Blow-up Ratio Research Articles

Classification performance analysis of a louver classifier with a tilted sidewall and its application to the separation of unburned carbon from biomass combustion ash

Separating unburned carbon (UC) from biomass combustion ash is necessary to achieve high-quality ash as recyclable raw material and improve energy efficiency by reburning the UC in the furnace. In this study, a novel louver classifier geometry with tilted sidewall was proposed to separate the UC from biomass ash and its classification performance was analyzed via experiments and simulations. The louver classifier with a tilted sidewall provided a smaller 50% cut size and classification accuracy index indicating that the separation performance is improved. The CFD simulations revealed that tilted sidewall in the louver increased gas flow downward velocity in the classification region, increasing the inertia of the particles, and causing more particles to leave gas flow and deposit into the collection box as coarse ash. The UC of classified combustion ash increased with a decrease in the median mass diameter, indicating that the classification process for combustion ash produced coarse ash with a lower UC. The tilted sidewall in the modified louver classifier increased the reduction of unburned carbon (RUC) in ash up to 83.8%. The RUC increased with a cut size of the classified ash which was achieved when a high inlet flow velocity and high blow-up ratio are applied.

Influence of the Main Blown Film Extrusion Process Parameters on the Mechanical Properties of a High-Density Polyethylene Hexene Copolymer and Linear Low-Density Polyethylene Butene Copolymer Blend Used for Plastic Bags

Polyethylene plastic bags manufactured via blown film extrusion have different quality specifications depending on their intended use. It is known that the mechanical properties of a film depend on the process parameters established, but little is known concerning how they affect one another, even more so due to the variety of polyethylene materials and processing techniques. This study focuses on establishing a proper correspondence of important mechanical properties like the dart impact, tensile strength at break, and elongation at break with commonly used process parameters like the blow-up ratio, take-up ratio, thickness reduction, and neck height, for a high-density polyethylene hexene copolymer and a linear low-density polyethylene butene copolymer blend film. Because this polyethylene mixture is an anisotropic material, interesting R2 values equal to or higher than 0.90 were found: a BUR with elongation at break and tensile strength at break in the MD and TD, a TUR with elongation at break in the MD and tensile strength at break in the MD and TD, and a TR with elongation at break and tensile strength at break in the MD. Also, a relationship between the dart impact and both the neck height and thickness were found.

Tailored biodegradable films via extrusion blow molding using PBS, PBAT, and TPS

AbstractResearch to replace synthetic polymers with biodegradable polymers is on the rise because common plastics have generated serious ecosystem problems. Films with thermoplastic starch (TPS), poly(butylene succinate) (PBS), poly(butylene adipate‐co‐butylene terephthalate (PBAT), and citric acid (CA) were produced by blown extrusion. They were characterized by blow‐up ratio (BUR), water vapor permeability (WVP), soluble ratio (SR), water sorption isotherm, and thermogravimetric (TG) techniques. Films were uniform and showed BUR > 205%. The different proportions of PBS and PBAT significantly influenced the WVP of the films. All samples had WVP with an order of magnitude similar to other blends with high starch content (10−6 g m−1 day−1 Pa−1). CA efficiently decreased the WVP of the PBS/PBAT/TPS formulations (15/15/70% and 20/10/70% by mass) by 25.2% and 24.7% compared to the acid‐free formulations. There was no significant difference in SR (19.0%–20.1%). These materials were sensitive to moisture since the equilibrium moisture content increased pronouncedly from water activity of 0.5. Films showed good thermal stability, with a maximum decomposition temperature close to pure polyesters. CA did not increase the thermal stability of blends, probably because of the low content used (0.1%). Given the outcomes of this study, these films could be deemed appropriate for applications in food packaging.

