Step-change in Enhancing Extrusion as a Unit Operation

YesExtrusion-a unit operation in polymer processing has been in extensive use since the great age of plastic technology. It is a simple operation that enables within one equipment the sequential conveying of solid polymer chips or powder, their melting, mixing, pumping and shaping via a die into a variety of high tonnage and/or value products. Pipes, bottles, films are the most common examples but the list of applications is endless from tiny micromoulded parts to large structural profiles. Extrusion is not limited to plastics but is used hot or cold to process soft solids like food, industrial and pharmaceutical pastes, as well as metals and ceramics. Most of the advances in extrusion processing have concentrated in improving the essential functions of extrusion: solid conveying, melting, pumping and mixing. The literature abounds with descriptions of such advances pushing the limits of the extrusion in an incremental way. In this paper, we describe step-changes in enhancing extrusion, which opens up new applications to better old technology-make them safer, cheaper and cleaner. The new designs presented in this paper have also the potential to develop new reactor technology for viscous fluids

Advances in Dynamic Wetting in Coating Flows

Ye

Direct forward gravure coating on unsupported web

YesThis experimental study of forward gravure coating considers the effects of operating variables on air entrainment, ribbing instabilities and the thickness of the film formed. The data show that this coating method can yield very thin films of thickness of order of 15 - 20% at most of the equivalent cell depth of a gravure roller. Air free and non ribbed stable uniform films can however only be obtained in a narrow window of operating conditions at very low substrate capillary number (CaS ~ 0.02) equivalent to substrate speeds typically less than 20m/min. The paper draws a similarity with flow features observed with smooth forward roll coating and slide coating. It is shown that the onset of ribbing and the flux distribution between the gravure roller and the substrate at the exit of the nip obey approximately the same rules as in smooth forward roll coating, whereas the onset of air entrainment actually corresponds to a low-flow limit of coatability similar to that observed in slide coating

Chain extension of polyamide 6/organoclay nanocomposites

YesThermal degradation of polyamide 6 (PA6)/organoclay nanocomposites is a serious impediment to wider applications of these nanocomposites. In this study, a solution is proposed based on the well‐established use of chain extenders. As in PA6, thermal degradation, in the absence of moisture, produces broken polymer chains with amide end groups, a chain extender with anhydride functionalities, known to be strongly reactive with amide groups, was used to reconnect the chains. Experiments conducted using a laboratory twin‐screw extruder were first checked, through transmission electron microscopy observations, to have produced good organoclay intercalation and exfoliation into PA6. Following from this, samples with the chain extender added were produced and characterized. The data obtained were conclusive in the effectiveness of the chain extender: for the chain extended nanocomposites, there is an enhancement in the value of the complex viscosity by 7 times and in the storage modulus by 88 times, while the tensile modulus increased by 57% compared with the neat PA6. The nonchain extended nanocomposite achieved in comparison an enhancement of 2 times the value of the complex viscosity and 19 times the storage modulus while the tensile modulus increased by 53% compared to the neat PA6. These data provide conclusive proof on the rationale that anhydride functionalities should be sought when developing chain extenders for PA6 nanocomposites.Government of Turke

Replication of mixing achieved in large co-rotating screw extruder using a novel laboratory 10-100g minimixer

YesWhen compounding polymers with additives to develop materials at specifications (colouring plastics is the simplest example), the difficulties is in getting the formulation right the first time. Also, when developing completely new materials such as in nanotechnology applications, there is a need to do the initial trials safely and with as small quantities as possible to enable a wide range of experimentation. Wiith traditional applications, often the initial compounding formulation is done using small single or twin screw extruders but with machines that have a fair output to instruct the large scale operation. This step is costly in material wastage and time but more importantly it often does not provide the right formulation which in turn results in bigger wastage cost at the industrial scale before the right formulation is eventually obtained. With the very new material formulations, any reduction in cost of development is always essential. With these aims in mind, we have developed a new minimixer capable of handling tiny quantities of order 10-100g but the minimixer is capable of reproducing the very high mixing conditions experienced in large machines. This invention provides a new opportunity to develop new products quickly, safely and cheaply. The application is not restricted to polymers and can be extended to other soft materials. It has also other spin-offs as a research tool for studying mixing and developing new, more efficient, mixing flows. In this paper we explain the principle of operation we have engineered to produce such intense mixing. Basically, the device is based on combining two opposing flows: a single screw extruder circulation flow with a twin screw extruder mixing flow. The mixing is carried out as a batch but on its completion, the single screw extruder flow is reversed and becomes co-current with the twin extruder flow to enable the discharging of the batch through a die. In the paper we present mixing data obtained with various polymer-additive combinations tested in the minimixer under various conditions of screw speeds, mixing times and temperatures and at the larger scale to underpin the operation of this novel mixer. The quality of mixing of the extrudate was measured using a variety of methods depending on applications: using image analysis of microtome sections of the extrudate or of blown film samples produced from the formulations or measuring electrical properties

