ELECTROSTATICALLY SUPPORTED MIXING OF FINE GRAINED PARTICLES

The processing of fine-grained particles with diameters between 1 and 10 microns is difficult due to strong van-der-Waals attraction forces. In order to improve the handling properties, the fine-grained particles, i.e. host-particles,are coated with various nanoparticles, i.e. guest-particles. The mixing of fine-grained powders is influenced by particle-particle interactions. If these forces are distinctively used, both interactive and ordered mixtures can be produced.These particle mixtures consist of composite-particles that have new physical properties. These modified properties d epend strongly on the coating process, the diameter- and mass-relationship of the guest- and the host-particles. The properties of the composite-particles can systematically be adjusted to the requirements of industrial applications. For example, a laboratory bubbling fluidized bed can be used to describe the conveying behavior of the functionalized host-particles. Applications for the functionalized particles are in the pharmaceutical and the powder coating industries,e.g. enhanced dry powder inhalers and thin lacquer films. The present research compares three different mixing/coating processes. The composite-particles are characterized by TEM, SEM and with their fluidization characteristics. The coating process itself is monitored by the electrostatic charge of the particles.     

Application of Lattice-Boltzmann Method for Analysing Detachment of Micron-Sized Particles from Carrier Particles in Turbulent Flows

Numerical calculations based on the Lattice-Boltzmann method were performed for a particle cluster consisting of a large spherical carrier particle covered with hundreds of small spherical drug particles. This cluster, fixed in space within a cubic computational domain, was exposed to turbulent plug airflow with predefined intensity. Such a situation is found in dry powder inhalers where carrier particles blended with fine drug powder are dispersed in a highly turbulent flow with the objective of detaching the drug powder for pulmonary delivery. Turbulence was generated by a digital filtering technique applied to the inflow velocity boundary condition. This technique was first validated by analysing the turbulence intensity at 15 fluid nodes along the stream-wise direction of the computational domain. The size ratio between the drug and carrier particle was 5 μ m/100 μ m, and the coverage degree of the carrier by the small particles was 50%, which is a typical value for carrier particle blending. The range of carrier particle Reynolds numbers considered was between 80 and 200, typical values found in inhaler devices. Exemplarily, at Re = 200 turbulence intensity was varied from 0.3% to 9.0%. The systematic increase of the mean flow (i.e. 80 < Re <200) resulted in varying turbulence intensities from 20 to 9%. These simulations provided the temporal evolution of the fluid dynamic forces on the drug particles in dependence of their angular position on the carrier in order to estimate the possibility of drug particle detachment. For turbulent conditions (i.e. Re = 200 and I = 9.0%) the maximum fluid forces on the drug particles were found to be about 10-times larger than found in laminar flow. The fluctuations in the forces were found to be higher than the flow velocity fluctuations due to the modification of the boundary layer around the cluster and instabilities triggered by the turbulent flow. There are three possibilities for detaching the drug powder, namely, through lift-off and sliding or rolling. Lift-off was found to be of minor importance due to the observed small normal fluid forces even at Re = 200 and I = 9.0%. The probability of sliding and rolling detachment in dependence of the angular position was estimated based on measured adhesion properties, i.e. van der Waals force, adhesion surface energy and friction coefficient. The remarkable rise of detachment probability for both effects due to the action of turbulence is an important finding of this study. In accordance with laminar flow, rolling detachment occurs before sliding, however in turbulent conditions over the entire carrier particle. The present studies improve the understanding of drug particle detachment from carrier particles in an inhaler device. The results will be the basis for developing Lagrangian detachment models that eventually should allow the optimisation of dry powder inhalators through computational fluid dynamics.     

