Skip to main content
SpringerLink
Log in

The effect of particle shape on mixing in a high shear mixer

  • Published:
Computational Particle Mechanics Aims and scope Submit manuscript

Abstract

Discrete element method modelling is used to study the effect of particle shape on the flow dynamics and mixing in a high shear mixer. The blade generates strong flow over its top surface while compacting and pushing forward particles that are directly in front of the blade. A complex three dimensional flow is established with vertical and radial flow components that are shape dependent and which control the nature of the mixing. Mixing was found to be fast in the azimuthal direction, of intermediate speed in the vertical direction and comparatively slow in the radial mixing. Diffusive mixing is characterised using the granular temperature which shows that the regions of higher granular temperature are larger for round particles than non-round ones leading to stronger diffusive mixing. The spatial distribution of the convective component of mixing is identified using novel calculation of shear strain rate. This size and shape of the high shear region is found to be only slightly sensitive to the particle shape indicating that the convective mixing is relatively independent of shape, except in the middle of the mixer. The blockiness of the particles has the strongest impact on flow and mixing while the mixing has only a weak dependence on the particle aspect ratio.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26

Similar content being viewed by others

References

  1. Ai J, Chen JF, Rotter JM, Ooi JY (2011) Assessment of rolling resistance models in discrete element simulations. Powder Tech 206(3):269–282

    Article  Google Scholar 

  2. Arriata PE, Duong N, Muzzio FJ, Godbole P, Lange A, Reynolds S (2006a) Characterizing mixing and lubrication in the Bohle Bin blender. Powder Tech 161:202–208

    Article  Google Scholar 

  3. Arriata PE, Duong N, Muzzio FJ, Godbole P, Reynolds S (2006b) A study of the mixing and segregation mechanisms in the Bohle Tote blender via DEM simulations. Powder Tech 164:50–57

    Article  Google Scholar 

  4. Barker GC (1994) Computer simulations of granular materials. In: Mehta A (ed) Granular matter: an inter-disciplinary approach. Springer, Berlin

    Google Scholar 

  5. Bertrand F, Leclaire LA, Levecque G (2005) DEM based models for the mixing of granular materials. Chem Eng Sci 60:2517–2531

    Article  Google Scholar 

  6. Campbell CS (2006) Granular material flows-an overview. Powder Techn 162:208–229

    Article  Google Scholar 

  7. Chandratilleke GR, Zhou YC, Yu AB, Bridgwater J (2010) Effect of blade speed on granular flow and mixing in a cylindrical mixer. Indus Eng Chem Res 49(11):5467–5478

    Article  Google Scholar 

  8. Chaudhuri B, Mehrotra A, Muzzio FJ, Tomassone MS (2006) Cohesive effects in powder mixing in a tumbling blender. Powder Tech 165:105–114

    Article  Google Scholar 

  9. Cleary PW, Metcalfe G, Liffman K (1998) How well do discrete element granular flow models capture the essentials of mixing processes? Appl Math Model 22:995–1008

    Article  Google Scholar 

  10. Cleary PW, Sawley M (2002) DEM modelling of industrial granular flows: 3D case studies and the effect of particle shape on hopper discharge. Appl Math Model 26:89–111

    Article  MATH  Google Scholar 

  11. Cleary PW, Metcalfe G (2002) Quantitative comparison of mixing rates between DEM and experiment in a slowly rotating cylinder. In: Proceedings of World Congress on particle technology, vol 4, 21–25 July, Sydney

  12. Cleary PW (2004) Large scale industrial DEM modelling. Eng Comput 21:169–204

    Article  MATH  Google Scholar 

  13. Cleary PW (2008) The effect of particle shape on simple shear flows. Powder Tech 179:144–163

    Article  Google Scholar 

  14. Cleary PW (2009) Industrial particle flow modelling using DEM. Eng Comput 26:698–743

    Article  Google Scholar 

  15. Cleary PW (2013) Particulate mixing in a plough share mixer using dem with realistic shaped particles. Powder Tech 248:103–120

    Article  Google Scholar 

  16. Cleary PW, Sinnott MD (2008) Assessing mixing characteristics of particle-mixing and granulation devices. Particuology 6(6):419–444

    Article  Google Scholar 

  17. Conway SL, Lekhal A, Khinast JG, Glasser BJ (2005) Granular flow and segregation in a four-bladed mixer. Chem Eng Sci 60(24):7091–7107

    Article  Google Scholar 

  18. Debroux F, Cleary PW (2001) Characterising the angles of failure and repose of avalanching granular material using the DEM method. In: 6th World Congress of Chemical Engineering, Melbourne, Australia

