Académique Documents
Professionnel Documents
Culture Documents
Christophe Bliard
• Introduction
• Batch vs Extrusion Reactive
– Comparaison des deux technologies
• L’extrusion Réactive REX
– Fonctions d’un extrudeur ; paramètres.
• Les différentes technologies
– Mono/ Bivis co-rot contra-rot.
– La réaction en REX
• Modélisation
• L’EMS
• Modification des Agropolymères
• Les exemples au labo CMS
• Régiosélectivité « Modèle de Spurlin »
• Lignin
• Scale-up
A+ B C + D
Christophe Bliard
Réactions en batch
Pbl changement d’échelle : Mélange
D=KT/(6prm)
1/3
R = 1/2(V/N)
(μ viscosité dynamique)
Christophe Bliard
Réactions en batch
Pbl changement d’échelle : sous produits
Christophe Bliard
Réactions en batch Goscinny Uderzo Pilote 1966
! Danger !
Christophe Bliard
Réactions en batch
A+ B C + D (+ e + f + g)
- Not good
quantity solvent & reagents used
low RE & Poor reaction control
high residence time
slow heat transfer
by-products
- Good
In practice, it is fairly difficult to achieve a high reaction efficiency
(RE) and avoid by - products formation ubiquitous equipment
well known technology
Christophe Bliard
Extrusion réactive
A+ B C + D +e
Specific equipment
Viscosity constraints
Christophe Bliard
Batch vs Extrusion
Christophe Bliard
Du Batch à l’ Extrusion réactive
Goscinny & Uderzo
A+ B C + D
Christophe Bliard
L’ Extrusion Réactive
REX
« Le procédé de transformation des polymères,
comme l’extrusion bivis, et le contrôle d’une
réaction chimique dans des conditions particulières
(milieux très visqueux, haute température, temps
de séjour court). …. calculs d’écoulement en
géométrie complexe, des cinétiques de réaction et B
des comportements rhéologiques évolutifs. … S T
F E
approche de mécanique des milieux continus. «
Christophe Bliard
Extrusion Réactive : Réacteur en continu
Température
Substrat + réactifs
Buse
Extrudat
Produit de réaction
Réaction
Pression
Christophe Bliard
L’ Extrusion :
Technologie majeure de transformation
des matériaux polymères
Marché de transformation
des matière plastiques 300 Mt
www.plasticseurope.org
Christophe Bliard
Quelques fournisseurs
Industriels
Extrudeuses contrarotatives interpénétrées
Christophe Bliard
Systèmes monovis
Christophe Bliard
Systèmes bi-vis
Corotatives vs contra-rotatives
Christophe Bliard
Systèmes bi-vis
Corotatives vs contra-rotatives
Christophe Bliard
La réaction chimique en
REX
Alimentation
A+B+C… D+E Extrusion Bi-Vis
Kg/h Pression matière
Dégazage Intensification
Puissance P
Vide
bar Sans solvant
KW T oC Concentration
Température
Rotation des vis
Extrudat Cinétique
N\N\N\N\N\N\N\N\N
t/min w
Sélectivité :
Extrusion Contrôle
Fusion
Couple
Nm Kg/h des réactions
Refroidissement Chauffage secondaires
Christophe Bliard
Extrusion :
Christophe Bliard
Pharma 11 & Process 11
A Strong Team
Christophe Bliard
Process 11 TSE: Segmented Screws
Christophe Bliard
Process 11 TSE: Touch Screen Control
Christophe Bliard
Process 11 – Easy to Use Touchscreen
• All Set-Points:
– Temperatures
– Screw Speed
– Feed rate(s)
• Processing data
– Torque
– Pressure
– Melt Temperature
• Processing trend
– M, n, p, TM, FR vs. time
• Temperature trend
• Temperature profile
• Recipe storage
• Alarm history
Christophe Bliard
Dispersive and Distributive mixing
Christophe Bliard
Eléments de vis modulables :
Convoyage
malaxage
contrefilets
Christophe Bliard
Assemblage des éléments le long de la vis
Christophe Bliard
Melt Temperature Dependence
140 oC
130 oC
120
115 oC
oC
o
110 C
100
oC
