Using the discrete element method to assess the mixing of polydisperse solid particles in a rotary drum

Despite the wide applications of powder and solid mixing in industry, knowledge on the mixing of polydisperse solid particles in rotary drum blenders is lacking. This study investigates the mixing of monodisperse, bidisperse, tridisperse, and polydisperse solid particles in a rotary drum using the discrete element method. To validate the model developed in this study, experimental and simulation results were compared. The validated model was then employed to investigate the effects of the drum rotational speed, particle size, and initial loading method on the mixing quality. The degree of mixing of polydisperse particles was smaller than that for monodisperse particles owing to the segregation phenomenon. The mixing index increased from an initial value to a maximum and decreased slightly before reaching a plateau for bidisperse, tridisperse, and polydisperse particles as a direct result of the segregation of particles of different sizes. Final mixing indices were higher for polydisperse particles than for tridisperse and bidisperse particles. Additionally, segregation was weakened by introducing additional particles of intermediate size. The best mixing of bidisperse and tridisperse particles was achieved for top–bottom smaller-to-larger initial loading, while that of polydisperse systems was achieved using top–bottom smaller-to-larger and top–bottom larger-to-smaller initial loading methods.     

Viscosity of concentrated noncolloidal bidisperse suspensions

At the same solid volume fraction (Φ) the relative viscosity (η _r ) of a concentrated noncolloidal bidisperse suspension of hard spherical particles is lower than that of a monodisperse suspension. In this paper a semi-analytical viscosity model of noncolloidal bidisperse suspensions is derived using an integration method. In this model the random loose packing density obtained by computer simulation is taken as the limit of solid volume fraction Φ _m which depends upon both the diameter ratio (λ) of large to small particles and the volume fraction of large particles (ξ=Φ _l /Φ). This model shows that at high solid volume fraction, Φ > 0.40, both λ and ξ significantly influence η _r . For example, at Φ=0.5, it predicts that for monodisperse suspensions η _r =70, while for bidisperse suspensions (λ=2 and ξ=0.7) η _r =40. Comparison shows that, at high solid volume fraction (0.4–0.5), the relative viscosity predicted by this model is in good agreement with that predicted by the work of Shapiro and Probstein (1992) and of Patlazhan (1993), but is higher than that predicted by the work of others. Received: 27 February 2001 Accepted: 25 April 2001     

The effect of mixing particles of different size on the electrorheological response under steady shear flow

 The effect of mixing particles of different sizes on the electrorheological response of suspensions under steady shear flow was investigated. Two sizes, 15 μm and 50 μm, of monodisperse spherical sulfonated poly(styrene-co-divinylbenzene) particles were used. Several electrorheological fluids were made containing different proportions of small and large particles dispersed in silicone oil, but with constant overall particulate concentration. It was found that the mixed size system produced the highest electrorheological response under the shear rates used (10 s⁻¹ to 500 s⁻¹), which is the opposite trend to previous studies of bimodal systems with larger size ratios. Received: 21 December 2000 Accepted: 29 March 2001     

Gas-solid interaction force from direct numerical simulation (DNS) of binary systems with extreme diameter ratios

nding the large particles becomes less in case ofa bidisperse mixture, as compared to a monodisperse system with the same volume fraction. We further investigated this discrepancy by calculating the volume per particle by means of Voronoi tessellation.     

Gas–solid interaction force from direct numerical simulation (DNS) of binary systems with extreme diameter ratios

Fluid–particle systems as commonly encountered in chemical, metallurgical and petroleum industries are mostly polydisperse in nature. However, the relations used to describe fluid–particle interactions are originally derived from monodisperse systems, with ad hoc modifications to account for polydispersity. In previous work it was shown that for bidisperse systems with moderate diameter ratios of 1:2 to 1:4, this approach leads to discrepancies, and a correction factor is needed. In this work we demonstrate that this correction factor also holds for more extreme diameter ratios of 1:5, 1:7 and 1:10, although the force on the large particles is slightly overestimated when using the correction factor. The main origin of the correction is that the void surrounding the large particles becomes less in case of a bidisperse mixture, as compared to a monodisperse system with the same volume fraction. We further investigated this discrepancy by calculating the volume per particle by means of Voronoi tessellation.     

