Mixing ratios obtained using screw disc and screw extruders, and selected properties of mixture of reglanulate and original material

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1 Mixing ratios obtained using screw disc and screw extruders, and selected properties of mixture of reglanulate and original material T. Rydzkowski* and G. Radomski Experimental effect of a screw disc clearance size on the homogenisation level and the mechanical properties of extrudate obtained using the mixture of original low density polyethylene (LDPE) and commercial LDPE recyclate were discussed in the present paper. For the purpose of experiments a screw disc extruder was applied. Some tensile tests results and photographs of the extrudate cross-sections obtained at different clearance settings were presented. The results show that the mixing in the conical screw disc zone was carried out more thoroughly than in a helical channel of a single screw extruder. Plasticising in the disc zone of a screw disc extruder makes it possible to obtain extrudate with better properties than in the case of classical extrusion. Keywords: Extrusion, Screw disc extruder, Recyclate, Homogeneity Introduction The disc extrusion dates back to the 1960s. 1 3 A new, original screw disc extruder construction, 4 6 based on analyses of Diaskun s active feeding zone theory, 7 has been developed in Koszalin University of Technology. This theory examines the mechanism of groove reactions in the feeding zone and develops the complexity of processes proceeding in this zone. It was subjected to the computer process simulations and the optimising calculations of the design. After the results being analysed, the set of optimum geometrical/design features of a screw disc extruder have been distinguished. 8 Classical systems are marked by large irregularities on the individual surfaces of a screw system. Therefore, the classical systems require the transition zone where the thermal homogenising and the thorough remelting of the material could occur. In the case of optimum geometrical/design features the temperatures computed at very similar levels and the temperature inside material rapidly approached the melting point. Thus, it was possible to develop the plasticising systems, where due to similar temperatures on the individual surfaces of the plasticising system and inside the material, the complete melting could occur at the end of the feeding zone. It is possible to reduce the length of the plasticising system with the melting zone. It was also possible to depart from the classical geometrical/design features towards a non-conventional extruder marked by a short screw with a large diameter and a screw lead much smaller than a screw diameter. Then the disc of a significant diameter would appear on the screw face if the extrudate outlet Koszalin University of Technology, Department of Mechanical Engineering, Division of Food Engineering and Plastics, Racławicka 15-17, PL Koszalin, Poland *Corresponding author, tomasz.rydzkowski@tu.koszalin.pl was situated traditionally, on the axis of the screw, and then two large conical surfaces of a screw disc type extruder system were obtained. Such machine was designed (Fig. 1), constructed and set working. A series of investigations aimed to determine the processing properties of this machine has been carried out. 9,10 It was found that the mechanism of raw material homogenisation in a screw disc type system is different from the classical one. 11,12 The homogenisation of the material in a classical (single screw) extruder proceeds in a helical channel of the screw. Trajectories of particles of the material are in the helical shape, whereas in a screw disc system they form spirals with a decreasing diameter. It follows from the shape of channels extruding the material. It is a helical channel in screw extruders, however in the case of a screw disc system the extrudate in a plasticising zone is displaced between two conical discs: a movable end face of a screw and a stationary cylinder head. The distance between both the surfaces is adjustable (within the range from 0 to 6 mm) in order to enable changing the values of shearing stress in the material. The results of the authors past investigations have revealed that the change in this distance may affect the properties of extrudate obtained. Experimental Experimental investigations were conducted using a T- 32 classical single screw extruder manufactured by Metalchem in Gliwice Poland (Fig. 2a) and a prototype screw disc type extruder (Fig. 2b). These extruders differ mostly in the construction of a working member, i.e. a screw. Constructions of extruder screws are illustrated in Fig. 3. A screw of the first extruder was 32 mm in diameter D; its working length (L5800 mm) was equal to 25D; it 376 ß 2008 Institute of Materials, Minerals and Mining Published by Maney on behalf of the Institute Received 4 June 2007; accepted 25 July 2008 DOI / X Plastics, Rubber and Composites 2008 VOL 37 NO 8

