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CHEE418/801

CHEE418/801. Using Statistical Techniques for Process Improvement: ILC-based workshop for CHEE418/801. Case Study. Twin-screw extruder for grafting functional chemical groups on commodity polyethylene Why graft? Improve product value Enhance product workability and applications

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CHEE418/801

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  1. CHEE418/801 Using Statistical Techniques for Process Improvement: ILC-based workshop for CHEE418/801 J. McLellan

  2. Case Study Twin-screw extruder for grafting functional chemical groups on commodity polyethylene Why graft? • Improve product value • Enhance product workability and applications • e.g., compatibilization to use for blends, colouring, performance properties (e.g., stiffness) J. McLellan

  3. Twin-Screw Extruder • Has a feed hopper, twin screws in a barrel which is also heated • Extruded polymer goes through a water bath for quenching • Grafting reactions occur by using an initiator to provide radicals to start reactions • Results in grafting of functional chemical groups onto polyethylene backbone, as well some cross-linking of the polyethylene • Performance of the grafting is frequently measured in terms of the grafting efficiency (% of functional group available that is grafted onto polymer) J. McLellan

  4. Twin Screw Extruder • Used for the experiments J. McLellan

  5. Twin Screw Extruder J. McLellan

  6. Process Improvement • Can we find a better set of operating conditions to improve grafting efficiency? • IMPROVING THE EXTRUDER GRAFTING EFFICIENCY • Brainstorming exercise – • What are the potential factors that have an impact on grafting efficiency? • What graphical tool should we use to organize our brainstorming? J. McLellan

  7. Improving the extruder grafting efficiency • Once we have identified our factors, what experiments should we run? • Layout, range, … • Can we get a clear indication of the effect of each operating variable by making good choices of experimental conditions? J. McLellan

  8. Improving the extruder grafting efficiency • Run experiments, collect data • Now it’s time to analyze the results • Goal – identify those operating variables (factors) having a significant impact on grafting efficiency • How can we characterize the impact of operating variables on grafting efficiency? • Graphically • Quantitatively • We want to RANK the operating variables from most effective to least, and understand the SIZE of their IMPACT J. McLellan

  9. How much variability is there in our experiments? • Can we tell this from our experimental results? • How will this variability carry through into our calculations? • How can we factor in the variability into our decisions about which operating variables are important? J. McLellan

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