The material selection platform
Plastics & Elastomers
The material selection platform
Plastics & Elastomers
Online Course

Reactive Extrusion for Twin Screw Extrusion Professionals

On-Demand Course

Recorded on Sep 13, 2023

Get started with reactive extrusion for your thermoplastics by getting a 360⁰ view of the process, reaction chemistry as well as how to configure the extruder.

In this live course, Kenneth Russell will help you spend less time on trial and error & develop materials with reactive extrusion principles and practices faster by sharing hands-on tips on injecting liquids, defining the right residence time distribution (RTD)…

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Read the full Course Outline

Kenneth Russel Presented By:
Kenneth W Russell

Length: 75 min

Course Type: Technology
Level: Beginner

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Package includes:

.wmv Courses Recording, Presentation Slides & Transcript of Q&A session

Why should you view this course?

The environmental advantages of reactive extruder compared to the traditional reactors' present huge potential. Moreover, reactive extrusion can be used for a lot of reactions.

But do you have a structured methodology to determine the parameters for your thermoplastics’ reactive extrusion (right number of residues, the right temperature, the right screw speed…)? Are you clear on the effect of reaction chemistry on extruder? Without that you might end up doing trial-and-error & that can result in quality issues. This course will help you:

  1. Save time by knowing the basics of reactive extrusion and how to achieve desired polymer properties using your extruder as a reactor

  2. Understand the very important reaction chemistry (Free-Radical, Saponification and more...) governing the whole process

  3. Achieve good mixing by understanding how to best configure the reactive extrusion process (Screw design, Liquid injection, Mixing configurations...)
Reactive Extrusion

Who should view this course?

  1. R&D Chemists, Research Engineers working with twin-screw extrusion
  2. Product Development Manager
  3. Compounders
  4. Masterbatchers
  5. Application Development Manager
who are willing to step into Reactive Extrusion. The course is particularly suited for people with prior experience in Twin Screw Extrusion

Complete the course and (unlock your personalized certificate) – your badge of accomplishment awaits!

Course Outline

The following sections will be covered during this course:
  1. Introduction

  2. Why use an extruder as a reactor?

  3. Configuring the process for reactive extrusion
    • Screw design concerns
    • Liquid injection
      • How to inject liquid
      • Why liquids should should be handled in a certain way
    • Mixing configurations
    • Screw elements that should be used for good mixing and elements that should be avoided
    • Measuring residence time distribution (RTD)
    • General trends in how RTD is affected by screw configuration

  4. Reaction Chemistry and Effect on Extruder Configuration
    • Free-Radical chemistry
      • Initiation
      • Propagation
      • PE crosslinking
      • PP chain scission
      • Grafting
    • Saponification
      • Patent examples
      • Making ionomers with ethylene – acrylate polymers
    • Trans-esterification
      • Patent examples – ethylene acrylate polymers with alcohol
      • Use of a Partial condenser to improve conversion

  5. Safety
    • Raw material hazards
      • Maleic anhydride
      • Organic peroxides
      • Alcohols
    • Hazards due to reactivity
      • Volatile by-products
    • Thermal hazards
    • Melt temperature
    • Pressure development

  6. Practical heat transfer concerns for Good Reaction Control (at the Expected Rate)

  7. 15 mins Q&A - Send your questions in chat or mail upto 3 days (Questions directly answered by expert in QnA document)
  8. Have a query? Email us for any help!

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Members Reviews

This course provided a quick but comprehensive overview of both the mechanical and chemical aspects that reactive extrusion entails. The course looked at both the engineering and processing side of reactive extrusion and extrusion in general, while also maintaining focus on the chemistry involved and how it can impact extrusion not only from a product quality viewpoint but also from a process safety view.

Michael A. , from Michelman

Very good, the course gave me some background information and a reference document

Stephen K. , from Nomaco Inc.

Great introductory course. Excellent speaker with substantial experience.

Sarah Patterson , from Plastics Pipe Institute

It's a very good tool for professionals that work on research and processing.

Serrano , from Cipa Chile

The explanations about how to inject liquids and the proper screw design was useful.

Jan M. , from Lehmann & Voss & Co. KG

It was useful to have a general overview of some key points/parameter in REX in twin screw. The Q&A was useful.

Joachim S. , from PolyOne

Learnt about possibilities of using a twin screw extruder as a reactor. Also, learnt about set up, start up and potential designs.

Robin van V. , from Kraton Polymers

This was a good introduction to reactive extrusion.

Brett R. , from Total Cray Valley

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