barrier flighted screws ‘work’ the polymers harder lated for each case and showed that conduction was the dominant
as the melt is forced to flow over extra flights in the barrier and form of heat generation within the process at lower throughputs,
mixer sections of the screw. This extra work, required at lower up to screw speeds of approximately 50 rpm at 180 C and w70 rpm
temperatures appears here to inhibit the total throughput, espe- at 220 C which could also explain the higher values of energy
cially at higher speeds where achieving melting is more chal- consumption observed. Set temperature appeared to have a rela-
lenging. At 220 C however, the barrier flighted screw produced tively minor effect on energy consumption especially for the barrier
higher throughputs than the single flighted screws. Furthermore, flighted screw. Higher set extruder temperatures requires a more
the barrier flighted screw had a higher free volume than the single significant contribution from the electrical barrel and die heaters
flighted screw which may be able to explain the higher throughput but also causes the polymer melt to have a lower viscosity and
produced at 220 C, the lower melt viscosity allowing channel therefore a lower torque requirement for viscous shearing along
filling more readily. Barrier flighted screws have been shown in the screw channels. These two competing effects appeared here to
previous studies to provide higher throughputs [18]. be mutually cancelling to a large extent for this particular grade of
Measured die head pressures are displayed in Fig. 5. For single polymer.
flighted screws the increase in pressure was relatively linear with Melt homogeneity can be assessed by measurement of pressure
screw speed and was affected significantly by set temperature. Lowest and temperature at the extruder die. A typical set of raw data is
set temperature caused the highest die pressure due the temperature- shown in Fig. 7 for the tapered compression screw at a set
dependent viscosity of the polymer. For the barrier flighted screw, temperature of 220 C and set screw rotation speeds of 10, 30, 50,
pressure increase was not linear with screw rotation speed; screw 70 and 90 rpm. Melt pressure was found to increase with extruder
rotation speed having less effect on pressure at higher speeds. In screw speed and rapidly reached an equilibrium at each speed. The
contrast to the single flighted screws, set extruder temperature had wall thermocouple reflected only the temperature of polymer at or
a relatively minor effect on die pressure for this screw. close to the metal wall and maintained at relatively constant levels
Total energy consumption per unit mass was defined as the except at the highest speed of 90 rpm when it reduced by around
energy output from the energy meter divided by throughput. Both 2 C. Temperature measurements made using a junction of the
values, the monitored measurement of energy and the throughput, thermocouple grid and infra-red sensor reflected much higher
were obtained over a period of 1 min. deviation in temperature with increasing screw speed, showing
temperature to reach maximum values at a screw speed of 30 rpm.
Total energy consumption per unit massðJ=gÞ
At high throughputs, single screw extruders have been found to
Energy outputðJ=sÞ have limited melting ability, especially those with simpler single
¼ :
Throughput ðg=sÞ flighted designs. Fig. 7 also shows a high level of variation in melt
temperature at high screw speeds whereas levels of pressure
Table 2
variation remained relatively constant. The good correlation
Extruder set temperatures.
between measurements made with the infra-red sensor in the
Code Zone 1 Zone 2 Zone 3 Zone 4 Die zones screw channel and thermocouple grid at the extruder die suggest
180 C 130 155 165 180 180 C that this use of infra-red could be potentially useful for industrial
200 C 140 170 185 200 200 C extrusion applications, and will be explored more fully during our
220 C 150 185 205 220 220 C
studies.
J. Vera-Sorroche et al. / Applied Thermal Engineering 53 (2013) 405e413 409
Fig. 5. Measured extruder die head pressures from each extruder screw. a) Tapered
Fig. 4. Measured extruder throughputs from each extruder screw. a) Tapered
compression. b) Stepped compression. c) Barrier flighted.
compression. b) Stepped compression. c) Barrier flighted.
410 J. Vera-Sorroche et al. / Applied Thermal Engineering 53 (2013) 405e413
Fig. 10. Measured average melt temperature profiles; stepped compression screw
geometry at 3 set temperatures and screw speeds of 50 and 90 rpm.
Fig. 9. Measured average melt temperature profiles; tapered compression screw Fig. 11. Measured average melt temperature profiles; barrier flighted screw geometry
geometry at 3 set temperatures and screw speeds of 50 and 90 rpm. with spiral mixer at 3 set temperatures and screw speeds of 50 and 90 rpm.
412 J. Vera-Sorroche et al. / Applied Thermal Engineering 53 (2013) 405e413
Fig. 12. Measured infra-red melt temperature in the channel of the metering section:
set die temperature 200 C. a) Screw speed at 10 rpm. b) Screw speed at 50 rpm. c)
Screw speed at 90 rpm.
Acknowledgements
References