Investigating the effects of material properties on the mixing dynamics of cohesive particles in a twin screw mixer using a discrete element method approach

A discrete element method (DEM) model was developed for a co-rotating twin-screw mixer (TSM) consisting of conveying and kneading elements. This model was used to simulate the mixing of a cohesive binary system of particles (P1 and P2). The particles were calibrated using angle of repose and dynamic yield strength simulations. Properties of P1 were kept constant throughout the study while properties of P2 were varied. The TSM model was used to study the influence of particle size, density, and flowability of P2 on process outputs such as powder holdup, mean residence time (MRT), and degree of mixing along the length of the TSM. All the three particle properties were varied at three-factor levels with flowability ranging from good flow (GF), poor flow (PF), and very very poor flow (VVPF) based on Carr's classification. The model provides fundamental insights into the differences in mixing in the conveying sections of the mixer for materials with different flowability. Due to the co-rotating nature of the screws, the majority of the material in the conveying sections was carried on one side of the TSM for GF and PF particles, while both the screws carried VVPF particles. The total steady-state holdup and the mean residence time (MRT) of particles inside the TSM were heavily influenced by particle flowability compared to the other two tested particle parameters. The holdup in the conveying compartments ranged from 11%-15% of the total holdup, while the kneading compartment comprised 40% of the total holdup in the mixer. The simulations found that VVPF particles mixed the fastest and that the GF particles had the highest tendency to demix. The model was also used to suggest and test other screw design configurations to improve mixing. A screw design with kneading elements closer to the mixer outlet resulted in better mixing of GF particles. A screw design consisting only of conveying elements achieved the same degree of mixing as the original screw design for VVPF particles.