Screw Speed
[rpm]with increased Feed Rate and Screw Speed
The Melt Temperature increases
Christophe Bliard
Influence on Residence Time
5 kg/h @ 100
Tracer Concentration
rpm
5 kg/h @ 300
rpm
Christophe Bliard
Residence Time Dependence
10
sec
Feed Rate [kg/h]
30
sec
60
sec
100
sec
Screw Speed [rpm]
The Retention Time decreases with increased Feed Rate
Christophe Bliard
Optimization of the Compounding Process
A Start with low screw speed
and low throughput
B Increase screw speed
C Increase throughput (at same
speed) until maximum torque
G
is reached
D Increase Screw speed, torque
decreases
E F
Repeat A-D until maximum of
system capacity
C D
Process boundary can be torque
and volume limited
A B Slope of boundary depends on:
Temperature profile
Screw Design
Material Blend
Christophe Bliard
Degree of Fill along the Screws
100
80
% Fill
60
40
20
Christophe Bliard
Extrusion réactive
Injection de CO2 supercritique
Christophe Bliard
Modélisation de l’écoulement
Christophe Bliard
LUDOVIC
Scale Up
Les paramètres à optimiser sont :
1. Le profil de vis (suite ordonnée d’élt de vis)
2. Les températures des fourreaux
3. La température de la filière
4. La vitesse d rotation de la vis
5. Le débit
Christophe Bliard
Extrusion réactive et passage d’échelle
1 2 3 4
1. Zone de convoyage
2. Zone de malaxage
3. Zone de convoyage
4. Zone restrictive
Christophe Bliard
Residence Time Measurement
30
• All known methods use tracers 25
Mean residence
time
– At t0 tracer added to feed port
Concentration [%]
Feed
20
– Record tracer concentration at exit port
15
– Result: Residence time distribution
• Mean residence time 10
(calculated) 5
• Width of distribution 0
– Tracer selection criteria 0 60 120 180
Time [s]
• Easy to detect
• No influence on process
• Our approach:
– Digital camera takes pictures
(and records time),
– Software detects strand and
– calculates tracer color ratio
(concentration)
– Plots concentration vs. time
Christophe Bliard
EMS -- L ’énergie mécanique spécifique
SME (J/kg) =
Christophe Bliard
Process 11: Scale up Case Study
Residence time
11 mm vs. 16 mm
• Same process as production 12
machine 4
2
Example (residence time)
æ ö
3
• Same screw configuration m = DP × m 0
1. RTm: 65.3 s
• Throughput transfer by: 2. RTm: 51.0 s
• Adjust throughput until 3. RTm: 67.3 s
same specific energy obtained.
Almost perfect match within just 2 steps
Addition séquentielle
et profil de pression
Christophe Bliard
HAAKE MiniLab
Micro Rheology Compound
Conical twin-screw
1996 microcompoundeur compounder:
Christophe Bliard
HAAKE MiniLab
Micro Rheology Compound
Conical twin-screw
2000 microcompoundeur compounder:
Christophe Bliard
Mini Extrudeuse 10g
« De la Paillasse …
Bi- vis avec mode recirculation (cinétique) co- ou contra-rotative
Christophe Bliard
HAAKE MiniLab II –
Typical Applications
Micro sample-amount (5 g)
• Development of new polymers
• Testing of expensive materials
• Material studies at universities
• Reactive extrusion
• Compounding of nano materials
• Sample preparation (in combination with
the HAAKE MiniJet injection moulder)
Microextrudeur Bi-vis (10g)
Minilab rheomex (Thermo Process
• Mini production e.g. “50 grams per hour”
• Hot Melt Extrusion (pharma)
• Additive formulation
• Quality Control
Christophe Bliard
HAAKE MiniLab
- Barrel Desig
• Backflow channel
with rheological slit
capillary die
• Pressure
transducers
• Bypass valve
Christophe Bliard
Optional sensor and feed ports 557-2197
½“ UNF port
opposite 2nd.
