Thermal Management in Polymer Processing
Lead Research Organisation:
University of Bradford
Department Name: Faculty of Engineering and Informatics
Abstract
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Organisations
- University of Bradford (Lead Research Organisation)
- QUEEN'S UNIVERSITY BELFAST (Collaboration)
- Sichuan University (Collaboration)
- TSM Control Systems (Ireland) (Project Partner)
- Tangram Technology Ltd (Project Partner)
- All-Island Polymer & Plastic Network (Project Partner)
- Brett Martin Ltd (Project Partner)
People |
ORCID iD |
| Adrian Kelly (Principal Investigator) | |
| Phil Coates (Co-Investigator) |
Publications
Abeykoon C
(2014)
Monitoring and modelling of the energy consumption in polymer extrusion
Abeykoon C
(2016)
The effect of materials, process settings and screw geometry on energy consumption and melt temperature in single screw extrusion
in Applied Energy
Abeykoon C
(2013)
Investigation of the temperature homogeneity of die melt flows in polymer extrusion
in Polymer Engineering & Science
Abeykoon C
(2014)
Dynamic modelling of die melt temperature profile in polymer extrusion: Effects of process settings, screw geometry and material
in Applied Mathematical Modelling
Deng J
(2013)
Low-cost process monitoring for polymer extrusion
in Transactions of the Institute of Measurement and Control
Martyn M
(2013)
Pressure Variation during Interfacial Instability in the Coextrusion of Low Density Polyethylene Melts
in International Polymer Processing
Vera-Sorroche J
(2014)
The effect of melt viscosity on thermal efficiency for single screw extrusion of HDPE
in Chemical Engineering Research and Design
Vera-Sorroche J
(2014)
Infrared melt temperature measurement of single screw extrusion
in Polymer Engineering & Science
Vera-Sorroche J
(2013)
Thermal optimisation of polymer extrusion using in-process monitoring techniques
in Applied Thermal Engineering
| Description | The aim of this project was to investigate and improve the efficiency of single screw extrusion, one of the most important processes used to manufacture plastic products. Highly instrumented extruders were used, allowing the energy consumption and melt quality of polymer to be measured in real-time at a range of different conditions. Key indicators of melt quality included mass throughput and melt temperature and pressure stability. The effect of polymer type, set temperature, extruder screw screw geometry and extruder scale were examined. Results showed that process efficiency and melt quality depended in a complex way on many different variables. However, a number of key findings included: 1. Extruder screw rotation speed was the single most important variable; using low screw rotation speeds used the most energy per kg of polymer, but produced the most stable output. High screw rotation speeds caused the process to consume least specific energy but conversely produced the highest levels of variation in output. 2. Extruder screw geometry had a significant influence on process efficiency and quality. For many polymers, use of barrier flighted extruder screws provided better performance because of the better melting capability. 3. Melt viscosity (resistance to flow) had a measurable effect on both process efficiency and stability. Higher viscosity polymer melts required more energy per kg to process and were less stable. 4. The scale of extruder had a strong effect on process efficiency. Smaller extruders were comparably less efficient than larger counterparts, although lower levels of variation were produced. 5. Novel dynamic models were produced to try to predict aspects of the extrusion process, such as throughput, energy consumption and melt quality. Experimental data were used to train these models, which were found to predict process conditions well. Overall, the findings of this research, combined with the sister grant EP/G059489/1, hosted at Queens University, Belfast, have led to an improved understanding of the thermal efficiency of polymer extrusion. These findings and the tools developed will be useful for polymer processors wishing to better understand and optimise industrial processes. |
| Exploitation Route | The findings of this research has direct industrial applications. In addition to the project partners, a number of industrial representatives have had exposure to the research through conferences and workshops. A number of journal papers have been published to disseminate the findings of this research to the wider industrial and academic communities. Conference papers were presented in the UK (SUSTEM and Polymer Process Engineering conferences) and internationally (Society of Plastics Engineers, USA; Polymer Processing Society Annual Meeting, Germany) |
| Sectors | Energy,Manufacturing, including Industrial Biotechology,Other |
| Description | The findings of the research project have been used to inform the UK and international polymer processing industry of important considerations related to the efficiency of polymer extrusion. In particular, the research has highlighted the importance of carefully choosing the type of extruder screw, set temperature and screw rotation speed used for each polymer and product type. |
| First Year Of Impact | 2013 |
| Sector | Manufacturing, including Industrial Biotechology,Other |
| Impact Types | Economic |
| Description | Belfast |
| Organisation | Queen's University Belfast |
| Country | United Kingdom |
| Sector | Academic/University |
| PI Contribution | The grant was run in parallel with an associated EPSRC grant at QUB (EP/G059489/1). Complementary and directly linked research was performed at both sites. The focus at Bradford was on understanding the thermal efficiency of the extrusion process, whereas the focus at QUB was to build on this understanding, complement it with data measured in an industrial setting and to develop a tool which industry could use. |
| Collaborator Contribution | One PDRA at Queens focused on the development of a low cost monitoring system to measure and control the extrusion process; the other worked closely with a collaborating company to develop a software tool. |
| Impact | 9 co-authored journal papers (as listed in publications); one follow-on grant at QUB (2013-2015, Proof of Concept (PoC) project, "Integrating energy efficiency monitoring, control and optimization for plastics industry". Invest Northern Ireland and European Regional Development Fund). |
| Start Year | 2010 |
| Description | Joint International Laboratory for Polymer Micro Processing |
| Organisation | Sichuan University |
| Country | China |
| Sector | Academic/University |
| PI Contribution | Establishment of a micro moulding facility in Sichuan, to mirror the (more extensive) facilities in Bradford, to develop further our collaborative research. Joint IP for conducting polymer products. |
| Collaborator Contribution | Materials engineering expertise, including polymer nano composite products, especially for electrically conducting products. Joint IP for conducting polymer products. |
| Impact | Joint publications. Joint IP |
| Start Year | 2010 |
| Description | Polymer engineering/processing conferences in USA (Orlando) and Germany (Nuremberg) |
| Form Of Engagement Activity | Participation in an activity, workshop or similar |
| Part Of Official Scheme? | No |
| Geographic Reach | International |
| Primary Audience | Industry/Business |
| Results and Impact | The project findinds were disseminated widely through the relevant fields of industrial and academic research and development. |
| Year(s) Of Engagement Activity | 2012,2013,2014 |