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Byun J, Son KJ. Experimental and Numerical Study of Computer Vision-Based Real-Time Monitoring of Polymeric Particle Mixing Process in Rotary Drum. Polymers (Basel) 2024; 16:1524. [PMID: 38891470 PMCID: PMC11174632 DOI: 10.3390/polym16111524] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/05/2024] [Revised: 05/26/2024] [Accepted: 05/27/2024] [Indexed: 06/21/2024] Open
Abstract
In the drum mixing of particulate polymers, segregation may occur. By measuring the mixing status in real time, it is possible to implement corrective measures to prevent separation and improve the efficiency of the process. This study aims to develop and validate a real-time vision system designed to monitor the mixing process of polymeric particles in a rotary drum mixer, employing a novel centroid-based model for determining the mixing index. The proposed centroid-based model is capable of addressing the radial particle segregation issue without the need for extra image-processing procedures like image subdivision or pixel randomization. This innovative approach greatly improves computational efficiency by processing over 68 image frames per second. The new processing method is 2.8 times faster than the gray-level co-occurrence matrix method and 21.6 times faster than the Lacey index approach. This significantly improves real-time monitoring capabilities and enables real-time image processing using only affordable single-board computers and webcams. The proposed vision-based system for monitoring rotary drum mixing has undergone validation via cross-validation using discrete element method simulations, ensuring its accuracy and reliability.
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Affiliation(s)
| | - Kwon Joong Son
- Department of Mechanical and Design Engineering, Hongik University, Sejong 30016, Republic of Korea;
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Jadidi B, Ebrahimi M, Ein-Mozaffari F, Lohi A. A comprehensive review of the application of DEM in the investigation of batch solid mixers. REV CHEM ENG 2022. [DOI: 10.1515/revce-2021-0049] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 01/02/2023]
Abstract
Abstract
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.
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Affiliation(s)
- Behrooz Jadidi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Mohammadreza Ebrahimi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Farhad Ein-Mozaffari
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
| | - Ali Lohi
- Department of Chemical Engineering , Ryerson University , 350 Victoria Street , Toronto M5B 2K3 , Canada
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Chen M, Chen Z, Tang Y, Liu M. CFD-DEM simulation of particle coating process coupled with chemical reaction flow model. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2021. [DOI: 10.1515/ijcre-2020-0241] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
Particle coating process, one of the main methods to improve the particle properties, is widely used in industrial production and pharmaceutical industry. For the scale up and optimization of this process, a mechanistic and detailed study is needed or numerical simulation as an alternative way. Decomposition of substances usually involves multiple chemical reactions and produces multiple substances in the actual chemical reaction. In the study, a chemical reaction flow (CRF) model has been established based on kinetic mechanism of elementary reaction, the theory of molecular thermodynamics and the sweep theory. It was established with the comprehensive consideration of the decomposition of substances, deposition process, adhesion process, desorption process, hydrogen inhibition, and clearance effect. Then the CFD-DEM model was coupled with CRF model to simulate particle coating process by FB-CVD method, and the CFD-DEM-CRF coupling model was implemented in the software Fluent-EDEM with their user definition function (UDF) and application programming interface (API). The coating process in the spouted bed was analyzed in detail and the coating behavior under different conditions were compared at the aspects of CVD rate, coating efficiency, particle concentration distribution, particle mixing index and gas concentration distribution. It is found that the average CVD rate is 6.06 × 10−4 mg/s when the inlet gas velocity is 11 m/s and bed temperature is 1273 K, and simulation result agrees with the experimental result well. Average CVD rate and coating efficiency increase with temperature increasing, but decrease acutely with mass fraction of injected hydrogen increasing. The CFD-DEM-CRF coupling model can be developed as a basic model for investigating particle coating process in detail and depth and can provide some guidance for the operating conditions and parameters design of the spouted bed in the real coating process.
