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• W173806037 abstract "Since the beginning of the 1960s, agglomeration process has been a commonly used and important unit-operation to convert fine powders to granular materials with controlled physical properties in many industrial sectors, from the pharmaceutical industry to fertilizer, food or detergents production and to the mineral processing industries (Iveson et al., 2001). Agglomeration and related process cover a wide range of application which handle particulate feeds, intermediates or products. This in itself is testimony to the value of this operation. However, in spite of its widespread use, economic importance and almost 50 years of research, agglomeration has in practice remained more of an art than a science.Wet granulation process is a subset of size enlargement methods, which involves any process whereby small particles are formed into structural, larger and physically strong aggregates (granules) in which the original particles can still be identified. This is performed by adding a liquid binder onto the powder mass and by the agitation imposed through an impeller turning at moderate to high speed in a tumbling drum, fluidized bed, low and high shear mixer or similar device. A chopper, with the function as a breakage device is often situated inside the vessel. The liquids binds the single primary particles together by a combination of capillary and viscous forces until more permanent bonds are formed by subsequent drying.Wet granulation process have been traditionally been considered an empirical art, with great problems in predicting and understanding observed behaviour. Industries dealt with a range of problems caused by improper granulation such as segregation, caking and poor product performances.In the last decades, there have been significant advancements in understanding of the mechanisms of size enlargement. Quantitative prediction of granules attributes is difficult but we have a qualitative understanding of the effects of different variables on granulation behaviour.However in the literature most reports on granulation process have focused on the agglomeration of pharmaceutical ingredients (microcrystalline cellulose powder, lactose, mannitol, calcium carbonate powder) with common polymeric binders for instance hydroxypropyl-cellulose (HPC), polyvinylpyrrolidone (PVP) and polyethylene glycol (PEG) in high - shear mixer.No published work has been found in the literature on how the wet granulation is sensitive to changes in product properties (binder viscosity, powder wettability) and process variables (impeller rotational speed, mixing time) in the case of mineral and metallic powders. Moreover there is a limited data available on wet granulation in low shear mixer.The need of additional research is obvious and this forms the motivation of the main part of this work.Since agglomeration process is often required to prevent segregation of critical components in a powder mixture, the present work deals also with this problem which is of particular interest to those industries where homogeneity is a critical requirement. In particular in the pharmaceutical industry demixing during handling and processing of such granules might give problems in meeting the demands on the content uniformity of the final dosage form. However not only the drug substance is susceptible to demixing. but also pharmaceutical filler materials tend to segregate. A good granulation process can therefore create designed structure agglomerates having similar size and composition, thus reducing segregation of materials.The present research mainly focuses on the low shear wet agglomeration of mineral and metallic powders. Particularly, this experimental study is a practical framework of binder granulation which takes place in the process of manufacturing of welding rods. The aim of this work is to better understand the effect of starting materials properties (e.g. formulation composition, primary particle size distribution) and operating parameters (e.g. mixing speed, agglomeration time) on the final granules attributes. The effect of binder properties such as viscosity, surface tension on the final granule characteristics were investigated as well. Particular attention has also paid to the effect of particle size on the internal structure of granules and to investigate this effect the process of seeded granulation is simulated by the Discrete Element Method (DEM). Finally a new sampling device for assessing the composition of granulated powder mass and for finding evidence of segregation during agglomeration process is developed and characterized. The research activities were mainly carried out in:-Dipartimento di Principi e Impianti Ingegneria Chimica “I. Sorgato”, Universita degli Studi di Padova, Padova (Italy);-Trafilerie di Cittadella, Fileur®, RD -Institute of Particle Science and Engineering, University of Leeds, Leeds (UK).Results of research activities are here summarized in five chapters:-Chapter 1 gives a brief overview on the main powder agglomeration process and on the techniques for measurement of contact angles on powder surface. A brief description of segregation mechanisms which can occur during agglomeration is also provided; -in Chapter 2 wettability of mineral and metallic solids is characterized, particularly applicability and limitations of sessile drop method and Washburn technique on metallic surface are discussed;-the experimental study of agglomeration of mineral and metallic powders in a low shear pilot plant is described by Chapter 3. The effects of physical properties of starting feed and the operative variables on the granule characteristics are analyzed as well in this chapter;-Chapter 4 is about the application of Discrete Element Method (DEM) for simulation of seeded granulation;-in Chapter 5 a new sampling device for evaluating the composition of bulk solids is presented;-conclusions and proposals for future work can be found in Chapter 6." @default.
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• W173806037 date "2012-01-16" @default.
• W173806037 modified "2023-09-27" @default.
• W173806037 title "Low shear wet agglomeration of mineral and metallic powders" @default.
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