Investigating mixing in a multi-dimensional rotary mixer: Experiments and simulations

Mixing is an important but poorly understood aspect in petrochemical, food, ceramics, fertilizer and pharmaceutical processing and manufacturing. Segregation and mixing phenomenon occur in most systems of powdered or granular solids and have a significant influence on their behavior. Deliberate mixing of granular solids is an essential operation in the production of industrial powder products usually constituted from different ingredients. The knowledge of particle flow and mixing in a blender is critical to optimize the design and operation. Since performance of the product depends on blend homogeneity, the consequence of variability can be detrimental. A common approach to powder mixing is to use a tumbling blender, which is essentially a hollow vessel horizontally attached to a rotating shaft. This single axis rotary blender is one of the most common batch mixers among in industry, and finds use in myriad of application as dryers, kilns, coaters, mills and granulators. In most of the rotary mixers, the radial convection is faster than axial dispersion transport. This slow dispersive process hinders mixing performance in many blending, drying and coating applications. A double cone mixer is designed and fabricated which rotates around two axes, causing axial mixing competitive to its radial counterpart. Discrete Element Method (DEM) based numerical model is developed to simulate the granular flow within the mixer. Digitally recorded mixing states from experiments are used to fine-tune the numerical model. Discrete pocket samplers are also used in the experiments to quantify the characteristics of mixing. A parametric study of the effect of initial loading, particle size, fill ratio, vessel speeds, on the granular mixing is investigated by experiments and numerical simulation. Incorporation of dual axis rotation enhances axial mixing by 60 to 90% in comparison to single axis rotation. Mixing is achieved faster with front–back initial loading than with side–side loading. Particle size and fill level are found to have no significant effect on mixing characteristics.