pressure port ½“ UNF port
(upper barrel half) (upper barrel half)
for non return
e.g. NIR valve
measurements, p2
UV–curing e.g. liquid, or gas
p1
injection
Christophe Bliard
HAAKE MiniLab II - Barrel Design
Easy cleaning
of the outlet
channel
Improved
hardness,
58HRc, no TiN
coating
necessary
Christophe Bliard
Characteristics of HAAKE MiniLab screw
types
Counter-
Co-Rotating Rotating
Residence time
distribution wide narrow
Forced extrusion - +
Cleaning + -
Extruded amount + o
Mixing properties ++ o
Pressure built-up o ++
Rheological
measurements o ++
Required duration of
blending ++ o
Christophe Bliard
HAAKE MiniLab Counter Rotating
Screws
Christophe Bliard
Crosslinking
/ Grafting Nitrogen
purge
Thermo-oxidative
Degradation
Christophe Bliard
PLA
cyclo-polymerisation du L-lactide par
Extrusion reactive
Christophe Bliard
Extrusion réactive de
polymères naturels
Amylose
20-25% linear polymer of D glucose
glucose unit
Amylopectin
Starch 75-80%
Cellulose
Lignin
Lignin
Christophe Bliard
PFR
Chemical modification of starch by reactive extrusion.
Christophe Bliard
Extrusion et
Photoréticulation
Premiers travaux
Amidon natif
+ Plastifiant Extrusion
+ Photoactivateur
Photoréticulation
Insoluble &
biodégradable
Amidon Photoréticulé
Irradiation
Christophe Bliard
Benzoate blanching
2,5
2 3
minutes
Intermediate(268 nm)
5
Absorbance
1,5 7
10
1 120
180
0,5 amidon
0
200 220 240 260 280 300 320 340
Christophe Bliard
Optimal System
• 20% sorbitol/glycerol
3% Sodium benzoate
• 10 min. UV Curing
• Insolubles : 98%
• Swelling : 4
Christophe Bliard
NMR imaging of a UV cured starch film in D2O
D2O
200 m 300 m
Film sample
The max depth of photo crosslinking is 100 mm
Christophe Bliard
Cationic starch by REX
Cationic Starch
Francoise Berzin, Lan Tighzert, Christophe Bliard, Ali Ayoub. Study of the Thermoplastic Wheat Starch Cationisation Reaction
under Molten Condition. Starch/Stärke, 2004, 56 (11), pp.513-519. ⟨10.1002/star.200300272⟩. ⟨hal-02074504⟩
Christophe Bliard
Cationisation de l’Amidon
par Extrusion réactive
0.60
0.55
0.50
0.45
RE, %
0.40
0.35
0.30
NaOH/SMCA ratio
Christophe Bliard
Amylolyse enzymatique de l’Amidon
par Extrusion réactive
Christophe Bliard
MOS
OR
Amylose
O
O
RO OR
RO
DP:1 2 3 4 5 6 7 8 9 …
O
O OR
RO
RO O
ORO OR
O
ORO OR
RO O RO
OO
R OH O H O H
RO O OR
+
O
RO O O H O O H
+ + ….
