L'objectif principal de ce travail de recherche est de contrôler l'évolution de la distribution des tailles de cristaux (DTC) dans un procédé de cristallisation en batch. Nous avons été amenés à chercher une résolution numérique du bilan de population et à proposer un algorithme rapide et précis. La méthode numérique a été étendue au cas de la taille des cristaux multidimensionnels en utilisant un maillage mouvant. Nous avons étudié le problème de la commandabilité du système à partir de son modèle discrétisé et puis à partir du modèle continu. Nous avons conçu une loi de commande en boucle fermée pour atteindre la DTC désirée à partir de la condition initiale. Pour compenser l'incertitude des paramètres du modèle, nous avons ajouté un second contrôle par retour d'état afin d'assurer la poursuite de la DTC désirée en présence de l'incertitude des paramètres. Nous avons construit un observateur qui nous permet d'avoir en ligne l'estimation des variables d'états. Ces variables d'état estimées sont utilisées dans la synthèse de la loi du contrôle / The main objective of this research is to control the evolution of the Crystal Size Distribution (CSD) in a batch crystallization process. We are led to study a numerical resolution of the population balance and propose an algorithm for fast and accurate simulation. This method was extended to the case of the two-dimensional crystal by using a moving mesh. We studied the problem of controllability of the system from its discretized model and then from the continuous model. To compensate the uncertainty of the model parameters, we added the second state feedback control to ensure the tracking of the desired CSD in presence of parameter uncertainty. We constructed an observer who provides us with on-line estimation of state variables. These state variables estimated are used in the control law synthesis

Un modèle complet permettant de simuler la dynamique d'un nano-aérosol est présenté et discuté. On considère une équation Eulérienne de type « Diffusion-Inertia » réécrite en moments en incluant un terme source de coagulation. Le phénomène de dépôt est pris en compte par l'intermédiaire d'une condition aux limites sur le flux de moments à la paroi. L'expression de la granulométrie en moments permet d'obtenir une très bonne efficacité de calcul et rend ainsi le modèle utilisable pour des applications industrielles ou en santé au travail. L'implémentation de cette approche dans un code de CFD est validée sur des cas simples par comparaison avec une méthode des classes ainsi que des données expérimentales. La méthode des moments n'introduit pas de biais particulier et les résultats numériques sont en accord avec les résultats expérimentaux. Un nouveau dispositif expérimental, qui consiste en une enceinte ventilée, est également proposé afin de maîtriser au mieux l'écoulement et de caractériser la morphologie des agrégats générés. La confrontation entre les résultats numériques et expérimentaux met en évidence le fait que la détermination des paramètres fractals est un élément clé de la modélisation / A complete CFD model for nano-aerosol dynamics is presented and discussed. It consists in an Eulerian "Diffusion-Inertia" equation including a coagulation source term which is rewritten in terms of moments. Deposition phenomenon is taken into account by means of a boundary condition on the flux of moments at walls. The moment transformation allows good computational performances and makes thus the model tractable for industrial and occupational health applications. The implementation of this approach into a CFD code is assessed for simple cases by comparison with sectional approach results and experimental data. These comparisons show that the method of moments does not induce particular bias and that numerical results are in good agreement with available experimental data. An experimental set-up, which consists in a ventilated chamber, is also proposed for allowing a good control of the flow and for allowing the investigation of aggregates morphology. The confrontation between numerical and experimental results highlights that the determination of the fractal parameters is a modelling key point

L'objectif de cette étude est de développer une méthodologie permettant de déterminer et de mettre en \oe{}uvre les conditions opératoires optimales du procédé fed-batch de copolymérisation en émulsion du styrène et de l'acrylate de butyle en présence d'un agent de transfert de chaîne (CTA). Elle vise particulièrement à optimiser la production et les caractéristiques physico-chimiques de particules de latex à propriétés d'usage ciblées. Après une étude expérimentale de l'impact des différents facteurs, le modèle mathématique du procédé a été développé traduisant l'effet particulier de l'agent de transfert de chaîne sur la cinétique de polymérisation et mettant l'accent sur une les bilans de population. Une approche basée sur l'analyse de l'estimabilité des paramètres a ensuite permis de sélectionner 21 paramètres parmi les 49 paramètres du modèle mathématique dont les valeurs ont été identifiées grâce à un algorithme génétique. Le modèle mathématique validé en modes batch et fed-batch a ensuite été exploité pour l'optimisation multicritère du procédé orientée vers la maximisation de la production de particules de latex possédant une morphologie de type coeur-écorce avec un profil de température de transition vitreuse prédéfini. L'ensemble des solutions du front de Pareto a été obtenu grâce à un algorithme évolutionnaire développé et testé à cet effet. La meilleure alternative obtenue grâce à un outil d'aide à la décision a été implémentée expérimentalement et comparée avec succès aux prédictions du modèle mathématique / The objective of this study is to develop a methodology in order to determine and implement the optimal operating conditions of the emulsion fed-batch copolymerization process of styrene and butyl acrylate in the presence of a chain transfer agent. It particularly aims to optimize the production and the physico-chemical characteristics of latex particles with targeted end-use properties. After an experimental study, the process model has been developed taking into account the particular effect of the chain transfer agent on the polymerization kinetic and highlights the population balance. Thanks to an estimability analysis approach, 21 parameters among the 49 parameters of the model have been selected whose values have been identified by using a genetic algorithm. The mathematical model validated in both batch and fed-batch modes was then exploited for the multicriteria optimization of the process oriented towards the maximization of the production of latex particles having a core-shell type morphology with a given glass transition temperature profile. The Pareto's front solutions were obtained thanks to an evolutionary algorithm developed and tested for this purpose. The best alternative obtained by a decision-making aid tool was finally experimentally implemented and successfully compared with the predictions of the mathematical model

