Numerical Simulation Of Mixing Performance And Energy-saving Research Of Masterbatch Extruder

Masterbatch products have a pivotal role in the production industry,masterbatch production technology is also more and more important.Screw extruder is an important equipment for masterbatch in heating?melting and extrusion.Because of its complex processing principle,the numerical simulation technology for solving the mixing effect has an important guiding effect on the actual production,and it is an important criterion to measure the quality of the masterbatch product.In this paper,the fluid simulation software POLYFLOW is used to simulate the movement of the masterbatch melt,including the pressure field,the velocity field,the temperature field and the mixing performance.Through the analysis simulation,the torque can be get in the run log.At the same time,based on the results of the POLYFLOW flow field analysis,the mixing performance in the masterbatch melt processing was numerically simulated through the particle tracing method.The results of the mixing performance analysis were analyzed by using the software POLYSTAT.The mixing performance curve was obtained,including residence time,shear rate,the maximum shear rate,etc.In order to research the effects of mixing performance,parameters in the production were changed,including the speed of the screw,the amount of feed at the screw inlet,and the outlet pressure setting.The experimental results show that the changes of the production parameters will change the flow field of the screw and the energy consumption and the mixing performance.The rotational speed of the screw has the greatest effect on the extrusion performance.The larger the speed,the greater the shear rate and the flow rate of the particles,but the shorter the residence time,so the reasonable choice of screw speed to achieve the best mixing performance and the Minimal energy consumption.The feed volume of the feed inlet has a large influence on the inlet and outlet pressure difference,and the proper increase of the feed quantity can improve the extrusion efficiency.Finally,according to the factors that affect the energy consumption,the optimization of the barrel structure and the optimization of the temperature control system algorithm are carried out to reduce the energy consumption.In the aspect of structure,according to the heat transfer characteristics of temperature,the ANSYS thermodynamic analysis is carried out to determine the wall thickness of the optimal heat transfer barrel.On the basis of the traditional PID control algorithm,a fuzzy control is proposed which combined PID control with the fuzzy adaptive PID algorithm.And through simulation,the temperature curve of the material is obtained,and the PID parameters which are most suitable for the heating of the extruder are qualitatively determined.So It makes the energy consumption of the extruder during the heating process to a minimum,greatly saving energy.The numerical simulation results of the masterbatch extruder were simulated by a large amount of data.The results were in agreement with the experimental results.And in the processing of masterbatch actual production,the reasonable setting of process parameters improved the quality and reduced energy waste.