Computer simulation of the packing of fine particles

Effects of the deformation and size of the upper airway on the deposition of aerosols

Aerosol drug delivery in the human airway is significantly affected by the morphology and size of the airway. This work developed a CFD-DEM model to simulate and analyze air flow and powder dynamics in combined inhaler-airway systems with different degrees of airway deformation (non-deformed, 50%, and 75% deformed) and sizes (adult, 0.80, and 0.62 scaled). The airways were generated based on a regular airway constructed from the MRI images through finite element method (for deformed airways) or scaling-down (for smaller airways). The airways were connected to Turbuhaler® through a connector. The results showed that under the same flow rate, the variation in the airway geometry and size had a minimum impact on the flow field and powder deposition in the device and the connector. However, deformation caused more particle deposition in the deformed region. Notably, the airway with 50% deformation had the most particles passing through the airway with the largest particle sizes due to its lower air velocity in the deformed area. Reducing airway size resulted in more powder deposition on the airway, particularly at the pharynx and mouth regions. This was because, with the same flow rate, the flow velocity in the smaller airway was higher, causing more particle-wall collisions in the mouth and pharynx regions. More importantly, the deposition efficiency in the 0.62-scaled airway was significantly higher than the other two airways, highlighting the importance of the different administration of aerosol drugs for young children.

CFD-DEM investigation of the effects of aperture size for a capsule-based dry powder inhaler

Capsule based dry powder inhalers (DPIs) often require piercing of the capsule before inhalation, and the characteristics of the apertures (punctured holes) affect air flow and the release of powders from the capsule. This work develops a numerical model based on the two-way coupling of computational fluid dynamics and discrete element method (CFD-DEM) to investigate the effect of aperture size on powder dispersion in the Aerolizer® device loaded with only carrier particles (lactose). Powders (carrier particles) in the size range 60-140 μm (d50: 90 μm and span: 0.66) were initialized in a capsule which had a circular aperture at each end. Boundary conditions corresponding to an air flow rate of 45 L/min were specified at each inlet to the mixing chamber (i.e., a total flow rate 90 L/min), and a capsule spin speed of ∼ 4050 rpm. The velocity magnitudes inside the capsule were considerably lower than those in the mixing chamber in the vicinity of the rotating capsule, with the exception of the capsules featuring 2.5 mm and 4 mm apertures. Larger apertures reduced the capsule emptying time and increased the particle evacuation velocity; the fluid drag force on the particles issuing from the capsule peaked for an aperture of 1.3 mm. Inside the capsule, particle-particle (PP) collisions were more frequent than particle-wall (PW) collisions due to high concentration of powder, but PP collisions had smaller (median) impact energy than PW collisions. Larger apertures resulted in fewer collisions in the capsule with higher PW and virtually unchanged PP collision energies. Outside the capsule (i.e., in the inhaler mixing chamber), PW collisions occurred more frequently than PP collisions with median collision energies typically two orders of magnitude higher than inside the capsule. Larger apertures resulted in more collisions with slightly reduced collision energy, but this effect plateaued for aperture sizes larger than 1.3 mm. Powder dispersion, expressed as the fine particle fraction (FPF) of the powder, was predicted using an empirical equation based on carrier PW collisions. Therefore, consistent with the model prediction of the effect of aperture sizes on the chamber collision frequency, FPF increased with aperture size but plateaued beyond 1.3 mm.

Study on the Powder-Spreading Process of Walnut Shell/Co-PES Biomass Composite Powder in Additive Manufacturing

