Continuous Production of Melamine-Formaldehyde Microcapsules Using a Mesostructured Reactor

Study of Melamine-Formaldehyde/Phase Change Material Microcapsules for the Preparation of Polymer Films by Extrusion

n-Eicosane-melamine formaldehyde microcapsules of an average size of 1.1 μm and latent heat of fusion of 146.2 ± 5.3 J/g have been prepared. They have been characterized by scanning electron microscopy, FTIR spectroscopy, calorimetric techniques, and thermogravimetric analyses. Under processing conditions, the microcapsules apparently preserved their properties, also maintaining their n-eicosane loading and heat storage capacity under washing conditions (water with detergent at 60 °C). The microcapsules synthesis has been scaled up for the fabrication of functional films by extrusion. For that, polymer films containing 10 wt.% of microcapsules were prepared at a pilot plant level. In those films, even though a fraction of the n-eicosane loading was lost during the extrusion process, the microcapsules showed good compatibility within the polyamide. The percentage of PCM in the polyamide 6 films was estimated by TGA, verifying also the heat storage capacity predicted by DSC (2.6 ± 0.7 J/g).

Mixing in the NETmix Reactor

NETmix is a static mixing reactor composed of a network of mixing chambers interconnected by channels. The repetitive mixing pattern inside the reactor enables the use of reduced geometries to represent the NETmix network, such as the ExtendedNUB model, used in this work. Mixing in NETmix is based on the impingement of jets, issuing from channels. Inside the chambers, the jets are engulfed by dynamic vortices which can be quantified using Lagrangian techniques. Batch Lagrangian Mixing Simulation (BLMS) is based on successive injections of particles to measure the fraction of the fluids at the outlet of the mixing chambers. The distribution of the outlet fraction of particles indicates that it is possible to have nearly perfect mixing inside the NETmix chambers, depending on the dimensions of the channels and chambers. The NETmix design is here optimized in relation to the chamber diameter to channel width ratio, D/d. Results from BLMS show that best performance in NETmix occurs for 6.65≤D/d≤6.85.