DONALD G. BAIRD, PhD, is the Alexander F. Giacco and Harry C. Wyatt Professor of Chemical Engineering at Virginia Tech. His research centers on the use of fundamental non-Newtonian fluid mechanics to develop improved processing operations for polymers and polymer composites. Among his many honors, the Society of Plastics Engineers has awarded him the International Award, the International Award for Research, and the International Award for Education. A holder of seven patents, Dr. Baird has published some 300 refereed publications.

DIMITRIS I. COLLIAS, PhD, is with the corporate R&D department of the Procter & Gamble Co. in Cincinnati, Ohio. He earned his PhD degree from Princeton University. With twenty years of industry experience in polymers, polymer processing, packaging, paper, and activated carbon, his current research focuses on developing renewable materials and processes for key products in the company’s portfolio. Dr. Collias holds fifty-four issued U.S. patents and is inventor or co-inventor in more than thirty U.S. patent applications.

Chapter 1 -- Importance of Process Design 1

1.1 Classification of Polymer Processes 2

1.2 Film Blowing - Case Study 8

1.3 Basics of Polymer Process Design 11

References 13

Design Problem I - Design of a Blow Molding Die 14

Chapter 2 -- Isothermal Flow of Purely Viscous Non-Newtonian Fluids 16

2.1 Viscous Behavior of Polymer Melts 17

2.2 One Dimensional Isothermal Flows 24

2.3 Equations of Change for Isothermal Systems 39

2.4 Useful Approximations 50

2.5 Solution to Design Problem I 56

References 66

Problems 67

Design Problem II - Design of a Parison Die for a Viscoelastic Fluid 80

Chapter 3 -- Viscoelastic Response of Polymeric Fluids 81

3.1 Material Functions for Viscoelastic Fluids 83

3.2 Non-linear Constitutive Equations 95

3.3 Rheometry 119

3.4 Useful Relations for Material Functions 128

3.5 Rheological Measurements and Polymer Processability 133

3.6 Solution to Design Problem II 136

References 142

Problems 145

Design Problem III - Design of a Dry-Spinning System 156

Chapter 4 -- Diffusion and Mass Transfer 158

4.1 Mass Transfer Fundamentals 161

4.2 Diffusivity, Solubility and Permeability in Polymer Systems 181

4.3 Non-Fickian Transport 202

4.4 Mass Transfer Coefficients 204

4.5 Solution to Design Problem III 211

References 216

Problems 221

Design Problem IV -- Casting of Polypropylene Film 233

Chapter 5 -- Nonisothermal Aspects of Polymer Processing 234

5.1 Temperature and Pressure Effects on Rheological Properties 235

5.2 The Energy Equation 240

5.3 Thermal Transport Properties 259

5.4  Heating and Cooling of Non-Deforming Polymeric Materials 264

5.5 Crystallization, Morphology, and Orientation 293

5.6 Solution to Design Problem IV 315

References 320

Problems 324

Design Problem V -- Design of a Multi-layered Extrusion Die 336

Chapter 6 -- Mixing 338

6.1 Description of Mixing 340

6.2 Characterization of the State of Mixture 345

6.3 Striation Thickness and Laminar Mixing 371

6.4 Residence Time and Strain Distributions 402

6.5 Dispersive Mixing 425

6.6 Thermodynamics of Mixing 445

6.7 Chaotic Mixing 446

6.8 Solution to Design Problem V 450

References 458

Problems 465

Design Problem VI -- Coextrusion Blow Molding Die 475

Chapter 7 -- Extrusion Dies 477

7.1 Extrudate Nonuniformities 478

7.2 Viscoelastic Phenomena 480

7.3 Sheet and Film Dies 491

7.4 Annular Dies 497

7.5 Profile Extrusion Dies 502

7.6 Multiple Layer Extrusion 506

7.7 Solution to Design Problem VI 520

References 525

Problems 528

Design Problem VII -- Design of a Devolatilization Section for a Single Screw Extruder 541

Chapter 8 -- Extruders 543

8.1 Description of Extruders 544

8.2 Hopper Design 549

8.3 Plasticating Single Screw Extruders 555

8.4 Twin Screw Extruders 592

8.5 Mixing, Devolatilization, and Reactions in Extruders 602

8.6 Solution to Design Problem VII 625

References 635

Problems 638

Design Problem VIII -- Design of a Film Blowing Process for Garbage Bags 655

Chapter 9 -- Post Die Processing 657

9.1 Fiber Spinning 658

9.2 Film Casting and Stretching 706

9.3 Film Blowing 717

References 745

Problems 752

Design Problem IX -- Design of a Compression Molding Process 760

Chapter 10 -- Molding and Forming 762

10.1 Injection Molding 762

10.2 Micro-Injection Molding 776

10.3  Compression Molding 777

10.4 Thermoforming 786

10.5 Blow Molding 801

10.6 Solution to Design Problem IX 812

References 821

Problems 824

Chapter 11-Proces Engineering for Recycled and Renewable Polymers

11.1 Life Cycle Assessment

11.2 Primary Recycling\

11.3 Mechanical or Secondary Recycling

11.4 Tertiary or Feedstock Recycling

11.5 Renewable Polymers and Their Processing

Notation 839

Appendix A -- Rheological Data for Several Polymer Melts 870

Appendix B -- Physical Properties and Friction Coefficients for Some Common Polymers in the Bulk State 891

Appendix C -- Thermal Properties of Materials 892

Appendix D – Conversion Tables 968