O
HO HO
RO O HO
OH HO H HO H
O OR HO O H
O
O H
O
RO R O H
O HO O HO
OH
RO O
O O H O H
O
ORO O H O
HHO
OH
RO O HO
O H
O RO
RO
Amylopectin MIMOS
DP:1 2 3 4 5 6 7 8 9 …
ubiquitous equipment
producing large amount of CMS
quantity solvent & reagents used
• substitution at the 3 OH positions of the AGU C2, C3 and C6
• maximum theoretical DS for starch is 3 low RE & Poor reaction control
• In practice, it is fairly difficult to achieve a high DS and reaction high residence time
efficiency (RE) values without damaging the starch molecules
slow heat transfer
by-products
Christophe Bliard
Carboxyméthyl Amidon
par Extrusion réactive
Specific equipment
producing large amount of CMS
High RE & good reaction control
• substitution at the 3 OH positions of the AGU C2, C3 and C6
• maximum theoretical DS for starch is 3 Short residence time
• In practice, it is fairly difficult to achieve a high DS and reaction Fast heat transfer
efficiency (RE) values without damaging the starch molecules
Few by-products
Christophe Bliard
Amorphisation de l’amidon après extrusion
Spectre RX
Amidon de départ
Relative intensity
b
Extrudé 1
c
Extrudé 2
d Extrudé 3
5 10 15 20 25 30 35 40
XRD B patterns for native potato starch (a), CMS 30 min-1 (b),CMS 60 min-1 (c), CMS 180 min-1 (d).
Christophe Bliard
Plasticized Starch (glycerol, dextrins)
+ Reagent (SMCA)
+ NaOH
Experimental conditions:
• elimination of all by-products
• different starch sources
• analysis of ultra-concentrate (UC)
• starch plasticized with 15-30% glycerol and dextrin and ultra-filtrate (UF)
• T = 70-140°C, n = 60-180 min-1
CMS
Absorbance
Efficient purification
a: glycerol
b: carboxymethylated glycerol Native starch
c: SMCA b
a
c
Christophe Bliard
Mesures des DS & fonctions
The DS of CMS samples studied by NMR. de distribution
The CMS samples were hydrolyzed to substituted
monomeric glucose using D2SO4.
40
R= H or CH2COONa 30
%
20
10
0
H-1β (O-2U) O-2α O-2β
H-1β (O-2S) to 2
ta
O-6 Po
H-1α (O-2S) O-3 at 3
he
H-1α (O-2U) W
rn 6
Co
Christophe Bliard
Mesures des DS & fonctions
The DS of CMS samples studied by NMR. de distribution
The CMS samples were hydrolyzed to substituted
monomeric glucose using D2SO4.
Christophe Bliard
Carboxyméthylation de Amidon
1 modèle de Spurlin *
0,9 glucose
▲ glucose
0,8
♦ mono - CMS
0,7
● di - CMS
■
Molar fraction
0,4
0,3
0,2
mono
tri
0,1
0
0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 2
DS
Christophe Bliard
Carboxyméthylation de Amidon
modèle de Spurlin *
▲ glucose C0
1
0,9
♦ mono – CMS C1
0,8
C0 ● di – CMS C2
0,7
■ tri – CMS C3 C3
Molar fraction
0,6
0,5
0,4
0,3 C2
0,2
C1
0,1
0
0 0,5 1 1,5 2 2,5 3
* Spurlin, H.M.: Arrangement of substituents in cellulose derivatives. J. Am. Chem. Soc., 1939. 61. 2222-2227.
** Heinze Th., U. Erler, I. Nehls, and D. Klemm. Angew. Makromol. Chem., 215 (1994), 93–106.
Christophe Bliard
The reaction kinetics was studied using loop (recirculation) mode of extruder by varying the residence time of the melt.
Different residence times of the CMS samples were studied: continuous direct extrusion, 2 min, 5 min and 10 min.
70
1.4
70
REX 60
1.2
50
40 1.0
Reaction rate of reagent SMCA :
RE (%)
30 0.8
1: dN/dt = 600 mmol/min 2: dN/dt = 16,5 mmol/min
60
20
0.6
10
0.4
55
0 2 4 6 8 10
20 40 60 80 100 120 140 160 180 200
loop residence time (min)
Batch N (rpm)
1 RE (%) = x 100%,
70
60
No significant changes 50
40
in the distribution for different SME 30
%
(O-2>>O-6>O-3) 20
10
0
30
60 2
sc
re 12
0
3
w
sp
ee 0
d 18
6
Tijsen, C. J., Kolk, H. J., Stamhuis, E. J., & Beenackers, A. A. C. M. (2001). . Carbohydrate Polymers, 45, 219-226.
