A full 3D simulation for twin screw extrusion based on an immersion domain method. application to mixing elements

A full 3D simulation software has been applied for characterizing the flow conditions in mixing processes (batch mixers, single and twin screw extruders, co-kneaders...). The approach is based on an immersion domain approach and uses the Finite Element Method. In the present work, we studied the flow conditions of a Carreau-Yasuda fluid in a portion of twin screw extruder, constituted by different types of conveying elements and blocks of kneading discs. The influence of geometrical parameters (staggering angle, number of tips, disc thickness...) on the flow conditions (pressure and pressure gradients, flow patterns, mixing efficiency...) has been characterized and compared to previous studies from the literature.