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Abstract
Kneaders reactors are used for combined unitary
processing in the polymer industry for devolatilization,
compounding or polymerization. Multiple feed ports are
used in screw type reactors to allow adding multiple
substrates into one product whereas one unitary operation
has to get to a certain degree of completion before the next
substrate can be added. We have found that even for
identical substrates multiple feed ports can be
advantageous to avoid specific working points, where the
product behavior is disadvantageous for efficient
processing. Such processes require advanced design
simulation tools to predict process behavior. We compare
simulation results on pilot and the scale up.
Experimental
Introduction
Screw type reactors including kneaders are generally
described as plug flow machines. Typically a high degree
of mixing efficiency is desired. Therefore there is always
some degree of axial dispersion associated with the desired
radial and tangential dispersion (see Figure 1). The typical
approach to account for this dispersion is to describe it by
an axial dispersion model characterized by the Bodenstein
number. The modeling of this is a common engineering
practice in chemical engineering. As an example Trolstra
[1] has applied this method to describe PMMA bulk
polymerization in a Buss Co-kneader. The advantage of
this approach is that the energy and mass balance can be
described by using a differential term just like the plug
flow model, and then numerically integrating over the
reactor length. If additional feed ports are distributed over
the length of the machine, the numerical method to account
for them is to interrupt the integration and adjust the
boundary conditions (the additional feed) and restart the
integration again.
In high volume kneaders, mixing sections are typically
identical over the length of the machine. These machines
have a much higher hold up than extruders and co-
2.
c m silicon
E (t ) = ink
mink ,tot
(1)
E (t )
E (t )dt
(2)
The E-function has the dimension 1/s. The tank-inseries model is applicable for any residence time. The
missing link to get a general expression from the Efunction is the mean residence time. This is the time when
50 % of the ink has passed:
E
0
corr
(t )dt 0.5 = 0
(3)
N tk Ntk e Ntk
(N tk )
(4)
N tk (l1 ) N tk (l2 )l s
l1 l2
(5)
wi
w
wi
= hv m pol i 1
1 wi 1 1 wi
(5)
(6)
mech,i
= 2 nS TS
(7)
i =1
For this part of the study we added a 2nd feed port into
the vapor section further down the length of the kneader to
the experimental set up (see Figure 4). This feed port had
its dedicated Coriolis mass flow meter.
The extrapolation of the results was much different
from the second part of this study. During operation, we
were trying to match a certain temperature profile by
increasing or reducing feed from the particular feed port.
That means the feed distribution is now a potential control
parameter, whereas with one feed port it is not. The
simulation is therefore done by calculating the solvent
concentration profile using eq. 6 and then resolving eq. 5,
where the additional contribution (enthalpy) of the feed
port of chamber i has been added. Again, the initial fill of
chamber 1 is estimated, but the axial conveying has been
integrated into the calculation, because the additional feed
ports may influence the conveying. The sum of all
Summary
References
1.
2.
3.
Manufactured by GE Bayer
4.
5.
Nomenclature
A
c
cP
E(t)
li
m
m
N
nS
p
p0
t
TS
T
w
X
time
shaft torque
temperature
solvent content
volume fraction
greek:
ls
hv
indices:
corr
ink
L
pol
liq
S
silicon
tk
tot
corrected
of ink
kneader process chamber length
polymer
liquid (solvent)
shaft
of silicon
of theoretical stirred tanks in series
total
Key Words
Multiple, feed port, evaporation, kneader, simulation,
tank-in-series
Figure 1: Cylindrical coordinates, z would be the main transport direction, which is horizontal in kneaders and extruders. The
radial direction is described by r and the tangential direction by
run 1
1.021
run 2
1.653
run 3
1.78
run 4
1.581
run 5
1.915
run 6
1.006
run 7
1.106
run 8
0.803
Table 1: Results of RTD (number of stirred tanks) on one disc length for various working conditions on a 6 l kneader
10%
20%
30%
40%
50%
60%
70%
80%
90%
100%
solution
0.5
?w,.1_flash
?x?w .1_flash
Backmix
Q?st
H1 ?i
mech
i + Qcontact
,i + ?
n.P
?
=? 0
Hz
?
0.5
? 1
1
60
50
80
100
Ti 120
100
T feed x
140
Figure 6: Heat and mass balance criterion over product temperature of vessel I
160
180
200
200
50
45
40
35
30
25
20
15
10
5
0
0
0.2
0.4
0.6
0.8
[kg/h]
0.68
23
0.67
1.00
32
41
Fraction of
Fraction of
feed rate
feed rate
(geometrical) (simulated)
0.671
0.739
0.329
0.258
0.000
0.070
0.000
-0.067
0.336
0.534
0.486
0.386
0.178
0.175
0.000
-0.095
0.336
0.458
0.486
0.545
0.178
-0.007
0.000
0.004
1.2