Abstract
Purpose
Particle breakage in milling operations is often modeled using population balance models (PBMs). A discrete element method (DEM) model can be coupled with a PBM in order to explicitly identify the effect of material properties on breakage rate. However, the DEM-PBM framework is computationally expensive to evaluate due to high-fidelity DEM simulations. This limits its application in continuous process modeling for dynamic simulation, optimization, or control purposes.
Methods
The current work proposes the use of surrogate modeling (SM) techniques to map mechanistic data obtained from DEM simulations as a function of processing conditions. To demonstrate the benefit of the SM-PBM approach in developing integrated process models for continuous pharmaceutical manufacturing, a comill-tablet press model integration utilizing the proposed framework is presented.
Results
The SM-PBM approach is in excellent agreement with the DEM-PBM approach to predict particle size distributions (PSDs) and dynamic holdup, with a maximum sum of square errors of 0.0012 for PSD in volume fraction and 0.93 for holdup in grams. In addition, the time taken to run a DEM simulation is in the order of days whereas the proposed hybrid model takes few seconds. The SM-PBM approach also enables comill-tablet press model integration to predict tablet properties such as weight and hardness.
Conclusions
The proposed hybrid framework compares well with a DEM-PBM framework and addresses limitations on computational expense, thus enabling its use in continuous process modeling.
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- E :
-
specific energy, J/kg
- F :
-
force, N
- v :
-
velocity, m/s
- M(x, t):
-
particle mass of size x and at time t, kg
- ℝ form :
-
rate of formation of particles, kg/s
- ℝ dep :
-
rate of depletion of particles, kg/s
- \( {\dot{M}}_{in} \) :
-
rate of particles entering the mill, kg/s
- \( {\dot{M}}_{out} \) :
-
rate of particles exiting the mill, kg/s
- b :
-
breakage distribution function, dimensionless
- u :
-
daughter particle volume, mm3
- w :
-
parent particle volume, mm3
- n :
-
breakage distribution function parameter, dimensionless
- σ :
-
log normal distribution standard deviation, mm3
- C :
-
breakage distribution function parameter for mass conservation, mm6
- K :
-
breakage kernel, 1/s
- f mat :
-
material strength parameter, kg/J m
- E const :
-
size-independent threshold energy, J m/kg
- f coll :
-
collision frequency per particle per second, 1/s
- E min :
-
threshold energy, J/kg
- f d :
-
size-dependent parameter to define screen model, dimensionless
- Δ :
-
critical screen size, μm
- δ :
-
critical screen size ratio
- d screen :
-
screen size, μm
- v imp :
-
impeller speed, rpm
- v imp, min :
-
minimum impeller speed, rpm
- ε :
-
critical size ratio coefficient, dimensionless
- α :
-
critical size ratio exponent, dimensionless
- Δt :
-
time interval, s
- \( \widehat{f}\left({x}^i\right) \) :
-
kriging model predictor for a d dimensional input xi
- \( \widehat{\mu}\left({x}^i\right) \) :
-
regression term in the kriging model predictor
- \( \widehat{\varepsilon}\left({x}^i\right) \) :
-
error term in the kriging model predictor
- R :
-
correlation model in kriging, size mxm
- θ :
-
vector of kriging correlation model parameters [θ1, θ2, θ3, θ4]
- β :
-
kriging regression model parameter, constant
- γ :
-
kriging model correlation factors, size mx1
- σ krig :
-
kriging model variance parameter
- Sx :
-
kriging model scaling factors for design sites, size 2 × 3
- Sy :
-
kriging model scaling factors for responses, size 2 × 1
- x new :
-
vector representing untried point, size 3 × 1
- x scale,new :
-
scaled vector representing untried point, size 3 × 1
- b I → H :
-
ANN model biases, input to hidden layer, size 10 × 1
- w I → H :
-
ANN model weights, input to hidden layer, size 10 × 3
- b H → O :
-
ANN model bias, hidden to output layer, size 1 × 1
- w H → O :
-
ANN model weight, hidden to output layer, size 10 × 1
- L :
-
maximum likelihood function
- SSE PSD :
-
sum of square errors of steady state particle size distribution defined by ns bins
- SSE holdup :
-
sum of square errors of dynamic holdup computed for pre-defined time intervals
- ρ bulk :
-
granule bulk density, kg/m3
- a i :
-
bulk density regression model parameters, i = 0,1,2,3,4
- ρ true :
-
granule true density, kg/m3
- ρ r :
-
relative density of material in the die, kg/m3
- ρ r,cr :
-
critical relative density of material in the die, dimensionless
- D tablet :
-
diameter of the tablet, m
- L tablet :
-
length of the tablet, m
- FD :
-
fill depth in the die, m
- H :
-
tablet hardness, N
- H max :
-
maximum tablet hardness, N
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Acknowledgements
The authors would like to thank Stephen Cole for insights into DEM model setup. The authors also gratefully acknowledge support from Process Systems Enterprise and EDEM solutions for providing academic licenses.
Funding
This work is supported by the US Food and Drug Administration (FDA), through grant 11695471, and a Consortium Agreement between Janssen Pharmaceutica, University of Ghent, and Rutgers University.
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Metta, N., Ramachandran, R. & Ierapetritou, M. A Computationally Efficient Surrogate-Based Reduction of a Multiscale Comill Process Model. J Pharm Innov 15, 424–444 (2020). https://doi.org/10.1007/s12247-019-09388-2
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DOI: https://doi.org/10.1007/s12247-019-09388-2