Powder laying is a necessary procedure during powder bed additive manufacturing (PBAM), and the quality of powder bed has an important effect on the performance of products. Because the powder particle motion state during the powder laying process of biomass composites is difficult to observe, and the influence of the powder laying process parameters on the quality of the powder bed is still unclear, a simulation study of the biomass composite powder laying process during powder bed additive manufacturing was conducted using the discrete element method. A discrete element model of walnut shell/Co-PES composite powder was established using the multi-sphere unit method, and the powder-spreading process was numerically simulated using two different powder spreading methods (rollers/scrapers). The results showed that the quality of powder bed formed by roller laying was better than that formed by scrapers with the same powder laying speed and powder laying thickness. For both of the two different spreading methods, the uniformity and density of the powder bed decreased as spreading speed increased, although the spreading speed had a more important influence on scraper spreading compared to roller spreading. As powder laying thickness increased, the powder bed formed by the two different powder laying methods became more uniform and denser. When the powder laying thickness was less than 110μm, the particles were easily blocked at the powder laying gap and are pushed out of the forming platform, forming many voids, and decreasing the powder bed's quality. When the powder thickness was greater than 140 μm, the uniformity and density of the powder bed increased gradually, the number of voids decreased, and the quality of the powder bed improved.

Study of CFD-DEM on the Impact of the Rolling Friction Coefficient on Deposition of Lignin Particles in a Single Ceramic Membrane Pore

The discrete element method coupled with the computational fluid dynamic (CFD-DEM) method is effective for studying the micro-flow process of lignin particles in ceramic membranes. Lignin particles may exhibit various shapes in industry, so it is difficult to model their real shapes in CFD-DEM coupled solutions. Meanwhile, the solution of non-spherical particles requires a very small time-step, which significantly lowers the computational efficiency. Based on this, we proposed a method to simplify the shape of lignin particles into spheres. However, the rolling friction coefficient during the replacement was hard to be obtained. Therefore, the CFD-DEM method was employed to simulate the deposition of lignin particles on a ceramic membrane. Impacts of the rolling friction coefficient on the deposition morphology of the lignin particles were analyzed. The coordination number and porosity of the lignin particles after deposition were calculated, based on which the rolling friction coefficient was calibrated. The results indicated that the deposition morphology, coordination number, and porosity of the lignin particles can be significantly affected by the rolling friction coefficient and slightly influenced by that between the lignin particles and membranes. When the rolling friction coefficient among different particles increased from 0.1 to 3.0, the average coordination number decreased from 3.96 to 2.73, and the porosity increased from 0.65 to 0.73. Besides, when the rolling friction coefficient among the lignin particles was set to 0.6-2.4, the spherical lignin particles could replace the non-spherical particles.

Analytical modelling of soil porosity and bulk density across the soil organic matter and land-use continuum

The thin layer of soil at the earth's surface supports life, storing water and nutrients for plant uptake. These processes occur in the soil pore space, often half the soil volume, but our understanding of how this volume responds to environmental change is poor. Convention, has been to predict soil porosity, or its reciprocal bulk density (BD), from soil texture using pedotransfer functions (PTFs). A texture based approach, invariant to environmental change, prevents feedback from land use or climate change to soil porosity. Moreover, PTFs are often limited to mineral soils with < 20% soil organic matter (SOM) content. Here, we develop an analytical model to predict soil porosity, or BD, as a function of SOM. We test it on two comprehensive, methodologically consistent, temperate national-scale topsoil data sets (0-15 cm) (Wales, n = 1385; Great Britain, n = 2570). The purpose of the approach is to generate an analytical function suitable for predicting soil porosity change with SOM content, while providing insight into the main grain-scale factors determining the porosity emergence. The newly developed function covering the entire SOM gradient allows for impacts of land use, management or climate change to feedback on soil porosity or bulk density through decadal dynamic changes in SOM.

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.

Neighborhood Relationships of Widely Distributed and Irregularly Shaped Particles in Partially Dewatered Filter Cakes

A more thorough understanding of the properties of bulk material structures in solid–liquid separation processes is essential to understand better and optimize industrially established processes, such as cake filtration, whose process outcome is mainly dependent on the properties of the bulk material structure. Here, changes of bulk properties like porosity and permeability can originate from local variations in particle size, especially for non-spherical particles. In this study, we mix self-similar fractions of crushed, irregularly shaped Al2O3 particles (20 to 90 µm and 55 to 300 µm) to bimodal distributions. These mixtures vary in volume fraction of fines (0, 20, 30, 40, 50, 60 and 100 vol.%). The self-similarity of both systems serves the improved parameter correlation in the case of multimodal distributed particle systems. We use nondestructive 3D X-ray microscopy to capture the filter cake microstructure directly after mechanical dewatering, whereby we give particular attention to packing structure and particle–particle relationships (porosity, coordination number, particle size and corresponding hydraulic isolated liquid areas). Our results reveal widely varying distributions of local porosity and particle contact points. An average coordination number (here 5.84 to 6.04) is no longer a sufficient measure to describe the significant bulk porosity variation (in our case, 40 and 49%). Therefore, the explanation of the correlation is provided on a discrete particle level. While individual particles < 90 µm had only two or three contacts, others > 100 µm took up to 25. Due to this higher local coordination number, the liquid load of corresponding particles (liquid volume/particle volume) after mechanical dewatering increases from 0.48 to 1.47.

