Multi-scale modeling of granulation processes: Bi-directional coupling of PBM with DEM via collision frequencies

Wet granulation is a complex particle design process often operated inefficiently in industrial applications. Enhanced process understanding is required to facilitate design, control, and optimization. In this study, a hybrid multi-scale model is presented using a bi-directional coupling approach between DEM and PBM. The hybrid model takes into account particle collision frequencies and liquid distribution, providing a framework suitable for the complex sub-processes in wet granulation. The effect of particle size distribution on the collision frequency function was demonstrated, indicating the need for a multi-scale model. Results of the hybrid model show an increase in particle size over time from an average diameter of 0.98 mm to 2.5 mm, which qualitatively agrees with experimental trends observed during the liquid addition and wet massing stages. Two-dimensional distributions in particle size and liquid fraction are also presented incorporating the key effect of liquid distribution on the evolution of granule PSD.