IMPROVEMENT OF FLUIDIZABILITY OF FINE POWDERS ——A COMPUTER STUDY

Simulations of the gas fluidization of a cohesive powder were performed using the Stokesian Dynamics method and an agglomeration-deagglomeration model to investigate methods of improving the fluidizability of fine powders. Three techniques (a) high gas velocity (b) vibration-assisted fluidization and (c) tapered fluidizer were used in the simulations which provided detailed information on the bed microscopy such as the motion of 1 O0 particles in a fluidizing vessel along with the formation and destruction of cohesive bonds dudng collisions. While all three techniques were found to effectively improve the fluidizability of a strongly cohesive powder, we suggest a combination of high velocity fluidization assisted by extemal vibration of the fluidized bed to minimize entrainment of particles.     

An update on electrostatic powder coating for pharmaceuticals

Derived from dry powder coating of metals, electrostatic powder coating for pharmaceuticals is a technology for coating drug solid dosage forms. In this technology, coating powders, containing coating polymers, pigments, and other excipients, are directly sprayed onto the surface of the solid dosage forms through an electrostatic gun without using any organic solvent or water. The deposited coating powders are further cured to form a coating film. Electrostatic powder coating technology has many advantages compared to other pharmaceutical coating methods. It can eliminate the limitations caused by the organic solvent in solvent coating such as environmental issues and health problems. And electrostatic powder coating technology also surpasses aqueous coating due to its shorter processing time and less energy consumption, leading to a lower overall cost. Furthermore, the utilization of electrical attraction can promote the movement of coating powders towards the substrate, leading to an enhanced coating powder adhesion and coating efficiency, which make it more promising compared to other dry coating technologies. The objective of this review is to summarize the coating principles, apparatus, and formulations of different electrostatic powder coating technologies, giving their advantages and limitations and also analyzing the future application in the industry for each technology.     

超细二氧化硅粉体对淀粉火焰抑制的实验研究

为了探究不同粒径二氧化硅粉体抑制效果上的差异,采用小尺寸竖直燃烧管道系统,研究添加10 μm和30 nm二氧化硅粉体时,不同粒径小麦淀粉燃烧的火焰传播、温度、速度等参数特性的变化。实验结果表明:超细二氧化硅粉体能减弱小麦淀粉燃烧反应强度;30 nm二氧化硅粉体抑制效果优于10 μm二氧化硅,当小麦淀粉粒径小于25 μm时,质量浓度为0.43 kg/m3、粒径30 nm的超细二氧化硅粉体可使小麦淀粉火焰亮度明显下降,最高温度下降38.07%,最大速度和平均速度分别下降42.25%、65.59%;超细二氧化硅粉体主要起物理抑制作用,抑制效果与小麦粒径成反比关系,小麦粒径越小,二氧化硅抑制效果越好。     

Effect of acoustic field on heat transfer in a sound assisted fluidized bed of fine powders

The fluidized beds are widely used in a variety of industries where heat transfer properties of the fluidized system become important for successful operation. Fluidized are preferred in heat recovery processes because of their unique ability of rapid heat transfer and uniform temperature. Fine powders handling and processing technologies have received widespread attention due to increased use of fine powders in the manufacture of drugs, cosmetics, plastics, catalysts, energetics and other advanced materials. A better understanding of fluidization behavior of fine powders is of great importance in applications involving heat transfer, mass transfer, mixing, transporting and modifying surface properties etc. The difficulty in putting the fine powders in suspension with the fluidizing gas is related to the cohesive structure and to the physical forces between the primary particles. The sound waves agitate bubbling and this results in improving solids mixing in the fluidized bed. The improved solids mixing results in uniform and smooth fluidization, which leads to better heat transfer rates in the fluidized bed.     

Fluidization of a bed of solid particles

As is known, fluidization of a bed of solid particles by liquid or gas filtration takes place for certain critical values of the parameters of the filtration regime. The determination of these critical values and the nature of the transition is of interest in connection with the development of fluidization technology in many branches of industry, and also in connection with certain other questions, among which we note the problem of the suspension of a sand plug in an oil well.The two-dimensional fluidization problem has been examined previously [1] as the problem of the limiting equilibrium of a medium which cannot withstand arbitrarily small tensile stresses. This model describes well the behavior of many types of bulk media encountered in practice. However, many cases lie beyond the limits of this model because of the presence of bonding forces between the particles. Bonding may be due to the adhesive forces which arise during the fluidization of fine powders [2, 3], and/or to magnetic and electrostatic forces [3, 4]. Another example is the agglomeration of particles during gas fluidization when small amounts of liquid are injected [5]; still another is the case in which sand particles are surrounded by thin films of oil when a sand plug is suspended in an oil well.In the present paper an extension of the results obtained in [1] is used to examine fluidization of a bed with account taken of the bonding forces between the particles. The two- and three-dimensional problems are studied.     

