Segregation of cohesive granular materials during discharge from a rectangular hopper

Granular materials may readily segregate due to differences in particle properties such as size, shape, and density. Segregation is common in industrial processes involving granular materials and can occur even after a material has been uniformly blended. The specific objective of this work is to investigate via simulation the effect of particle cohesion due to liquid bridging on particle segregation. Specifically, a bi-disperse granular material flowing from a 3-D hopper is simulated using the discrete element method (DEM) for cohesive particles and the extent of discharge segregation is characterized over time. The cohesion between the particles is described by a pendular liquid bridge force model and the strength of the cohesive bond is characterized by the Bond number determined with respect to the smaller particle species. As the Bond number of the system increases, the extent of discharge segregation in the system decreases. A critical value of Bo = 1 is identified as the condition where the primary mechanism of segregation in the cohesionless hopper system, i.e. gravity-induced percolation, is essentially eliminated due to the liquid bridges between particles.     

Segregation due to particle shape of a granular mixture in a slowly rotating tumbler

Using DEM particle simulations we consider segregation of a binary granular particle mixture in a slowly rotating cylindrical tumbler where the particles differ only in their shape—spherical versus more cubical particles. We find that the more cubical particles segregate to the inner core of the particle bed while the spherical particles segregate to the curved walls of the tumbler. The main mechanism for this segregation is different energy dissipation rates for the different particle shape types when avalanching down along the free surface. The cubical particles, due to their sharper corners, dissipate energy much faster than the spherical particles. This results in spherical particles reaching the bottom end of the sloped, free surface which are then transported around the cylinder adjacent to the cylinder wall, as rigid body motion. In contrast to size or density segregation, the segregation due to shape is much weaker and takes longer to reach its equilibrium or steady state. In addition, the segregation occurs along the top surface rather than through the top surface (as occurs for size and density segregation). In general, in situations where two particles differ in their ease of flow (viz flowability) the more rapidly flowing particle will segregate to the base of the free surface (which in the case of the tumbler results in spherical particles near the periphery) and the more slowly flowing particle will segregate underneath.     

Radial segregation of multi-component granular media in a rotating tumbler

Segregation and mixing of granular mixtures are important to the minerals, food processing and pharmaceuticals industry to name just a few. It has recently been demonstrated that a rotating tumbler is a suitable device for separating out binary granular mixtures, i.e. mixtures composed of only two different particle types. However, most practical granular mixtures are composed of multi-component particle types. We therefore study the capability of this rotating tumbler to segregate mixtures composed of more than two components where the particles differ either in size or density. The general pattern of segregation involves the formation of an inner core of smallest or densest particles followed, at larger radii, by the next largest or densest particle type and so-on in an onion-like pattern. In the mixtures where particles differ in size we always get relatively pure inner cores of the smallest particles, while the other regions are less segregated. On the other hand for mixtures whose particles differ in density we get a relatively pure outer region (adjacent to cylinder wall) consisting of the least dense particles while the other regions are less segregated. We attempt to relate the simulation results to phenomenological theory and find that size segregation in a specific multi-component mixture can be suitably described by a recent theoretical model.     

Effect of external factors on segregation of different granular mixtures

Segregation is a common problem faced by different pharmaceutical, chemical, and food processing industries due to non-uniformity in the end-products. Our aim is to minimize the segregation of binary granular mixture by changing the external chute-related factors rather than internal factors like material properties which is often not possible in industries. We investigate the effect of inclination angle, friction, fill volume and channel geometry in a steady, gravity driven flow of granular mixture in an inclined plane. We perform the numerical simulation using an open-source Discrete Element Method code - LIGGGHTS. We observe that the segregation of dry granular particles in stream-wise direction of the chute is minimum at low stream-wise velocity i.e. by keeping the chute at a low inclination and adding the wall roughness. The segregation in cross-stream and vertical direction is at a minimum when the chute is filled to at least 40% of its height. We also investigated the optimal conditions for minimum segregation in different granular mixtures and found that a mixture with size or density ratio up to 4 can have minimum segregation, if we fill the chute to 75% height. For a greater size or density ratio, it is difficult to minimize the segregation. The optimal segregation conditions for mixtures with different elastic modulus ratio were generally constant.     

