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Grohn P, Heinrich S, Antonyuk S. Numerical Investigation of the Particle Dynamics in a Rotorgranulator Depending on the Properties of the Coating Liquid. Pharmaceutics 2023; 15:pharmaceutics15020469. [PMID: 36839791 PMCID: PMC9963257 DOI: 10.3390/pharmaceutics15020469] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/14/2022] [Revised: 01/20/2023] [Accepted: 01/27/2023] [Indexed: 02/04/2023] Open
Abstract
In the pharmaceutical industry, the coating of particles is a widely used technique to obtain desired surface modifications of the final product, e.g., controlled release of the active agents. The production of round, coated particles is particularly important, which is why fluidized bed rotor granulators (FBRG) are often used for this process. In this work, Computational Fluid Dynamics (CFD) coupled with the Discrete Element Method (DEM) is used to investigate the wet particle dynamics, depending on the properties of the coating liquid in a FBRG. The DEM contact model was extended by liquid bridge model to account for capillary and viscous forces during wet contact of particles. The influence of the relative contact velocity on the maximum length of the liquid bridge is also considered in the model. Five different cases were compared, in which the particles were initially wetted, and the liquid loading as well as the surface tension and viscosity of the liquid were changed. The results show that increasing viscosity leads to a denser particle bed and a significant decrease in particle rotational velocities and particle motion in the poloidal plane of the FBRG. Reducing the liquid loading and surface tension results in increased particle movement.
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Affiliation(s)
- Philipp Grohn
- Institute of Particle Process Engineering, University of Kaiserslautern-Landau, Gottlieb-Daimler-Straße 44, 67663 Kaiserslautern, Germany
- Correspondence:
| | - Stefan Heinrich
- Institute of Solids Process Engineering and Particle Technology, Hamburg University of Technology, Denickestraße 15, 21073 Hamburg, Germany
| | - Sergiy Antonyuk
- Institute of Particle Process Engineering, University of Kaiserslautern-Landau, Gottlieb-Daimler-Straße 44, 67663 Kaiserslautern, Germany
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2
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Grohn P, Schaedler L, Atxutegi A, Heinrich S, Antonyuk S. CFD‐DEM Simulation of Superquadric Cylindrical Particles in a Spouted Bed and a Rotor Granulator. CHEM-ING-TECH 2022. [DOI: 10.1002/cite.202200121] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/12/2022]
Affiliation(s)
- Philipp Grohn
- Technische Universität Kaiserslautern Institute of Particle Process Engineering Gottlieb-Daimler-Straße 44 67663 Kaiserslautern Germany
| | - Luca Schaedler
- Technische Universität Kaiserslautern Institute of Particle Process Engineering Gottlieb-Daimler-Straße 44 67663 Kaiserslautern Germany
| | - Aitor Atxutegi
- Hamburg University of Technology Institute of Solids Process Engineering and Particle Technology Denickestraße 15 (K) 21073 Hamburg Germany
| | - Stefan Heinrich
- Hamburg University of Technology Institute of Solids Process Engineering and Particle Technology Denickestraße 15 (K) 21073 Hamburg Germany
| | - Sergiy Antonyuk
- Technische Universität Kaiserslautern Institute of Particle Process Engineering Gottlieb-Daimler-Straße 44 67663 Kaiserslautern Germany
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3
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Milacic E, Rantong DR, Kuipers JAM, Baltussen MW. Temperature Distribution in Fluidized Beds of Porous Particles with LiquidInjection. CHEM-ING-TECH 2022. [DOI: 10.1002/cite.202200136] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
Affiliation(s)
- Evan Milacic
- Eindhoven University Department of Chemical Engineering and Chemistry P.O. Box 513 5600 MB Eindhoven The Netherlands
- DPI P.O. Box 902 5600 AX Eindhoven The Netherlands
| | - Dylan R. Rantong
- Eindhoven University Department of Chemical Engineering and Chemistry P.O. Box 513 5600 MB Eindhoven The Netherlands
| | - J. A. M. Kuipers
- Eindhoven University Department of Chemical Engineering and Chemistry P.O. Box 513 5600 MB Eindhoven The Netherlands
- DPI P.O. Box 902 5600 AX Eindhoven The Netherlands
| | - Maike. W. Baltussen
- Eindhoven University Department of Chemical Engineering and Chemistry P.O. Box 513 5600 MB Eindhoven The Netherlands