Blown film stability for low, medium, and high molecular weight polylactic acid and their tensile properties

Three poly (lactic acid) (PLA) resins with molecular weight (Mw) equal to 55 (3251D), 125 (L105) and 163 (LX175) kg/mol were characterized in terms of capillary viscosity, mechanical and thermal properties and used to produce blown films. The effect of temperature, extrusion rate, stretching (TUR) and blow-up (BUR) ratios were evaluated to determine the optimum processing conditions for blown films based on the bubble stability and to determine their final tensile properties. As expected, the processing temperature was the most critical parameter on the film stability. The lower Mw PLA showed limited processing stability. Stable conditions were found at higher temperature (200°C) for higher Mw. These results correlate with the PLA viscosity (melt strength). Finally, the PLA film tensile strength (TS) strongly depended on their processability. For example, 3251D and L105 required high stretching (TUR = 3.4 and 7) for maximum TS (30 and 64 MPa) with a low blow-up ratio (BUR = 1.02–1.15). However, a moderate increase in BUR (10% at TUR = 3) led to a substantial drop in TS (from 29 MPa to 21 MPa for PLA 3251D and 44 MPa–34 MPa for L105). Overall, LX175 was the most interesting resin with 49 MPa TS which was independent of the BUR and TUR used in this investigation.

Development of Novel Blown Shrink Films from Poly(Lactide)/Poly(Butylene-Adipate-co-Terephthalate) Blends for Sustainable Food Packaging Applications.

Heat-shrinkable films, largely made of polyolefins and widely employed in the packaging sector as collation or barrier films, due to their short service life, are held responsible for high environmental impact. One possible strategy for reduction in their carbon footprint can be the use of biodegradable polymers. Thus, this work aimed to develop novel, heat-shrinkable, fully biodegradable films for green packaging applications and to analyze their functional performance. Films were obtained from blends of amorphous polylactic acid (PLA) and poly(butylene-adipate-co-terephthalate) (PBAT) at different mass ratios and compatibilized with a chain extender. They were produced by means of a lab-scale film blowing extrusion apparatus and characterized in terms of physical–mechanical properties and shrinkability. The influence of the processing parameters during the extrusion blowing process on the films’ behavior was investigated, highlighting the effects of blend composition and stretching drawing conditions. Shrinkage tests demonstrated that the produced films have shrinkability values in the typical range of mono-oriented films (ca. 60–80% in machine direction and ca. 10–20% in transverse direction). Moreover, the shrinkage in machine direction increases both with the mass flow rate, the take-up ratio to blow-up ratio and the bubble cooling of the film blowing process, and with the PLA content into the blend. In particular, films at higher PLA content also exhibit higher transparency and stiffness.

Effect of Aerodynamics on Film Blowing Process

Abstract A Computational Fluid Dynamics (CFD) technique using a renormalization group (RNG) k –ε model and Fluent software was employed to analyze numerically the effects of aerodynamics on the air ring cooling system of a film blowing process. An in-line scanning camera system developed in our lab was used to study experimentally the detailed dynamics of bubble instabilities. An operation window for the heat transfer coefficient and the maximum air velocity function was established. The simulation results showed that it is adequate mainly at low BUR (Blow-Up-Ratio) outside of the air ring. The relationship between thermal inertia and cooling air aerodynamics for different bubble geometries was also explored. Different bubble shapes, for the same BUR, produced significant differences in the airflow pattern and heat transfer coefficient. The combination of experimental measurements and numerical simulations indicated that various cooling rates result in important variations in the dynamics of bubble instabilities for different BUR bubbles. It was observed that increasing the cooling rate can destabilize the lower BUR bubbles, but stabilize the higher ones due to the production of different bubble shapes. Finally, it is shown that the bubble instabilities depend on the static pressure distribution along the bubble surface, and that minimizing the pressure gradient can stabilize the bubbles.

