Modelling non-homogeneous flow and residence time distribution in a single-screw extruder by means of Markov chains

Non-homogeneous velocity distribution of the flow in the channel of a single-screw extruder is taken into account by a new model developed on the basis of the Markov chains. This model allows calculating the Residence Time Distribution (RTD) as well as the influence of the operating conditions on the process at any velocity distribution in the channel. It has been used to represent experimental results on mass flow rate and RTD previously obtained by extrusion of an acrylic polymer, Eudragit E100, at different temperatures and screw rotation speeds. The diffusion coefficient is the only adjusting parameter of the model. It was shown that it does not depend on the screw rotation speed and a correlation between this diffusion coefficient and the barrel temperature was found. The model provides global understanding of the transport kinetics of the flowing material through the extruder according to its behaviour and better describes the progress of the polymer flow all along the barrel from the hopper to the die.