A Novel Micro- -Batch Mixer Batch Mixer A Novel Micro That Scales To That Scales To The Single Screw Extruder The Single Screw Extruder By By Keith Luker, Randcastle Extrusion Keith Luker, Randcastle Extrusion Systems, Inc., Cedar Grove, NJ Systems, Inc., Cedar Grove, NJ Jennifer K. Lynch, Rutgers University Jennifer K. Lynch, Rutgers University Thomas J. Nosker Nosker, Rutgers University , Rutgers University Thomas J.
Co- -Authors Authors Co � Jennifer Lynch, of Rutgers � Jennifer Lynch, of Rutgers � Tom � Tom Nosker Nosker, of Rutgers , of Rutgers
Background Background � Batch mixers mix. � Batch mixers mix.
Background Background � Batch mixers mix. � Batch mixers mix. � Single Screw Extruders (SSE) do not � Single Screw Extruders (SSE) do not mix. mix.
Background Background � Batch mixers mix. � Batch mixers mix. � Single Screw Extruders (SSE) do not � Single Screw Extruders (SSE) do not mix. mix. � Therefore, to suggest making a batch � Therefore, to suggest making a batch mixer to scale to a single screw mixer to scale to a single screw extruder, is an oxymoron. extruder, is an oxymoron.
Background Background � Until Antec 07, few took the SSE as a � Until Antec 07, few took the SSE as a serious compounder. serious compounder.
Background Background � Until Antec 07, few took the SSE as a � Until Antec 07, few took the SSE as a serious compounder. serious compounder. � At Antec 07, an SSE was described that: � At Antec 07, an SSE was described that: � Compounded to the 500 nm scale. Compounded to the 500 nm scale. �
Background Background � Until Antec 07, no one took the SSE as a � Until Antec 07, no one took the SSE as a serious compounder. serious compounder. � At Antec 07, an SSE was described that: � At Antec 07, an SSE was described that: � Compounded to the 500 nm scale. Compounded to the 500 nm scale. � � Vented over a thin film. Vented over a thin film. �
Background Background � Until Antec 07, no one took the SSE as a � Until Antec 07, no one took the SSE as a serious compounder. serious compounder. � At Antec 07, an SSE was described that: � At Antec 07, an SSE was described that: � Compounded to the 500 nm scale. Compounded to the 500 nm scale. � � Vented over a thin film. Vented over a thin film. � � Used 3 vents in a 36/1 L/D Used 3 vents in a 36/1 L/D �
Background Background � Until Antec 07, no one took the SSE as a � Until Antec 07, no one took the SSE as a serious compounder. serious compounder. � At Antec 07, an SSE was described that: � At Antec 07, an SSE was described that: � Compounded to the 500 nm scale. Compounded to the 500 nm scale. � � Vented over a thin film. Vented over a thin film. � � Used 3 vents in a 36/1 L/D Used 3 vents in a 36/1 L/D � � Created multiple elongational flow fields Created multiple elongational flow fields— —the the � same mechanism as the parallel twin same mechanism as the parallel twin compounder. compounder.
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � A variant of this 07 SSE reported the � A variant of this 07 SSE reported the ability to compound thermally sensitive ability to compound thermally sensitive materials: materials: � EVOH in multilayer regrind. EVOH in multilayer regrind. �
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � A variant of this 07 SSE reported the � A variant of this 07 SSE reported the ability to compound thermally sensitive ability to compound thermally sensitive materials: materials: � EVOH in multilayer regrind. EVOH in multilayer regrind. � � Cellulose and oil Cellulose and oil �
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � A variant of this 07 SSE reported the ability � A variant of this 07 SSE reported the ability to compound thermally sensitive materials: to compound thermally sensitive materials: � EVOH in multilayer regrind. EVOH in multilayer regrind. � � Cellulose and oil Cellulose and oil � � RPVC Pellets RPVC Pellets— —at unheard of high screw speeds. at unheard of high screw speeds. �
Output RPVC Pellets Output RPVC Pellets 1 Inch 36/1 Extruder 1 Inch 36/1 Extruder Grams/ Minute 8.5 kg/ h 140 120 100 80 60 40 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 Screw RPM
Stock Temperature Stock Temperature RPVC Pellets 25 mm, 36/1 Extruder RPVC Pellets 25 mm, 36/1 Extruder Degrees C 196 195 195 194 194 96 rpm 192 192 81 rpm 189 188 60 rpm 187 187 186 185 46 rpm 184 184 184 183 182 30 rpm 181 179 178 176 175 0 2.5 5 8 0 (Flush) 0.1 0.2 0.3 I mmersion Depth (mm) (Through a 25 mm bore)
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � A variant of this 07 SSE reported the ability to � A variant of this 07 SSE reported the ability to compound thermally sensitive materials: compound thermally sensitive materials: � EVOH in multilayer regrind. EVOH in multilayer regrind. � � Cellulose and oil Cellulose and oil � � RPVC Pellets RPVC Pellets— —at unheard of high screw speeds. at unheard of high screw speeds. � � RPVC Powder RPVC Powder— —currently dominated by the conical currently dominated by the conical � twin— —now processed easily at even higher screw now processed easily at even higher screw twin speed and scaled up to production! speed and scaled up to production!