Experimental Investigation of the Effect of the Bubble Cone on the Cooling Jets used in the Blown Film Manufacturing Process

Abstract An experimental investigation was performed to characterize the flow field produced by a dual-lip air ring used in the blown-film manufacturing process for a solid model with a blow-up ratio of 3.5 similar to the shape of a typical LLDPE bubble. Distributions of the static and fluctuating pressure on the model and the flow field above the forming cone were measured for a range of settings on the dual-lip air ring. It was found that the distribution of the pressure on the bubble below the forming cone had many features similar to the measurements for a bubble with a blow-up ratio of 2.5 [1]. In the region above the forming cone, the upper jet appeared to merge with the lower jet rather than entraining the lower jet as was observed for a bubble with a blow-up ratio of 2.5 [1]. This resulted in a smaller local maximum in the normalized fluctuating pressure in the region above the forming cone and would likely result in less heat transfer in this region. It was also found that the initial angle of the upper jet exiting the air ring changed when the height of the bubble cone was adjusted for the bubble with the blow-up ratio of 3.5. This affected the static pressure in the region below the location where the upper jet attaches to the bubble and the pressure fluctuations in the region where the upper jet attaches to the surface. Finally, unlike the bubble with the blow-up-ratio of 2.5 [1], the presence of the bubble cone caused a region of negative gauge pressure in the region above the forming cone that should act to stabilize the bubble against the bubble cone. The pressure in this region and the region below the forming cone both decreased when the porosity of the bubble cone was reduced.

Analysis of Film Blowing with Flow-enhanced Crystallization

Abstract An analysis of the transient film blowing process is presented based on the two-phase Giesekus/rigid rod model for flow-enhanced crystallization described in Part 1 [1]. Linearized frequency analysis has been used to explore the effects of system disturbances on the process. Results show that perturbations related to heat transfer and inflation pressure are more significant than the effects of film thickness (die swell). In addition, crystallinity is shown to have a consistent stabilizing effect on the system, with more crystallinity dampening the perturbations. Stability diagrams for each material show relatively wide regions of convergence in the blow-up ratio (BUR) – draw ratio space, however, at higher BURs (≥ ~ 4) the system becomes unstable for all DRs.

Single and Double Bubble Tubular Film Extrusion of Polybutylene Terephthalate

Abstract An experimental study of film formation and structure development of polybutylene terephthalate (PBT) in single and double bubble tubular film extrusion processes is presented. PBT was found largely stable in the first stage. In the second stage, the bubble was unstable and biaxial inflation was achieved only with a blow-up ratio of one. The sources of second bubble instabilities were related to the crystalline nature of the first bubble being inflated in the second stage. The structure and properties in the films varied substantially with processing conditions. While the first bubble had poorly ordered α-structure, the double bubble possessed oriented polymorphic texture. The second deformation that induced high film-line stress favored the formation of a stable β phase. The mechanical behavior of the films reflected the crystal perfection as well as orientation in the films.

Compatibilization, processing and characterization of poly(butylene adipate terephthalate)/polylactide (PBAT/PLA) blends

A blend of poly(butylene adipate terephthalate) (PBAT) and polylactide (PLA) is a combination of biodegradable materials. This study aims to prepare compatibilized PBAT/PLA in a cost-effective and timesaving way and to process the material into blown films by fine-tuning the processing parameters. First, a catalyst masterbatch is prepared by transesterification of PBAT and PLA in the presence of tetrabutyl titanate (TBT) as a catalyst. This is followed by the compounding of the two polymer types in combination with the catalyst masterbatch. Third, the compounds are processed into blown films and panels. The processing parameters for film blowing are set to reduce the anisotropy. Finally, the material properties are evaluated such as mechanical tests. The fine-tuning of parameter settings including the blow-up ratio and draw-down ratio results in a higher degree of isotropy of the blown film. By adding the catalyst masterbatch (2 wt%, which corresponds to TBT of approximately 0.002 wt% with copolymers formed) in combination with the fine-tuning of parameter settings, the samples achieved a significant improvement on the material properties. The morphology of the cryogenically fractured panel samples shows a decrease in the diameter of the dispersed phase. In the cross and machine directions, the elongation at break increased by 85 and 93%, and the trouser tear propagation resistance increased by 2.4 and 10 N mm−1, respectively. Furthermore, both the elongation at break and the trouser tear propagation of the blown films achieved a higher degree of isotropy.