Direct reduction of hematite powders in a fluidized bed reactor

Ultrafine hematite powder was reduced to produce ultrafine iron powder in a 50%Ar–50%H₂ atmosphere at 450–550 °C in a fluidized bed reactor. The ultrafine hematite powder shows the typical agglomerating fluidization behavior with large agglomerates fluidized at the bottom of the bed and small agglomerates fluidized at the upper part of the bed. It was found that defluidization occurred even at the low temperature of 450 °C with low metallization rate. Defluidization was attributed mainly to the sintering of the newly formed iron particles. Granuation was employed to improve the fluidization quality and to tackle the defluidization problem, where granules fluidized like a Geldart's group A powder. Granulation was found to effectively reduce defluidization during reduction, without however sacrificing reduction speed. The as-reduced iron powders from both the ultrafine and the granulated hematite exhibited excellent sintering activity, that is, fast sintering at temperature of as low as ～580 °C, which is much superior as compared to that of nano/ultrafine iron powders made by other processes.     

Engineering of drug nanoparticles by HGCP for pharmaceutical applications

This paper reviews our work on the fundamental principles of high gravity controlled precipitation (HGCP) technology, and its applications in the production of drug nenoparticles, which was carded out in a rotating packed bed (RPB). Several kinds of drug nanoparticles with narrow particle size distributions (PSDs) were successfully prepared via HGCP, including the 300-nm Cefuroxirne Axetil (CFA) particles, 200-400-nm cephradine particles, 500-nm salbutamol sulfate (SS) particles (100 nm in width), end 850-nm beclomethasone dipropionate (BDP) particles, etc. Compared to drugs available in the current market, all the drug nanoparticles produced by HGCP exhibited advantages in both formulation end drug delivery, thus improving the bioavailability of drugs. HGCP is essentially a platform technology for the preparation of poorly water-soluble drug nanoparticles for oral and injection delivery, and of inhalable drugs for pulmonary delivery. Consequently, HGCP offers potential applications in the pharmaceutical industry due to its cost-effectiveness, efficient processing end the ease of scaling-up.     

Longitudinal diffusion of solid particle admixture in a flow through a tube

The propagation of solid particle admixture in a flow through a flat channel is studied.The processes of diffusion and convective transfer as well as solid particle deposition due to gravity result in varying admixture concentration both in depth and longtitudinally.The study of admixture longitudinal distribution is of great interest in a lot of applications, therefore this paper gives the derivation of longitudinal diffusion equation for a mean cross-section admixture concentration.The equation contains three effective parameters; i.e. convective tranfer velocity, longitudinal diffusion coefficient and particle deposition time. These parameters integrally reflect local processes of matter transfer as well as momentum.The proposed model is specific and differs from Taylor equation for longitudinal diffusion, since the fact of particle deposition and adhesion is taken into account. As a result of particle deposition a sediment layer is formed on the channel bottom which increases in thickness with time. To describe this process balance conditions for the whole flow mass and admixture mass on sediment sediment surface are formulated and a condition for matter movement towards the channel bottom is derived that is different from zero due to particle adhesion.     