Effect of particle polydispersity on micromechanical properties and energy dissipation in granular mixtures

A series of numerical tests was conducted to study the micromechanical properties and energy dissipation in polydisperse assemblies of spherical particles subjected to uniaxial compression. In general, distributed particle size assemblies with standard deviations ranging from 0% to 80% of the particle mean diameter were examined. The microscale analyses included the trace of the fabric tensor, magnitude and orien- tation of the contact forces, trace of stress, number of contacts and degree of mobilization of friction in contacts between particles. In polydisperse samples, the average coordination numbers were lower than in monodisperse assemblies, and the mobilization of friction was higher than in monodisperse assemblies due to the non-uniform spatial rearrangement of spheres in the samples and the smaller displacements of the particles. The effect of particle size heterogeneity on both the energy density and energy dissipation in systems was also investigated.     

Effect of particle polydispersity on micromechanical properties and energy dissipation in granular mixtures

A series of numerical tests was conducted to study the micromechanical properties and energy dissipation in polydisperse assemblies of spherical particles subjected to uniaxial compression. In general, distributed particle size assemblies with standard deviations ranging from 0% to 80% of the particle mean diameter were examined. The microscale analyses included the trace of the fabric tensor, magnitude and orientation of the contact forces, trace of stress, number of contacts and degree of mobilization of friction in contacts between particles. In polydisperse samples, the average coordination numbers were lower than in monodisperse assemblies, and the mobilization of friction was higher than in monodisperse assemblies due to the non-uniform spatial rearrangement of spheres in the samples and the smaller displacements of the particles. The effect of particle size heterogeneity on both the energy density and energy dissipation in systems was also investigated.     

Rheology of concentrated suspensions containing mixtures of spheres and fibres

Optimising flow properties of concentrated suspensions is an important issue common for many industries. The rheology of concentrated suspensions has therefore been studied intensively both experimentally and theoretically. Most studies have focused on monodisperse and polydisperse suspensions of either spheres or fibres. In practice, most suspensions contain particles that are polydisperse both in size and shape. A mixing rule for such systems is expected to be a powerful tool for engineers and product designers. Therefore in this work, suspensions of spheres, fibres and mixtures thereof were characterised using rotational shear rheometry and in-line image analyses. Thereby, total solids volume concentration and fibre fraction was varied. Results from transient and steady-state shear rheometry are discussed with respect to concentration, fibre fraction, and shear induced microstructure. Experimentally obtained viscosity data were accurately fitted using the model proposed by Farris (T Soc Rheol 12:281, 1968) for mixtures of monodisperse non-interacting spheres of different sizes.Originally presented at the Annual European Rheology Conference 2003, AERC 2003     

Fibre suspension rheology: effect of concentration, aspect ratio and fibre size.

Viscosity data for fibre suspensions are produced using cone-and-plate geometry of enhanced dimensions for the reduced influence of fibre-wall interactions. Semi-concentrated suspensions of monodisperse polyamide fibres in silicone oil, with a variety of fibre concentrations (2, 5 and 8%), lengths and diameters, were studied. The suspension viscosity was measured in a range of shear stress in order to study the stress dependence. The study here focuses on the nature of the forces and interactions that contribute to the suspension viscosity. The results show that at sufficiently high stress levels, the suspension viscosity tends to reach a steady-state. At very low stress levels the suspension viscosity increases over time, most likely due to structures formed by adhesive forces. At higher concentrations, the viscosity depends on the absolute size of the fibres, again indicating the presence of non-hydrodynamic interactions.     

