Discrete particle simulation of particulate systems: A review of major applications and findings

Effect of bottom bumpiness of vibrated closed container on granular dissipation behavior

The dissipation behavior of granular balls inside quasi-two-dimensional closed containers with different levels of bottom bumpiness under vibration is examined in this article using the discrete element method. The quasi-two-dimensional closed granular system used in this paper has dimensions ofL x × L y × L z = 60 mm × 5 mm × 120 mm , and the diameters of the 279 filled granular balls are 4 mm. First, the dynamic behavior and damping effects of granular balls within a flat-bottomed closed container are explored across the range of relevant excitation parameters, identifying four high damping granular phases. Second, this study investigated the impact of the container's bottom surface bumpiness, convex height, and number of bumps on the dissipative behavior of internal granular balls. The findings reveal that a single 2 mm bump on the container's bottom surface maximally enhances the damping effect on the granular balls. Finally, by comparing the optimal damping behavior of granular balls inside a flat-bottomed container with that of a container featuring a single 2 mm bump at the bottom, this study revealed how the protruding bottom surface enhances the damping effect on the granular balls inside the container. This provides theoretical support for optimizing the performance of granular dampers in engineering practice by controlling the morphology of the cavity bottom surface.

Lattice Boltzmann simulation of deformable fluid-filled bodies: progress and perspectives

With the rapid development of studies involving droplet microfluidics, drug delivery, cell detection, and microparticle synthesis, among others, many scientists have invested significant efforts to model the flow of these fluid-filled bodies. Motivated by the intricate coupling between hydrodynamics and the interactions of fluid-filled bodies, several methods have been developed. The objective of this review is to present a compact foundation of the methods used in the literature in the context of lattice Boltzmann methods. For hydrodynamics, we focus on the lattice Boltzmann method due to its specific ability to treat time- and spatial-dependent boundary conditions and to incorporate new physical models in a computationally efficient way. We split the existing methods into two groups with regard to the interfacial boundary: fluid-structure and fluid-fluid methods. The fluid-structure methods are characterised by the coupling between fluid dynamics and mechanics of the flowing body, often used in applications involving membranes and similar flexible solid boundaries. We further divide fluid-structure-based methods into two subcategories, those which treat the fluid-structure boundary as a continuum medium and those that treat it as a discrete collection of individual springs and particles. Next, we discuss the fluid-fluid methods, particularly useful for the simulations of fluid-fluid interfaces. We focus on models for immiscible droplets and their interaction in a suspending fluid and describe benchmark tests to validate the models for fluid-filled bodies.

Optimizing of particle accelerated rotor parameters using the discrete element method

The acceleration capability of a centrifugal jet rotor plays a crucial role in achieving a high injection velocity of powder particles in the centrifugal impact moulding process. In this regard, the focus of this article is on optimization of the runner shape. To this end, the lengths of the first and second acceleration sections (L1 and L2), and the angles between the first and second acceleration sections and between the second and third sections (α1 and α2) are considered as the rotor parameters. Simulations were conducted using multiple discrete elements to explore the influence of multiple input parameters on the response value, and a regression model was established between the parameters and the particle injection rate. The experimental results show that the selected parameters significantly affect the rate of particle injection, and the interactions between the parameters L1 and L2, and between L2 and α2 have the largest effects. The results reveal that applying the optimized parameters improves the particle injection speed by 7.85% when compared to the pre-optimization model. This improvement in the rotor acceleration provides the basis for improving the efficiency of centrifugal impact moulding of metal powders.

Research on the screening mechanisms of composite vibrating screens based on discrete elements

To strengthen the screening efficiency of traditional vibrating screens, a new type of vibrating screen, namely the composite vibrating screen, has been proposed based on the Lissajous vibration synthesis theory. The working principles of composite vibrating screens have been explained. Numerical simulations of the sieving processes for such composite vibrating screens were carried out using the discrete element method. Compared with traditional linear vibrating screens, the force, stratification mechanisms, and throwing principles of the material on the screen's surface were studied, and the vibrating screens' material transportation and screening efficiency were analyzed. The results showed that with the existence of xyz three directions sub-vibrations of the composite vibrating screens, the material particle group is more diversified by the forces, the particle system is loose, the stratification effects are adequate, and the material is evenly distributed on the screen surfaces. Under the same vibration parameters, the composite vibrating screens' screening efficiencies and material transportation capacities were better than those of linear vibrating screens. This work provides a necessary reference for the development and application of new composite vibrating screens.

