Granular flow and segregation in a four-bladed mixer

In this study, we experimentally examine flow and segregation of granular material in a cylindrical mixer geometry agitated by four 45∘45∘ pitched blades, which is representative of equipment such as high-shear granulators and filter-dryers. We observe that the free surface of the granular bed deforms, rising where the blades are present and falling between blades passes. Using particle image velocimetry (PIV), we measure the instantaneous, average, and fluctuating velocity fields at exposed surfaces (top surface and near the wall), for both near-monodisperse and polydisperse granular materials. The radial and axial point-velocity profiles indicate three-dimensional recirculation patterns indicative of avalanching and bed penetration. For polydisperse mixtures, we find that depending on the shear rate, different segregation mechanisms can take place. Under low shear, complex lobe and striation segregation patterns occur through stretching and folding due to surface avalanching. This leads to enhanced initial mixing rates in a manner consistent with spontaneous chaotic granular mixing. At high-shear rates, segregation is controlled by the rotation of the blades. As a result, coarse particles have a tendency to migrate both to the free surface and the outer wall independently of initial bed loading conditions.