Computer Modeling System for Energy- and Resource-Saving Control of Multi-Assortment Polymeric Film Production

Abstract

AbstractThe chapter describes the questions of developing the flexible computer modeling system that allows us to realize the synthesis of mathematical models of hardware flexible extrusion processes for energy- and resource-saving control of large-capacity, multi-assortment production of polymeric films. The problem of energy- and resource-saving control, which is solved at each transition of the production to a new type of film, is to determine parameters of the extruder configuration and operating mode, ensuring the given extrudate quality when meeting the requirements for throughput and energy consumption. The library of mathematical models is the core of the system. It includes structural models of extruder elements for calculating the geometric parameters of extruders of various configurations and functional models of physical processes in the element channels. Static models for calculating throughput, energy consumption, extrudate quality indices (mixing degree, solid fraction, thermal destruction index), and dynamic models for calculating residence time in the extruder are synthesized based on the physical process models in the element channels. The structural synthesis of the models is based on a cell approach to modeling processes in partitioned apparatuses. Setting up the system is carried out using a data bank of production methods and types of films, parameters of extruders, polymer properties. A two-stage iterative algorithm is used to solve the control problem: the extruder configuration is formed in the external cycle, the extruder operating parameters, which ensure the required extrudate quality with given throughput, energy consumption, are determined in the internal cycle. Testing according to data of the polyvinyl chloride and polyethylene film productions in plants of Russia and Germany has confirmed the operability of the system and the possibility of its using as an adviser to operators.KeywordsMathematical modelingSoftware packageEnergy- and resource-saving controlPolymeric film productionExtruders with variable configurations