Melt strengthening of polylactic acid and its blends: Shear and elongation rheological investigations of the forming process

Polylactic acid (PLA) can be a good alternative to petroleum-based polymers thanks to its organic origin and its biodegradability. This study introduces some promising routes for enhancing the processability of PLA, which presents several challenges due mainly to the poor shear and elongation properties of this biopolymer. To our knowledge, this is the first paper dedicated to an investigation of foaming and/or blown extrusion of PLA that focuses on structural, rheological and thermomechanical properties. Two main routes were selected: (i) the modification of its structural, rheological and thermomechanical properties and (ii) blending the PLA with another ductile, thermoplastic biopolymer such as poly (butylene adipate-co-terephthalate) (PBAT) or polyamide (PA11). Various formulations of PLA with multifunctionalized epoxy, nucleating agents and plasticizer were prepared and characterized on the basis of their linear viscoelasticity and extensional properties. The balance of chain extension and branching was also investigated using solution viscosimetry, steric exclusion chromatography (SEC) and rheology (shear and elongation rheology). On one hand, a batch foaming process assisted by supercritical CO2 was carried out. The influence of the foaming parameters, the extent of chain modification and the contribution of crystallization to cell morphology were all evaluated. Based on these parameters, structures ranging from micro to macro-cellular-cell were obtained. On the other hand, the stability maps of blown extrusion for neat and modified PLA were established at different die temperatures. We succeeded in greatly enhancing the blown extrusion windows of PLA, achieving high blow-up ratio (BUR) and take-up ratio (TUR) values. We were able to demonstrate that faster kinetics of crystallization can also be reached for chain-extended and branched PLA formulated with adequate amounts of nucleating agents and plasticizers. Through this work, blown films with intriguing thermomechanical and mechanical properties were produced using an optimal formulation for PLA.

Effect of film fabricating conditions and its implications on mechanical properties of high-density polyethylene film

The use of plastics, especially High-Density Polyethylene (HDPE) film has increased rapidly in recent years due to its low cost, lightweight and excellent mechanical properties which is depended on the extrusion condition in the owner’s film fabrication machine. The blown film process is the common process used to make a thermoplastic film in large volumes. However, many research performed long ago in the mechanical properties of polyethylene only concerned on the effect of conventional processing parameters such as temperature and pressure in blown film machines and neglected the significant effect of critical extrusion conditions. We did the study to know the effect of critical extrusion conditions such as output rate, blow-up ratio (BUR) and neck-point height (NPH) which was intended to get the optimum film fabrication conditions in a blown film extrusion machine. Each parameter was performed in five different conditions by increasing one parameter and controlling the other. The resin first melted, conveyed, and delivered before finally blown to form the film. The mechanical properties observed were impact resistance, tensile strength, elongation, tear strength, and young modulus. The result indicates that increasing the output rate, BUR and NPH imparted in the film’s orientation balance, bubble shape, relaxation, and crystallization effects will lead to the increase of impact resistance, decrease of tear strength, and balance of film direction properties. The excessive and low amount of output rate, BUR and NPH are not desirable as it decreases the mechanical properties from HDPE film whether in mechanical direction or transverse direction. Hence, the optimum operating condition depends on which mechanical properties that needed to be achieved by film fabricators.

Modern Biodegradable Plastics-Processing and Properties: Part I.

This paper presents a characterization of a plastic extrusion process and the selected properties of three biodegradable plastic types, in comparison with LDPE (low-density polyethylene). The four plastics include: LDPE, commercial name Malen E FABS 23-D022; potato starch based plastic (TPS-P), BIOPLAST GF 106/02; corn starch based plastic (TPS-C), BioComp®BF 01HP; and a polylactic acid (polylactide) plastic (PLA), BioComp®BF 7210. Plastic films with determined geometric parameters (thickness of the foil layer and width of the flattened foil sleeve) were produced from these materials (at individually defined processing temperatures), using blown film extrusion, by applying different extrusion screw speeds. The produced plastic films were tested to determine the geometrical features, MFR (melt flow rate), blow-up ratio, draw down ratio, mass flow rate, and exit velocity. The tests were complemented by thermogravimetry, differential scanning calorimetry, and chemical structure analysis. It was found that the biodegradable films were extruded at higher rate and mass flow rate than LDPE; the lowest thermal stability was ascertained for the film samples extruded from TPS-C and TPS-P, and that all tested biodegradable plastics contained polyethylene.

