Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing

Mixing is the key component of polymer processing to achieve homogeneity of final product. Previous researchers have reported poor mixing performance of internal batch mixer (IBM) and twin screw extruder (TSE) due to improper distributive and dispersive mixings. This leads to poor product properties...

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Main Author:	Salahudeen, Shafaat Ahmed
Format:	Thesis
Language:	English
Published:	2017
Subjects:	TP Chemical technology
Online Access:	http://eprints.utm.my/id/eprint/79512/1/ShafaatAhmedSalahudeenPFChE2017.pdf
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spelling	my-utm-ep.795122018-10-31T12:52:58Z Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing 2017 Salahudeen, Shafaat Ahmed TP Chemical technology Mixing is the key component of polymer processing to achieve homogeneity of final product. Previous researchers have reported poor mixing performance of internal batch mixer (IBM) and twin screw extruder (TSE) due to improper distributive and dispersive mixings. This leads to poor product properties. Hence to overcome the problem, this research aims to design a rotor and mixing element to improve mixing performance of IBM and TSE. The basic rotor design for IBM was developed on the concept of Banbury and roller rotors and this design was then optimized to attain secondary flow. Distributive mixing performance of the optimized rotor was compared with commercial rotors using ANSYS Polyflow, with results showing the new rotor was found to be better than commercial rotors. Based on these results, a prototype of optimized design rotor was developed using Computer Numerical Control machine. Using this prototype rotor, nano calcium carbonate was dispersed in high density polyethylene and its morphology was analysed via scanning electron microscopy (SEM). SEM results showed improved dispersive mixing performance of prototype rotor compared to that of commercial rotor. This prototype rotor design was later modified into two mixing elements namely, Bean-UTM for intermeshing co-rotating TSE and Blade-UTM for intermeshing counter-rotating TSE. The Bean-UTM and Blade-UTM were examined for dispersive mixing (mixing index) and distributive mixing (logarithm of length of stretch, instantaneous efficiency and time average efficiency) and then were compared with commercial TSE mixing elements. The results showed Bean-UTM has better mixing performance than kneader mixing element of Dr. Collin TSE and the Blade-UTM has better mixing performance than screw mixing element of Coperian TSE. The findings of this research will hopefully solve the issue of poor mixing in IBM and TSE. 2017 Thesis http://eprints.utm.my/id/eprint/79512/ http://eprints.utm.my/id/eprint/79512/1/ShafaatAhmedSalahudeenPFChE2017.pdf application/pdf en public phd doctoral Universiti Teknologi Malaysia, Faculty of Chemical & Energy Engineering Faculty of Chemical & Energy Engineering
institution	Universiti Teknologi Malaysia
collection	UTM Institutional Repository
language	English
topic	TP Chemical technology
spellingShingle	TP Chemical technology Salahudeen, Shafaat Ahmed Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
description	Mixing is the key component of polymer processing to achieve homogeneity of final product. Previous researchers have reported poor mixing performance of internal batch mixer (IBM) and twin screw extruder (TSE) due to improper distributive and dispersive mixings. This leads to poor product properties. Hence to overcome the problem, this research aims to design a rotor and mixing element to improve mixing performance of IBM and TSE. The basic rotor design for IBM was developed on the concept of Banbury and roller rotors and this design was then optimized to attain secondary flow. Distributive mixing performance of the optimized rotor was compared with commercial rotors using ANSYS Polyflow, with results showing the new rotor was found to be better than commercial rotors. Based on these results, a prototype of optimized design rotor was developed using Computer Numerical Control machine. Using this prototype rotor, nano calcium carbonate was dispersed in high density polyethylene and its morphology was analysed via scanning electron microscopy (SEM). SEM results showed improved dispersive mixing performance of prototype rotor compared to that of commercial rotor. This prototype rotor design was later modified into two mixing elements namely, Bean-UTM for intermeshing co-rotating TSE and Blade-UTM for intermeshing counter-rotating TSE. The Bean-UTM and Blade-UTM were examined for dispersive mixing (mixing index) and distributive mixing (logarithm of length of stretch, instantaneous efficiency and time average efficiency) and then were compared with commercial TSE mixing elements. The results showed Bean-UTM has better mixing performance than kneader mixing element of Dr. Collin TSE and the Blade-UTM has better mixing performance than screw mixing element of Coperian TSE. The findings of this research will hopefully solve the issue of poor mixing in IBM and TSE.
format	Thesis
qualification_name	Doctor of Philosophy (PhD.)
qualification_level	Doctorate
author	Salahudeen, Shafaat Ahmed
author_facet	Salahudeen, Shafaat Ahmed
author_sort	Salahudeen, Shafaat Ahmed
title	Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
title_short	Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
title_full	Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
title_fullStr	Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
title_full_unstemmed	Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
title_sort	design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing
granting_institution	Universiti Teknologi Malaysia, Faculty of Chemical & Energy Engineering
granting_department	Faculty of Chemical & Energy Engineering
publishDate	2017
url	http://eprints.utm.my/id/eprint/79512/1/ShafaatAhmedSalahudeenPFChE2017.pdf
_version_	1747818244413063168

Design of rotor for internal batch mixer and mixing elements for twin screw extruder for polyolefin processing

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