Drag models for simulating gas–solid flow in the turbulent fluidization of FCC particles

This paper examines the suitability of various drag models for predicting the hydrodynamics of the turbulent fluidization of FCC particles on the Fluent V6.2 platform. The drag models included those of Syamlal–O’Brien, Gidaspow, modified Syamlal–O’Brien, and McKeen. Comparison between experimental data and simulated results showed that the Syamlal–O’Brien, Gidaspow, and modified Syamlal–O’Brien drag models highly overestimated gas–solid momentum exchange and could not predict the formation of dense phase in the fluidized bed, while the McKeen drag model could not capture the dilute characteristics due to underestimation of drag force. The standard Gidaspow drag model was then modified by adopting the effective particle cluster diameter to account for particle clusters, which was, however, proved inapplicable for FCC particle turbulent fluidization. A four-zone drag model (dense phase, sub-dense phase, sub-dilute phase and dilute phase) was finally proposed to calculate the gas–solid exchange coefficient in the turbulent fluidization of FCC particles, and was validated by satisfactory agreement between prediction and experiment.     

Fluidization behavior of graphitized glassy particles in a fluidized carbon bed cooling process for investment casting

Fluidized Carbon Bed Cooling (FCBC) is an innovative investment casting process for directional solidification of superalloy components. It takes advantage of a fluidized bed with a base of small glassy carbon beads for cooling and other low-density particles that form an insulating layer by floating to the bed surface. This so-called “Dynamic Baffle” protects the fluidized bed from the direct heat input from the high-temperature heating zone and provides the basis for an improved bed microstructure. The prerequisites for a stable casting process are stable fluidization conditions where neither collapse of the bed nor particle blow out at excessive bubble formation occur.This work aimed to investigate the fluidization behavior of spherical carbon bed material in argon and air at temperatures between 20 to 350 °C. Systematic studies at reduced pressures using the FCBC prototype device were performed to understand the stable fluidization conditions at all stages of the investment casting process. The particle shape factor and size distribution characterization and the measurement of the powder’s minimum fluidization velocity and bed voidage show that this material can be fully utilized as a cooling and buoyancy medium during the FCBC process.     

Flow regime diagrams for gas-solid fluidization and upward transport

Flow regime maps are presented for gas-solids fluidized beds and gas-solids upward transport lines. For conventional gas solids fluidization, the flow regimes include the fixed bed, bubbling fluidization, slugging fluidization and turbulent fluidization. For gas solids vertical transport operation, solids flux must be incorporated in the flow regime diagrams. The flow regimes then include dilute-phase transport, fast fluidization or turbulent flow, slug/bubbly flow, bubble-free dense-phase flow and packed bed flow. In practical circulating fluidized beds and transport risers, operation below the fast fluidization regime is commonly impossible due to equipment limitations. Practical flow regime maps are proposed with the flow regimes, including homogeneous dilute-phase flow, core-annular dilute-phase flow (where there are appreciable lateral gradients but small axial gradients) and fast fluidization (where there are both lateral and axial gradients). The boundary between fast fluidization and dilute-phase pneumatic transport is set by the type A choking velocity, at which the uniform suspension collapses and particles start to accumulate in the bottom region of the transport line, while the mechanism of transition from fast fluidization to dense-phase flow depends on the column and particle diameters.     

Validation of surface coating with nanoparticles to improve the flowability of fine cohesive powders

Fluidization of fine cohesive powders is seriously restricted by the strong interparticle cohesion. The rational combination of nanoparticles with fine cohesive powders is expected to obtain composite particles with improved flowability. In this work, we firstly reviewed the sandwich and three-point contact models regarding the fundamental principles of nano-additives in reducing cohesiveness. Based on these previous models, the effects of the size of nanoparticles, their agglomeration and coverage on the surface of cohesive powders in reducing interparticle forces were theoretically analyzed. To validate the theory effectiveness for the irregularly shaped cohesive powders, an extreme case of cubic powders coated with silica nanoparticles was fabricated, and the flowability of the composite particles was determined experimentally. Ultimately, based on force balance of a single particle, a semi-theoretical criterion for predicting the fluidization behavior of coated powders was developed to guide the practical applications of improving the flowability of cohesive powders through structural design and modulation.     

