Outflow and clogging of shape-anisotropic grains in hoppers with small apertures

Elongated particles discharged with a conveyor belt in a two-dimensional silo

The flow of elliptical particles out of a two-dimensional silo when extracted with a conveyor belt is analyzed experimentally. The conveyor belt-placed directly below the silo outlet-reduces the flow rate, increases the size of the stagnant zone, and it has a very strong influence on the relative velocity fluctuations as they strongly increase everywhere in the silo with decreasing belt speed. In other words, instead of slower but smooth flow, flow reduction by belt leads to intermittent flow. Interestingly, we show that this intermittency correlates with a strong reduction of the orientational order of the particles at the orifice region. Moreover, we observe that the average orientation of the grains passing through the outlet is modified when they are extracted with the belt, a feature that becomes more evident for large orifices.

Secondary flow in ensembles of nonconvex granular particles under shear

Studies of granular materials, both theoretical and experimental, are often restricted to convex grain shapes. We demonstrate that a nonconvex grain shape can lead to a qualitatively novel macroscopic dynamics. Spatial crosses (hexapods) are continuously sheared in a split-bottom container. Thereby, they develop a secondary flow profile that is completely opposite to that of rod-shaped or lentil-shaped convex grains in the same geometry. The crosses at the surface migrate towards the rotation center and sink there mimicking a "reverse Weissenberg effect." The observed surface flow field suggests the existence of a radial outward flow in the depth of the granular bed, thus, forming a convection cell. This flow field is connected with a dimple formed in the rotation center. The effect is strongly dependent on the particle geometry and the height of the granular bed.

Role of cohesion in the flow of active particles through bottlenecks

We experimentally and numerically study the flow of programmable active particles (APs) with tunable cohesion strength through geometric constrictions. Similar to purely repulsive granular systems, we observe an exponential distribution of burst sizes and power-law-distributed clogging durations. Upon increasing cohesion between APs, we find a rather abrupt transition from an arch-dominated clogging regime to a cohesion-dominated regime where droplets form at the aperture of the bottleneck. In the arch-dominated regime the flow-rate only weakly depends on the cohesion strength. This suggests that cohesion must not necessarily decrease the group's efficiency passing through geometric constrictions or pores. Such behavior is explained by "slippery" particle bonds which avoids the formation of a rigid particle network and thus prevents clogging. Overall, our results confirm the general applicability of the statistical framework of intermittent flow through bottlenecks developed for granular materials also in case of active microswimmers whose behavior is more complex than that of Brownian particles but which mimic the behavior of living systems.

Soft particles facilitate flow of rigid particles in a 2D hopper

The flow of granular materials through narrow openings governs flow and process efficiency in a variety of industrial settings. As the use of soft particles and other soft micro-materials becomes more widespread in consumer products, we seek to understand characteristics of granular flows beyond powder flows. We study clogging through a 2D hopper in systems consisting of a combination of soft and rigid particles of different sizes and mixing fractions. Our experimental results show that soft particles play a lubricating role in the flow of rigid spheres due to their deformability and slick surface, but the size of rigid particles influences clogging more than the size of soft ones. We simulate our results using a modification of the Durian bubble model to accommodate mixtures of particles of different softness. Without any adjustable parameters, the simulation results capture the clogging probability of soft-rigid particle mixtures through a 2D hopper.

Weak clogging in constricted channel flow

We investigate simple models of a monodisperse system of soft, frictionless disks flowing through a two-dimensional microchannel in the presence of a single or a double constriction using Brownian dynamics simulation. After a transient time, a stationary state is observed with an increase in particle density before the constriction and a depletion after it. For a constriction width to particle diameter ratio of less than 3, the mean particle velocity is reduced compared to the unimpeded flow and it falls to zero for ratios of less than 1. At low temperatures, the particle mean velocity may vary nonmonotonically with the constriction width. The associated intermittent behavior is due to the formation of small arches of particles with a finite lifetime. The distribution of the interparticle exit times rises rapidly at short times followed by an exponential decay with a large characteristic time, while the cascade size distribution displays prominent peaks for specific cluster sizes. Although the dependence of the mean velocity on the separation of two constrictions is not simple, the mean flow velocity of a system with a single constriction provides an upper envelope for the system with two constrictions. We also examine the orientation of the leading pair of particles in front of the constriction(s). With a single constriction in the intermittent regime, there is a strong preference for the leading pair to be orientated perpendicular to the flow. When two constrictions are present, orientations parallel to the flow are much more likely at the second constriction.