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Affiliation(s)
- Meng Chen
- Innovation Center for Advanced Nuclear Technology , Institute of Nuclear and New Energy Technology, Tsinghua University , Beijing 100084 , China
| | - Zhao Chen
- Innovation Center for Advanced Nuclear Technology , Institute of Nuclear and New Energy Technology, Tsinghua University , Beijing 100084 , China
| | - Yaping Tang
- Innovation Center for Advanced Nuclear Technology , Institute of Nuclear and New Energy Technology, Tsinghua University , Beijing 100084 , China
| | - Malin Liu
- Innovation Center for Advanced Nuclear Technology , Institute of Nuclear and New Energy Technology, Tsinghua University , Beijing 100084 , China
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Zhang Z, Gui N, Yang X, Tu J, Jiang S, Li Z. Discussion on the Construction Principle of New Mixing Indices and Application for Cubic Particle Mixing by SIPHPM. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c03185] [Citation(s) in RCA: 2] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/29/2022]
Affiliation(s)
- Ziwei Zhang
- Datang Thermal Power Technology Research Institute, China Datang Corporation Science and Technology Research Institute, Beijing 100033, China
| | - Nan Gui
- Institute of Nuclear and New Energy Technology, Collaborative Innovation Center of Advanced Nuclear Energy Technology, Key Laboratory of Advanced Reactor Engineering and Safety, Ministry of Education, Tsinghua University, Beijing 100084, China
| | - Xingtuan Yang
- Institute of Nuclear and New Energy Technology, Collaborative Innovation Center of Advanced Nuclear Energy Technology, Key Laboratory of Advanced Reactor Engineering and Safety, Ministry of Education, Tsinghua University, Beijing 100084, China
| | - Jiyuan Tu
- Institute of Nuclear and New Energy Technology, Collaborative Innovation Center of Advanced Nuclear Energy Technology, Key Laboratory of Advanced Reactor Engineering and Safety, Ministry of Education, Tsinghua University, Beijing 100084, China
- School of Engineering, RMIT University, Melbourne, VIC 3083, Australia
| | - Shengyao Jiang
- Institute of Nuclear and New Energy Technology, Collaborative Innovation Center of Advanced Nuclear Energy Technology, Key Laboratory of Advanced Reactor Engineering and Safety, Ministry of Education, Tsinghua University, Beijing 100084, China
| | - Zhenlin Li
- China University of Petroleum, Beijing 102249, China
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Yang Y, Huang Z, Sun J, Yang Y, Wang J, Yang Y. Dispersion Trajectory and Dynamics of Particles Injected from the Sidewall in the Gas–Solid Fluidized Bed. Ind Eng Chem Res 2020. [DOI: 10.1021/acs.iecr.0c03631] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/30/2022]
Affiliation(s)
- Yong Yang
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Zhengliang Huang
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Jingyuan Sun
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Yao Yang
- Zhejiang Provincial Key Laboratory of Advanced Chemical Engineering Manufacture Technology, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Jingdai Wang
- State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
| | - Yongrong Yang
- State Key Laboratory of Chemical Engineering, College of Chemical and Biological Engineering, Zhejiang University, Hangzhou 310027, P. R. China
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Matuszek DB. Fluorescence in the assessment of the share of a key component in the mixing of feed. OPEN CHEM 2020. [DOI: 10.1515/chem-2020-0145] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/15/2022] Open
Abstract
AbstractThis paper presents the results of the mixing of a multicomponent feed for cattle. Three types of mixtures with different proportions of individual components and granulometric composition were selected. After the mixing process, the fraction of the key component (tracer) was determined. Tracer consisted of crushed grains of yellow maize, which was wet treated with a 0.01% solution of Rhodamine B. A tracer with two different average particle sizes d1 = 2.0 mm and d2 = 1.25 mm was introduced into the mixture. Then, the sample was illuminated with UV light, and the content of the tracer in the sample was evaluated using the computer image analysis. In addition, the tracer was separated to determine its fraction using a laboratory scale. From the obtained results, the high reliability of the fluorescence optical method for the evaluation of the homogeneity of granular multicomponent mixtures was proved. It was also observed that slightly better results were obtained for a tracer with a larger average particle size (d = 2.0 mm), although the comparative analysis did not indicate a significant statistical difference in the results in each series of tests.
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Affiliation(s)
- Dominika Barbara Matuszek
- Department of Biosystems Engineering, Faculty of Production Engineering and Logistics, Opole University of Technology, ul. Mikolajczyka 5, PL-45-271, Opole, Poland
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Bhalode P, Ierapetritou M. A review of existing mixing indices in solid-based continuous blending operations. POWDER TECHNOL 2020. [DOI: 10.1016/j.powtec.2020.06.043] [Citation(s) in RCA: 13] [Impact Index Per Article: 3.3] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 10/24/2022]
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Chen M, Liu M, Tang Y. Comparison of Euler-Euler and Euler-Lagrange Approaches for Simulating Gas-Solid Flows in a Multiple-Spouted Bed. INTERNATIONAL JOURNAL OF CHEMICAL REACTOR ENGINEERING 2019. [DOI: 10.1515/ijcre-2018-0254] [Citation(s) in RCA: 5] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 11/15/2022]
Abstract
Abstract
In this work, a comparative study of Euler-Euler and Euler-Lagrange approaches for modeling gas-solid flows in the multiple-spouted bed has been carried out to investigate the hydrodynamics of gas-solid flows. The influence of inlet gas velocity on the hydrodynamics of gas-solid flows in the multiple-spouted bed is investigated as well. Hydrodynamic characteristics of gas-solid flows such as flow behaviors, solid volume fraction, particle velocity and particle trajectory are analyzed and discussed in detail, providing some basic mechanism analysis of the gas-solids in the multiple-spouted bed. It is found that the central spout gas jet is a little confined by the auxiliary gas jets, and the hole-to-hole synergy is quite obvious when the auxiliary spout gas velocity is higher than the central spout gas velocity. When central/auxiliary gas velocity is 10/20 m/s, the maximum vertical particle velocities predicted by Euler-Euler and Euler-Lagrange approaches are 452 mm/s and 721 mm/s at the height of 10 mm respectively. A typical cycle period of a single particle is about 1.25 s, and the residence time in the spout regions is about 0.14 s in one cycle period in auxiliary dominant pattern. The curves of bed expansion height versus time calculated by Euler-Lagrange approach rise and fall periodically, while the curves calculated by Euler-Euler approach keep steady with little change. It is much easier for particles to be blew in the multiple-spouted bed using the Euler-Lagrange approach. The simulation results obtained from two models can provide some guidance for modifying the multiple-spouted bed to optimize physical operations such as drying and coating in the multiple-spouted bed.
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