Numerical modeling of fill-level and residence time in starve-fed single-screw extrusion: a dimensionality reduction study from a 3D CFD model to a 2D convection-diffusion model

This research delves into the numerical predictions of fill-level and residence time distribution (RTD) in starve-fed single-screw extrusion systems. Starve-feeding, predominantly used in ceramic extrusion, introduces challenges which this study seeks to address. Based on a physical industrial system, a comprehensive 3D computational fluid dynamics (CFD) model was developed using a porous media representation of the complex multi-hole plate die. Validations performed using real sensor data, accounting for partial wear on auger screw flights, show an ~11% discrepancy without accounting for screw wear and ~6% when considering it. A 2D convection-diffusion model was introduced as a dimensionality reduced order model (ROM) with the intention of bridging the gap between comprehensive CFD simulations and real-time applications. Central to this model’s prediction ability was both the velocity field transfer from the CFD model and calibration of the ROM diffusion coefficient such that a precise agreement of residence time distribution (RTD) curves could be obtained. Some discrepancies between the CFD and the ROM were observed, attributed to the loss of physical information of the system when transitioning from a higher fidelity CFD model to a semi-mechanistic ROM and the inherent complexities of the starved flow in the compression zone of the extruder. This research offers a comprehensive methodology and insights into reduced order modeling of starve-fed extrusion systems, presenting opportunities for real-time optimization and enhanced process understanding.