Maximilian Cegla, Aleksandra Fage, Simon Kemmerling, Sebastian Engell
{"title":"Optimal design and operation of reactive extrusion processes: <scp>Application</scp> to the production and scale‐up of polyurethane rheology modifiers for paints","authors":"Maximilian Cegla, Aleksandra Fage, Simon Kemmerling, Sebastian Engell","doi":"10.1002/pen.26519","DOIUrl":null,"url":null,"abstract":"Abstract In this work, the methodology for the optimal design, operation and scale‐up of reactive extrusion processes in twin‐screw extruders previously presented in Reference (Cegla and Engell, 2023). is applied to the production of hydrophobically ethoxylated urethanes (HEURs). The new process is a promising alternative to the current batch technology in large reactors with long residence times. We demonstrate the use of model‐based design and scale‐up for this case. A novel mechanistic finite volume twin‐screw extruder model is used as the process model, which is adapted to the process at hand by embedding a detailed description of the HEUR chemistry and rheology. An economic cost function is used to examine the scale‐up process from an 18 mm extruder to a 27 and 75 mm extruders, considering a selected range of products. The comparison between the optimization results obtained for the individual products with the optimization results for the production of multiple material grades using the same screw setup shows the high flexibility of the extruder‐based process. Significant energy savings compared with the conventional batch process can be achieved using reactive extrusion. To quantify the effort for the transition to a purely continuous production in terms of flexibility and process logistics, product changeovers are investigated. Highlights Intensification of the HEUR production by reactive extrusion. Detailed model for the twin‐screw extruder and the chemistry. Optimization of extruder, screw design, and operating conditions. Model‐based scale‐up from laboratory to industrial scale. Investigation of flexible industrial production of different HEURs.","PeriodicalId":20281,"journal":{"name":"Polymer Engineering and Science","volume":null,"pages":null},"PeriodicalIF":3.2000,"publicationDate":"2023-10-10","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"1","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Polymer Engineering and Science","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1002/pen.26519","RegionNum":4,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, CHEMICAL","Score":null,"Total":0}
引用次数: 1
Abstract
Abstract In this work, the methodology for the optimal design, operation and scale‐up of reactive extrusion processes in twin‐screw extruders previously presented in Reference (Cegla and Engell, 2023). is applied to the production of hydrophobically ethoxylated urethanes (HEURs). The new process is a promising alternative to the current batch technology in large reactors with long residence times. We demonstrate the use of model‐based design and scale‐up for this case. A novel mechanistic finite volume twin‐screw extruder model is used as the process model, which is adapted to the process at hand by embedding a detailed description of the HEUR chemistry and rheology. An economic cost function is used to examine the scale‐up process from an 18 mm extruder to a 27 and 75 mm extruders, considering a selected range of products. The comparison between the optimization results obtained for the individual products with the optimization results for the production of multiple material grades using the same screw setup shows the high flexibility of the extruder‐based process. Significant energy savings compared with the conventional batch process can be achieved using reactive extrusion. To quantify the effort for the transition to a purely continuous production in terms of flexibility and process logistics, product changeovers are investigated. Highlights Intensification of the HEUR production by reactive extrusion. Detailed model for the twin‐screw extruder and the chemistry. Optimization of extruder, screw design, and operating conditions. Model‐based scale‐up from laboratory to industrial scale. Investigation of flexible industrial production of different HEURs.
期刊介绍:
For more than 30 years, Polymer Engineering & Science has been one of the most highly regarded journals in the field, serving as a forum for authors of treatises on the cutting edge of polymer science and technology. The importance of PE&S is underscored by the frequent rate at which its articles are cited, especially by other publications - literally thousand of times a year. Engineers, researchers, technicians, and academicians worldwide are looking to PE&S for the valuable information they need. There are special issues compiled by distinguished guest editors. These contain proceedings of symposia on such diverse topics as polyblends, mechanics of plastics and polymer welding.