- DPI P.O. Box 902 5600 AX Eindhoven The Netherlands
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Ge Wang L, Omar C, Litster J, Slade D, Li J, Salman A, Bellinghausen S, Barrasso D, Mitchell N. Model Driven Design for Integrated Twin Screw Granulator and Fluid Bed Dryer via Flowsheet Modelling. Int J Pharm 2022; 628:122186. [PMID: 36130681 DOI: 10.1016/j.ijpharm.2022.122186] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 04/07/2022] [Revised: 09/02/2022] [Accepted: 09/03/2022] [Indexed: 11/27/2022]
Abstract
This paper presents a flowsheet modelling of an integrated twin screw granulation (TSG) and fluid bed dryer (FBD) process using a Model Driven Design (MDD) approach. The MDD approach is featured by appropriate process models and efficient model calibration workflow to ensure the product quality. The design space exploration is driven by the physics of the process instead of extensive experimental trials. By means of MDD, the mechanistic-based process kernels are first defined for the TSG and FBD processes. With the awareness of the underlying physics, the complementary experiments are carried out with relevance to the kinetic parameters in the defined models. As a result, the experiments are specifically purposeful for model calibration and validation. The L/S ratio (liquid to solid ratio) and inlet air temperature are selected as the Critical Process Parameters (CPPs) in TSG and FBD for model validation, respectively. Global System Analysis (GSA) is further performed to assess the uncertainty of CPPs imposed on the Critical Quality Attributes (CQAs), which provides significant insights to the exploration of the design space considering both TSG and FBD process parameters.
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Affiliation(s)
- Li Ge Wang
- Siemens Process Systems Engineering, Hammersmith, London, UK; Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - Chalak Omar
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | - James Litster
- Department of Chemical and Biological Engineering, University of Sheffield, UK.
| | - David Slade
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Jianfeng Li
- Siemens Process Systems Engineering, Parsippany, New Jersey, USA
| | - Agba Salman
- Department of Chemical and Biological Engineering, University of Sheffield, UK
| | | | - Dana Barrasso
- Siemens Process Systems Engineering, Hammersmith, London, UK
| | - Niall Mitchell
- Siemens Process Systems Engineering, Hammersmith, London, UK
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5
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Grohn P, Oesau T, Heinrich S, Antonyuk S. Investigation of the influence of wetting on the particle dynamics in a fluidized bed rotor granulator by MPT measurements and CFD-DEM simulations. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117736] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/16/2022]
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6
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Milacic E, Nunez Manzano M, Madanikashani S, Heynderickx G, Van Geem K, Baltussen M, Kuipers J. Liquid injection in a fluidised bed: Temperature uniformity. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.117622] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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7
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Investigation of gas-solid heat and mass transfer in a Wurster coater using a scaled CFD-DEM model. POWDER TECHNOL 2022. [DOI: 10.1016/j.powtec.2022.117598] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/20/2022]
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8
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Grohn P, Oesau T, Heinrich S, Antonyuk S. Investigation of the influence of impact velocity and liquid bridge volume on the maximum liquid bridge length. ADV POWDER TECHNOL 2022. [DOI: 10.1016/j.apt.2022.103630] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/27/2022]
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9
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Madlmeir S, Forgber T, Trogrlic M, Jajcevic D, Kape A, Contreras L, Carmody A, Liu P, Davies C, Sarkar A, Khinast J. Quantifying the Coating Yield by Modeling Heat and Mass Transfer in a Wurster Fluidized Bed Coater. Chem Eng Sci 2022. [DOI: 10.1016/j.ces.2022.117505] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/28/2022]
