Granule efficiency evaluation process using two-way CFD-DEM coupling analysis

[Display omitted] •This study focused on evaluating the granulation efficiency of a fluidized bed granulator for producing bio-based amino acids.•CFD-DEM two-way coupling is employed to assess granulation efficiency.•Both experiments and analyses were performed to determine the material properties of the powder, which were then integrated into DEM simulations for a thorough analysis.•The particle behavior characteristics for each process condition, classified according to the strength of the fluid, were analyzed, and the relative granulation efficiency was predicted.•Here, a procedure for evaluating the amount of granules based on the time spent in the granulation region is presented.•The granule amount and uniformity for each process condition are evaluated, and process characteristics are analyzed. Amino acid granulation using a fluidized bed is an important process that can improve the fluidity of powders and provide better process control. In this study, a granulation process evaluation procedure using numerical analysis is presented. Before analyzing the flow and particle behavior during the process, experiments and analyses such as pour angle of repose, drained angle of repose, and static angle of repose were performed to measure material properties and ensure the reliability of the numerical model. Material properties determined through experiments and numerical analyses were applied to an evaluation model of the granulation process. The granulation process is characterized by the interdependent behavior of a strong flow and large amounts of powder inside the equipment. A Computational Fluid Dynamics (CFD)-Discrete Element Model (DEM) coupled numerical model was presented for simulating particle and multiphase flow phenomena. Additionally, because there is a strong correlation between particle behavior and flow, a two-way coupling model was applied. The particle behavior characteristics are directly related to the granulation efficiency. Particle behavior was analyzed by setting four process conditions depending on the flow intensity. In this study, the concept of a dead zone was introduced to evaluate the kinetic performance of the particles under different process conditions. A dead zone is an area where the particles do not move actively and are unable to mix. The creation and size of the dead zone were compared based on the process conditions. Additionally, this study presents a procedure to evaluate the mass, volume, and size increase due to th