Batch extruders

There are two primary types of mixers propeller/paddle and screw. Screw mixers can be further divided into two types batch and mixer-extruder. 

With a history of more than 25 years, the free radical-induced grafting of MAH onto polyolefin substrates is one of the most studied polyolefin modification processes.29 "29, 302 The process has been carried out in the melt phase, in various forms of extruders and batch mixers, and there are numerous patents covering various aspects of the process. It has also been carried out successfully in solution and in the solid state. The materials have a range of applications including their use as precursors to graft copolymers, either directly, or during the preparation of blends.297... 

Process flow for a typical batch-mass polystyrene process(1) is shown in Figure 1. Styrene monomer is charged to the low conversion prepolymerization reactor with catalyst and other additives, and the temperature is increased stepwise until the desired conversion is reached. It is then transferred into the press. Polycycles are 6 to 14 hours in the low conversion reactor, and 16 to 24 hours in the press. At completion, the cakes are then cooled with water and removed from the press to be ground and then (usually) extruded into pellets. 

Calcium caseinate and butter oil have been extruded directly at 50-60% moisture levels to obtain a cheese analog with no surface water or fat (Cheftel et ah, 1992). The fat emulsification and melting ability increased with screw speed or barrel temperature. The texture of the extmded analogs was similar to those obtained by batch cooking and was affected by pH (Cheftel et ah, 1992) and emulsifying salts (Cavalier-Salou and Cheftel, 1991). The product can be used as adjimcts for hamburger, pizza, and sauces. 

Batch ovens Forced convection Paste, granules, extrude cake Pigment dyestuffs, pharmaceuticals, fibres... 

Create a table listing two or more advantages and disadvantages of each of the following compounding systems batch mixers, continuous mixers, single screw extruders and twin screw extruders. 

The additives can be added during the polymerisation (either in the form of a reactive monomer or as an inert material — advantages include better dispersion and increased retention), but they are usually added immediately postpolymerisation of the polymer and extruded with the polymer. Often a concentrated mix with the plastic (master-batch) is prepared by the plastic manufacturer and this can be sold to the fabricators to be added during subsequent processing. 

Any method of vulcanising rubber products which proceeds without interruption from start to finish as compared to the method of vulcanising separate batches of products or sections of a product. Continuous vulcanisation processes include the cold curing of proofed cloth, the vulcanisation of belting and flooring, of cables and certain extruded products by either the Liquid Curing Medium, Fluid Bed, Microwave, or Hot Air techniques. 

Reasonably constant throughput can be obtained from most dump extruders, as long as the extruder speed is set so that one batch is just running out as the next one is dropped from the mixer. The extrudate is not good enough to form an accurate finished product directly. 

Expandable PS beads are a material devised to accommodate the transportation drawbacks of foams. Foams take up a lot of room, but not much weight, so a truck or boxcar cannot be used very efficiently. Expandable PS beads can be readily turned into foam at their destination. The beads are impregnated with a volatile liquid like pentane as they are extruded, chopped, and cooled. Later, on site, the beads are heated in small batches with steam. The vaporization temperature of the pentane is just below the melting point of the PS beads. As the beads soften, the pentane flashes (volatilizes) and causes the PS to foam. The polymer is then ready for molding. Coffee cups, ice chests, life preservers, buoys, and floats are often fabricated this way. 

Fig. 2.15. Reactors for producing these materials include batch, continuously vented, tray reactors, twin-screw extruders, and vented single-screw extruders. These production devices will not be covered in this text because they are of more interest to the manufacturing engineer than the extrusion process engineer.

In this series of experiments, the catalysts were used over five repeat contacts with fresh coal liquid. Point of Ayr coal liquid was supplied by the British Coal Corporation, Coal Research Establishment (CF ) one batch of this coal liquid was used in experiments with CoMo and NiMo catalysts and a further batch was used in experiments with ZnMo and ZnW. The catalysts were prepared as extrudates by the technique of incipient wetness which requires stirring the dry alumina support with a set volume of a pre-determined concentration of an appropriate soluble salt of the metal such that the pore space is just taken up by the metals at the required concentration. The alumina support was supplied by Akzo Chemie, The Netherlands and the catalysts were made up to contain 15% WO3 or M0O3 and 3% NiO, CoO, or ZnO, expressed as a weight percentage of the weight of support... 

In the Redaimator, a bigb pressure extruder, fiber-free mbber is heated to 175—205°C with oils and other ingredients. High pressure and shear between the mbber mixture and the extruder barrel walls effectivdy devulcanize the mixture in one to three minutes. In the Lancaster-Banbury method, bigb temperature, pressure, and shear are applied to the mbber in a batch process that is otherwise similar to the Redaimator process. In another high pressure process, scrap mbber is devulcanized at 5.5—6.9 MPa (54—68 atm) for ca five minutes. The product is milled, baled, or pelletized as in other processes. 

Given that extruders of various designs, types and geometries are available in the marketplace, let us examine some aspects that drive selection of the appropriate extruder for a product. The key factors relevant in selecting the extruders are formulation factors (selection of excipients, thermal stability, plasticity, aqueous solubility, and moisture holding capacity) and equipment factors (batch versus continuous operation and scalability of the extruder). 

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