Enhanced Rheological Properties of PLLA with a Purpose-Designed PDLA-b-PEG-b-PDLA Triblock Copolymer and the Application in the Film Blowing Process to Acquire Biodegradable PLLA Films.

The inadequate rheological properties limit the film blowing process of biodegradable polylactic acid (PLA), thus hindering its potential application in environmentally friendly packaging films and mulch films. Herein, biodegradable polyethylene glycol (PEG) and d-lactide were used to synthesize three kinds of poly-d-lactic acid (PDLA)-b-PEG-b-PDLA (DPD) triblock copolymers, and their effects on stereocomplex (sc) structure formation and rheological properties of the composites were studied. The results showed that the poly l-lactic acid (PLLA)/DPD4k sample introduced the highest sc content, storage modulus, and complex viscosity value compared with PLLA/DPD2k and PLLA/DPD10k at the same loading condition, indicating that the PEG4k chains can better accelerate the formation of a sc network between DPD4k and the PLLA matrix. The introduction of 10 wt % DPD4k also resulted in about 38 times longer relaxation time and a strain-hardening behavior during the steady biaxial extension of PLLA. At last, the continuous film blowing process was successfully conducted in the PLLA/DPD4k composites, which acquired a stable blow-up ratio of 3.07. On the basis of the above results, the soft chain-grafted PDLA copolymer may provide a novel method for film blowing of biodegradable PLA.

Optimization of the cellular morphology of biaxially stretched thin polyethylene foams produced by extrusion film blowing

This work presents the production of cellular polymer films using extrusion blowing to impose biaxial stretching on the cellular structure while processing. The materials selected are linear low-density polyethylene (LLDPE) and low density polyethylene (LDPE) as the matrix, azodicarbonamide as the chemical blowing agent, and talc as the nucleating agent. The processing parameters, namely, the temperature profile, screw speed, feed rate, take-up ratio, blow-up ratio, and the matrix composition were all optimized to produce a homogeneous cellular structure with defined morphologies. The optimized films had a thickness below 300 µm, a relative density around 0.6, a cell density above 2 × 106cells/cm3, and biaxially stretched cells with aspect ratios above 4 longitudinally and 3.8 transversally.

A process-oriented scale-up/scale-down strategy for industrial blown film processes: Theory and experiments

To gain a competitive edge in developing innovative products, new multi-layer film manufacturers need to know whether laboratory-scale blown film line results reliably translate to large-scale production. This, however, is not always the case: Transferring process conditions and getting equal final film properties are not ensured. To address this problem, this paper presents a scale-independent scale-up/scale-down strategy to produce films with consistently similar properties regardless of a plant’s size and design. A second aim is to prove this strategy is applicable by comparing the reference and experimental film mechanical properties. Here, experimental scale-down runs were carried out based on a process-oriented scale-up/scale-down strategy for the blown film process. An industrial production process (>800 kg/h), successfully transferred to a laboratory-scale blown film line, was used as the reference. The introduced process-oriented scale-up/scale-down is based on geometric and dynamic similarity. In this context, blow-up ratio, draw-down ratio and process time have been identified as major scale-up/scale-down variables. Unlike existing scale-up strategies, the process-oriented approach is more flexible in practice. Film mechanical properties taken from the experimental runs were determined by tensile and puncture resistance tests. The compared results confirmed that process-oriented scale-up/scale-down is feasible for the applied material and under the existing plant-specific restrictions. The comparison indicated that most film properties produced on the laboratory-scale plant were comparable to those from the high-capacity blown film line.