Segregation pattern of binary-size mixtures in a double-walled rotating drum

Size-induced granular segregation was performed systematically and experimentally in an almost fully filled double-walled rotating drum at 10 different rotation speeds and two different side wall types. The motion of the granular materials was recorded using a high-speed camera for image analysis of particle segregation development in the drum. With continual tracking of the particle movements, the velocity, fluctuations, and granular temperatures were measured. The experimental results indicate that both rotation speeds and friction coefficient of side walls significantly affect segregation phenomena in binary-size mixture granular flows. The results demonstrate similar situations to the Brazil-nut effect and its reverse in the radial direction at either high or a low rotational speed (where the Froude number (Fr) is far from 1). At these instances, the maximum granular temperature occurs near the side walls. Specifically, a double segregation effect (DSE) is found at Froude number (Fr) close to 1. These results can be used in many industrial processes, for example, size grading of materials, screening of impurities, and different structures of functionally graded materials. Moreover, the maximum granular temperature occurs in the middle of the ring space. It causes small particles to move toward both side walls as it pushes bigger particles to accumulate in the middle of the ring space of rotating drum.     

Segregation behavior of particles with Gaussian distributions in the rotating drum with rolling regime

The mixing and segregation of granular materials are essential to provide valuable insights and references for practical industrial production. In this paper, the segregation behaviors of particles with Gaussian distributions and 40% filling level in the rotating drum with rolling regime were numerically studied by the discrete element method. The effects of rotation speed and particle size parameter λ (size ratio of the largest versus smallest particles) on the segregation behavior (mixing index, segregation rate), flow characteristics (particle velocity and trajectory, gyration degree and radius, particle size distributions) and the microscopic properties (collision, contact force, axial diffusion, and kinetic energy) of granular systems were systematically investigated. The results show that the segregation rate and degree of particles with Gaussian distributions gradually increase with the increase of the rotation speed and particle size parameter λ. The radial and axial segregation patterns become more obvious with the increase of λ. And the variation of the flow characteristics of particles with different sizes in the same system is also inconsistent. The microscopic properties of Gaussian-dispersed particles change with the rotation speed and λ. The rapid radial segregation depends on the larger pores existed in the granular system, which leads to a gradual increase of the axial dispersion coefficient of large particles and a gradual decrease of the axial dispersion coefficient of small particles.     

Mixing of solids in different mixing devices

Mixing of powders is a common operation in any industry. Most powders are known to be cohesive, many agglomerate spontaneously when exposed to humid atmosphere or elevated storage temperature. Agitation of the powder (especially powders with different bulk densities) may result in migration of smaller particles downwards and of larger ones upwards. Another problem is segregation whose main cause is the difference in particle size, density shape and resilience. There are standard mixing devices, such as drum tumblers or Turbula mixers. Alternate device type used is the static mixer of Kenics type. Static mixers save energy, disable segregation and effect particle migration. In this paper, static mixers, as devices for powder mixing, are tested as well as Turbula and V-shaped drum mixer, since those devices are commonly used for powder blending in industry. Mixtures that were blended by means of those three devices were made out of the model material, quartz sand, in different component ratios (20:80 and 30:70). The results were statistically calculated and graphically presented. Cohesion indexes were measured with Powder Flow Analyser to see the effect of material flow on the mixture quality. The results obtained by those three devices, the particle size effect and cohesion indexes, bring us to the conclusion that static mixers could be used for mixing of powders, but their shape, number of mixing elements and the mixer length should be adapted for each mixture separately, experimentally and mathematically, through modelling of the system.     

Radial segregation of ternary granular mixtures in rotating cylinders

We carry out an experimental study of the equilibrium segregation of ternary granular mixtures in a rotating cylinder. In all the experiments, 50% of the volume of the cylinder is filled with the granular mixture and the rotational speed used ensures operation in the rolling regime of flow. Mixtures of spherical particles differing only in size and of spherical particles differing in size and density are considered, using steel balls and glass beads of different sizes. Volume fractions of the components (f{\phi}) are measured by sampling at different radial positions (r) to yield the radial volume fraction profiles (f(r){\phi(r)}). Results for mixtures differing only in size of the components indicate that the segregation process is nearly independent of the sizes of the large and middle size particles for the same size of small particles. In the case of mixtures with different size and density components, the segregation patterns depend on the direction of the resultant driving force. In many of the mixtures considered, the pattern of segregation can be qualitatively predicted by considering binary interactions between the components. However, in some mixtures, ternary interactions are found to determine the pattern obtained.     