2 1 charging hopper; 2 cold zone of screw and barrel; 3 hot zone of screw and barrel; 4 chink; 5 insulating separators; 6 electric heaters; 7 thermal insulator; 8 drive shaft 1 Longitudinal section of plasticising system of screw disc extruder had a constant pitch and a variable depth of a helical channel. A screw disc extruder had a screw 130 mm in diameter. Its 260 mm working length was equal to 2D, and was marked by a constant pitch and a variable depth of a helical channel. Both the extruders were operated with the same peripheral speed on the outside diameter of the screw n50?1 ms 21, which responds to the rotational speed 15 min 21 for a screw disc extruder and 60 min 21 for a T-32 single screw extruder. An extruding head with a circular nozzle applied to both the extruders produced extrudate in the form of a rod 10 mm in diameter. Before the extruding tests, the mixture of material with 2?5, 5, 10, 30, 50 and 80% regranulate concentrations in weigh were prepared. Suitable amounts of material were initially mixed in a drum mixer. For a single screw extruder, the temperature of material in respective zones was set according to the producer s requirements (130, 160, 150 and 140uC for the head); for a screw disc type extruder, the temperature was set in the disc zone at 160 and at 140uC for the head. For a screw disc extruder, the interdisc clearance was adjusted at 0?3 mm. After starting the extruder, the charging hopper was fed with the material/reglanulate mixture. The extrudate after leaving the extrusion head was cooled down in two air cooled zones. The systems between individual mixtures were subjected to cleaning by extruding the pure original material. Obtained rods coloured in black with regranulate were divided into sections, which were then cross-sliced into samples 0?5 mm in thickness. These specimens were used as the basis of valuation for the homogeneity of obtained extrudate. The samples prepared in this way were subjected to the assessment by the computer aided image analysis. 13,14 The images of samples were taken using a high resolution video camera connected to the computer with a card digitising the video image. The image received from the camera was analysed using a MultiScan v. 8?08 computer program. This image was subjected to freezing on the video display. Measurements of brightness distribution for individual points of the outlined surface of the sample were taken on this image. For each a single srew extruder; b pilot autothermal screw disc extruder 2 Test stand a single, screw one; b screw, disc one 3 Screws of extruders (L screw working length) Plastics, Rubber and Composites 2008 VOL 37 NO 8 377

3 4 Homogenisation effect in disc zone of screw disc type extruder (s50?3 mm, magnifaction 62?5) and histogram of sample with 5% content of regranulate sample the average brightness and later the mixing ratio were computed. The test specimens for tensile properties testing were prepared according to the standard EN ISO 527 2:1998. Strength of polymer was tested using the universal materials testing machine Instron 3367 at ambient temperature. The tensile speed amounted to v5100 mm min 21.Thetests were carried out on 60 specimens. Results and discussion The programme included a very wide scope of research. The paper presents the results of mixing ratio obtained from a disc zone of a screw disc type extruder, where an interdisc clearance was s50?3 mm and from a helical channel of a single screw extruder. The second part of paper presents the results of tensile tests. Mixing ratio tests The homogenisation effect in a disc zone of a screw disc extruder with a clearance s50?3 mm is presented in Fig. 4, which shows a cross-section of obtained rope. A regranulate content in a screw disc type extruder amounted to 2?5, 5, 10 and 30%. Multiscan, a program for an image analysis, counted a number of points at an