Mixing performance in an asymmetrical non-twin kneading element channel

The kneading elements play a crucial role in the distributive and dispersive mixing in the conventional co-rotating twin screw extruders. A novel kind of asymmetrical dual-speed co-rotating non-twin kneading elements (NTKE) with a zero staggered angle was designed to introduce symmetry break to improve mixing. Finite element method was applied to solve the time-dependent flow field where mesh superposition technique was used to impose the boundary conditions of moving parts and further to avoid the remeshing at every time steps. The flow and mixing of several fluids obeying the Carreau constitutive model with the different power law exponents were investigated numerically and compared with the conventional co-rotating twin kneading elements (TKE). Distributive mixing was evaluated through evolution of tracer droplets and decaying of variance index with time. Moreover, the dispersive mixing was examined in terms of the statistical distributions of mixing index. An integral function with regard to the mixing index was proposed to evaluate the proportion of tracer particles subjected to the elongation.