Segregation Quantification of Two-Component Particulate Mixtures: Effect of Particle Size,Density, Shape,and Surface Texture

Segregation, which occurs during handling, processing, and storage of particulate material, is highly dependent on properties such as particle size, size distribution (for continuous mixtures) or size ratio (for binary mixtures), particle density, shape, and surface texture. Quantification of the relationship of material properties to segregation becomes an important link in understanding and controlling segregation. Due to lack of well-developed equipment in the market, quantification of segregation of multicomponent particulate mixtures is currently a challenge. In this study, the effects of particle size, density, shape, and surface texture of two-component particulate mixtures (glass beads and mash poultry feed) on segregation were quantified with the use of the second generation of primary segregation shear cell (PSSC-II) developed at Penn State. It was concluded that (1) irregularly shaped (nonspherical) coarse particles or higher porosity of coarse component of a binary mixture lead to higher segregation potential; (2) the higher the density and smoother the surface of the fine component of a binary mixture, the higher the segregation potential; and (3) the fine particle properties, to a certain extent, determine the particle size–related effects such as absolute size and size ratios, i.e., if fine particle properties of a binary mixture change, the size-related effect on segregation potential would definitely change.     

Segregation Quantification of Two-Component Particulate Mixtures: Effect of Particle Size, Density, Shape, and Surface Texture

Segregation, which occurs during handling, processing, and storage of particulate material, is highly dependent on properties such as particle size, size distribution (for continuous mixtures) or size ratio (for binary mixtures), particle density, shape, and surface texture. Quantification of the relationship of material properties to segregation becomes an important link in understanding and controlling segregation. Due to lack of well-developed equipment in the market, quantification of segregation of multicomponent particulate mixtures is currently a challenge. In this study, the effects of particle size, density, shape, and surface texture of two-component particulate mixtures (glass beads and mash poultry feed) on segregation were quantified with the use of the second generation of primary segregation shear cell (PSSC-II) developed at Penn State. It was concluded that (1) irregularly shaped (nonspherical) coarse particles or higher porosity of coarse component of a binary mixture lead to higher segregation potential; (2) the higher the density and smoother the surface of the fine component of a binary mixture, the higher the segregation potential; and (3) the fine particle properties, to a certain extent, determine the particle size-related effects such as absolute size and size ratios, i.e., if fine particle properties of a binary mixture change, the size-related effect on segregation potential would definitely change.     

Regimes of segregation and mixing in combined size and density granular systems: an experimental study

Granular segregation in a rotating tumbler occurs due to differences in either particle size or density, which are often varied individually while the other is held constant. Both cases present theoretical challenges; even more challenging, however, is the case where density and size segregation may compete or reinforce each other. The number of studies addressing this situation is small. Here we present an experimental study of how the combination of size and density of the granular material affects mixing and segregation. Digital images are obtained of experiments performed in a half-filled quasi-2D circular tumbler using a bi-disperse mixture of equal volumes of different sizes of steel and glass beads. For particle size and density combinations where percolation and buoyancy both contribute to segregation, either radial streaks or a “classical” core can occur, depending on the particle size ratio. For particle combinations where percolation and buoyancy oppose one another, there is a transition between a core composed of denser beads to a core composed of smaller beads. Mixing can be achieved instead of segregation if the denser beads are also bigger and if the ratio of particle size is greater than the ratio of particle density. Temporal evolution of these segregated patterns is quantified in terms of a “segregation index” (based on the area of the segregated pattern) and a “shape index” (based on the area and perimeter of the segregated pattern).     

Experimental study of density segregation at end walls in a horizontal rotating cylinder saturated with fluid: friction to lubrication transition

What is the effect of interstitial fluid viscosity on granular density segregation in a horizontal rotating cylinder? We conducted experiments in the rolling regime with equal amounts of equal sized high and low density, nearly spherical granular particles saturated with air, water, and water-glycerin mixtures. We held particle density, rotation rate and characteristic length scale constant to highlight differences due purely to the interstitial fluid. Images of the granular flow at an end wall were used to determine radial and axial density segregation rates and patterns. Over a four decade change in viscosity, segregation rates varied by only a factor of two. However, for ratios of lubrication to frictional stresses above one, segregation rates decreased by about 30%, and we observed several notable phenomena in the segregation pattern formation. These were a creeping mode of radial density segregation, a change in shape of the granular bed to kidney shaped from flat, and for cylinders more than half full the typically reported unsheared central portion of the granular bed (often referred to in the literature as a core region) was disrupted by a wavy instability where the rate of disappearance of the core region decreased as the fill level increased.     