Helical instability in film blowing process: Analogy to buckling instability

The film blowing process is one of the most important polymer processing operations, widely used for producing bi-axially oriented film products in a single-step process. Among the instabilities observed in this film blowing process, i.e., draw resonance and helical motion occurring on the inflated film bubble, the helical instability is a unique phenomenon portraying the snake-like undulation motion of the bubble, having the period on the order of few seconds. This helical instability in the film blowing process is commonly found at the process conditions of a high blow-up ratio with too low a freezeline position and/or too high extrusion temperature. In this study, employing an analogy to the buckling instability for falling viscous threads, the compressive force caused by the pressure difference between inside and outside of the film bubble is introduced into the simulation model along with the scaling law derived from the force balance between viscous force and centripetal force of the film bubble. The simulation using this model reveals a close agreement with the experimental results of the film blowing process of polyethylene polymers such as low density polyethylene and linear low density polyethylene.

Effect of the blow-up ratio on morphology and engineering properties of three-layered linear low-density polyethylene blown films

A series of linear low-density polyethylene films were produced using a three-layer co-extrusion machine. How the blow-up ratio and resin characteristics affected the final film morphology and engineering properties were studied. The crystalline morphology and orientation during the blown film process of the low-density polyethylene film were investigated using small-angle X-ray scattering, transmission electron microscopy and scanning electron microscopy. Increasing the blow-up ratio increased the transverse direction molecular orientation and decreased the machine direction orientation. The resulting low-density polyethylene morphology was a regular lamellar stacking parallel to the machine direction. The film morphology strongly influenced the mechanical properties. Increasing the blow-up ratio from 1.7 to 2.8 decreased the machine direction tensile strength by 14% and increased the transverse direction tensile strength up to 27% for both the low-density polyethylene/1-butene and low-density polyethylene/1-octene co-monomers, while the machine direction tear strength increased up to 36% and the transverse direction decreased by 16%. Moreover, the first and second heating characteristics from differential scanning calorimeter showed the inherent crystallinity change with increasing blow-up ratio for both the low-density polyethylene/1-octene and the low-density polyethylene/1-butene copolymer. The crystalline orientation changes induced with increasing blow-up ratio affected the film water vapor and oxygen permeability.

Structure evolution during film blowing: An experimental study using in-situ small angle X-ray scattering

The on-line morphological development during film blowing of 2 different linear low density polyethylenes (LLDPEs) and a blend of LLDPE with low density polyethylene (LDPE) has been investigated, for the first time, using synchrotron Small Angle X-ray Scattering (SAXS). The processing conditions, blow-up ratio and take-up ratio, have been varied and the resulting lamellar thickness, linear crystallinity and orientation evolution in machine direction is obtained from a detailed analysis of SAXS data. Ex-situ SAXS and wide angle X-ray Diffraction (WAXD) confirmed the effect of molecular structure and composition on structure evolution observed in the on-line experiments. The results obtained provide a valuable set of data for the understanding of the film blowing process and can be used to extend and improve numerical model.

Structure, mechanical, and electrical properties of high‐density polyethylene/multi‐walled carbon nanotube composites processed by compression molding and blown film extrusion

ABSTRACTThe structure and properties of melt mixed high‐density polyethylene/multi‐walled carbon nanotube (HDPE/MWCNT) composites processed by compression molding and blown film extrusion were investigated to assess the influence of processing route on properties. The addition of MWCNTs leads to a more elastic response during deformations that result in a more uniform thickness distribution in the blown films. Blown film composites exhibit better mechanical properties due to the enhanced orientation and disentanglement of MWCNTs. At a blow up ratio (BUR) of 3 the breaking strength and elongation in the machine direction of the film with 4 wt % MWCNTs are 239% and 1054% higher than those of compression molded (CM) samples. Resistivity of the composite films increases significantly with increasing BURs due to the destruction of conductive pathways. These pathways can be recovered partially using an appropriate annealing process. At 8 wt % MWCNTs, there is a sufficient density of nanotubes to maintain a robust network even at high BURs. © 2015 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2015, 132, 42665.