Christophe Bliard
CMS / REX
Effets des Plastifiants
Sample DS RE % SME (kJ/kg)
CMS (glycerol 25%) 0.57 57 75
CMS (water 40%) 0.31 31 45
CMS (Glucor® 25%) 0.44 44 140
CMS (H-Maltor® 25%) 0.15 15 225
CMS (EP2 25%) 0.22 22 90
Christophe Bliard
Carboxyméthyl Amidons Influence de l’Extrusion réactive
130
sur la masse moléculaire
120
Intrinsic viscosity (ml/g)
110
200 Amidons cationiques
100
SEC
OR detection [mV]
N
(non normalised)
150
90 F
80
100 FOH
70 50
200
OR detection [mV]
(non normalised)
150
DS 0.02
DS 0.13
100
50
Christophe Bliard
Esters de diacides de lignine
par Extrusion réactive
Christophe Bliard
Esters de diacides de lignine
par Extrusion réactive
DMSO
Glycol
Glycérol
Christophe Bliard
Esters de diacides de lignine
par Extrusion réactive
DMSO
Glycol
Glycérol
Christophe Bliard
Esters de diacides de lignine
par Extrusion réactive
FTIR spectra of KL modified with different ratio of maleic (left) and succinic (right) anhydrides
2D NMR spectra of KL modified with different ratio of maleic (left) and succinic (right) anhydrides
Phosphinylation with 2-chloro-4,4,5,5-tetramethyl-dioxaphospholane
P NMR spectra results of Phosphinylated KL modified with maleic and succinic anhydrides
31
MILOTSKYI, R., Szabó, L., Takahashi, K., Bliard, C. Chemical Modification of Plasticized Lignins Using Reactive Extrusion
Frontiers in Chemistry, section Chemical and Process Engineering (in press)
« de l’échelle laboratoire
Christophe Bliard
… à la halle prépilote »
Christophe Bliard
Perspectives
t/h
15 kg/h
Great challenge
2 kg/h
Christophe Bliard
Conclusions REX
Christophe Bliard
Groupe Polymères Fonctionnels et Réseaux
O
O
O
O
ICMR - PFRO
O
O
O
OH
O
O O HO
O O N
O O
O O O O -
O O HO
O Cl
O
O
O O
h 365 nm
O
O
O
O
O
O
O
O
O O
O
O
HO O
HO
O
OH
OH micro nano
O O
capsules
O
O
O
O AIRF
O
O
O
O
h 365 nm
darocur1173
O
O O
O O
O
O
Extrusion HO
OH
O
capsules
O
O
O O
O
AIRF
O O darocur1173
O
O
OO
O O
réactive
O O O
O O O
Synthèse, O
O
O
O O O
O O O
polymérisation
O O
Détermination
réseau tridimensionnel réseau tridimensionnel
physico-
0.7
synthèse
0.6
des masses molaires
chimie
Conversion
0.5
0.4 19 kGy/s
0.3
0.2
Cinétique 37 kGy/s
réac- 1,125
100%
98% 96%
X2,PUA
1,5
75 kGy/s
0.1 chimique 110 kGy/s
propriétés 0,875
1
94%
1
0,5
96%
dose (J/cm²)
0
0 2 4 6 8 tivité 0,625
0,75
-1,5 -1
70%
50% -0,5
30%
0
-0,5
0 0,5
10%
1
X1,PUA
1,5
Irradiation time (s)
E 2
E1
RT
Rp M 0 1 p p A D 0.5 exp a 1 p B D exp a
RT
0,5
0,375
Plans d’expérience -1
-1,5
2,5 12,5 22,5 32,5 42,5 52,5 62,5
%w HDDA
Christophe Bliard
Acknowledgement
Christophe Bliard
PFR
Christophe Bliard