Technical Problem Solving

Master Reactive Extrusion in Twin Screw for Enhanced Quality & Safety

Master Reactive Extrusion in Twin Screw for Enhanced Quality & Safety
Language: English
Length: 75 min
Recorded on: 12 Jun 24

Package Includes

6 months access to Course Recording, Presentation Slides, Q&A Transcript

Course Description

Get started with reactive extrusion for your thermoplastics by gaining a 360⁰ view of the process, the reaction chemistry, and how to configure the extruder.



In this simulated live course, Kenneth Russell will help you spend less time on trial and error and develop materials with reactive extrusion principles and practices faster by sharing hands-on tips on injecting liquids, defining the right residence time distribution (RTD), and more.

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Kenneth W Russell
Kenneth W Russell
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Kenneth W. Russell has more than 25 years of experience working with polymer processing and resin companies delivering results in new product development, process improvement, scale-up and customer technical support. Kenneth’s expertise includes polyolefin polymerization, polymer compounding, reactive extrusion, and film extrusion.

Kenneth has transferred product developments and processes into Europe, India and China from the US while maintaining product equivalency between locations. He has a strong belief in continuous process improvement and statistical process control. Kenneth is certified as a CPlasT from the Society of Plastics Engineers. He has earned a BS in Chemical Engineering from Rutgers University in Piscataway, NJ, a MS in Chemical Engineering from Auburn University, AL. and a Master of Engineering Management from Lamar University in Beaumont, TX. Kenneth has been consulting for over 5 years as an expert in leading process improvement, product development, new process development, operator process training and as a resin subject matter expert.

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Why should you view this course?

The environmental advantages of reactive extrusion compared to traditional reactors present huge potential. Moreover, reactive extrusion can be used for a variety of reactions.

But do you have a structured methodology to determine the parameters for your thermoplastics' reactive extrusion (right number of residues, the right temperature, the right screw speed, etc.)? Are you clear on the effect of reaction chemistry on the extruder? Without that clarity, you might end up relying on trial and error, which can lead to quality issues. This course will help you:

  1. Save time by knowing the basics of reactive extrusion and how to achieve desired polymer properties using your extruder as a reactor.

  2. Understand the very important reaction chemistry (Free-Radical, Saponification, and more...) governing the whole process.

  3. Achieve good mixing by understanding how to best configure the reactive extrusion process (Screw design, Liquid injection, Mixing configurations...).

Who should join this course?

  • R&D Chemists, Research Engineers working with twin-screw extrusion

  • Product Development Managers

  • Compounders

  • Masterbatchers

  • Application Development Managers

  • Who are willing to step into Reactive Extrusion. The course is particularly suited for people with prior experience in Twin Screw Extrusion.

    Complete the course and (unlock your personalized certificate) – your badge of accomplishment awaits!

  • This course is suitable for beginner level proficiency
    Beginner
Course Outline

Introduction

Why use an extruder as a reactor?

Configuring the process for reactive extrusion

  • Screw design concerns
  • Liquid injection
    - How to inject liquid
    - Why liquids should be handled in a certain way
  • Mixing configurations
  • Screw elements that should be used for good mixing and elements that should be avoided
  • Measuring residence time distribution (RTD)
  • General trends in how RTD is affected by screw configuration

Reaction Chemistry and Effect on Extruder Configuration

  • Free-Radical chemistry
    -     Initiation
    - Propagation
    - PE crosslinking
    - PP chain scission
    - Grafting
  • Saponification
    - Patent examples
    - Making ionomers with ethylene – acrylate polymers
  • Trans-esterification
    - Patent examples – ethylene acrylate polymers with alcohol
    - Use of a partial condenser to improve conversion

Safety

  • Raw material hazards
    - Maleic anhydride
    - Organic peroxides
    - Alcohols
  • Hazards due to reactivity
    - Volatile by-products
  • Thermal hazards
    - Melt temperature
    - Pressure development

Practical heat transfer concerns for Good Reaction Control (at the Expected Rate)

15 mins Q&A

  • Send your questions in chat or mail up to 3 days (Questions directly answered by expert in QnA document)
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Master Reactive Extrusion in Twin Screw for Enhanced Quality & Safety
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