A concise treatise on model-based enhancements of cohesive powder properties via dry particle coating

This paper presents a review of our key advances in model-guided dry coating-based enhancements of poor flow and packing of fine cohesive powders. The existing van der Waals force-based particle-contact models are reviewed to elucidate the main mechanism of flow enhancement through silica dry coating. Our multi-asperity model explains the effect of the amount of silica, insufficient flowability enhancements through conventional blending, and the predominant effect of particle surface roughness on cohesion reduction. Models are presented for the determination of the amount and type of guest particles, and estimation of the granular Bond number, used for cohesion nondimensionalization, based on particle size, particle density, asperity size, surface area coverage, and dispersive surface energy. Selection of the processing conditions for LabRAM, a benchmarking device, is presented followed by key examples of enhancements of flow, packing, agglomeration, and dissolution through the dry coating. Powder agglomeration is shown as a screening indicator of powder flowability. The mixing synergy is identified as a cause for enhanced blend flowability with a minor dry coated constituent at silica < 0.01%. The analysis and outcomes presented in this paper are intended to demonstrate the importance of dry coating as an essential tool for industry practitioners.     

Insights from simulations into mechanisms for density segregation of granular mixtures in rotating cylinders

The Discrete Element Method (DEM) is used to study the segregation of a binary mixture of differing density (but same size) granular material in an axially rotating cylinder. The rotation rates used produce a flow that is on the borderline between the avalanching and rolling regimes. The simulations replicate the experimental data well at both qualitative and quantitative levels. Both wall-induced and radial segregation are observed. The simulations show segregation is delineated into two main time regimes. At early times segregation is rapid (when the dense core is being established) and slows down appreciably thereafter. The final asymptotic state is found to be independent of the initial segregation state of the particles. We compare these results with previous theoretical models and relate these two distinct time regimes to the underlying segregation mechanisms. These comparisons suggest segregation varies as a function of two fundamental quantities (a) density ratio of particles and (b) angular speed of the rotating cylinder. It is shown that maximal segregation occurs for specific ranges of these quantities.     

Effect of size distribution on mixing of a polydisperse wet granular material in a belt-driven enclosure

We use a recently developed coupled fluid–particle discrete element model to study mixing of a wet granular material in a two dimensional setting. The particles are modeled as linearly elastic disks and are considered to be immersed in a Newtonian fluid. The fluid–particle interaction is modeled using a linear drag model under the assumption that the fluid inertia is small compared to particle inertia. The granular slurry is driven by a belt moving at constant velocity in a square cavity. In the simulations, we consider three types of size distributions: monodisperse, bidisperse with several particle size ratios, and polydisperse Gaussian distributions with several different standard deviations. Mixing is characterized using both strong and weak measures. Size segregation is observed only in the bidisperse simulations. The energy required for mixing polydisperse slurries decreases with increasing standard deviation of the particle sizes. Finally, we show the benefits of engineering certain polydisperse particle size distributions towards minimizing energy consumption.     

Influences of fine powder on dynamic properties and density segregation in a rotating drum

In this paper, the influences of the addition of a small amount of fine powder and rotation speed on the dynamic properties and density-induced segregation behavior of granular matter in a quasi-two-dimensional rotating drum were experimentally investigated. An optical camera was applied to capture the motion of the particles in the drum. Image-processing technology and a particle tracking method were applied for determining the velocity, granular temperature and segregation index of granular materials. The results indicate that the addition of a small amount of fine powder has a significant effect on dynamic properties and density-induced segregation behavior. The average velocity and the average granular temperature are enhanced with the increase of the fine powder content because of the lubrication effect between particles. Additionally, the results indicate that density segregation is strengthened with the increase of fine powder.     

Numerical studies of particle segregation in a rotating drum based on Eulerian continuum approach

Solid–solid–gas three-phase particle segregation in a half-filled rotating drum is simulated using Eulerian continuum approach coupling the kinetic theory of granular flow. A dynamic angle of repose fitting (DARF) method is proposed to determine granular kinetic viscosities of particles of six different sizes moving in the drum rotating at 10 rpm, 20 rpm or 30 rpm. The DARF granular kinetic viscosity increases and decreases with the increasing of particle size and drum rotational speed, respectively. The determined DARF granular viscosity values are used to simulate size-induced particle segregation in a rotating drum. The simulated small-particle-rich segregation structure shows a central small-particle-rich band together with two small-particle-rich side wings. The size of the wings decreases with the increasing of the drum rotational speed. The formation of radial segregation core and axial segregation bands qualitatively agree with the experimental observations.     