Effect of interparticle dipolar interaction on pore clogging during microfiltration

We present numerical investigations on the clogging of adhesive particles carrying electric dipoles at pore scale using an adhesive discrete element method (DEM). Based on the simulation results, the long-range dipolar interaction is reported to promote the clogging process, which is quantified by the bulk permeability, the penetrating particle number, and the particle capture efficiency. A clogging phase diagram is constructed in terms of the Stokes number (St) and the adhesion parameter (Ad) for both neutral and polarized particles. The influence of the dipolar interaction on the clogging-nonclogging transition is then described by the shifted boundary on the diagram. Also, the cake structure is characterized by different mathematical descriptions. A looser structure is formed with the increase of both the short-range adhesion and the long-range dipolar interaction. More ordered structures, such as particle chains, are observed in the presence of the stronger dipolar interaction. Furthermore, fluid stress is found to be essential in the compression and restructuring of the cake structure. Finally, a schematic representation of the cake structure is established, which provides a general physical picture showing the relationship between the cake structure and the particle-scale interactions.

Stress propagation in locally loaded packings of disks and pentagons

The mechanical strength and flow of granular materials can depend strongly on the shapes of individual grains. We report quantitative results obtained from photoelasticimetry experiments on locally loaded, quasi-two-dimensional granular packings of either disks or pentagons exhibiting stick-slip dynamics. Packings of pentagons resist the intruder at significantly lower packing fractions than packings of disks, transmitting stresses from the intruder to the boundaries over a smaller spatial extent. Moreover, packings of pentagons feature significantly fewer back-bending force chains than packings of disks. Data obtained on the forward spatial extent of stresses and back-bending force chains collapse when the packing fraction is rescaled according to the packing fraction of steady state open channel formation, though data on intruder forces and dynamics do not collapse. We comment on the influence of system size on these findings and highlight connections with the dynamics of the disks and pentagons during slip events.

Discharge Flow of Spherical Particles from a Cylindrical Bin: Experiment and DEM Simulations

A series of the DEM simulations of the outflow of wooden spheres from a flat-bottomed container was reported, considering the maximum diameter to arrest the flow. Numerical simulations of the discharge process were performed, and the micro-mechanics of the discharged particles were described. The effect of the sliding friction coefficient between particles, rolling friction coefficient, and modulus of elasticity of particles on the clogging process was investigated. The results of the simulations of the mass flow rate of spheres have shown a fairly close agreement with the experimental results. The real particles of wood were not perfectly spherical, their properties were anisotropic, and their frictional properties were non-homogenously distributed on the surface. Nevertheless, these deviations from ideal conditions did not produce a considerable discrepancy in the results. No direct relationship between the interparticle friction and the clogging was found; however, a relationship between the stability of the dome formed at flow arrest and the rolling friction was observed. An increase in Young’s modulus of particles by two orders of magnitude did not affect the clogging process, but a slightly higher probability of clogging was found for softer particles.

Discharge of elongated grains from silo with rotating bottom

We study the flow of elongated grains (wooden pegs of length L=20 mm with circular cross section of diameter d_{c}=6 and 8 mm) from a silo with a rotating bottom and a circular orifice of diameter D. In the small orifice range (D/d<5) clogs are mostly broken by the rotating base, and the flow is intermittent with avalanches and temporary clogs. Here d≡(3/2d_{c}^{2}L)^{1/3} is the effective grain diameter. Unlike for spherical grains, for rods the flow rate W clearly deviates from the power law dependence W∝(D-kd)^{2.5} at lower orifice sizes in the intermittent regime, where W is measured in between temporary clogs only. Instead, below about D/d<3 an exponential dependence W∝e^{κD} is detected. Here k and κ are constants of order unity. Even more importantly, rotating the silo base leads to a strong-more than 50%-decrease of the flow rate, which otherwise does not depend significantly on the value of ω in the continuous flow regime. In the intermittent regime, W(ω) appears to follow a nonmonotonic trend, although with considerable noise. A simple picture, in terms of the switching from funnel flow to mass flow and the alignment of the pegs due to rotation, is proposed to explain the observed difference between spherical and elongated grains. We also observe shear-induced orientational ordering of the pegs at the bottom such that their long axes in average are oriented at a small angle 〈θ〉≈15^{∘} to the motion of the bottom.

