Analysis of granule breakage in a rotary mixing drum: Experimental study and distinct element analysis

Residence Time Distribution of Non-Spherical Particles in a Continuous Rotary Drum

The motion of non-spherical particles with sharp edges, as they are commonly involved in practice, was characterized by residence time distribution (RTD) measurement in a continuous drum. Particles with two sizes, 6 and 10 mm, and two densities, 750 and 2085 kg/m3, were used in the experiments. The effects of rotation speed (3–11 rpm), incline angle (2–4°), feed rate, and mixture composition were investigated and compared to the results of other researchers on particles without sharp edges. We also fitted the RTD with an axial dispersion model to obtain a better insight into the flow behavior. MRT of non-spherical particles with sharp edges depends on ω−α similar to other shapes, while the value of alpha is higher for particles with sharp edges (0.9 < α < 1.24), especially at high incline angles. The MRT depends on incline angle, β−b, where b varies between 0.81 (at low ω) and 1.34 (at high ω), while it is close to 1 for other shapes. Feed rate has a slight effect on the MRT of particles with sharp edges and the effect of particle size diminishes when rotation speed increases. The MRT linearly increases with volume fraction of light particles in a mixture of light and heavy particles (from pure heavy to pure light particles).

Simulation of the Attrition of Recycled Concrete Aggregates during Concrete Mixing

Concrete mixing can lead to mechanical degradation of aggregates, particularly when dealing with recycled concrete aggregates. In this work, the attrition of such materials during mixing is studied by means of experiments and simulations. The effect of the presence of fines, water addition, flow configuration of the mixer (co- or counter-current) and impeller frequency is discussed. Experiments were performed in a laboratory Eirich mixer. Discrete element numerical simulations (DEM) were performed on the same geometry by mimicking the behaviour of the material and, in particular, the cohesion induced by water and the cement paste using either Hertz–Mindlin or Hertz–Mindlin with Johnson–Kendall–Roberts (JKR) contact laws. The combination of the collision energy spectra extracted from the DEM simulations and an attrition model allowed the prediction of the mass loss due to attrition in 1-min experiments. Semi-quantitative agreement was observed between experiments and simulations, with a mean relative error of 26.4%. These showed that higher mass losses resulted from operation at the highest impeller speeds, co-current operation, and also with the wet aggregate. Mixing of the agglomerate in the concrete mix resulted in a significant reduction in attrition when compared to mixing aggregates alone. With further validation, the proposed simulation approach can become a valuable tool in the optimization of mixing by allowing the effects of material, machine and process variables to be studied on the mass loss due to attrition.

Mixing of Particles in a Rotating Drum with Inclined Axis of Rotation

Various experimental and numerical studies have been carried out to study the mixing processes inside rotating drums with a horizontal axis of rotation in the past, but little effort has been made to investigate the rotating drums with an inclined axis of rotation, though such inclined drums exist in industrial waste management, food processing, power and pharmaceutical industries. To fill this gap, in this work, the discrete element method was used to study the mixing phenomena of a rotating drum for different angles of inclination from 0° to 15°. It was found that for inclined rotating drums, the whole bed Lacey mixing index is higher than that for the horizontal drum by 7.2% when the angle of inclination is 10°. The mixing index is related to the area ratio of the active region to the whole bed and volumetric fill. Increase in volumetric fill would lead to the decrease of the mixing index. The mixing index and area ratio exhibit similar patterns along the length of the drum for different angles of inclination.

Experimental analysis of tablet properties for discrete element modeling of an active coating process

Coating of solid dosage forms is an important unit operation in the pharmaceutical industry. In recent years, numerical simulations of drug manufacturing processes have been gaining interest as process analytical technology tools. The discrete element method (DEM) in particular is suitable to model tablet-coating processes. For the development of accurate simulations, information on the material properties of the tablets is required. In this study, the mechanical parameters Young's modulus, coefficient of restitution (CoR), and coefficients of friction (CoF) of gastrointestinal therapeutic systems (GITS) and of active-coated GITS were measured experimentally. The dynamic angle of repose of these tablets in a drum coater was investigated to revise the CoF. The resulting values were used as input data in DEM simulations to compare simulation and experiment. A mean value of Young's modulus of 31.9 MPa was determined by the uniaxial compression test. The CoR was found to be 0.78. For both tablet-steel and tablet-tablet friction, active-coated GITS showed a higher CoF compared with GITS. According to the values of the dynamic angle of repose, the CoF was adjusted to obtain consistent tablet motion in the simulation and in the experiment. On the basis of this experimental characterization, mechanical parameters are integrated into DEM simulation programs to perform numerical analysis of coating processes.