1 1. introduction to polymer blending. 2 size of initial polymer pellets ( 1 to 5 mm) flow, melting,...
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Size of initial polymer pellets( 1 to 5 mm)
Flow, melting, mixing, reaction, structuring
Size of final polymer particles
( 0.1 to 5 µm;10 to 100 nm)
Twin screw extruder
A continuous process Short residence times ( < 60 s) Throughput of a few tons per hour
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The geometry of kneading discs and flow channel
Flow channel
XY Z
XY Z
XY Z
Outlet section
Transport direction
Inlet section
Kneading disc
s sect
ion
XY
Z
XY Z
XY Z
KD1: 45/5/32 KD2: 60/4/32 KD3: 90/5/32
KD5: 90/5/64KD4: 90/10/64
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Emulsification curve
Construction of an emulsificaiton curve is tedious and material-consuming,especially for industrial processes.
Blend:1000 kg/h
Compatibilizer:
>10 kg/h
PS/PA6
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PS
PA6 PA6
Concept of compatibilizer-tracer
Fluorescent moities
Zhang, Cai-Liang; Feng, Lian-Fang; Hoppe, Sandrine; Hu, Guo-Hua. AIChE Journal (2009), 55, 279-283. Zhang, Cai-Liang; Feng, Lian-Fang; Hoppe, Sandrine; Hu, Guo-Hua. AIChE Journal (2012), 58,1931-1928.
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0 50 100 150 200 250 3005
4
3
2
1
00.00
0.01
0.02
DSD 1.6 g 3.2 g
d v (m
)
Time (s)
RTD 1.6 g 3.2 g
E(t
) (s
-1)
DSD
RTD
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0.0 0.5 1.0 1.5 2.00
1
2
3
4
5
short time domain long time domain 1.6 g 1.6 g 3.2 g 3.2 g
dv (
m)
Tracer-emulsifier content (%)
An emulsification curve from RTD & DSD
Unique feature:two curves that
form a closed loop.
Short time domain Long time domain
Concept of compatibilizer-tracer
Construction of emulsification curves for industrial polymer blending processes
Molecular design of the compatibilizer Mixing assessement
Process designProcess optimization
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0.0 0.5 1.0 1.5 2.00
1
2
3
4
5
short time domain long time domain 100 rpm 100 rpm 150 rpm 150 rpm
d v (m
)
Tracer-emulsifier content (%)
Effect of screw speed on the emulsification curve
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Reactive compatibilizer-tracerPS-co-TMI-AntN CO N CO
PS
PA6-NH2 Interfacial Reaction
PS-g-PA6 graft copolymers
PS/PA6PS-co-TMI-Ant
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Two reactive compatibilizers with different reactive groups
0.0 0.5 1.0 1.5 2.00
2
4
6
8
dv (
m)
Tracer-emulsifier content (%)
Short time domain Long time domain Anh-PS-Ant Anh-PS-Ant PS-co-TMI-Ant PS-co-TMI-Ant
Anh-PS-Ant
NCO NCO
PS-co-TMI-Ant
O
O
O
CH2 CH O C
O
n
Concept of compatibilizer-tracer (reactive or not)
Construction of emulsification curves for industrial polymer blending processes
• Molecular design of the compatibilizer • Assessement of mixing mechanisms mixing efficiency• Modeling & model validation• Design of screw profile & proces• Process optimization