Strategic placement of an obstacle suppresses droplet break up in the hopper flow of a microfluidic soft crystal

When granular materials, colloidal suspensions, and even animals and crowds exit through a narrow outlet, clogs can form spontaneously when multiple particles or entities attempt to exit simultaneously, thereby obstructing the outlet and ultimately halting the flow. Counterintuitively, the presence of an obstacle upstream of the outlet has been found to suppress clog formation. For soft particles such as emulsion drops, clogging has not been observed in the fast flow limit due to their deformability and vanishing interparticle friction. Instead, they pinch off each other and undergo break up when multiple drops attempt to exit simultaneously. Similar to how an obstacle reduces clogging in a rigid particle system, we hypothesize and demonstrate that an obstacle could suppress break up in the two-dimensional hopper flow of a microfluidic crystal consisting of dense emulsion drops by preventing the simultaneous exit of multiple drops. A regime map plotting the fraction of drops that undergo break up in a channel with different obstacle sizes and locations delineates the geometrical constraints necessary for effective break up suppression. When optimally placed, the obstacle induced an unexpected ordering of the drops, causing them to alternate and exit the outlet one at a time. Droplet break up is suppressed drastically by almost three orders of magnitude compared to when the obstacle is absent. This result can provide a simple, passive strategy to prevent droplet break up and can find use in improving the robustness and integrity of droplet microfluidic biochemical assays as well as in extrusion-based three-dimensional printing of emulsion or foam-based materials.

Clogging of granular materials in a horizontal hopper: Effect of outlet size, hopper angle, and driving velocity

Due to the independence of the driving velocity and outlet size, it is possible to isolate geometrical and kinematic contributions to clogging in two-dimensional horizontal flow in a hopper driven by a conveyor belt. We experimentally investigate the geometric (outlet size and hopper angle) and kinematic effects (driving velocity) on the clogging in such a horizontal flow. Based on quantitative measurements and analysis of the avalanche size, blocking probability of a particle at the outlet, and other parameters, we show that the geometric factors can more effectively affect clogging. In addition, we find that the clogging tends to be alleviated with the increases of the driving velocity, suggesting a possible "fast is fast" behavior within a wide range of driving velocity. We borrow and modify a model from clogging in gravity-driven hoppers, which can accurately describe the shape of the clogging probability function in the conveyor belt driven flow, suggesting that these two systems could share some mechanisms for clogging.

Study of Clogging Phenomenon for a Conical Hopper: The Influence of Particle Bed Height and Hopper Angle

The granular flow is one of the principal issues for the design of pebble bed reactors. Particularly, the clogging phenomenon raises an important issue for pebble bed reactors. In this paper, we conduct experiments and discrete particle simulation of two-dimensional discharge granular flow from a conical hopper, to study the effect of the particle bed height $h$ and hopper angle $\alpha$ on the clogging phenomenon. In general, the clogging probability $J$ increases with height $h$ and starts to saturate when $h$ is larger than a critical value. The experimental result trends are supported by discrete simulations. To understand the underlying physical mechanism, we conduct discrete particle simulations for various $h$ values, focusing on the following parameters: the statistical averaging of the volume fraction, velocity, and contact pressure of particles near the aperture during the discharge. We found that, among all relevant variables, the contact pressure of particles is the main cause of the increasement of J when $h$ increases. An exponential law between the pebble bed $h$ and clogging probability J has been established based on these observations and Janssen model. As for hopper angle $\alpha$ , J shows an almost constant behavior for any rise in $\alpha$ followed by a sudden regression at $\alpha ={75}^{°}$ . Surprisingly, the effect of $\alpha$ is most obvious for intermediate values of $h$ , where we observe a sharp increasement of clogging probability. The same trend is observed in the two-dimensional discrete simulation results.