Bidisperse polymeric mixtures for independent control of viscosity and elasticity

 It is known that the zero shear viscosity of a polydisperse melt of linear polymers depends only on its weight-average molecular weight, whereas its recoverable compliance increases with polydispersity. These facts can be exploited to design model viscoelastic fluids using mixtures of short and long chains of the same homopolymer (bidisperse mixtures). The composition required to obtain a bidisperse mixture with the desired viscosity can be calculated from the molecular weights of the components, and the known relationship between viscosity and weight-average molecular weight. The terminal viscoelastic properties of such a bidisperse mixture are estimated from theoretical predictions for the compliance of bidisperse mixtures available in the literature. These predictions suggest that the elasticity of bidisperse mixtures can be varied independent of their viscosity by appropriately choosing the molecular weights of their components and their composition. This strategy is applied here on bidisperse mixtures of monodisperse 1,4-polyisoprene, which are shown to display second-order fluid behavior over a reasonable range of accessible shear rates. The same procedure is also applied to mixtures of PDMS polymers which are not particularly monodisperse. Rheological measurements show that the elasticity of these polyisoprene and PDMS mixtures can indeed be varied without changing their viscosity. Such materials are ideally suited to study structure-rheological properties relationships in blends of immiscible viscoelastic fluids. Received: 12 April 2001 Accepted: 28 August 2001     

Size segregation and particle velocity fluctuations in settling concentrated suspensions

We investigate the sedimentation of concentrated suspensions at low Reynolds numbers to study collective particle effects on local particle velocity fluctuations and size segregation effects. Experiments are carried out with polymethylmetacrylate (PMMA) spheres of two different mean diameters (190 and 25 μm) suspended in a hydrophobic index-matched fluid. Spatial repartitions of both small and large spheres and velocity fluctuations of particles are measured using fluorescently labelled PMMA spheres and a particle image velocimetry method. We also report measurements of the interstitial fluid pressure during settling. Experiments show that size segregation effects can occur during the sedimentation of concentrated suspensions of either quasi-monodisperse or bidisperse spheres. Size segregation is correlated to the organisation of the sedimentation velocity field into vortex-like structures of finite size. A loss of size segregation together with a significant decrease of the fluid pressure gradient in the bulk suspension is observed when the size of vortex-like structures gets on the order of the container size. However, the emergence of channels through the settling zone prevents a complete loss of size segregation in very concentrated suspensions.     

Determining a representative element volume for DEM simulations of samples with non-circular particles

Numerical studies on the number of particles or system size required to attain a representative element volume (REV) for discrete element method (DEM) simulations of granular materials have almost always considered samples with spherical or circular particles. This study considers how many particles are needed to attain a REV for 2D samples of 2-disc cluster particles where the particle aspect ratio (AR) was systematically varied. Dense and loose assemblies of particles were simulated. The minimum REV was assessed both by considering the repeatability of static packing characteristics and the shearing behaviour in biaxial compression tests, and by investigating the effect of sample size on the measured characteristics and observed shearing behaviour. The repeatability of the data considered generally improved with increasing sample size. The packing characteristics of the dense samples were more repeatable suggesting that the minimum REV reduces with increasing packing density. The minimum REV was observed to be sensitive to the characteristic measured. Although the overall responses of the samples during shear deformation were similar irrespective of the sample sizes, the smaller the sample size, the higher the fluctuations observed in the responses. Analysis of the coefficient of variation of the fluctuations around the critical state stress ratio can provide insight as to whether a REV is attained. The particle AR influences the effect of sample size on shearing characteristics and thus the minimum number of particles required to attain a REV; this can be explained by the influence of AR on the number of contacts within the samples.     

Prediction of multiple overshoots in shear stress during fast flows of bidisperse polymer melts

We present a differential constitutive model of stress relaxation in polydisperse linear polymer melts and solutions that contains contributions from reptation, contour-length fluctuations, and chain stretching. The predictions of the model during fast start-up and steady shear flows of polymer melts are in accord with experimental observations. Moreover, in accordance with reported experimental literature (Osaki et al. in J Polym Sci B Polym Phys 38:2043–2050, 2000), the model predicts, for a range of shear rates, two overshoots in shear stress during start-up of steady shear flows of bidisperse polymer melts having components with widely separated molar masses. Two overshoots result only when the stretch or Rouse relaxation time of the higher molar mass component is longer than the terminal relaxation time of the lower molar mass component. The “first overshoot” is the first to appear with increasing shear rate and occurs as a result of the stretching of longer chains. Transient stretching of the short chains is responsible for the early time second overshoot. The model predictions in steady and transitional extensional flows are also remarkable for both monodisperse and bidisperse polymer solutions. The computationally efficient differential model can be used to predict rheology of commercial polydisperse polymer melts and solutions.     

