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Inventing Apparatus and Processes 2011

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malcolmmackley

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.

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Cambridge 2011 Inventing apparatus and processes By Malcolm Mackley Department of Chemical Engineering and Biotechnology University of Cambridge UK
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 Whats crucial is whether (your writing) attains the standards you have set yourself. Im not the brightest person. Im the kind of person who has to experience something physically, actually touch something, before I have a clear sense of it. . Im a physical, not intellectual, kind of person. Of course I 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 Chocolate Cambridge Trimaster Micro Capillary Films (MCF)
Bristol 1970-1976; the genesis for invention Sir Charles Frank Andrew Keller
Bristol 1972
Extensional Flows 1970s; scientific curiosity 1970 Frank &Mackley, Double Jet 1974 G.I.Taylor (1934), Four Roll Mill 1974 Two Roll Mill 1976 Berry & Mackley, Six Roll Mill
High Modulus Polyethylene (HMP) 1980s; process Piston Solvent UHMWPE Polymer powde r Low entanglement polymer gel 1. Low entanglement UHMWPE polymer gel Screw extruder Spinnere t Solvent recovery Solvent recovery Gel fibres 2. Unoriented Gel fibre Hot draw 4. Hot draw Quench bath Quench bath 5. Oriented High Modulus Polyethylene 3. Unoriented Low entanglement semi crystalline fibre Low entanglement semi crystalline fibre Schematic diagram of continuous High Modulus Polyethylene (HMP) process
Oscillatory Flow Mixing (OFM) 1980s; process
Cambridge 1980s
Cambridge Shear System (CSS), 1980s; apparatus 0 s-1 1 s-1 10 s-1 100 s-1 1000 s-1 I. Untreated SWNT II. Treated SWNT III. Untreated MWNT IV. Treated MWNT
CNTs Go to CNT helical banding movie
Cambridge 1990s
Flexible Chocolate 1990s; process Extrusion processing Cold Melt Polyethylene Extrusion Processing H 50 100 150 200 0 Temperature C Chocolate 16 0 Cold Melt Extrusion Processing H 14 0 12 0 Piston/(ram) A Yield 10 0 10 20 30 40 pressure Chocolate feed Pressure transducer 0 80 Die Temperature C 60 B Extrusion pressure 40 20 0 5 10 15 20 25 30 35 C Compaction (no flow) t (s)
Stuttgart 1990s
Multipass Rheometer 1990s; apparatus
The Multipass Rheometer Top section Test section Bottom section
Scientific Art Go to MPR slit movie
Matching Experiment with Simulation Vp = 0.44 mms-1 3D EUsolve Polystyrene (PS2) 10mm depth LHS Pom Pom RHS Experiment 3D simulation Experiment dP = 3.76 bar dP = 3.96 bar
France 2000s
France 2000s
Cambridge Trimaster 2000s; apparatus
MicroCapillary Films (MCFs) 2000s; process Polymer flow Injector Die land MCF extrudate Quench bath Extrudate to haul off
.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 Chocolate Cambridge 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 Chocolate Cambridge Trimaster Micro Capillary Films (MCF) Author
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Inventing Apparatus and Processes 2011

  • 1. Cambridge 2011 Inventing apparatus and processes By Malcolm Mackley Department of Chemical Engineering and Biotechnology University of Cambridge UK
  • 2. 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
  • 3. Haruki Marakami Whats crucial is whether (your writing) attains the standards you have set yourself. Im not the brightest person. Im the kind of person who has to experience something physically, actually touch something, before I have a clear sense of it. . Im a physical, not intellectual, kind of person. Of course I have a certain amount of intelligence - at least I think I have. Haruki Marukami What I talk about when I talk about running 2009
  • 4. Malcolm Mackley Scientist Engineer Inventor Apparatus Processes High Modulus Polyethylene (HMP) Cambridge Shear System (CSS) Oscillatory flow mixing (OFM) Multipass Rheometer (MPR) Flexible Chocolate Cambridge Trimaster Micro Capillary Films (MCF)
  • 5. Bristol 1970-1976; the genesis for invention Sir Charles Frank Andrew Keller
  • 6. Bristol 1972
  • 7. Extensional Flows 1970s; scientific curiosity 1970 Frank &Mackley, Double Jet 1974 G.I.Taylor (1934), Four Roll Mill 1974 Two Roll Mill 1976 Berry & Mackley, Six Roll Mill
  • 8. High Modulus Polyethylene (HMP) 1980s; process Piston Solvent UHMWPE Polymer powde r Low entanglement polymer gel 1. Low entanglement UHMWPE polymer gel Screw extruder Spinnere t Solvent recovery Solvent recovery Gel fibres 2. Unoriented Gel fibre Hot draw 4. Hot draw Quench bath Quench bath 5. Oriented High Modulus Polyethylene 3. Unoriented Low entanglement semi crystalline fibre Low entanglement semi crystalline fibre Schematic diagram of continuous High Modulus Polyethylene (HMP) process
  • 9. Oscillatory Flow Mixing (OFM) 1980s; process
  • 11. Cambridge Shear System (CSS), 1980s; apparatus 0 s-1 1 s-1 10 s-1 100 s-1 1000 s-1 I. Untreated SWNT II. Treated SWNT III. Untreated MWNT IV. Treated MWNT
  • 12. CNTs Go to CNT helical banding movie
  • 14. Flexible Chocolate 1990s; process Extrusion processing Cold Melt Polyethylene Extrusion Processing H 50 100 150 200 0 Temperature C Chocolate 16 0 Cold Melt Extrusion Processing H 14 0 12 0 Piston/(ram) A Yield 10 0 10 20 30 40 pressure Chocolate feed Pressure transducer 0 80 Die Temperature C 60 B Extrusion pressure 40 20 0 5 10 15 20 25 30 35 C Compaction (no flow) t (s)
  • 17. The Multipass Rheometer Top section Test section Bottom section
  • 18. Scientific Art Go to MPR slit movie
  • 19. Matching Experiment with Simulation Vp = 0.44 mms-1 3D EUsolve Polystyrene (PS2) 10mm depth LHS Pom Pom RHS Experiment 3D simulation Experiment dP = 3.76 bar dP = 3.96 bar
  • 23. MicroCapillary Films (MCFs) 2000s; process Polymer flow Injector Die land MCF extrudate Quench bath Extrudate to haul off
  • 24. .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
  • 25. Malcolm Mackley Scientist Engineer Inventor Apparatus Processes High Modulus Polyethylene (HMP) Cambridge Shear System (CSS) Oscillatory flow mixing (OFM) Multipass Rheometer (MPR) Flexible Chocolate Cambridge Trimaster Micro Capillary Films (MCF)
  • 26. Malcolm Mackley Scientist Engineer Inventor Apparatus Processes High Modulus Polyethylene (HMP) Cambridge Shear System (CSS) Oscillatory flow mixing (OFM) Multipass Rheometer (MPR) Flexible Chocolate Cambridge Trimaster Micro Capillary Films (MCF) Author