Reverse roll coating with a deformable roll operating at negative gaps

YesReverse roll coating is probably the most widely used coating operation, yet its full potential has not been exploited as it is shown in this paper which considers operation with a negative gap. We demonstrate through a wide range of experimental data that such operation can yield very thin and stable films with no ribbing or cascade instabilities when low viscosity fluids are used. Typically, stable film thickness less than 5μm can be obtained at speeds up to 150 m/min when a rubber roller is used at -100 μm gap with fluids of viscosity in the range 10-200 mPa.s. These film thicknesses can be made to decrease further down to 1 or 2 microns with a judicious choice of speed ratios (applicator to metering roller) and rubber hardness. Such new findings make this simple coating method an attractive roll to roll technique for application in the newer coating technologies, such as in the production of solar cells and plastic electronics. The data obtained in this study have been underpinned by a model based on the classical lubrication theory, well developed for such flow situations. Essentially it is shown that the film thickness non dimensionalised with respect to the set negative gap is controlled through a single parameter, the elasticity number Ne which combines all the operating parameters. Of course, this flow problem has complexities, particularly at high speed ratios and at zero gap so the data obtained here can serve as a basis for more comprehensive modelling of this classical fluid mechanic problem.Films R&D Centre of Toyobo Co. Ltd., Otsu, Japan and the Thin Films Research Group of the University of Bradford, UK

Rheology of waxy crude oils in relation to restart of gelled pipelines

YesWaxy crude oils are pumped hot but upon power cut, pumping stops, the oil cools leading below the wax appearance temperature to precipitation of the wax and the formation of a gel throughout the pipe. In such a situation, what is the minimum pressure required to restart flow, not to merely deform the gel or break it? This paper provides a solution to this problem using microscopic observations under controlled cooling conditions and rheological data conducted in constant stress mode under controlled temperature and cooling conditions and restart experiments in laboratory pipelines replicating the rheometric conditions and deviations from them to inform large diameter operation in the field. Three important findings derive from the experimental data collected: (i) A fragmentation stress , rather than the static stress that precedes it, is found to be the more accurate predictor of flow re-start pressures; (ii) Waxy crude oils gels exhibit true yield stress and yielding process but also show flow on application of the slightest stress below yielding; (iii) This flow, in the elastic region, is jagged rather than continuous suggesting a consolidation process of the crystals and their agglomerates forming the gel. In the broader context of the existence of a yield stress, the data presented here show that there is such a thing as a yield stress and the concepts of a yield stress and that everything flows are not mutually exclusive

Carbon dioxide sequestration methodothologies - A review

YesThe process of capturing and storing carbon dioxide (CCS) was previously considered a crucial and time-sensitive approach for diminishing CO2 emissions originating from coal, oil, and gas sectors. Its implementation was seen necessary to address the detrimental effects of CO2 on the atmosphere and the ecosystem. This recognition was achieved by previous substantial study efforts. The carbon capture and storage (CCS) cycle concludes with the final stage of CO2 storage. This stage involves primarily the adsorption of CO2 in the ocean and the injection of CO2 into subsurface reservoir formations. Additionally, the process of CO2 reactivity with minerals in the reservoir formations leads to the formation of limestone through injectivities. Carbon capture and storage (CCS) is the final phase in the CCS cycle, mostly achieved by the use of marine and underground geological sequestration methods, along with mineral carbonation techniques. The introduction of supercritical CO2 into geological formations has the potential to alter the prevailing physical and chemical characteristics of the subsurface environment. This process can lead to modifications in the pore fluid pressure, temperature conditions, chemical reactivity, and stress distribution within the reservoir rock. The objective of this study is to enhance our existing understanding of CO2 injection and storage systems, with a specific focus on CO2 storage techniques and the associated issues faced during their implementation. Additionally, this research examines strategies for mitigating important uncertainties in carbon capture and storage (CCS) practises. Carbon capture and storage (CCS) facilities can be considered as integrated systems. However, in scientific research, these storage systems are often divided based on the physical and spatial scales relevant to the investigations. Utilising the chosen system as a boundary condition is a highly effective method for segregating the physics in a diverse range of physical applications. Regrettably, the used separation technique fails to effectively depict the behaviour of the broader significant system in the context of water and gas movement within porous media. The limited efficacy of the technique in capturing the behaviour of the broader relevant system can be attributed to the intricate nature of geological subsurface systems. As a result, various carbon capture and storage (CCS) technologies have emerged, each with distinct applications, associated prices, and social and environmental implications. The results of this study have the potential to enhance comprehension regarding the selection of an appropriate carbon capture and storage (CCS) application method. Moreover, these findings can contribute to the optimisation of greenhouse gas emissions and their associated environmental consequences. By promoting process sustainability, this research can address critical challenges related to global climate change, which are currently of utmost importance to humanity. Despite the significant advancements in this technology over the past decade, various concerns and ambiguities have been highlighted. Considerable emphasis was placed on the fundamental discoveries made in practical programmes related to the storage of CO2 thus far. The study has provided evidence that despite the extensive research and implementation of several CCS technologies thus far, the process of selecting an appropriate and widely accepted CCS technology remains challenging due to considerations related to its technological feasibility, economic viability, and societal and environmental acceptance

