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dc.contributor.authorDeng, J.*
dc.contributor.authorLi, K.*
dc.contributor.authorHarkin-Jones, E.*
dc.contributor.authorPrice, M.*
dc.contributor.authorKarnachi, N.*
dc.contributor.authorKelly, Adrian L.*
dc.contributor.authorVera-Sorroche, Javier*
dc.contributor.authorCoates, Philip D.*
dc.contributor.authorBrown, Elaine C.*
dc.contributor.authorFei, M.R.*
dc.date.accessioned2016-11-23T18:23:21Z
dc.date.available2016-11-23T18:23:21Z
dc.date.issued2014-01
dc.identifier.citationDeng J, Li K, Harkin-Jones E et al (2014) Energy monitoring and quality control of a single screw extruder. Applied Energy. 113: 1775-1785.
dc.identifier.urihttp://hdl.handle.net/10454/10619
dc.descriptionYes
dc.description.abstractPolymer extrusion, in which a polymer is melted and conveyed to a mould or die, forms the basis of most polymer processing techniques. Extruders frequently run at non-optimised conditions and can account for 15-20% of overall process energy losses. In times of increasing energy efficiency such losses are a major concern for the industry. Product quality, which depends on the homogeneity and stability of the melt flow which in turn depends on melt temperature and screw speed, is also an issue of concern of processors. Gear pumps can be used to improve the stability of the production line, but the cost is usually high. Likewise it is possible to introduce energy meters but they also add to the capital cost of the machine. Advanced control incorporating soft sensing capabilities offers opportunities to this industry to improve both quality and energy efficiency. Due to strong correlations between the critical variables, such as the melt temperature and melt pressure, traditional decentralized PID (Proportional-Integral-Derivative) control is incapable of handling such processes if stricter product specifications are imposed or the material is changed from one batch to another. In this paper, new real-time energy monitoring methods have been introduced without the need to install power meters or develop data-driven models. The effects of process settings on energy efficiency and melt quality are then studied based on developed monitoring methods. Process variables include barrel heating temperature, water cooling temperature, and screw speed. Finally, a fuzzy logic controller is developed for a single screw extruder to achieve high melt quality. The resultant performance of the developed controller has shown it to be a satisfactory alternative to the expensive gear pump. Energy efficiency of the extruder can further be achieved by optimising the temperature settings. Experimental results from open-loop control and fuzzy control on a Killion 25 mm single screw extruder are presented to confirm the efficacy of the proposed approach. (C) 2013 Elsevier Ltd. All rights reserved.
dc.relation.isreferencedbyhttps://doi.org/10.1016/j.apenergy.2013.08.084
dc.rights© 2016 The Authors. This article is distributed under the Creative Commons CC-BY license (http://creativecommons.org/licenses/by/4.0/)
dc.subjectPolymer extrusion
dc.subject; Single screw extruder
dc.subject; Melt quality
dc.subject; Fuzzy control
dc.subject; Energy efficiency
dc.subject; Polymer melts
dc.subject; Extrusion
dc.subject; Viscosity
dc.subject; System
dc.subject; Geometry
dc.titleEnergy monitoring and quality control of a single screw extruder
dc.status.refereedYes
dc.typeArticle
dc.type.versionPublished version
refterms.dateFOA2018-07-26T09:39:37Z


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