Mixing and segregation assessment of bi-disperse solid particles in a double paddle mixer

A double paddle blender's flow patterns and mixing mechanisms were analyzed using discrete element method (DEM) and experiments. The mixing performance of this type of the blender containing bi-disperse particles has been rarely studied in the literature. Plackett-Burman design of experiments (DoE) methodology was used to calibrate the DEM input parameters. Subsequently, the impact of the particle number ratio, vessel fill level, and paddle rotational speed on mixing performance was investigated using the calibrated DEM model. The mixing performance was assessed using relative standard deviation and segregation intensity. Mixing performance was significantly affected by the paddle rotational speed and particle number ratio. Moreover, the Peclet number and diffusivity coefficient were used to evaluate the mixing mechanism in the blender. Results revealed that the diffusion was the predominant mixing mechanism, and the best mixing performance was observed when the diffusivity coefficients of 3 mm and 5 mm particles were almost equal.