A comprehensive review on carbon dioxide sequestration methods

YesCapturing and storing CO2 (CCS) was once regarded as a significant, urgent, and necessary option for reducing the emissions of CO2 from coal and oil and gas industries and mitigating the serious impacts of CO2 on the atmosphere and the environment. This recognition came about as a result of extensive research conducted in the past. The CCS cycle comes to a close with the last phase of CO2 storage, which is accomplished primarily by the adsorption of CO2 in the ocean and injection of CO2 subsurface reservoir formation, in addition to the formation of limestone via the process of CO2 reactivity with reservoir formation minerals through injectivities. CCS is the last stage in the carbon capture and storage (CCS) cycle and is accomplished chiefly via oceanic and subterranean geological sequestration, as well as mineral carbonation. The injection of supercritical CO2 into geological formations disrupts the sub-surface’s existing physical and chemical conditions; changes can occur in the pore fluid pressure, temperature state, chemical reactivity, and stress distribution of the reservoir rock. This paper aims at advancing our current knowledge in CO2 injection and storage systems, particularly CO2 storage methods and the challenges encountered during the implementation of each method and analyses on how key uncertainties in CCS can be reduced. CCS sites are essentially unified systems; yet, given the scientific context, these storage systems are typically split during scientific investigations based on the physics and spatial scales involved. Separating the physics by using the chosen system as a boundary condition is a strategy that works effectively for a wide variety of physical applications. Unfortunately, the separation technique does not accurately capture the behaviour of the larger important system in the case of water and gas flow in porous media. This is due to the complexity of geological subsurface systems, which prevents the approach from being able to effectively capture the behaviour of the larger relevant system. This consequently gives rise to different CCS technology with different applications, costs and social and environmental impacts. The findings of this study can help improve the ability to select a suitable CCS application method and can further improve the efficiency of greenhouse gas emissions and their environmental impact, promoting the process sustainability and helping to tackle some of the most important issues that human being is currently accounting global climate change. Though this technology has already had large-scale development for the last decade, some issues and uncertainties are identified. Special attention was focused on the basic findings achieved in CO2 storage operational projects to date. The study has demonstrated that though a number of CCS technologies have been researched and implemented to date, choosing a suitable and acceptable CCS technology is still daunting in terms of its technological application, cost effectiveness and socio-environmental acceptance

The effect of continuous pore stratification on the acoustic absorption in open cell foams

This work reports new data on the acoustical properties of open cell foam with pore stratification. The pore size distribution as a function of the sample depth is determined in the laboratory using methods of optical image analysis. It is shown that the pore size distribution in this class of materials changes gradually with the depth. It is also shown that the observed pore size distribution gradient is responsible for the air flow resistivity stratification, which is measured acoustically and non-acoustically. The acoustical absorption coefficient of the developed porous sample is measured using a standard laboratory method. A suitable theoretical model for the acoustical properties of porous media with pore size distribution is adopted. The measured data for open porosity, tortuosity, and standard deviation data are used together with this model to predict the observed acoustic absorption behavior of the developed material sample. The transfer matrix approach is used in the modeling process to account for the pore size stratification. This work suggests that it is possible to design and manufacture porous media with continuous pore size stratification, which can provide an improvement to conventional porous media with uniform pore size distribution in terms of the attained acoustic absorption coefficient