Effect of excitation frequency on dissipation behavior of vibrated granular balls

The dissipation behavior of granular balls in a quasi-2D vertically oscillating closed container is studied by the discrete element method with varying excitation frequencies in this work. Combining the dynamic behavior with dissipation effect of vibrated granular balls, the optimal damping effect of the phase transition critical stage between granular density inversion and granular Leidenfrost effect that involves four high damping granular phases (HDGPs) is revealed. Moreover, the high damping granular phases near and away from this phase transition critical stage are compared and analyzed further, which indicates the universal dynamic behavior of dense granular clusters playing the optimal damping effect. Finally, the optimal damping mechanism of granular balls in the quasi-2D closed container is clarified. Damping properties and motion states of partic.

Study of CFD-DEM on the Impact of the Rolling Friction Coefficient on Deposition of Lignin Particles in a Single Ceramic Membrane Pore

The discrete element method coupled with the computational fluid dynamic (CFD-DEM) method is effective for studying the micro-flow process of lignin particles in ceramic membranes. Lignin particles may exhibit various shapes in industry, so it is difficult to model their real shapes in CFD-DEM coupled solutions. Meanwhile, the solution of non-spherical particles requires a very small time-step, which significantly lowers the computational efficiency. Based on this, we proposed a method to simplify the shape of lignin particles into spheres. However, the rolling friction coefficient during the replacement was hard to be obtained. Therefore, the CFD-DEM method was employed to simulate the deposition of lignin particles on a ceramic membrane. Impacts of the rolling friction coefficient on the deposition morphology of the lignin particles were analyzed. The coordination number and porosity of the lignin particles after deposition were calculated, based on which the rolling friction coefficient was calibrated. The results indicated that the deposition morphology, coordination number, and porosity of the lignin particles can be significantly affected by the rolling friction coefficient and slightly influenced by that between the lignin particles and membranes. When the rolling friction coefficient among different particles increased from 0.1 to 3.0, the average coordination number decreased from 3.96 to 2.73, and the porosity increased from 0.65 to 0.73. Besides, when the rolling friction coefficient among the lignin particles was set to 0.6-2.4, the spherical lignin particles could replace the non-spherical particles.

Review on the chemical reduction modelling of hematite iron ore to magnetite in fluidized bed reactor

Steel production is considered as one of the major backbones of many economies. Though blast furnace is the primary route of steel production, the industries are willing to alternatives technologies such as the high temperature-controlled conversion of hematite to magnetite. The geological and mineralogical characteristics of the low-grade iron ores possess difficulties in their conventional enrichment. The literature concludes the advantages of high-temperature conversion in terms of easiness in downstream operations caused by decreased hardness and increased magnetic susceptibility of magnetite. The modelling work has been primarily focused on the direct reduction of iron ore to metallic iron. The present compilation discusses the scientific and engineering developments on the reduction-roasting of iron-ore followed by the CFD–DEM modelling and simulation work performed to reduce iron ore to magnetite. It provides a comprehensive review of the experimental and industrial progress done in the area.

Numerical Study of Factors Affecting Particle Suction Efficiency of Pick-Up Head of a Regenerative Air Vacuum Sweeper

The influence of variable operational conditions affects the performance of particle collection and separation of a regenerative air vacuum sweeper. Therefore, the purpose of this paper was to numerically investigate the factors affecting the particle suction efficiency of the pick-up head. Using computational fluid dynamics (CFD), a model of an integrated pick-up head was developed based on the particle suction process to evaluate the particle removal performance. The realizable k-ε and discrete particle models were utilized to study the gas flow field and solid particle trajectories. The particle structure, sweeping speed, secondary airflow, pressure drop, and distance between the particle suction port and the road surface, as factors that affect the particle removal efficiency, were investigated. The results indicate that the particle suction efficiency increases with decreasing sweeper speed. Furthermore, the particle overall removal efficiency increased with a reduction in the distance between the suction port and the road surface as well as the control of the secondary airflow in the system. By increasing the airflow rate at the suction port, high efficiencies were achieved at a high sweeper speed and high particle densities. At a sweeper speed of 6–10 km/h, the results showed that the secondary airflow recirculation varied between 60 to 80 %, while the high-pressure drop ranged from 2200 to 2400 Pa, and the particle suction efficiency recorded was 95%. The numerical analysis results provide a better understanding of the particle suction process and hence could lead to an improvement in the design of the pick-up head.