  19. Delaney GW, Cleary PW, Hilden M, Morrison RD (2012) Testing the validity of the spherical DEM model in simulating real granular screening processes. Chem Eng Sci 68(1):215–226

    Article  Google Scholar 

  20. Ding YL, Forster RN, Seville JPK, Parker DJ (2001) Scaling relationships for rotating drums. Chem Eng Sci 56:3737–3750

    Article  Google Scholar 

  21. Donzé FV, Richefeu V, Magnier SA (2009) Advances in discrete element method applied to soil, rock and concrete mechanics. Electron J Geotech Eng 44:31

    Google Scholar 

  22. Dubey A, Sarkar A, Ierapetritou M, Wassgren CR, Muzzio FJ (2011) Computational approaches for studying the granular dynamics of continuous blending processes, 1-DEM based methods. Macromol Materials Eng 296(3–4):290–307

    Article  Google Scholar 

  23. Ferellec JF, McDowell GR (2010) A method to model realistic particle shape and inertia in DEM. Granular Matter 12(5):459–467

    Article  MATH  Google Scholar 

  24. Finnie GJ, Kruyt NP, Ye M, Zeilstra C, Kuipers JAM (2005) Longitudinal and transverse mixing in rotary kilns: A discrete element method approach. Chem Eng Sci 60:4083–4091

    Article  Google Scholar 

  25. Fleissner F, Gaugele T, Eberhard P (2007) Applications of the discrete element method in mechanical engineering. Multibody Syst Dyn 18(1):81–94

    Article  MathSciNet  MATH  Google Scholar 

  26. Ganesan V, Rosentrater KA, Muthukumarappan K (2008) Flowability and handling characteristics of bulk solids and powders-a review with implications for DDGS. Biosyst Eng 101(4):425–435

    Article  Google Scholar 

  27. Garcia X, Latham JP, Xiang J, Harrison JP (2009) A clustered overlapping sphere algorithm to represent real particles in discrete element modelling. Geotechnique 59(9):779–784

    Article  Google Scholar 

  28. Hassanpour A, Tan H, Bayly A, Gopalkrishnan P, Ng B, Ghadiri M (2011) Analysis of particle motion in a paddle mixer using Discrete Element Method (DEM). Powder Techn 206(1):189–194

    Article  Google Scholar 

  29. Knight PC, Seville JPK, Wellm AB, Instone T (2001) Prediction of impeller torque in high shear powder mixers. Chem Eng Sci 56(15):4457–4471

    Article  Google Scholar 

  30. Kuo HP, Knight PC, Parker DJ, Adams MJ, Seville JPK (2004) Discrete element simulations of a high-shear mixer. Adv Powder Tech 15(3):297–309

    Article  Google Scholar 

  31. Kwapinska M, Saage G, Tsotsas E (2006) Mixing of particles in rotary drums: a comparison of discrete element simulations with experimental results and penetration models for thermal processes. Powder Tech 161:69–78

    Article  Google Scholar 

  32. Lacey PMC (1997) The mixing of solid particles. Chem Eng Res Design 75:S49–S55

    Article  Google Scholar 

  33. Laurent BFC, Cleary PW (2012) Comparative study of DEM and experimental results of flow patterns in a ploughshare mixer. Powder Tech 228:171–186

    Article  Google Scholar 

  34. Lemieux M, Bertrand F, Chaouki J, Gosselin P (2007) Comparative study of the mixing of free-flowing particles in a V-blender and a bin-blender. Chem Eng Sci 62:1783–1802

    Article  Google Scholar 

  35. Lemieux M, Leonard G, Doucet J, Leclaire LA, Viens F, Chaouki J, Bertrand F (2008) Large-scale numerical investigation of solids mixing in a V-blender using the discrete element method. Powder Tech 181:205–216

    Article  Google Scholar 

  36. Liu PY, Yang RY, Yu AB (2013) DEM study of the transverse mixing of wet particles in rotating drums. Chem Eng Sci 86:99–107

    Article  Google Scholar 

  37. Lu LS, Hsiau SS (2008) DEM simulation of particle mixing in a sheared granular flow. Particuology 6(6):445–454

    Article  Google Scholar 

  38. Markauskas D, Kačianauskas R, Džiugys A, Navakas R (2010) Investigation of adequacy of multi-sphere approximation of elliptical particles for DEM simulations. Granul Matter 12(1):107–123

  39. Mead SR, Cleary PW, Robinson GK (2012) Characterising the failure and repose angles of irregularly shaped three-dimensional particles using DEM. In: Proc. ninth international conference on CFD in the minerals and process industries, CSIRO, Melbourne, Australia. 10–12 Dec 2012

