Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation
This work presents a comprehensive review of the evolution in modeling reactive extrusion (REx), tracing developments from early analytical models to advanced computational fluid dynamics (CFD) simulations. Additionally, it highlights the key challenges and future directions in this field. Analytica...
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| Format: | Article |
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MDPI AG
2025-01-01
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| Series: | Fluids |
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| Online Access: | https://www.mdpi.com/2311-5521/10/1/9 |
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| author | Elham Delvar Inês Oliveira Margarida S. C. A. Brito Cláudia G. Silva Arantzazu Santamaria-Echart Maria-Filomena Barreiro Ricardo J. Santos |
| author_facet | Elham Delvar Inês Oliveira Margarida S. C. A. Brito Cláudia G. Silva Arantzazu Santamaria-Echart Maria-Filomena Barreiro Ricardo J. Santos |
| author_sort | Elham Delvar |
| collection | DOAJ |
| description | This work presents a comprehensive review of the evolution in modeling reactive extrusion (REx), tracing developments from early analytical models to advanced computational fluid dynamics (CFD) simulations. Additionally, it highlights the key challenges and future directions in this field. Analytical models to describe the velocity profiles were proposed in the 1950s, involving certain geometrical simplifications. However, numerical models of melt polymeric flow in extruders have proven to be crucial for optimizing screw design and predicting process characteristics. The state-of-the-art CFD models for single and twin-screw extruders design address the impact of geometry (type of mixing elements and geometrical simplifications of CFD geometries), pressure and temperature gradients, and quantification of mixing. Despite the extensive work conducted, modeling reactive extrusion using CFD remains challenging due to the intricate interplay of mixing, heat transfer, chemical reactions, and non-Newtonian fluid behavior under high shear and temperature gradients. These challenges are further intensified by the presence of multiphase flows and the complexity of extruder geometries. Future advancements should enhance simulation accuracy, incorporate multiphase flow models, and utilize real-time sensor data for adaptive modeling approaches. |
| format | Article |
| id | doaj-art-3fbf52cef8e04d4fb89f78ac97a1d847 |
| institution | Kabale University |
| issn | 2311-5521 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Fluids |
| spelling | doaj-art-3fbf52cef8e04d4fb89f78ac97a1d8472025-01-24T13:32:34ZengMDPI AGFluids2311-55212025-01-01101910.3390/fluids10010009Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD SimulationElham Delvar0Inês Oliveira1Margarida S. C. A. Brito2Cláudia G. Silva3Arantzazu Santamaria-Echart4Maria-Filomena Barreiro5Ricardo J. Santos6Associate Laboratory in Chemical Engineering (ALiCE), Faculty of Engineering, University of Porto, 4200-465 Porto, PortugalAssociate Laboratory in Chemical Engineering (ALiCE), Faculty of Engineering, University of Porto, 4200-465 Porto, PortugalAssociate Laboratory in Chemical Engineering (ALiCE), Faculty of Engineering, University of Porto, 4200-465 Porto, PortugalAssociate Laboratory in Chemical Engineering (ALiCE), Faculty of Engineering, University of Porto, 4200-465 Porto, PortugalCIMO, LA SusTEC, Instituto Politécnico de Bragança, Campus de Santa Apolónia, 5300-253 Bragança, PortugalCIMO, LA SusTEC, Instituto Politécnico de Bragança, Campus de Santa Apolónia, 5300-253 Bragança, PortugalAssociate Laboratory in Chemical Engineering (ALiCE), Faculty of Engineering, University of Porto, 4200-465 Porto, PortugalThis work presents a comprehensive review of the evolution in modeling reactive extrusion (REx), tracing developments from early analytical models to advanced computational fluid dynamics (CFD) simulations. Additionally, it highlights the key challenges and future directions in this field. Analytical models to describe the velocity profiles were proposed in the 1950s, involving certain geometrical simplifications. However, numerical models of melt polymeric flow in extruders have proven to be crucial for optimizing screw design and predicting process characteristics. The state-of-the-art CFD models for single and twin-screw extruders design address the impact of geometry (type of mixing elements and geometrical simplifications of CFD geometries), pressure and temperature gradients, and quantification of mixing. Despite the extensive work conducted, modeling reactive extrusion using CFD remains challenging due to the intricate interplay of mixing, heat transfer, chemical reactions, and non-Newtonian fluid behavior under high shear and temperature gradients. These challenges are further intensified by the presence of multiphase flows and the complexity of extruder geometries. Future advancements should enhance simulation accuracy, incorporate multiphase flow models, and utilize real-time sensor data for adaptive modeling approaches.https://www.mdpi.com/2311-5521/10/1/9reactive extrusion processCFD simulationpolymerizationextruder designing |
| spellingShingle | Elham Delvar Inês Oliveira Margarida S. C. A. Brito Cláudia G. Silva Arantzazu Santamaria-Echart Maria-Filomena Barreiro Ricardo J. Santos Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation Fluids reactive extrusion process CFD simulation polymerization extruder designing |
| title | Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation |
| title_full | Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation |
| title_fullStr | Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation |
| title_full_unstemmed | Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation |
| title_short | Literature Review on Single and Twin-Screw Extruders Design for Polymerization Using CFD Simulation |
| title_sort | literature review on single and twin screw extruders design for polymerization using cfd simulation |
| topic | reactive extrusion process CFD simulation polymerization extruder designing |
| url | https://www.mdpi.com/2311-5521/10/1/9 |
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