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10
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Numerical and experimental validation of a detailed non-isothermal CFD-DEM model of a pilot-scale Wurster coater. POWDER TECHNOL 2021. [DOI: 10.1016/j.powtec.2021.05.100] [Citation(s) in RCA: 6] [Impact Index Per Article: 2.0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 02/01/2023]
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11
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Madlmeir S, Forgber T, Trogrlic M, Jajcevic D, Kape A, Contreras L, Carmody A, Liu P, Davies C, Sarkar A, Khinast JG. Modeling the coating layer thickness in a pharmaceutical coating process. Eur J Pharm Sci 2021; 161:105770. [PMID: 33610738 DOI: 10.1016/j.ejps.2021.105770] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.7] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/13/2020] [Revised: 01/25/2021] [Accepted: 02/15/2021] [Indexed: 11/16/2022]
Abstract
Although mechanistic numerical simulations can offer great insights into a process, they are limited with respect to resolved process time. While statistical models provide long-term predictability, determining the underlying probability distributions is often challenging. In this work, detailed CFD-DEM simulations of a pharmaceutical Wurster coating process for microspheres are used to evaluate the input parameters for a novel Monte-Carlo simulation approach. The combined strengths of both modeling approaches make it possible to predict the coating mass and thickness distributions over the entire process time. It was observed that smaller beads receive a thicker coating layer since they pass the spray zone closer to the nozzle. Moreover, it was established that, in contrast to the airflow rate, the spray rate has a great impact on the inter-particle coating variability. A stochastic model was developed to investigate the relative contribution of coating layer variability and fill weight variability to the product non-uniformity in a capsule filling process of Multiple Unit Pellet Systems (MUPS).
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Affiliation(s)
- S Madlmeir
- Research Center Pharmaceutical Engineering, Graz, Austria
| | - T Forgber
- Research Center Pharmaceutical Engineering, Graz, Austria
| | - M Trogrlic
- Research Center Pharmaceutical Engineering, Graz, Austria
| | - D Jajcevic
- Research Center Pharmaceutical Engineering, Graz, Austria
| | - A Kape
- Glatt, Integrated Process Solution, Binzen, Germany
| | - L Contreras
- Worldwide Research, Development and Medical, Pfizer Inc., Sandwich, UK
| | - A Carmody
- Worldwide Research, Development and Medical, Pfizer Inc., Sandwich, UK
| | - P Liu
- Worldwide Research, Development and Medical, Pfizer Inc., Groton CT, USA
| | - C Davies
- Worldwide Research, Development and Medical, Pfizer Inc., Groton CT, USA
| | - A Sarkar
- Worldwide Research, Development and Medical, Pfizer Inc., Groton CT, USA
| | - J G Khinast
- Research Center Pharmaceutical Engineering, Graz, Austria; Institute of Process and Particle Engineering, Technical University of Graz, Austria.
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Farivar F, Zhang H, Tian ZF, Gupte A. CFD-DEM -DDM Model for Spray Coating Process in a Wurster Coater. J Pharm Sci 2020; 109:3678-3689. [PMID: 33007276 DOI: 10.1016/j.xphs.2020.09.032] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 06/01/2020] [Revised: 07/30/2020] [Accepted: 09/21/2020] [Indexed: 10/23/2022]
Abstract
A multiscale model by coupling computational fluid dynamics (CFD) with a discrete element model (DEM) and discrete droplet model (DDM) is developed to simulate a lab-scale Wurster coater. Two case studies are conducted to study the effect of particle shape in the system. In the first case study, 45,000 spherical particles are coated for 5 s while for the second case study, a mixture of 22,500 spherical particles and 22,500 cylindrical particles is simulated. The residence time distributions (RTD) of particles in different spray zones are compared, and the best spray zone is derived by analysing the positions of spray droplet-particle contacts. The simulation results show that the RTD of the particles within an accurate spray zone can provide valuable information on the final product's particles size distribution. Furthermore, the coefficient of variation (COV) for the coating mass received by the particles is studied for both case studies.