  40. Metcalfe G, Shinbrot T, Mccarthy JJ, Ottino JM (1995) Avalanche mixing of granular solids. Nature 374:39–41

  41. McCarthy JJ, Shinbrot T, Metcalfe G, Wolf JE, Ottino JM (1996) Mixing of granular materials in slowly rotated containers. AIChE J 42(12):3351–3363

    Article  Google Scholar 

  42. McCarthy JJ, Khakhar DV, Ottino JM (2000) Computational studies of granular mixing. Powder Tech 109(1):72–82

    Article  Google Scholar 

  43. Ottino JM, Lueptow RM (2008) On mixing and demixing. Science 319:912–913

    Article  Google Scholar 

  44. Pernenkil L, Cooney CL (2006) A review on the continuous blending of powders. Chem Eng Sci 61(2):720–742

    Article  Google Scholar 

  45. Radl S, Kalvoda E, Glasser BJ, Khinast JG (2010) Mixing characteristics of wet granular matter in a bladed mixer. Powder Tech 200(3):171–189

    Article  Google Scholar 

  46. Remy B, Khinast JG, Glasser BJ (2009) Discrete element simulation of free flowing grains in a four-bladed mixer. AIChE J 55(8):2035–2048

    Article  Google Scholar 

  47. Sarkar A, Wassgren C (2010) Continuous blending of cohesive Granular material. Chem Eng Sci 65(21):5687–5698

    Article  Google Scholar 

  48. Sato Y, Nakamura H, Watano S (2008) Numerical analysis of agitation torque and particle motion in a high shear mixer. Powder Tech 186(2):130–136

    Article  Google Scholar 

  49. Stewart RL, Bridgewater J, Parker DJ (2001a) Granular flow over a flat-bladed stirrer. Chem Eng Sci 56:4257–4271

    Article  Google Scholar 

  50. Stewart RL, Bridgewater J, Zhou YC, Yu AB (2001b) Simulated and measured flow of granules in a bladed mixer—a detailed comparison. Chem Eng Sci 56:5457–5471

    Article  Google Scholar 

  51. Sudah OS, Coffin-Beach D, Muzzio FJ (2002) Effects of blender rotational speed and discharge on the homogeneity of cohesive and free flowing mixtures. Int J Pharm 247:57–68

    Article  Google Scholar 

  52. Sinnott MD, Cleary PW, Morrison RD (2011) Is media shape important for grinding performance in tower mills? Miner Eng 24:38–151

    Google Scholar 

  53. Terashita K, Nishimura T, Natsuyama S, Satoh M (2002) DEM simulation of mixing and segregation in high-shear mixer. J Jpn Soc Powder Powder Metal 49(7):638–645

    Article  Google Scholar 

  54. Thornton C, Cummins S, Cleary PW (2013) An investigation of the comparative behaviour of alternative contact force models during inelastic collisions. Powder Tech 233:30–46

    Article  Google Scholar 

  55. Weerasekara NS, Powell MS, Cleary PW, Tavares LM, Evertsson M, Morrison RD, Quist J, Carvalho RM (2013) The contribution of DEM to the science of comminution. Powder Tech 248:3–24

    Article  Google Scholar 

  56. Zhang MH, Chu KW, Wei F, Yu AB (2008) A CFD-DEM study of the cluster behavior in riser and downer reactors. Powder Techn 184(2):151–165

    Article  Google Scholar 

  57. Zhou YC, Yu AB, Bridgewater J (2003) Segregation of binary mixture of particles in a bladed mixer. J Chem Tech Biotechnol 78(2–3):187–193

    Article  Google Scholar 

  58. Zhou YC, Yu AB, Stewart RL, Bridgewater J (2004) Microdynamic analysis of the particle flow in a cylindrical bladed mixer. Chem Eng Sci 59:1343–1364

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

  1. CSIRO Digital Productivity Flagship, Private Bag 10, Clayton South, Vic, 3168, Australia

    Matthew D. Sinnott & Paul W. Cleary

Authors
  1. Matthew D. Sinnott
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Paul W. Cleary
    View author publications

    You can also search for this author in PubMed Google Scholar

Corresponding author

Correspondence to Paul W. Cleary.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Sinnott, M.D., Cleary, P.W. The effect of particle shape on mixing in a high shear mixer. Comp. Part. Mech. 3, 477–504 (2016). https://doi.org/10.1007/s40571-015-0065-4

Download citation

  • Received:

  • Revised:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40571-015-0065-4

Keywords

Search

Navigation