appropriate level of brightness and on the basis of their number, size and dispersion the average brightness B of the specimen was calculated. Figure 5 illustrates the effects of the polyethylene regranulate homogenisation in a helical channel of a single screw extruder. Samples with 5, 10, 30 and 50% content of regranulate were obtained from a single screw extruder. The obtained samples correspond to the histograms with brightens equal to 129?4, 110?4, 73?9 and 73?2 respectively. Owing to limited visibility with the naked eye, only the photographs of cross-sections containing 5% regranulate are included in Figs. 4 and 5. Figures show that the brightness of samples decreases along with an increase in a regranulate content. The best results of the distribution and homogenisation of the material mixed with regranulate were obtained using a screw disc type extruder. It is affected by the displacement mechanism and the different trajectories of movement for individual points of polymer chain in a single screw extruder and a screw disc type extruder. It was confirmed by a computer simulation. 15 The movement trajectory in a helical channel of a single screw extruder is in the shape of a screw line, however in the case of a screw disc type extruder they are spiral in the conical interdisc zone. Thus, the regranulate in a single screw extruder is distributed from the middle of extrudate towards the external surface, however in the case of the extrudate produced by a screw disc type extruder, it is distributed from the externals surface towards the axis. From the comparison of the obtained images of samples and their histograms one may observe that the homogenisation of the material mixed with regranulate proceeds much better in an interdisc clearance of a screw disc type extruder than in a helical channel of a single screw extruder. Figures show that an increase in a regranulate content in extrudate leads to a proportional decrease in brightness. The homogeneity extrudate with a specified content of regranulate was determined by the mixing ratio g, which was obtained by solving the Rose s 16,17 equation g~1{ s s o (1) where s~ 1 X 1=2 (Bmg {B ml ) 2 (2) n or the standard deviation making allowance for mean global brightness B mg and mean local brightness B ml and 5 Effect of homogenisation in helical channel of single screw extruder (magnifaction 62?5) and histogram of sample with 5% content of regranulate 378 Plastics, Rubber and Composites 2008 VOL 37 NO 8

4 a screw extruder; b screw disc type extruder, 0?3 mm interdisc clearance 6 Mixing ratio as function of concentration of regranulate in extrudate s o ~B max {B min (3) which signifies the maximum difference of the measured brightness B of extrudate from a series of measurements. The computed values of the mixing ratio as a function of a regranulate concentration are presented in Fig. 6. The diagram shows that the mixing ratio is increasing along with an increase in the regranulate concentration in the primary mass of material. After reaching the homogeneity defined by the ratio g50?9 in a screw disc type extruder, where the interdisc clearance amounted to 0?3 and 1 mm respectively, whereas a further increase in a regranulate content brings about a smaller increase in the mixing ratio which asymptotically approaches the value g51, i.e. the ideal homogeneity. A different way of the reglanulate distribution in extrudate indicates the different runs of homogenising. Black regranulate in a single screw extruder is distributed in the homogenisation zone from the middle towards the external surface, however in the case of a screw disc type extruder it is distributed in the interdisck clearance from the external surface to the centre. It was found that the homogenisation of the raw material with regranulate in the interdisc clearance proceeds much more effectively than in a helical channel of a single screw extruder. Tensile properties tests The results of average stress at break tests for extrudate from a screw disc type and classical extruder are presented in Table 1 and Fig. 7. Table 1 Average results of testing stress at break for polymer plasticised using classical extruder and screw disc one with clearance 0?3, 1?0 and 3?0 mm Average stress at break, MPa Recyclate share, % 7 Diagram of ultimate strength averages versus recyclate share for classical extruder and screw disc one for three values of clearance In all cases 5% content of recyclate