Percolation Segregation in Binary Size Mixtures of Spherical and Angular-Shaped Particles of Different Densities

Percolation segregation in binary size mixtures for two particulate types, urea (spherical) and potash (angular), were studied. Materials chosen are major raw ingredients of blended fertilizer that represent two extremes based on shape and density. In this study, the coarse and fine particles were classified using particle sizes larger and smaller than 2,000 μm, respectively. Three coarse mean sizes (3,675 μm, 3,075 μm, and 2,580 μm) for both spherical and angular particles and three fines mean sizes (2,180 μm, 1,850 μm, and 1,550 μm) for angular particles and two fines mean sizes (2,180 μm and 1,850 μm) for spherical particles were selected for tests. Size ratio for binary size mixture is defined as the ratio of mean size of coarse to fine particles. Binary mixed samples of coarse and fine particles were placed into the shear box of the primary segregation shear cell (PSSC-II) very gently to avoid segregation. Percolation segregation was quantified using PSSC-II. Based on experimental results, the segregated fines mass, normalized segregation rate (NSR), and segregation rate of fines for binary mixtures were higher for larger size ratios as expected (2.4 > 2.0 > 1.7). The NSR is defined as the amount of fines percolated from initial fines present in the binary mixture based on total time of PSSC-II operation (kg/kg-h). Segregation rate was the highest and lowest for mixing ratios 33:67 and 67:33, respectively, when coarse mean size was 3,675 μm, where mixing ratio for binary mixtures is the ratio of the mass of coarse particles to the mass of fine particles. For the same size ratio, segregated fines mass for coarse-fine size combinations in the binary mixtures of urea and potash were significantly different (p < 0.05). Segregated fines mass of potash and urea particles was significantly different for the same size ratio and the same coarse sizes (p < 0.05). Percent segregated fines of angular particles (59%) was higher than that of spherical particles (45%) for the size ratio 2.0 and coarse mean size of 3,675 μm.     

Using PIV to measure granular temperature in saturated unsteady polydisperse granular flows

The motion of debris flows, gravity-driven fast moving mixtures of rock, soil and water can be interpreted using the theories developed to describe the shearing motion of highly concentrated granular fluid flows. Frictional, collisional and viscous stress transfer between particles and fluid characterizes the mechanics of debris flows. To quantify the influence of collisional stress transfer, kinetic models have been proposed. Collisions among particles result in random fluctuations in their velocity that can be represented by their granular temperature, T. In this paper particle image velocimetry, PIV, is used to measure the instantaneous velocity field found internally to a physical model of an unsteady debris flow created by using “transparent soil”—i.e. a mixture of graded glass particles and a refractively matched fluid. The ensemble possesses bulk properties similar to that of real soil-pore fluid mixtures, but has the advantage of giving optical access to the interior of the flow by use of plane laser induced fluorescence, PLIF. The relationship between PIV patch size and particle size distribution for the front and tail of the flows is examined in order to assess their influences on the measured granular temperature of the system. We find that while PIV can be used to ascertain values of granular temperature in dense granular flows, due to increasing spatial correlation with widening gradation, a technique proposed to infer the true granular temperature may be limited to flows of relatively uniform particle size or large bulk.     

Particle screening phenomena in an oblique multi-level tumbling reservoir: a numerical study using discrete element simulation

Due to their wide usage in industrial and technological processes, granular materials have captured great interest in recent research. The related studies are often based on numerical simulations and it is challenging to investigate computational phenomena of granular systems. Particle screening is an essential technology of particle separation in many industrial fields. This paper presents a numerical model for studying the particle screening process using the discrete element method that considers the motion of each particle individually. Dynamical quantities like particle positions, velocities and orientations are tracked at each time step of the simulation. The particular problem of interest is the separation of round shape particles of different sizes using a rotating tumbling vertical cylinder while the particulate material is continuously fed into its interior. This rotating cylinder can be designed as a uniform or stepped multi level obliqued vertical vessel and is considered as a big reservoir for the mixture of particulate material. The finer particles usually fall through the sieve openings while the oversized particles are rebounded and ejected through outlets located around the machine body. Particle–particle and particle–boundary collisions will appear under the tumbling motion of the rotating structure. A penalty method, which employs spring-damper models, will be applied to calculate the normal and frictional forces. As a result of collisions, the particles will dissipate kinetic energy due to the normal and frictional contact losses. The particle distribution, sifting rate of the separated particles and the efficiency of the segregation process have been studied. It is recognized that the screening phenomenon is very sensitive to the machines geometrical parameters, i.e. plate inclinations, shaft eccentricities and aperture sizes in the sieving plates at different levels of the structure. The rotational speed of the machine and the feeding rate of the particles flow have also a great influence on the transportation and segregation rates of the particles. In an attempt to better understand the mechanism of the particle transport between the different layers of the sifting system, different computational studies for achieving optimal operation have been performed.