DEM investigation of the effect of particle breakage on compact properties

Particle breakage during compaction affects compaction behavior and the quality of the formed compact. This work conducted a numerical study based on the discrete element method (DEM) to investigate the effect of particle breakage on compaction dynamics and compact properties, including particle size and density distributions, and pore properties. A force-based breakage criterion and Apollonian sphere packing algorithm were employed to characterize particle breakage behavior. The pore structures of the compacts were characterized by the watershed pore segmentation method. Calibrated with experimental data, the model was able to simulate the stress-strain relation comparable with experimental observation. During compaction, the particles were gradually broken from top to bottom with increasing pressure. Both density and pore size of the compacts had relatively uniform distribution at larger stress, while the pore size decreased sharply when the particles started to break, indicating that the smaller fragments in the compact system have a significant effect on the pore size distribution.

X-ray nanotomography of dry colloidal packings

Random packings are crucial in understanding arrangement and geometry of particles. Random packings of dry small particles may be subject to adhesion or friction, as expected theoretically and numerically. We explore experimentally random packings of dry colloids with X-ray nanotomography that directly provides three-dimensional structural and geometric information of dry colloidal packings. We find that dry colloidal packings, as characterized by contact number and packing density, are quite consistent with adhesive loose packings that significantly deviate from random loose packings for hard spheres. This study may offer direct evidence for adhesive loose packings comprising dry small particles, as proven by X-ray nanotomography.

Application of the Discrete Element Method for Manufacturing Process Simulation in the Pharmaceutical Industry

Process simulation using mathematical modeling tools is becoming more common in the pharmaceutical industry. A mechanistic model is a mathematical modeling tool that can enhance process understanding, reduce experimentation cost and improve product quality. A commonly used mechanistic modeling approach for powder is the discrete element method (DEM). Most pharmaceutical materials have powder or granular material. Therefore, DEM might be widely applied in the pharmaceutical industry. This review focused on the basic elements of DEM and its implementations in pharmaceutical manufacturing simulation. Contact models and input parameters are essential elements in DEM simulation. Contact models computed contact forces acting on the particle-particle and particle-geometry interactions. Input parameters were divided into two types-material properties and interaction parameters. Various calibration methods were presented to define the interaction parameters of pharmaceutical materials. Several applications of DEM simulation in pharmaceutical manufacturing processes, such as milling, blending, granulation and coating, were categorized and summarized. Based on this review, DEM simulation might provide a systematic process understanding and process control to ensure the quality of a drug product.

Unified size-density and size-topology relations in random packings of dry adhesive polydisperse spheres

We study the size-density and size-topology relations in random packings of dry adhesive polydisperse microspheres with Gaussian and lognormal size distributions through a geometric tessellation. We find that the dependence of the neighbor number on the centric particle size is always quasilinear, regardless of the size distribution, size span, or interparticle adhesion. The average local packing fraction as a function of normalized particle size for different size variances is well regressed on the same profile, which increases to larger values as the relative strength of adhesion decreases. The variations of the local coordination number with the particle size converge onto a single curve for all adhesive particles, but gradually transfer to another branch for nonadhesive particles. Such adhesion-induced size-density and size-topology relations are interpreted theoretically with a modified geometrical "granocentric" model, where the model parameters are dependent on a single dimensionless adhesion number. Our findings, together with the modified theory, provide a more unified perspective on the substantial geometry of amorphous polydisperse systems, especially those with fairly loose structures.