Design, Modeling, and Validation of a Compact, Energy-Efficient Mixing Screw for Sustainable Polymer Processing.

ABSTRACT: This study presents the design, modeling, and validation of a mixing screw for energy-efficient single-screw extrusion. The screw features a short length-to-diameter (L/D) ratio of 8:1 and incorporates double flights with variable pitch and counter-rotating mixing slots. These features promote enhanced plastication by breaking up the solid bed and improving thermal homogeneity through backflow mechanisms relieving a 3.75 compression ratio. Non-isothermal, non-Newtonian simulations modeled the thermal and flow behavior for high-impact polystyrene (HIPS) and recycled polypropylene (rPP) under various operating conditions. Experimental validation was conducted using a 20 mm pilot-scale extruder with screw speeds ranging from 10 to 40 RPM and barrel temperatures of 220 °C and 240 °C. Results s

SUBMITTER: Kazmer DO 

PROVIDER: S-EPMC11768437 | biostudies-literature | 2025 Jan

REPOSITORIES: biostudies-literature