The effect of particle shape on discharge and clogging

Granular flow is common across different fields from energy resource recovery and mineral processing to grain transport and traffic flow. Migrating particles may jam and form arches that span constrictions and hinder particle flow. Most studies have investigated the migration and clogging of spherical particles, however, natural particles are rarely spherical, but exhibit eccentricity, angularity and roughness. New experiments explore the discharge of cubes, 2D crosses, 3D crosses and spheres under dry conditions and during particle-laden fluid flow. Variables include orifice-to-particle size ratio and solidity. Cubes and 3D crosses are the most prone to clogging because of their ability to interlock or the development of face-to-face contacts that can resist torque and enhance bridging. Spheres arriving to the orifice must be correctly positioned to create stable bridges, while flat 2D crosses orient their longest axes in the direction of flowlines across the orifice and favor flow. Intermittent clogging causes kinetic retardation in particle-laden flow even in the absence of inertial effects; the gradual increase in the local particle solidity above the constriction enhances particle interactions and the probability of clogging. The discharge volume before clogging is a Poisson process for small orifice-to-particle size ratio; however, the clogging probability becomes history-dependent for non-spherical particles at large orifice-to-particle size ratio and high solidities, i.e., when particle–particle interactions and interlocking gain significance.

Intermittent flow and transient congestions of soft spheres passing narrow orifices

Soft, low-friction particles in silos show peculiar features during their discharge. The outflow velocity and the clogging probability both depend upon the momentary silo fill height, in sharp contrast to silos filled with hard particles. The reason is the fill-height dependence of the pressure at the orifice. We study the statistics of silo discharge of soft hydrogel spheres. The outflow is found to become increasingly fluctuating and even intermittent with decreasing orifice size, and with decreasing fill height. In orifices narrower than two particle diameters, outflow can stop completely, but in contrast to clogs formed by rigid particles, these congestions may dissolve spontaneously. We analyze such non-permanent congestions and attribute them to slow reorganization processes in the container, caused by viscoelasticity of the material.

Clogging-jamming connection in narrow vertical pipes

We report experimental evidence of clogging due to the spontaneous development of hanging arches when a granular sample composed of spherical particles flows down a narrow vertical pipe. These arches, akin to the ones responsible for silo clogging, can only be possible due to the role of frictional forces; otherwise they will be unstable. We find that, contrary to the silo case, the probability of clogging in vertical narrow tubes does not decrease monotonically with the ratio of the pipe-to-particle diameters. This behavior is related to the clogging prevention caused by the spontaneous ordering of particles apparent in certain aspect ratios. More importantly, by means of numerical simulations, we discover that the interparticle normal force distributions broaden in systems with higher probability of clogging. This feature, which has been proposed before as a distinctive feature of jamming in sheared granular samples, suggests that clogging and jamming are connected in pipe flow.

Nonergodicity in silo unclogging: Broken and unbroken arches

We report an experiment on the unclogging dynamics in a two-dimensional silo submitted to a sustained gentle vibration. We find that arches present a jerking motion where rearrangements in the positions of their beads are interspersed with quiescent periods. This behavior occurs for both arches that break down and those that withstand the external perturbation: Arches evolve until they either collapse or get trapped in a stable configuration. This evolution is described in terms of a scalar variable characterizing the arch shape that can be modeled as a continuous-time random walk. By studying the diffusivity of this variable, we show that the unclogging is a weakly nonergodic process. Remarkably, arches that do not collapse explore different configurations before settling in one of them and break ergodicity much in the same way than arches that break down.

Enabling low power acoustics for capillary sonoreactors

Capillary reactors demonstrate outstanding potential for on-demand flow chemistry applications. However, non-uniform distribution of multiphase flows, poor solid handling, and the risk of clogging limit their usability for continuous manufacturing. While ultrasonic irradiation has been traditionally applied to address some of these limitations, their acoustic efficiency, uniformity and scalability to larger reactor systems are often disregarded. In this work, high-speed microscopic imaging reveals how cavitation-free ultrasound can unclog and prevent the blockage of capillary reactors. Modeling techniques are then adapted from traditional acoustic designs and applied to simulate and prototype sonoreactors with wider and more uniform sonication areas. Blade-, block- and cylindrical shape sonotrodes are optimized to accommodate longer capillary lengths in sonoreactors resonating at 28 kHz. Finally, a novel helicoidal capillary sonoreactor is proposed to potentially deal with a high concentration of solid particles in miniaturized flow chemistry. The acoustic designs and first principle rationalization presented here offer a transformative step forward in the scale-up of efficient capillary sonoreactors.