decreases the value of the average breaking stress. In all cases for samples with the recyclate percentage from 5 to 50% were at a very similar level of approximately 6 6?5 MPa. Extrudate obtained from the same recyclate were marked by higher breaking stress. The lowest average value equal to 8?71 MPa was obtained using a classical T-32 extruder. Samples of extrudate produced with a screw disc type extruder were y20% stronger; samples obtained at the 3 mm clearance showed the highest average breaking stress equal to 11?76 MPa. It also should be mentioned that the extrudate obtained at a 1 mm clearance showed the most similar value of the breaking stress to the extrudate obtained from a T-32 extruder. The results of average strain at break tests for extrudate from a screw disc type and classical extruder are presented in Table 2 and Fig. 8. It follows from the ultimate elongation results presented in Fig. 8 that the average value of elongation for all the tested samples was increasing along with an increase in a recyclate content. The extrudate obtained by a classical method and using a screw disc type extruder at a 1 mm clearance is marked by very similar values of the breaking stress. Samples obtained from 100% recyclate at the remaining settings of the interdisc clearance revealed y35% higher relative elongation. Conclusions 1. The comparison shows that the mixing in the conical screw disc zone is carried out more Table 2 Average results of testing strain at break for polymer plasticised using classical extruder and screw disc one with clearance 0?3, 1?0 and 3?0 mm Average strain at break, % Recyclate share, % Extruder Extruder Classical T Screw disc Screw disc Screw disc Classical T Screw disc Screw disc Screw disc Plastics, Rubber and Composites 2008 VOL 37 NO 8 379

5 5. Plasticising in the disc zone of a screw disc extruder makes it possible to obtain extrudate with better properties than in the case of classical extrusion. 8 Diagram of ultimate strain averages versus recyclate share for classical extruder and screw disc one for three values of clearance thoroughly than in a helical channel of a single screw extruder. 2. Calculated mixing ratio shows that the homogenisation of the raw material with regranulate in the interdisc clearance proceeds much more effectively than in a helical channel of a single screw extruder. 3. The tensile values of extrudate obtained using a classical screw extruder were the most similar to the values of extrudate from a screw disc type extruder at a 1 mm interdisc clearance. 4. The extrudate obtained by screw disc type extrusion at 0?3 and 3 mm interdisc clearance are marked by higher values than the extrudate obtained at a 1 mm clearance. References: 1. J. E. Lukacz: Oborudowanie dla proizwodstwa polimernych plenok ; 1981, Moscow: Maszinostrojenije. 2. R. Sikora: Macromolecular materials processing ; 1993, Warszawa, Żak. 3. J. W. Sikora: Studium autotermiczności procesu wytłaczania i strefy rowkowanej wytłaczarki ; 2000, Lublin, Lublin University of Technology. 4. J. Diakun: Proc VIII Sem. on Artificial materials in machine building, 75 81; 1997, Crakow, Cracow University of Technology. 5. T. Rydzkowski and J. Diakun: in Novelties in polymer materials processing, (ed. J. Koszkul), ; 2002, Czestochowa, Czestochowa University of Technology. 6. T. Rydzkowski: Proc. 21 Ann. Meet. Polimer Processing Society, Niemcy, Lipsk, June 2005, Polimer Processing Society, paper p J. Diakun: Fundamentals for activating the feeding zone in design for a screw extruder ; 1991, Koszalin, WSInż. 8. J. Diakun and T. Bil: Plastverabeiter, 1988, 39, (4), T. Rydzkowski: in Novelties in polymer materials processing, (ed. J. Koszkul and E. Bociąga), ; 2004, Czestochowa, Czestochowa University of Technology. 10. T. Rydzkowski and I. Michalska-Pożoga: in New directions of modification and application of polymers, (ed. J. Jurga), ; 2004, Poznan, Poznan Univesity of Technology. 11. G. Radomski: Inzynieria i Aparatura Chemiczna, 2003, 42, (33), G. Radomski: Polimery, 2005, L/50, H. Potente and M. Koch: Plastverarbeiter, 1986, 37, J. Stasiek: Polimery, 1996, 41, J. Diakun and I. Michalska-Pożoga: Polimery, 2004, 49, J. Boss: Mixing of grainy materials ; 1987, Warszawa, PWN Warszawa. 17. J. M. McKelvey: Polymer processing ; 1962, New York/London, John Wiley and Sons Inc. 380 Plastics, Rubber and Composites 2008 VOL 37 NO 8

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