The Effect of Materials, Process Settings and Screw Geometry on Energy Consumption and Melt Temperature in Single Screw Extrusion
The Effect of Materials, Process Settings and Screw Geometry on Energy Consumption and Melt Temperature in Single Screw Extrusion
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DOI：
10.1016/j.apenergy.2016.07.014
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发表时间：
2016-10
期刊：
影响因子：
11.2
通讯作者：
C. Abeykoon;A. Kelly;E. Brown;P. Coates
中科院分区：
文献类型：
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作者：
C. Abeykoon;A. Kelly;E. Brown;P. Coates
聚合物挤出是一种能源密集型生产工艺，随着全球碳足迹减少的压力，工艺能效已成为当前行业的关键问题。在这里，了解工厂中每个组件的能量使用和损失的模式在过程能量优化中非常有用。此外，在聚合物加工中保持熔体质量同时提高能量效率是至关重要的。在这项工作中，调查的总能耗，驱动电机能耗，功率因数和熔体温度分布在整个模具熔体流动（作为熔体热质量的指示）的工业规模的挤出机与三种不同的螺杆几何形状，三种聚合物类型和广泛的加工条件（共135个不同的加工情况进行了观察）。这旨在扩大对工艺能量和热行为的了解，同时探索能量需求和熔体质量之间可能的相关性（就熔体流动中的熔体温度波动而言）。结果表明，挤出机的功率因数的水平和波动特别取决于被加工的材料。此外，加热器的能量需求水平与熔体温度波动水平之间似乎存在关系。虽然挤出机的比能耗随着螺杆速度的增加而降低，但驱动电机的比能耗可能具有增加或减少的行为。总的来说，这项研究提供了新的见解，在广泛的过程中的能源需求和熔体热质量的聚合物挤出。此外，进一步的研究建议建立强相关性/S之间的过程能耗和熔体热质量，这应该有助于加强过程控制，从而在单螺杆聚合物挤出的产品质量。
Polymer extrusion is an energy intensive production process and process energy efficiency has become a key concern in the current industry with the pressure of reducing the global carbon footprint. Here, knowledge of the pattern of energy usage and losses of each component in the plant is highly useful in the process energy optimization. Moreover, it is essential to maintain the melt quality while improving the energy efficiency in polymer processing. In this work, an investigation was made on the total energy consumption, drive motor energy consumption, power factor and the melt temperature profile across the die melt flow (as an indication of the melt thermal quality) of an industrial scale extruder with three different screw geometries, three polymer types and wide range of processing conditions (altogether 135 different processing situations were observed). This aims to widen the knowledge on process energy and thermal behaviors while exploring possible correlation/s between energy demand and melt quality (in terms of melt temperature fluctuations across the melt flow). The results showed that the level and fluctuations of the extruder’s power factor is particularly dependent upon the material being processed. Moreover, it seems that there is a relation between the level of energy demand of the heaters and the level of melt temperature fluctuations. While the extruder specific energy consumption decreases with increasing screw speed, specific energy consumption of the drive motor may have either increasing or decreasing behavior. Overall, this study provides new insights in a wide range on process energy demand and melt thermal quality in polymer extrusion. Moreover, further research is recommended to establish strong correlation/s between process energy consumption and melt thermal quality which should help to enhance process control and hence the product quality in single screw polymer extrusion.