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Affiliation(s)
- Foad Farivar
- School of Chemical Engineering, The University of Adelaide, Adelaide, SA 5005, Australia.
| | - Hu Zhang
- School of Chemical Engineering, The University of Adelaide, Adelaide, SA 5005, Australia; Amgen Bioprocessing Centre, Keck Graduate Institute, Claremont, CA 91711, USA
| | - Zhao F Tian
- School of Mechanical Engineering, The University of Adelaide, Adelaide, SA 5005, Australia
| | - Anshul Gupte
- Mayne Pharma, Salisbury South, Adelaide, SA 5106, Australia
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13
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Abstract
Coating of particles is a widely used technique in order to obtain the desired surface modification of the final product, e.g., specific color or taste. Especially in the pharmaceutical industry, rotor granulators are used to produce round, coated pellets. In this work, the coating process in a rotor granulator is investigated numerically using computational fluid dynamics (CFD) coupled with the discrete element method (DEM). The droplets are generated as a second particulate phase in DEM. A liquid bridge model is implemented in the DEM model to take the capillary and viscous forces during the wet contact of the particles into account. A coating model is developed, where the drying of the liquid layer on the particles, as well as the particle growth, is considered. The simulation results of the dry process compared to the simulations with liquid injection show an important influence of the liquid on the particle dynamics. The formation of liquid bridges and the viscous forces in the liquid layer lead to an increase of the average particle velocity and contact time. Changing the injection rate of water has an influence on the contact duration but no significant effect on the particle dynamics. In contrast, the aqueous binder solution has an important influence on the particle movement.
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14
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A semi-theoretical model for simulating the temporal evolution of moisture-temperature during industrial fluidized bed granulation. Eur J Pharm Biopharm 2020; 151:137-152. [PMID: 32304867 DOI: 10.1016/j.ejpb.2020.03.014] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 01/17/2020] [Revised: 03/09/2020] [Accepted: 03/16/2020] [Indexed: 11/23/2022]
Abstract
Moisture plays a major role in determining the attributes of granules prepared by fluidized bed granulation (FBG). Here, a semi-theoretical droplet-based evaporation rate model was developed and incorporated into moisture mass-enthalpy balances to simulate the temporal evolution of bed moisture-temperature. Experimental data from a GPCG30 unit were used to fit the model parameters. With only two fitting parameters, the model demonstrated excellent capability to describe the moisture-temperature evolution for a wide range of operating conditions. Then, in a global process model (GPM) approach, the evaporation parameters were fitted to multi-linear functions of inlet air temperature, binder concentration, and spray rate. The GPM was validated successfully by simulating a different data set which was not used in its calibration. As the GPM demonstrated a good predictive capability, it was further used to investigate the impacts of process parameters. Numerical simulations suggest that the proposed GPM predicts the experimentally well-established trends of moisture-temperature profiles in previously published data, proving the applicability of the GPM approach. This study has demonstrated the capabilities of simple process models as a practical approach to predict time-wise evolution of bed moisture-temperature profiles in industrial FBG modeling, while also pointing out their limitations.
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15
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Ahmadi Motlagh AH, Pougatch K, Maturi A, Salcudean M, Grace JR, Grecov D, McMillan J. CFD Study of Wet Agglomerate Growth and Breakage in a Fluidized Bed Containing Hot Silica Sand Particles with Evaporative Liquid Injection. Ind Eng Chem Res 2019. [DOI: 10.1021/acs.iecr.8b05174] [Citation(s) in RCA: 4] [Impact Index Per Article: 0.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- A. H. Ahmadi Motlagh
- Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z3, Canada
- Department of Mechanical Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z4, Canada
| | | | - Anish Maturi
- Department of Mechanical Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z4, Canada
| | - Martha Salcudean
- Department of Mechanical Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z4, Canada
| | - John R. Grace
- Department of Chemical and Biological Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z3, Canada
| | - Dana Grecov
- Department of Mechanical Engineering, University of British Columbia, Vancouver, British Columbia V6T 1Z4, Canada
| | - Jennifer McMillan
- Edmonton Research Centre, Syncrude Canada Ltd., Edmonton, Alberta T6N 1H4, Canada
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16
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Affiliation(s)
- Maksym Dosta
- Hamburg University of TechnologyInstitute of Solids Process Engineering and Particle Technology Denickestrasse 15 21073 Hamburg Germany
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17
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Model Development and Validation of Fluid Bed Wet Granulation with Dry Binder Addition Using a Population Balance Model Methodology. Processes (Basel) 2018. [DOI: 10.3390/pr6090154] [Citation(s) in RCA: 15] [Impact Index Per Article: 2.5] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/17/2022] Open
Abstract
An experimental study in industry was previously carried out on a batch fluid bed granulation system by varying the inlet fluidizing air temperature, binder liquid spray atomization pressure, the binder liquid spray rate and the disintegrant composition in the formulation. A population balance model framework integrated with heat transfer and moisture balance due to liquid addition and evaporation was developed to simulate the fluid bed granulation system. The model predictions were compared with the industry data, namely, the particle size distributions (PSDs) and geometric mean diameters (GMDs) at various time-points in the granulation process. The model also predicted the trends for binder particle dissolution in the wetting liquid and the temperatures of the bed particles in the fluid bed granulator. Lastly, various process parameters were varied and extended beyond the region studied in the aforementioned experimental study to identify optimal regimes for granulation.
