Grant: Collaborative Research and Development Grants

Blending of plastic and rubber with a cross-linking or grafting agent to manufacture new modified polymers such as TPVs (thermoplastic vulcanizates) and grafted polymers, by reactive extrusion, is a highly non-linear and complex process. High degree of complexity is mainly due to the chemical reactivity and selectivity, sensitivity to the equipment configuration, as well as the processing conditions. From the process control point of view, the reactive extrusion represents a multi-variable non-linear system. A simple control algorithm, such as a PID (proportional, integral and differential) controller is not sufficient for controlling such a highly non-linear process. At Lambton College, the unique Advanced Material Engineering Research (AMER) laboratory is equipped with a pilot scale extrusion equipment. In addition to this laboratory, the Advanced Process Control and Simulation (APCS) Research laboratory offers real-time instrumentation and distributed control system (DCS), which are ideal for implementing advanced control methodologies. The main objective of this research is to develop new functionalized polymers (e.g. TPVs, grafted polymers) from various commercially available LANXESS' polymers. In order to achieve this objective, a comprehensive reaction and process analysis will be required in order to ascertain optimal operating conditions. Understanding of rheological properties, as well as the flow characteristics through the extruder will be of utmost importance. Thus, simulation and analysis of the twin-screw extruder, by means of rheological and flow models will be performed. In addition, advanced process control methodologies and mathematical modeling of the extrusion process will be developed to automate and optimize the process.