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Single Screw Extrusion Do not duplicate Extrusion Technology for the production of food and non-food materials Osvaldo H. Campanella PRESENTATION OUTLINE Do not duplicate • The Whistler Center and its Activities in Extrusion • Extrusion Introduction – Applications • Extrusion Technology – Single Screw Extrusion (SSE) versus Twin Screw Extrusion (TSE) • Transformation of Raw Materials • Quality of Final Product • Some Extrusion Processes PRESENTATION OUTLINE Do not duplicate • The Whistler Center and its Activities in Extrusion • Extrusion Introduction – Applications • Extrusion Technology – Single Screw Extrusion (SSE) versus Twin Screw Extrusion (TSE) • Transformation of Raw Materials • Quality of Final Product • Some Extrusion Processes Whistler Center Activities in Extrusion Do not duplicate • Mission to Mars • 6-8 months outbound • 600 day surface stay • 6-8 months return Lift cost to Mars: ~$200,000/kg Whistler Center Activities in Extrusion Do not duplicate Design a multipurpose small extruder First Extrusion soybeans soy flour Extrusion Pressing Drying Grinding meal oil Second Extrusion soy flour Texturized soy protein Extrusion Drying Whistler Center Activities in Extrusion Do not duplicate LARGE SCALE “MODEL” EXTRUDER Triple F - Model RC 2000 Whistler Center Activities in Extrusion Cutaway views of extruder Do not duplicate Steam locks Die Cut-away view Of steam locks 4.125” 5.375” 5.625” 0.562” 0.313” Actual geometry with mesh 1.625” Whistler Center Activities in Extrusion Do not duplicate Design a multipurpose small extruder Modeling an Extrusion Process Balance of mass u=0 Momentum Transfer (forces and velocities ) p 0 Rheology Energy Transfer (temperatures) Pressure dT Cpuu (): k T Length dt Rheology Whistler Center Activities in Extrusion Do not duplicate Rheological Model For Soy Flour 3.5 Temperatures = 50oC - 90oC Moistures = 30% - 42% 3.0 Oil = 0% - 12.2% 2.5 2.0 1.5 log (Viscosity) 1.0 0.5 0.0 2.0 2.5 3.0 3.5 4.0 4.5 5.0 log (a x a x a x Shear Rate) M T o 0... 852 1 373 0 373 log0 . 70 log ( aM a T a o ) 5 . 7 log aM 12.55(M b) - 2.13 b -0.00034 T 0.0223 log aT 0.020 T - 1.23 log ao 9.3 (Oil Content A) - 0.088 A - 0.001347 T 0.06866 Whistler Center Activities in Extrusion Pressure measurements duringDo not duplicate soy dough extrusion 450 Port 4 400 Port 5 350 Port 6 Port 7 300 250 200 Pressure (Psi) Pressure 150 100 50 0 0 10 20 30 40 50 60 350 Time (min) 300 250 200 150 Pressure (Psi) 100 50 0 3 4 5 6 7 8 Port number Whistler Center Activities in Extrusion Do not duplicate Whistler Center Activities in Extrusion Do not duplicate Design of the Small (60 lb/h) extruder Whistler Center Activities in Extrusion Interrelationship between activities Doassociated not duplicate with extrusion modeling Experimental trials Production scale Planned process Extrusion Process results Raw materials Modeling Finished product Scale up concepts Model validation Experimental trials Pilot scale Whistler Center Activities in Extrusion Modeling Thermo-Mechanical ProcessingDo not duplicate • How rigorous do we need to find useful models? • Could we use simple models to describe extrusion processes? • Could we have models that have a perfect description of the process? Whistler Center Activities in Extrusion Do not duplicate Dimension “0” models Pshaft q barrel U Q p q loss H vap H melting Pshaft : is the power in the extruder motor U : the rate of internal energy change in the product p : is the pressure Hvap : the rate of enthalpy (heat) change involved in the vaporization of the plasticizer/solvent Hmelting : the rate of enthalpy necessary for the transformation of the feed from a powdery solid to a melt qbarrel : rate of heat transferred through the extruder barrels qloss : heat loss Whistler Center Activities in Extrusion The value of process modeling Do not duplicate Pshaft q barrel U Q p q loss H vap H melting A simple “autogenous” extruder U Pshaft Q p Heating the material U m c() Tout T in Pm/ p e p TT shaft out in m cc c c Q Important to analyze the sign of p , it is not so important in single screw extruders because is always positive. However in twin screw extruders the pressure difference can be negative or positive Whistler Center Activities in Extrusion The value of process modeling Do not duplicate 2D-3D Models – Importance of the extruded material Whistler Center Activities in Extrusion Do not duplicate The value of process Flow field (velocity, pressure) modeling Primary Temperature field fields Concentration field (reactive extrusion) Viscosity field Secondary Shear stress field Process fields Diffusion flux fields variables (reactive extrusion) Power Scalar Axial pressure shaft variables Temperature Temperature field Product Time Reaction kinetics transformation Concentration field