Mixing, Devolatilization, and Reactive Processing in the a Farrel Continuous Mixer**

  • L. N. Valsamis
    Research and Development Division, Farrel Corporation, Ansonia, U.S.A.
  • E. L. Canedo
    Research and Development Division, Farrel Corporation, Ansonia, U.S.A.

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<jats:title>Abstract</jats:title> <jats:p>The Farrel Continuous Mixer, developed in the late 50s and introduced to the market in the early 60s, has been extensively used in plastics and rubber mixing and compounding for several decades, and has undergone several design changes and refinements. This paper reviews and discusses in detail the unique mixing characteristics of the FCM. Recent developments in rotor design for controlled residence time and processing temperatures, sequential incorporation of additives, post-reactor reactive processing, and improved energy efficiency by means of total process control are presented. Flow patterns inside the mixer are established using freezing and tracer techniques. Mathematical models for mixing and devolatilization are developed and verified with pilot plant data. As an example of reactive processing, data on the vis breaking of polypropylene with organic peroxides are presented. Controlled rheology of the polymer is achieved and undesirable volatile by-products, tert-butyl alcohol in the present case, are effectively vented. Experimental residence time distribution, and calculated passage and maximum shear rate distribution functions are also presented and discussed.</jats:p>

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