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � RPVC Powder: � RPVC Powder: � 25 mm: � 25 mm: � 180 RPM 180 RPM � � Melt 177C Melt 177C � � 13.2 kg/hr 13.2 kg/hr �
Background: Yesterday Antec 08 Background: Yesterday Antec 08 � RPVC Powder: � RPVC Powder: � 25 mm: � 25 mm: � 180 RPM 180 RPM � � Melt 177C Melt 177C � � 13.2 kg/hr 13.2 kg/hr � � 63 mm: � 63 mm: � 70 RPM 70 RPM � � Melt 191 Melt 191 � � 70 kg/hr 70 kg/hr �
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Coloring Vinyl Film Coloring Vinyl Film Flexible PVC pellets/0.5% red/0.5% yellow concentrate Flexible PVC pellets/0.5% red/0.5% yellow concentrate UC Mixer SFEM UC Mixer SFEM
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Single Screw Mixer Comparison Single Screw Mixer Comparison 10% Elastomer & LDPE 10% Elastomer & LDPE UC Mixer Double Wave SFEM
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Single Screw vs vs Twin Screw Twin Screw Single Screw Continuous: 20PS/80PE Continuous: 20PS/80PE SFEM Single Screw Twin Screw SFEM Single Screw Twin Screw Advanced Materials via Immiscible Polymer Processing RUTGERS A Cooperative Center for Research, Development and Commercialization THE STATE UNIVERSITY OF NEW JERSEY
Background: Background: SSE Compounding SFEM SSE Compounding SFEM 10 microns Picture courtesy Rutgers . Single Screw SFEM @ 2,000 X 10 microns Note: Material viscosity different. Twin @ 2,000 X Right picture, Antec 95, “CO-CONTINUITY AND PHASE INVERSION IN HDPE/PS BLENDS: THE ROLE OF INTERFACIAL MODIFICATION” by Daniel Bourry and Basis D. Favis Advanced Materials via Immiscible Polymer Processing RUTGERS A Cooperative Center for Research, Development and Commercialization THE STATE UNIVERSITY OF NEW JERSEY
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Ceramic Nano- -Composites Composites Ceramic Nano PMMA Pellets & 5% Nano Ceramic 30 to 60 nm PMMA Pellets & 5% Nano Ceramic 30 to 60 nm 5,000 X 10,000X 50,000X Advanced Materials via Immiscible Polymer Processing RUTGERS A Cooperative Center for Research, Development and Commercialization THE STATE UNIVERSITY OF NEW JERSEY
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Single Wall Carbon Nano Tubes Single Wall Carbon Nano Tubes This picture shows untangled CNT’s
Background: Background: SSE Compounding SFEM SSE Compounding SFEM 2% Carbon Nano- -Tubes & PC Tubes & PC 2% Carbon Nano 100,000 X 100,000 X (Enhanced)
Background: Background: SSE Compounding SFEM SSE Compounding SFEM 5% Carbon Nano- -Tubes In Tubes In Acetal Acetal 5% Carbon Nano Conductive to Dissapative Dissapative Range Range Conductive to Multi-wall CNT’s tested IEC 60093: 35 to 85 Ohms/ sq
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Wood Flour & LDPE Pellets Wood Flour & LDPE Pellets 40% 25% Flour Flour
Background: Background: SSE Compounding SFEM SSE Compounding SFEM Wood Flour & RPVC Powder Wood Flour & RPVC Powder 100% RPVC Powder 60% RPVC 40% Woodflour Before Degassing 1” x 0.125 Tensile Bar 1” x 0.062 Tensile Bar
Background: Background: SSE Compounding SFEM SSE Compounding SFEM RPVC Pellets & RPVC Pellets & 15% Calcium Carbonate 15% Calcium Carbonate
Background: Background: SSE Compounding SFEM SSE Compounding SFEM 35% Calcium Carbonate Powder 35% Calcium Carbonate Powder With PP Pellets: Two Vents With PP Pellets: Two Vents
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