Granular flow from silos with rotating orifice

For dry granular materials falling through a circular exit at the bottom of a silo, no continuous flow can be sustained when the diameter D of the exit is less than five times the characteristic size of the grains. If the bottom of the silo rotates horizontally with respect to the wall of the silo, finite flow rate can be sustained even at small D. We investigate the effect of bottom rotation to the flow rate of monodisperse plastic beads of d=6mm diameter from a cylindrical silo of 19 cm inner diameter. We find that the flow rate W follows Beverloo law down to D=1.3d and that W increases with the rotation speed ω in the small exit regime. If the exit is at an off-center distance R from the axis of the silo, W increases with the rate of area swept by the exit. On the other hand, when the exit diameter is large, W decreases with increasing ω at small ω but increases with ω at large ω. Such nonmonotonic dependence of flow rate on rotation speed may be explained as a gradual change from funnel flow to mass flow due to the shear at the bottom of the silo.

Effect of hopper angle on granular clogging

We present experimental results of the effect of the hopper angle on the clogging of grains discharged from a two-dimensional silo under gravity action. We observe that the probability of clogging can be reduced by three orders of magnitude by increasing the hopper angle. In addition, we find that for very large hopper angles, the avalanche size (〈s〉) grows with the outlet size (D) stepwise, in contrast to the case of a flat-bottom silo for which 〈s〉 grows smoothly with D. This surprising effect is originated from the static equilibrium requirement imposed by the hopper geometry to the arch that arrests the flow. The hopper angle sets the bounds of the possible angles of the vectors connecting consecutive beads in the arch. As a consequence, only a small and specific portion of the arches that jam a flat-bottom silo can survive in hoppers.

Investigation on the impact of powder arching in small die filling

The flow of particulate materials is critical during processes such as mixing, compression and packing. Non-cohesive arching, a feature characteristic of coarse and free-flowing particles, has been studied extensively for silos and hoppers. However, the arching of powders during die fill has received much less attention. In this study, die fill performance of coarse and free-flowing nonpareils was evaluated using a specially designed die filling device in order to investigate the impact of non-cohesive arching during die fill under gravity flow. Through evaluating die fill performance, the arching phenomenon during dynamic conditions of die fill could be captured. Nonpareils with large particle size increased the likelihood of arching and caused poorer die fill performance for narrow orifices. In contrast, die fill in large orifices was generally better with larger particles due to reduced inter-particulate friction. Both particle size and size distribution influenced non-cohesive arching during die fill. Forced feeding did not appear to affect die fill performance and non-cohesive arching. A critical particle size range beyond which die fill performance would decrease, particularly for the narrow orifices, was identified. Findings from this study provided a better insight into non-cohesive arching during die fill.

Decoupling Geometrical and Kinematic Contributions to the Silo Clogging Process

Based on the implementation of a novel silo discharge procedure, we are able to control the grains velocities regardless of the outlet size. This allows isolating the geometrical and kinematic contributions to the clogging process. We find that, for a given outlet size, reducing the grains velocities to extremely low values leads to a clogging probability increment of almost two orders of magnitude, hence revealing the importance of particle kinematics in the silo clogging process. Then, we explore the contribution of both variables, outlet size and grains velocity, and we find that our results agree with an already known exponential expression that relates clogging probability with outlet size. We propose a modification of such expression revealing that only two parameters are necessary to fit all the data: one is related with the geometry of the problem, and the other with the grains kinematics.

Granular silo flow of inelastic dumbbells: Clogging and its reduction

We study the discharge of inelastic, two-dimensional dumbbells through an orifice in the bottom wall of a silo using discrete element method (DEM) simulations. As with spherical particles, clogging may occur due to the formation of arches of particles around the orifice. The clogging probability decreases with increasing orifice width in both cases. For a given width, however, the clogging probability is much higher for the nonspherical particles due to their arbitrary orientations and the possibility of geometrical interlocking. We also examine the effect of placing a fixed, circular obstacle above the orifice. The clogging probability depends strongly on the vertical and lateral position of the obstacle, as well as its size. By suitably placing the obstacle the clogging probability can be significantly reduced compared to a system with no obstacle. We attempt to elucidate the clogging reduction mechanism by examining the packing fraction, granular temperature, and velocity distributions of the particles in the vicinity of the orifice.