Dual characters of interaction between particles and fluid

The unique characteristics of gas-solids two-phase flow and fluidization in terms of the flow structures and the apparent behavior of particles and fluid-particle interactions are closely linked to physical properties of the particles, operating conditions and bed configurations. Fluidized beds behave quite differently when solid properties, gas velocities or vessel geometries are varied. An understanding of hydrodynamic changes and how they, in turn, influence the transfer and reaction characteristics of chemical and thermal operations by variations in gas-solid contact, residence time, solid circulation and mixing and gas distribution is very important for the proper design and scale-up of fluidized bed reactors. In this paper, rather than attempting a comprehensive survey, we concentrate on examining some important positive and negative impacts of particle sizes, bubbles, clusters and column walls on the physical and chemical aspects of chemical reactor performance from the engineering application point of view with the aim of forming an adequate concept for guiding the design of multiphase fluidized bed chemical reactors.One unique phenomenon associated with particle size is that fluidized bed behavior does not always vary monotonically with changing the average particle size. Different behaviors of particles with difference sizes can be well understood by analyzing the relationship between particle size and various forces. For both fine and coarse particles, too narrow a distribution is generally not favorable for smooth fluidization. A too wide size distribution, on the other hand, may lead to particle segregation and high particle elutriation. Good fluidization performance can be established with a proper size distribution in which inter-particle cohesive forces are reduced by the lubricating effect of fine particles on coarse particles for Type A, B and D particles or by the spacing effect of coarse particles or aggregates for Type C powders.Much emphasis has been paid to the negative impacts of bubbles, such as gas bypassing through bubbles, poor bubble-to-dense phase heat & mass transfer, bubble-induced large pressure fluctuations, process instabilities, catalyst attrition and equipment erosion, and high entrainment of particles induced by erupting bubbles at the bed surface. However, it should be noted that bubble motion and gas circulation through bubbles, together with the motion of particles in bubble wakes and clouds, contribute to good gas and solids mixing. The formation of clusters can be attributed to the movement of trailing particles into the low-pressure wake region of leading particles or clusters. On one hand, the existence of down-flowing clusters induces strong solid back-mixing and non-uniform radial distributions of particle velocities and holdups, which is undesirable for chemical reactions. On the other hand, the formation of clusters creates high solids holdups in the riser by inducing internal solids circulations, which are usually beneficial for increasing concentrations of solid catalysts or solid reactants.Wall effects have widely been blamed for complicating the scale-up and design of fluidized-bed reactors. The decrease in wall friction with increasing the column diameter can significantly change the flow patterns and other important characteristics even under identical operating conditions with the same gas and particles. However, internals, which can be considered as a special wall, have been used to improve the fluidized bed reactor performance.Generally, desirable and undesirable dual characteristics of interaction between particles and fluid are one of the important natures of multiphase flow. It is shown that there exists a critical balance between those positive and negative impacts. Good fluidization quality can always be achieved with a proper choice of right combinations of particle size and size distribution, bubble size and wall design to alleviate the negative impacts.     

CFD-DEM investigation into flow characteristics in mixed pulsed fluidized bed under electrostatic effects

Static electricity has an important effect on gas–solid fluidized bed reactor fluidization performance. In the process of fluidization, electrostatic interaction between particles will obviously accelerate particle agglomerate formation, which consequently reduces the fluidization performance. Pulsed gas flow injection is an efficient method to enhance particle mixing, thereby weakening the occurrence of particle agglomerate. In this study, the two-dimensional hybrid pulsed fluidized bed is established. The flow characteristics are studied by using the coupled CFD-DEM numerical simulation model considering electrostatic effects. Influences of different pulsed frequencies and gas flow ratios on fluidized bed fluidization performance are investigated to obtain the optimal pulsed gas flow condition. Results show that in the presence of static electricity, the bubble generation position is lower, which is conducive to the particle flow. Pulsed gas flow can increase the particle velocity and improve the diffusion ability. The bubble generation time is different at different frequencies, and the frequency of 2.5 Hz has the most obvious effect on the flow characteristics. Different gas flow ratios have significant impacts on the particle movement amplitude. When the pulse gas flow accounts for a large ratio, the particle agglomerate tends to be larger. Therefore, in order to improve the fluidization effect, the ratio of pulsed gas flow to stable gas flow should be appropriately reduced to 0.5 or less.     

