“Inventing apparatus and processes”

ByMalcolm Mackley

Department of Chemical Engineering and BiotechnologyUniversity of Cambridge

UK

Cambridge 2011

Acknowledgements

Cambridge. (1979 - 2011)

Sir Sam Edwards and Lord Lewis, John Davidson and John Bridgwater.

Alan Butcher, Dr Tim Nicholson (Cambridge Shear System CSS) Prof Xiongwei Ni, (OFM) Dr S Beckett, Peter Schroeder. (Nestle). Peter Dummett. Robert Marshall, Dr Bas Smeulders, Dr Simon Butler

(Multipass Rheometer, MPR) Dr Bart Hallmark (Microcapillary Films MCF)

DrTri Tuladhar (Cambridge Trimaster)

The Department support staff, ( particularly the workshop)

An army of final year project students, PhDs, Post Docs

My wife, Margaret

Haruki Marakami

“What’s crucial is whether (your writing) attains the standards you have set yourself.”

“I’m not the brightest person. I’m the kind of person who has to experience something physically, actually touch something, before I have a clear sense of it.” ……….I’m a physical, not intellectual, kind of person. Of courseI have a certain amount of intelligence - at least I think I have.”

Haruki Marukami“What I talk about when I talk about running”

2009

Malcolm Mackley

Scientist

Engineer

Inventor

Apparatus Processes High Modulus Polyethylene (HMP)

Cambridge Shear System (CSS) Oscillatory flow mixing (OFM)Multipass Rheometer (MPR) Flexible ChocolateCambridge Trimaster Micro Capillary Films (MCF)

Bristol 1970-1976; the genesis for invention

Sir Charles Frank Andrew Keller

1972

Bristol

Extensional Flows 1970s; scientific curiosity

1970 “Frank &Mackley, Double Jet” 1974 “G.I.Taylor (1934), Four Roll Mill”

1974 Two Roll Mill1976 “Berry & Mackley, Six Roll Mill”

High Modulus Polyethylene (HMP) 1980s; process

1. Low entanglement UHMWPE polymer gel

2. Unoriented Gel fibre

Quench bath

3. Unoriented Low entanglement semi crystalline fibre

4. Hot draw

5. Oriented High Modulus Polyethylene

Solvent recovery

Piston

1. Low entanglement UHMWPE polymer gel

2. Unoriented Gel fibre

Quench bath

3. Unoriented Low entanglement semi crystalline fibre

4. Hot draw

5. Oriented High Modulus Polyethylene

Solvent recovery

Piston

Screw extruder

UHMWPE Polymer powde r

Solvent

Low entanglement polymer gel

Spinnere t

Gel fibres

Quench bath

Low entanglement semi crystalline fibre

Hot draw

Solvent recovery

Schematic diagram of continuous High Modulus Polyethylene (HMP) process

Oscillatory Flow Mixing (OFM) 1980s; process

Cambridge 1980s

Cambridge Shear System (CSS), 1980s; apparatus

III. UntreatedMWNT

IV. TreatedMWNT

I. UntreatedSWNT

0 s-1 1 s-1 10 s-1 100 s-1 1000 s-1

II. TreatedSWNT

CNTs

Go to CNT helical banding movie

Cambridge 1990s

Flexible Chocolate 1990s; process

Temperature

50 100 150 200

C0

H

Cold Extrusion

Melt ProcessingPolyethylene

Temperature

10 20 30 40

C0

H

Cold Extrusion

Melt Processing

Chocolate

Extrusion processing

Temperature

50 100 150 200

C0

H

Cold Extrusion

Melt Processing

Temperature

50 100 150 200

C0

H

Cold Extrusion

Melt ProcessingPolyethylene

Temperature

10 20 30 40

C0

H

Cold Extrusion

Melt Processing

Temperature

10 20 30 40

C0

H

Cold Extrusion

Melt Processing

Chocolate

Extrusion processing

20

40

60

80

100

120

140

160

0 5 10 15 20 25 30 35

t (s)

Compaction

(no flow)

Yield pressure

A

Extrusion pressureB

C

Piston/(ram)

Chocolate feed

Die

Pressure transducer

20

40

60

80

100

120

140

160

0 5 10 15 20 25 30 35

t (s)

Compaction

(no flow)

Yield pressure

A Yield pressure

A

Extrusion pressureB Extrusion pressureB

C

Piston/(ram)

Chocolate feed

Die

Pressure transducer

Piston/(ram)

Chocolate feed

Die

Pressure transducer

Piston/(ram)

Chocolate feed

Die

Pressure transducer

Stuttgart 1990s

Multipass Rheometer 1990s; apparatus

The Multipass Rheometer

Top section

Test section

Bottom section

Scientific Art

Go to MPR slit movie

dP = 3.96 bardP = 3.76 bar

Vp = 0.44 mms-1

3D simulation Experiment

3D EUsolve

Polystyrene (PS2)

10mm depth

LHS Pom Pom

RHS Experiment

dP = 3.96 bardP = 3.76 bar

Vp = 0.44 mms-1

3D simulation Experiment

3D EUsolve

Polystyrene (PS2)

10mm depth

LHS Pom Pom

RHS Experiment

Matching Experiment with Simulation

France 2000s

France 2000s

Cambridge Trimaster 2000s; apparatus

MicroCapillary Films (MCFs) 2000s; process

Die land

Polymer flow

Quench bath Extrudate to haul off

Injector

MCF extrudate

….and finally

“…In other words , you cannot please everybody.”

“Just as in school, you enter it, learn something, and then its time to leave.”

Haruki Marukami“What I talk about when I talk about running”

2009

Malcolm Mackley

Scientist

Engineer

Inventor

Apparatus Processes High Modulus Polyethylene (HMP)

Cambridge Shear System (CSS) Oscillatory flow mixing (OFM)Multipass Rheometer (MPR) Flexible ChocolateCambridge Trimaster Micro Capillary Films (MCF)

Malcolm Mackley

Scientist

Engineer

Inventor

Apparatus Processes High Modulus Polyethylene (HMP)

Cambridge Shear System (CSS) Oscillatory flow mixing (OFM)Multipass Rheometer (MPR) Flexible ChocolateCambridge Trimaster Micro Capillary Films (MCF)

Author

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