Effect of pore size distribution in bidisperse wick on heat transfer in a loop heat pipe

The purpose of this article is to experimentally investigate the effect of different pore size distributions in bidisperse wicks upon the heat transfer performance in a LHP. Three bidisperse wicks and one monoporous wick were tested in a loop heat pipe. The pore size distributions of the bidisperse wicks were measured, and the results reflected the three different large/small pore size ratios. The experiments showed that the maximum heat load of the monoporous wick reached about 400 W; and the three bidisperse wicks showed improvements on the maximum heat load up to 570 W. For the monoporous wick, the evaporator heat transfer coefficients of 10 kW/m² K and total thermal resistance of 0.19°C/W were achieved at a high heat load of 400 W. For the better bidisperse wick, the evaporator heat transfer coefficients could attain about 23 kW/m² K and total thermal resistance of 0.13°C/W. The results also indicated that a smaller cluster size in a bidisperse structure created a small pore size ratio. It was also found that the bidisperse wick with smaller clusters had a better enhancement in terms of the evaporator heat transfer coefficient.     

Rheological characterization of bimodal colloidal dispersions

In order to investigate the effect of the particle size distribution on the rheological properties of concentrated colloidal dispersions both steady-state shear and oscillatory measurements have been performed on well-characterized bimodal dispersions of sterically stabilized PMMA particles. Replacing a minor amount of large particles by small ones in a concentrated dispersion, keeping the total effective volume fraction constant, decreases the viscosity quite drastically. On the other hand, replacing a small amount of small particles by big ones hardly effects the viscosity at all. This behavior can be attributed to the deformability of the stabilizing polymer layer. A procedure is proposed to calculate the limiting viscosities in a bimodal colloidal dispersion starting from the characteristics of the monodisperse systems. A good agreement has been obtained between the calculated values and the experimental results. The linear viscoelastic properties of the concentrated dispersions have been investigated by means of oscillatory measurements. The plateau values of the storage modulus for the bimodal dispersions decrease with an increasing fraction of the coarse particles. By substituting the bimodal dispersion by an equivalent monodisperse system the storage modulus can be superimposed on the values for the monodisperse suspensions when plotted as a function of the mean interparticle distance.     

Linear viscoelastic behavior of bidisperse polystyrene blends: experiments and slip-link predictions

The linear viscoelastic behavior of three well-entangled linear monodisperse polystyrene melts and their blends is investigated. The monodisperse melts are blended in a 1:1 weight ratio to obtain three polystyrene bidisperse blends for which the linear viscoelastic behavior is also measured. Special attention is paid to controlling sample size and solvent content, and checking for consistency in the high-frequency regime. We also attempt to estimate uncertainty quantitatively. The experimental results agree well with the discrete slip-link model, a robust mesoscopic theory that has been successful in predicting the rheology of flexible entangled polymer liquids and gels. Using recently developed analytic expressions for the relaxation modulus, predictions of the monodisperse samples are made. The parameters for the model are obtained from the low-frequency crossover of one experiment. Using this parameter set without adjustment, predictions over the fully accessible experimental frequency range are obtained for the monodisperse samples and their blends with very good agreement.     

On the elastic properties of model suspensions as investigated by creep recovery measurements in shear

 The elastic properties of model suspensions with spherical monodisperse hydrophilic glass spheres that were dispersed in a Newtonian liquid were determined in creep and creep recovery measurements in shear with a magnetic bearing torsional creep rheometer. The creep and creep recovery measurements were performed depending on the applied level of shear stresses ranging from 0.19 Pa to 200 Pa. Since the recoverable creep compliances of the chosen suspending medium (i.e. a low molecular weight polyisobutylene) were far below the lower limit of the resolution of the creep rheometer it can be considered to behave as purely viscous. By applying a large shear stress in the creep tests the investigated suspensions with a volume fraction of Φ _t =0.35 behave as Newtonian liquids, too. For these suspensions no significant recoverable creep compliances could be detected, as well. In contrast to the Newtonian state of suspensions at high shear stresses, where a shear induced ordering of the particles can be expected, a non-Newtonian behaviour arises by applying a very low shear stress in the creep test. In this state large recoverable creep compliances were detected for the suspensions. The magnitude of the recoverable creep compliances of the suspensions exceeded the largest creep compliances of polymer melts that are reported in the literature by more than two decades. From the results obtained by creep recovery measurements with a magnetic bearing torsional creep rheometer it can clearly be concluded that the particle structure present in the chosen model suspension gives rise to a pronounced elasticity. Received: 21 November 2000 Accepted: 12 July 2001     

