Modeling of reactive systems in twin-screw extrusion: challenges and applications

Reactive extrusion processes involve the difficulties of mastering classical polymer processes, such as twin-screw extrusion for example, and the problems of controlling a chemical reaction in very specific conditions (high-viscosity medium, high temperatures, short residence times). Therefore, it is often very difficult to intuitively understand all the aspects of the process and to clarify the complex interactions between the numerous variables, and then to properly design and optimize the industrial process. Numerical modeling can be a very efficient tool to overcome these difficulties. However, it remains a real challenge, as it necessitates to couple flow simulation in complex geometry, reaction kinetics and evolutionary rheological behavior. Moreover, the information needed is sometimes difficult to obtain with the required accuracy. After a general presentation of the principles of the different reactive extrusion modeling methodologies, we will focus on the models we developed, based on continuum mechanics. Different examples of applications are presented for illustrating the interest of this method. To cite this article: B. Vergnes et al., C. R. Chimie 9 (2006).