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18
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Börner M, Bück A, Tsotsas E. DEM-CFD investigation of particle residence time distribution in top-spray fluidised bed granulation. Chem Eng Sci 2017. [DOI: 10.1016/j.ces.2016.12.020] [Citation(s) in RCA: 26] [Impact Index Per Article: 3.7] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/20/2022]
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19
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Chaudhury A, Barrasso D, Pohlman D, Litster J, Ramachandran R. Mechanistic modeling of high-shear and twin screw mixer granulation processes. PREDICTIVE MODELING OF PHARMACEUTICAL UNIT OPERATIONS 2017:99-135. [DOI: 10.1016/b978-0-08-100154-7.00005-3] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.1] [Reference Citation Analysis] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 07/19/2023]
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20
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Schmitz-Schug I, Kulozik U, Foerst P. Modeling spray drying of dairy products – Impact of drying kinetics, reaction kinetics and spray drying conditions on lysine loss. Chem Eng Sci 2016. [DOI: 10.1016/j.ces.2015.11.008] [Citation(s) in RCA: 35] [Impact Index Per Article: 4.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/22/2022]
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21
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Dosta M, Antonyuk S, Hartge EU, Heinrich S. Parameter Estimation for the Flowsheet Simulation of Solids Processes. CHEM-ING-TECH 2014. [DOI: 10.1002/cite.201400021] [Citation(s) in RCA: 11] [Impact Index Per Article: 1.1] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
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22
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Derivation of parameters for a two compartment population balance model of Wurster fluidised bed granulation. POWDER TECHNOL 2013. [DOI: 10.1016/j.powtec.2012.04.014] [Citation(s) in RCA: 38] [Impact Index Per Article: 3.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/23/2022]
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23
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Fries L, Antonyuk S, Heinrich S, Dopfer D, Palzer S. Collision dynamics in fluidised bed granulators: A DEM-CFD study. Chem Eng Sci 2013. [DOI: 10.1016/j.ces.2012.06.026] [Citation(s) in RCA: 108] [Impact Index Per Article: 9.8] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
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24
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Heine M, Antonyuk S, Fries L, Niederreiter G, Heinrich S, Palzer S. Modeling of the Spray Zone for Particle Wetting in a Fluidized Bed. CHEM-ING-TECH 2013. [DOI: 10.1002/cite.201200148] [Citation(s) in RCA: 14] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/10/2022]
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25
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Antonyuk S, Heinrich S, Smirnova I. Discrete Element Study of Aerogel Particle Dynamics in a Spouted Bed Apparatus. Chem Eng Technol 2012. [DOI: 10.1002/ceat.201200083] [Citation(s) in RCA: 17] [Impact Index Per Article: 1.4] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/06/2022]
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26
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Dosta M, Antonyuk S, Heinrich S. Multiscale Simulation of the Fluidized Bed Granulation Process. Chem Eng Technol 2012. [DOI: 10.1002/ceat.201200075] [Citation(s) in RCA: 26] [Impact Index Per Article: 2.2] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/08/2022]
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