Active particles with desired orientation flowing through a bottleneck

We report extensive numerical simulations of the flow of anisotropic self-propelled particles through a constriction. In particular, we explore the role of the particles’ desired orientation with respect to the moving direction on the system flowability. We observe that when particles propel along the direction of their long axis (longitudinal orientation) the flow-rate notably reduces compared with the case of propulsion along the short axis (transversal orientation). And this is so even when the effective section (measured as the number of particles that are necessary to span the whole outlet) is larger for the case of longitudinal propulsion. This counterintuitive result is explained in terms of the formation of clogging structures at the outlet, which are revealed to have higher stability when the particles align along the long axis. This generic result might be applied to many different systems flowing through bottlenecks such as microbial populations or different kind of cells. Indeed, it has already a straightforward connection with recent results of pedestrian (which self-propel transversally oriented) and mice or sheep (which self-propel longitudinally oriented).

Flow of anisometric particles in a quasi-two-dimensional hopper

The stationary flow field in a quasi-two-dimensional hopper is investigated experimentally. The behavior of materials consisting of beads and elongated particles with different aspect ratio is compared. We show, that while the vertical velocity in the flowing region can be fitted with a Gaussian function for beads, in the case of elongated grains the flowing channel is narrower and is bordered with sharper velocity gradient. For this case, we quantify deviations from the Gaussian velocity profile. Relative velocity fluctuations are considerably larger and slower for elongated grains.

Slow relaxation dynamics of clogs in a vibrated granular silo

We experimentally explore the vibration-induced unclogging of arches halting the flow in a two-dimensional silo. The endurance of arches is determined by carrying out a survival analysis of their breaking times. By analyzing the dynamics of two morphological variables, we demonstrate that arches evolve toward less regular structures and it seems that there may exist a certain degree of irregularity that the arch reaches before collapsing. Moreover, we put forward that σ (the standard deviation of all angles between consecutive beads) describes faithfully the morphological evolution of the arch. Focusing on long-lasting arches, we study σ calculating its two-time autocorrelation function and its mean-squared displacement. In particular, the apparent logarithmic increase of the correlation and the decrease of the mean-squared displacement of σ when the waiting time is increased reveal a slowing down of the dynamics. This behavior is a clear hallmark of aging phenomena and confirms the lack of ergodicity in the unclogging dynamics. Our findings provide new insights on how an arch tends to destabilize and how the probability that it breaks with a long sustained vibration decreases with time.

Clogging Transition of Vibration-Driven Vehicles Passing through Constrictions

We report experimental results on the competitive passage of elongated self-propelled vehicles rushing through a constriction. For the chosen experimental conditions, we observe the emergence of intermittencies similar to those reported previously for active matter passing through narrow doors. Noteworthy, we find that, when the number of individuals crowding in front of the bottleneck increases, there is a transition from an unclogged to a clogged state characterized by a lack of convergence of the mean clog duration as the measuring time increases. It is demonstrated that this transition-which was reported previously only for externally vibrated systems such as colloids or granulars-appears also for self-propelled agents. This suggests that the transition should also occur for the flow through constrictions of living agents (e.g., humans and sheep), an issue that has been elusive so far in experiments due to safety risks.

Friction controls even submerged granular flows

We investigate the coupling between the interstitial medium and granular particles by studying the hopper flow of dry and submerged systems experimentally and numerically. In accordance with earlier studies, we find that the dry hopper empties at a constant rate. However, in the submerged system we observe the surging of the flow rate. We model both systems using the discrete element method, which we couple with computational fluid dynamics in the case of a submerged hopper. We are able to match the simulations and the experiments with good accuracy by fitting the particle-particle contact friction for each system separately. Submerging the hopper changes the particle-particle contact friction from μ_vacuum = 0.15 to μ_sub = 0.13, while all the other simulation parameters remain the same.