Inventing Apparatus and Processes 2011
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“Inventing apparatus and processes” By Malcolm Mackley Department of Chemical Engineering and Biotechnology University of Cambridge UK Cambridge 2011
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This was my last Departmental seminar given in Chemical Engineering at Cambridge. It tells the story of apparatus and process invention. I have included pictures that influenced my career.
Transcript of Inventing Apparatus and Processes 2011
“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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