Other process Mixing efficiency variables Residence time distribution Variables Involved in Extrusion Do not duplicate PRESENTATION OUTLINE Do not duplicate • The Whistler Center and its Activities in Extrusion • Extrusion Introduction – Applications • Extrusion Technology – Single Screw Extrusion (SSE) versus Twin Screw Extrusion (TSE) • Transformation of Raw Materials • Quality of Final Product • Some Extrusion Processes EXTRUSION INTRODUCTION Do not duplicate Extrude “To push or force out a material through an opening (Die)” Die Material • The extrusion process was first used in the plastic industry. In the food industry the process was first applied for the continuous extrusion of pasta in 1935 • It is a process of increasing importance in the food industry FOOD EXTRUSION COOKING VERSATILITY Do not duplicate Flat Bread Pellet-to- flakes cereals Directly expanded cereals Snack pellets Co-filled cereals Porous Powders Other Applications Do not duplicate Proteins • Textured Vegetable Proteins • Protein “Fibrilation” • Caseinates Other ……. • Functional Ingredients • Flavor Encapsulation • Pre-cooked flours • Pre-gelatinized starches • Oil seed Extraction • Confectionary Other Applications Animal Feed Do not duplicate Dry Pet Feed (cat & dog) Aquafeed pellets OUTLINE Do not duplicate • The Whistler Center and its Activities in Extrusion • Extrusion Introduction – Applications • Extrusion Technology – Single Screw Extrusion (SSE) versus Twin Screw Extrusion (TSE) • Transformation of Raw Materials • Quality of Final Products • Some Extrusion Processes • Extrusion Technology SSE and TSE Do not duplicate What is it ? How does it work ? Single Screw Extruder Design (SSE) What can I do with it ? Twin Screw Extruder Design (TSE) Extrusion Technology SSE Extruder Barrel Assembly Do not duplicate The Monoblock System (two options) • Screw design – a single piece (constant pitch, decreasing channel depth) • A splined shaft holding screw sections of varying pitch Bouvier and Campanella (2014). Extrusion Processing Technology. Wiley-Blackwell BASICS OF SSE TECHNOLOGY FLOW CHARACTERISTICS IN THE SCREW CHANNEL • The forward pitch of the screw flight conveys the materials down the channel by developing a DRAG FLOW, the velocity of that flow is directly proportional to the screw speed N. • Because of the die restriction at the extruder’s discharge, there is a PRESSURE FLOW, which is opposite in direction to the drag flow. Thus, SSE Flow rate = Drag flow rate – Pressure flow rate Pressure Flow K dP QN dZ Drag Flow a Operational flow rate is dictated by screw geometry, N, die pressure, and melt rheological properties: the coupling of these variables limits the operating range and flexibility of SSE technology BASICS OF SSE TECHNOLOGY Do not duplicate FLOW CHARACTERISTICS IN THE SCREW CHANNEL Drag flow Velocity profiles in the screw channel BARREL N SCREW Pressure flow FEED DIE Down channel direction Courtesy Professor Bouvier BASICS OF SSE TECHNOLOGY FLUID DYNAMICS IN THE SCREW CHANNEL – MixingDoand not Residence duplicatetime Screw channel (unwound) Down channel direction Mixing: fluid particles have different Screw channel velocities and do not mix. It leads to a (cross section) distribution of residence times and poor mixing. Heat transfer and mechanical energy input in the cooking section are limited. Shear is not uniform leading to product Flow pattern in the screw channel with heterogeneous properties. SSE TECHNOLOGY EFFECT OF MELT SLIP AT THE BARRELDo WALL not duplicate • In SSE, perfect melt adherence to the barrel wall is required to obtain maximum throughput of the extruder. Any change in the melt composition which generates MELT SLIP at the barrel wall would lead to dramatic decrease of the extruder throughput. For example, in feed extrusion processing, « SLIP INDUCERS » are : moisture, meat slurries, protein hydrolysates, fat, for instance. • Melt slip at the barrel wall decreases importantly the extent of mixing as well as the heat transfer and shear rate (mechanical energy input). Velocity profiles in the screw channel BARREL Melt Slip Perfect melt adherence SCREW Extrusion Technology TSE Do not duplicate The “modular” screw-barrel assembly – Twin-Screw Extruders (TSE) Bouvier and Campanella (2014). Extrusion Processing Technology. Wiley-Blackwell Extrusion Technology TSE Classification Do not duplicate Bouvier and Campanella (2014). Extrusion Processing Technology. Wiley-Blackwell Extrusion Technology TSE Do not duplicate Co-Rotating Screws Mixing Disks Compression disks BASICS OF COROTATING TSE DESIGN AND PROCESS CHARACTERISTICS Do not duplicate Feed • Splined shafts that hold screw sections of varying configuration (forward pitch, reverse screw, kneading disks…..) Venting PRECONDITIONER Compression
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