An Efficient Parallel Framework for the Discrete Element Method Using GPU

The discrete element method (DEM), a discontinuum-based method to simulate the interaction between neighbouring particles of granular materials, suffers from intensive computational workload caused by massive particle numbers, irregular particle shapes, and complicated interaction modes from the meso-scale representation of the macro information. To promote the efficiency of the DEM and enlarge the modelling scales with a higher realism of the particle shapes, parallel computing on the graphics processing unit (GPU) is developed in this paper. The potential data race between the computing cores in the parallelisation is tackled by establishing the contact pair list with a hybrid technique. All the computations in the DEM are made on the GPU cores. Three benchmark cases, a triaxial test of a sand specimen, cone penetration test and granular flow due to a dam break, are used to evaluate the performance of the GPU parallel strategy. Acceleration of the GPU parallel simulations over the conventional CPU sequential counterparts is quantified in terms of speedup. The average speedups with the GPU parallelisation are 84, 73, and 60 for the benchmark cases.

A “Sequential Design of Simulations” approach for exploiting and calibrating discrete element simulations of cohesive powders

The flow behaviours of cohesive particles in the ring shear test were simulated and examined using discrete element method guided by a design of experiments methodology. A full factorial design was used as a screening design to reveal the effects of material properties of partcles. An augmented design extending the screening design to a response surface design was constructed to establish the relations between macroscopic shear stresses and particle properties. It is found that the powder flow in the shear cell can be classified into four regimes. Shear stress is found to be sensitive to particle friction coefficient, surface energy and Young’s modulus. A considerable fluctuation of shear stress is observed in high friction and low cohesion regime. In high cohesion regime, Young’s modulus appears to have a more significant effect on the shear stress at the point of incipient flow than the shear stress during the pre-shear process. The predictions from response surface designs were validated and compared with shear stresses measured from the Schulze ring shear test. It is found that simulations and experiments showed excellent agreement under a variety of consolidation conditions, which verifies the advantages and feasibility of using the proposed “Sequential Design of Simulations” approach.

CFD-DEM Study of Bridging Mechanism of Particles in Ceramic Membrane Pores under Surface Filtration Conditions

In the surface filtration process with pores larger than the particle size, the formation of particle bridges plays a crucial role in the filter cake structure and the filtration efficiency throughout the filtration process. First, to understand the microscopic information required for the bridging mechanism, we use the two-way coupling of computational fluid dynamics (CFD)–discrete element method (DEM) to simulate the deposition characteristics of particles in the pores of ceramic membranes. Next, by dynamically observing the deposition morphology and bridging process of particles, the bridging mechanism was revealed at the level of a single hole. Then, we studied the influence of particle concentration and inlet velocity on the bridge erection process. The results show that the bridging function of particles runs through the clean filtration stage and the transition stage. Particle concentration and inlet flow rate have a crucial influence on the formation of particle bridges and filtration efficiency.

Focusing on powder processing in dry powder inhalation product development, manufacturing and performance

Dry powder inhalers (DPI) are well established products for the delivery of actives via the pulmonary route. Various DPI products are marketed or developed for the treatment of local lung diseases such as chronic obstructive pulmonary disease (COPD), asthma or cystic fibrosis as well as systemic diseases targeted through inhaled delivery (i.e. Diabetes Mellitus). One of the key prerequisites of DPI formulations is that the aerodynamic size of the drug particles needs to be below 5 µm to enter deeply into the respiratory tract. These inherently cohesive inhalable size particles are either formulated as adhesive mixture with coarse carrier particles like lactose called carrier-based DPI or are formulated as free-flowing carrier-free particles (e.g. soft agglomerates, large hollow particles). In either case, it is common practice that drug and/or excipient particles of DPI formulations are obtained by processing API and API/excipients. The DPI manufacturing process heavily involves several particle and powder technologies such as micronization of the API, dry blending, powder filling and other particle engineering processes such as spray drying, crystallization etc. In this context, it is essential to thoroughly understand the impact of powder/particle properties and processing on the quality and performance of the DPI formulations. This will enable prediction of the processability of the DPI formulations and controlling the manufacturing process so that meticulously designed formulations are able to be finally developed as the finished DPI dosage form. This article is intended to provide a concise account of various aspects of DPI powder processing, including the process understanding and material properties that are important to achieve the desired DPI product quality. Various endeavors of model informed formulation/process design and development for DPI powder and PAT enabled process monitoring and control are also discussed.