Discrete element study of viscous flow in magnetorheological fluids

Using discrete element simulations, we gain insight into the structure of a magnetorheological fluid (MRF) under shear. In simulations with flat walls, the particles arrange in chains, sheet-like structures, or columns along the magnetic field lines, depending on the strength of the applied external magnetic field. Corresponding to the structure formation, three different types of failure mechanisms can be identified. For the characterization of the different regimes, specific particle coordination numbers are introduced. The three structural regimes can be distinguished and described by means of these coordination numbers. To analyze the contact between the MRF particles and the walls of the shear cell, additional simulations with rough walls have been conducted. The resulting structure formation could be successfully classified by the introduced coordination numbers. Based on the analysis of the shear stress transmission both in the case of flat and rough walls, possibilities for shear stress enhancement for technological applications are discussed.     

The effect of particle size and migration on the formation of flow-induced structures in viscoelastic suspensions

Flow-induced structures in suspensions containing spheres in viscoelastic suspending media were investigated by microscopy and rheo-optical methods. Suspensions of monodisperse polystyrene spheres with diameters ranging from 1.2 to 2.8 μm and dispersed in aqueous solutions of hydroxypropylcellulose were studied in simple shear flows. Optical microscopy observations as well as small-angle light-scattering (SALS) experiments were performed using a parallel plate geometry. In agreement with previous work, necklaces of particles aligned in the flow direction were observed when shearing faster then a critical shear rate, which was found to be independent of particle size. In contrast to earlier work, however, the role of particle migration was found to be of prime importance. Particles were shown to migrate toward the plates where the particles assembled and aligned in strings running in the flow direction. For the smallest particles (1 μm diameter), the formation of particle doublets or short strings along the vorticity direction was observed at low shear rates, which flipped to an orientation into the flow direction and grew into longer strings at higher shear rates. SALS experiments were used to quantify the degree of alignment and its dependence on particle size, shear rate, and gap. For the system under investigation, the degree of alignment was found to increase with increasing shear rate and particle size and with decreasing gap. The present results suggest that, depending on the details of the suspending medium and the size and nature of the suspended particles, the formation of aligned structures is affected by the relative magnitude of the colloidal and hydrodynamic forces and the kinetics of string formation versus the kinetics of migration.     

Measuring static yield stress of electrorheological fluids using the slotted plate device

An electrorheological (ER) response is defined as the dramatic change in rheological properties of a suspension of small particles due to the application of a large electric field transverse to the direction of flow. ER fluids are typically composed of nonconducting or semiconducting particles dispersed in a nonconducting continuous phase. A sufficiently large electric field will cause ER fluids to solidify, giving rising to a yield stress. Many applications in torque and stress transfer devices were proposed employing the reversible yielding behavior of ER fluids. Successful applications depend on a large yield stress of ER fluids and therefore accurate measurements of the yield stress of ER fluids are required. Reported experimental yield stresses of ER fluids have been dynamic yield stresses obtained by extrapolating the shear stress–shear rate data to zero-shear rate. It would be very helpful to the understanding of ER behaviors and the applications of ER fluids to be able to measure the static yield stress of ER fluids accurately. The slotted plate technique has been shown to be a successful method to determine the static yield stress of suspensions. The values obtained via the slotted plate method are static yield stress as the platform is designed for extremely low-speed motion. In this study, we modified the slotted plate device for the application of large electric fields and measured the static yield stress of TiO₂ ER fluids under various electric fields. The measured static yield stress values are also compared with the static yield stress values from a commercial rheometer.