Analysis of process parameter sensitivities of jet-based direct mixing gas phase hetero-agglomeration by DEM/CFD-modelling

A new approach to the formation of hetero-agglomerates, originating from mixtures of particles of different materials, has been proposed and analysed. The aim is to develop a process capable of producing hetero-agglomerates with a high relative number of contacts between particles of different materials. The proposed process is a jet based mixing gas phase hetero-agglomeration approach where the particle systems are dispersed into the gas phase and brought together by two particle laden jets. The process is analysed using Discrete Element Method (DEM) one-way coupled with Computational Fluid Dynamics (CFD), including models for adhesive contact forces, turbulence-induced fluctuating fluid forces and Coulomb forces for charged materials. Particle mass flow, particle surface energy, jets relative alignment, gas inflow velocity, particle size and electrical charge are varied to understand their effect on the hetero-agglomerate formation. This allows conclusions to be drawn about process intensification that can be used in subsequent experimental investigations. [Display omitted] •Aim: Process optimisation of jet-based hetero-agglomeration in the gas phase.•Modelling: DEM/CFD coupling realizing for turbulence and particle adhesion.•Sensitivity study of process parameter influence on hetero-agglomeration.•Hetero-agglomeration influenced by residence time, concentration and adhesion.