Method of analyzing and quantifying the performance of mixing sections

Abstract

In this article, the performance of three different mixing elements on color dispersion in high-density polyethylene and linear low-density polyethylene polymer stream during extrusion is studied. Two similarly designed Maddock mixers and a Stratablend II mixer are used as the last part of a general purpose single screw. Moreover, an inline melt camera is used for the quantification of mixing quality by visualization of grayscale of the color dispersion and thus mixing. The Stratablend II mixer produces the lowest and most uniform standard deviation. Both the Maddock mixers showed the same trend but higher values of standard deviation. All results are then compared with a full 3D finite element method simulation. Simulations clearly indicate that the Stratablend II mixer has the best mixing abilities and that these are mainly given by its unique design with high average value of shear stress. The role of elongational stress does not appear to have a high influence on mixing for these mixers. The results also suggest that the key factor for achieving better mixing is the frequency by which a large fraction of the material passes through the high shear stress regions of the mixer. © 2012 Society of Plastics Engineers.