CFD simulation of the high shear mixing process using kinetic theory of granular flow and frictional stress models

In order to enhance process understanding and to develop predictive process models in high shear granulation, there is an ongoing search for simulation tools and experimental methods to model and measure the velocity and shear fields in the mixer. In this study, the Eulerian–Eulerian approach to model multiphase flows has been used to simulate the mixer flow. Experimental velocity profiles for the solid phase at the wall in the mixer have been obtained using a high speed camera following the experimental procedure as described by Darelius et al. [2007a. Measurement of the velocity field and frictional properties of wet masses in a high shear mixer. Chemical Engineering Science, 62, 2366–2374]. The governing equations for modelling the dense mixer flow have been closed by using closure relations from the kinetic theory of granular flow (KTGF) combined with frictional stress models. The free slip and partial slip boundary conditions for the solid phase velocity at the vessel wall have been utilized. The partial slip model originally developed for dilute flows by Tu and Fletcher [1995. Numerical computation of turbulent gas–solid particle flow in a 90∘90∘ bend. A.I.Ch.E. Journal, 41, 2187–2197] has been employed. It was found that the bed height could be well predicted by implementing the partial slip model, whereas the free slip model could not capture the experimentally found bed height satisfactorily. In the simulation, the swirling motion of the rotating torus formed was over-predicted and the tangential wall velocity was under-predicted, probably due to the fact that the frictional stress model needs to be further developed, e.g. to tackle cohesive particles in dense flow. The advantage of using the Eulerian–Eulerian approach compared to discrete element methods is that there is no computational limitation on the number of particles being modelled, and thus manufacturing scale granulators can be modelled as well.