Polydisperse granular flows in a bladed mixer: Experiments and simulations of cohesionless spheres

A comprehensive review of the application of DEM in the investigation of batch solid mixers

Powder mixing is a vital operation in a wide range of industries, such as food, pharmaceutical, and cosmetics. Despite the common use of mixing systems in various industries, often due to the complex nature of mixing systems, the effects of operating and design parameters on the mixers’ performance and final blend are not fully known, and therefore optimal parameters are selected through experience or trial and error. Experimental and numerical techniques have been widely used to analyze mixing systems and to gain a detailed understanding of mixing processes. The limitations associated with experimental techniques, however, have made discrete element method (DEM) a valuable complementary tool to obtain comprehensive particle level information about mixing systems. In the present study, the fundamentals of solid-solid mixing, segregation, and characteristics of different types of batch solid mixers are briefly reviewed. Previously published papers related to the application of DEM in studying mixing quality and assessing the influence of operating and design parameters on the mixing performance of various batch mixing systems are summarized in detail. The challenges with regards to the DEM simulation of mixing systems, the available solutions to address those challenges and our recommendations for future simulations of solid mixing are also presented and discussed.

Granular segregation induced by a moving subsurface blade

Size-driven particle segregation can occur when an object such as a blade moves through an otherwise static bed of granular material. Here we use discrete element method (DEM) simulations to study segregation resulting from a subsurface blade moving through a bed of size-bidisperse spherical particles. Segregation increases with each pass of the blade until a surface layer of mostly large particles forms above a small-particle layer adjacent to the bottom wall. The rate of segregation decreases with each pass so that the degree of segregation asymptotically approaches its maximum value, and the number of passes to reach a steady segregation state increases as the bed depth is increased or the blade height decreased. In shallow beds, the characteristic number of passes for segregation, τ, scales with the inverse of the granular inertial number, I. In deep beds with small blade heights, the effect of the blade is more localized to its immediate vicinity, resulting in many more passes of the blade to reach a steady segregation state, and a corresponding deviation from the shallow bed scaling of τ with I^{-1}.

Modeling Segregation in Granular Flows

Accurate continuum models of flow and segregation of dense granular flows are now possible. This is the result of extensive comparisons, over the last several years, of computer simulations of increasing accuracy and scale, experiments, and continuum models, in a variety of flows and for a variety of mixtures. Computer simulations-discrete element methods (DEM)-yield remarkably detailed views of granular flow and segregation. Conti-nuum models, however, offer the best possibility for parametric studies of outcomes in what could be a prohibitively large space resulting from the competition between three distinct driving mechanisms: advection, diffusion, and segregation. We present a continuum transport equation-based framework, informed by phenomenological constitutive equations, that accurately predicts segregation in many settings, both industrial and natural. Three-way comparisons among experiments, DEM, and theory are offered wherever possible to validate the approach. In addition to the flows and mixtures described here, many straightforward extensions of the framework appear possible.