Fluidization science, its development and future

By revisiting the three stage theory for the progress of science proposed by Taketani in 1942, the footmarks of fluidization research are examined. The bubbling and fast fluidization issues were emphasized so that the future offluidization research can be discussed among scientists and engineers in a wider perspective. The first cycle of fluidization research was started in the early 1940s by an initial stage of phenomenology. The second stage of structural studies was kicked off in the early 1950s with the introduction of the two phase theory. The third stage of essential studies occurred in the early 1960s in the form of bubble hydrodynamics. The second cycle, which confirmed the aforementioned three stages closed at the turn of the century, established a general understanding of suspension structures including agglomerating fluidization, bubbling, turbulent and fast fluidizations and pneumatic transport; also established powerful measurement and numerical simulation tools.After a general remark on science, technology and society issues the interactions between fluidization technology and science are revisited. Our future directions are discussed including the tasks in the third cycle, particularly in its phenomenology stage where strong motivation and intention are always necessary, in relation also to the green reforming of the present technology. A generalized definition of ＇fluidization＇ is proposed to extend fluidization principle into much wider scientific fields, which would be effective also for wider collaborations.     

MODELING TWO-PHASE FLOW IN PULSED FLUIDIZED BED

Mathematical models for pulsed fluidization are systematically discussed. Several undetermined constitutive relationships are included in the General Two-Fluid Model (GTFM), the adjustable parameters of which are always chosen at will to some extent. Although there are no adjustable parameters in the Basic Two-Fluid Model (BTFM), its eigenvalues are complex numbers and it is ill-posed for initial-value problems. The Local Equilibrium Model (LEM), a further simplification of BTFM, is discussed at length. Although the model is very simple, it is highly capable of simulating complex processes in pulsed fluidization over a broad range of operating parameters, and its numerical results well fit experimental results in both the variation of bed height and the distribution of particle concentration as fluidizina velocitv varies.     

Simulations of magnetic capturing of drug carriers in the brain vascular system

The present paper reports on numerical simulations of blood flow and magnetic drug carrier distributions in a complex brain vascular system. The blood is represented as a non-Newtonian fluid by the generalised power law. The Lagrangian tracking of the double-layer spherical particles is performed to estimate particle deposition under influence of imposed magnetic field gradients across arterial walls. Two situations are considered: neutral (magnetic field off) and active control (magnetic field on) case. The double-layer spherical particles that mimic a real medical drug are characterised by two characteristic diameters - the outer one and the inner one of the magnetic core. A numerical mesh of the brain vascular system consisting of multi-branching arteries is generated from raw MRI scan images of a patient. The blood is supplied through four main inlet arteries and the entire vascular system includes more than 30 outlets, which are modelled by Murray’s law. The no-slip boundary condition is applied for velocity components along the smooth and rigid arterial walls. Numerical simulations revealed detailed insights into blood flow patterns, wall-shear-stress and local particle deposition efficiency along arterial walls. It is demonstrated that magnetically targeted drug delivery significantly increased the particle capturing efficiency in the pre-defined regions. This feature can be potentially useful for localised, non-invasive treatment of brain tumours.     

Advances in scalable gas-phase manufacturing and processing of nanostructured solids: A review

Although the gas-phase production of nanostructured solids has already been carried out in industry for decades, only in recent years has research interest in this topic begun to increase. Nevertheless, despite the remarkable scientific progress made recently, many long-established processes are still used in industry. Scientific advancements can potentially lead to the improvement of existing industrial processes, but also to the development of completely new routes. This paper aims to review state-of-the-art synthesis and processing technologies, as well as the recent developments in academic research. Flame reactors that produce inorganic nanoparticles on industrial- and lab-scales are described, alongside a detailed overview of the different systems used for the production of carbon nanotubes and graphene. We discuss the problems of agglomeration and mixing of nanoparticles, which are strongly related to synthesis and processing. Finally, we focus on two promising processing techniques, namely nanoparticle fluidization and atomic layer deposition.