In this study, the effect of speed was investigated on the breakage rate of UG2 platinum ore in a batch mill of 5 dm3 and 175 mm internal diameter. One size fraction method was carried out to perform the experiment. Five mono-sized fractions in the range of 1.180 mm to 0.212 mm separated by √2 series interval were prepared. The fractions were milled at different grinding times (0.5, 2, 4, 15 and 30 min) and three fractions of mill critical speed were considered (20%, 30%, and 40%). The target of critical speed below 50% was due to the need of lower energy consumption in milling processes. The selection and breakage function parameters were determined and compared for fractions of critical speed. First the grinding kinetics of the ore was determined and it was found that the material breaks in non-first order manner. Thereafter, effective mean rate of breakage was determined. It was found that the rate of breakage increased with increase of mill speed and optimum speed was not reached in the range of chosen mill speed fractions. Again the rate of breakage was plotted as a function of particle size, the optimum size was 0.8 mm when milling at 30% critical speed. As for 20% and 30% optimum size was not reached. The selection function parameters estimated at 30% critical speed were 𝑎0 = 0.04 min−1 , 𝛼 = 1.36, 𝜇 = 0.9 mm, and Λ = 3. Breakage function parameters were determined and was noticed that the material UG2 platinum ore is non-normalised, i.e. Φ value was changing from 0.25 to 0.90 depending on feed size and mill speed. The parameters 𝛽 and 𝛾 were constant at 7.3 and 1.17 respectively. / College of Science, Engineering and Technology / M. Tech. (Chemical Engineering)

In einem Verbundprojekt im Rahmen des Programms „Energie 2020+“ gefördert durch das BMBF koordiniert durch das HZDR arbeiteten 4 Universitäten, 2 Forschungszentren und ANSYS zusammen. Der vorliegende Bericht beschreibt die Arbeiten des HZDR, die im Zeitraum September 2009 bis Januar 2013 durchgeführt wurden. Das Vorhaben war auf die Entwicklung und Validierung von CFD-Modellen von unterkühltem Sieden bis zu Filmsieden gerichtet. Im Bericht werden die entwickelten und verwendeten Modelle dargestellt. Anhand der Nachanalyse von Experimenten wird auf die vorgeschlagene Kalibrierung der Modelle eingegangen. Wichtig ist hierbei eine genauere Beschreibung der Zwischenphasengrenzfläche, die durch Kopplung des Wandsiedemodells mit einem Populationsmodell erreicht werden kann. Anhand der Analyse von Bündelexperimenten konnte gezeigt werden, dass die gemessenen querschnittsgemittelten Messwerte mit einem Satz im Rahmen der Modellunsicherheiten kalibrierter Modellparameter reproduziert werden kann. Für die Berechnung der Verteilungsmuster des Dampfgehaltes im Kanalquerschnitt muss die Modellierung der Turbulenz beachtet werden. Die experimentellen Arbeiten waren auf die Untersuchung eines Brennelementbündels gerichtet. An einer Versuchsanordnung zu einem Brennelementbündel werden die turbulente einphasige Geschwindigkeit (PIV), der mittlere Gasgehalt (Gamma-Densitometrie) sowie der zeitlich und räumlich aufgelöste Gasgehalt (Hochgeschwindigkeits-Röntgentomographie) gemessen. Letztere Methode wurde in Rossendorf entwickelt.

<p dir="ltr">The dissolution profile is one of the most important critical quality attributes (CQAs) for pharmaceutical solid oral dosage forms, as failure to meet the dissolution specification can impact bioavailability. Dissolution tests are essential to assess lot-to-lot product quality and guide the development of new formulations. Therefore, predictive dissolution reduced-order models (ROM) are crucial for the successful implementation of any real-time release testing (RTRT) strategy. Mechanistic and semi-mechanistic ROMs of tablet dissolution for realizing quality by control (QbC) and RTRT frameworks in continuous manufacturing are still scarce or nonexistent. Moreover, realizing the underlying coupled mechanics of wetting, swelling, disintegration, and dissolution is still an open question. This dissertation contributes to developing a mechanistic ROM of pharmaceutical tablet dissolution for the design, optimization, and control of manufacturing processes. We follow several steps towards the progression of the mechanistic model development. First, we develop a semi-mechanistic ROM to capture the relationship between critical process parameters (CPPs), critical material attributes (CMAs), and dissolution profiles. We demonstrate the versatility and the capability of the semi-mechanistic ROM to estimate changes in dissolution due to process disturbances in tablet porosity, lubrication conditions, and moisture content in the powder blend. Next, to understand the underlying coupled mechanism of wetting, swelling, disintegration, and dissolution, we use dynamic micro-computed tomography (micro-CT) with a high temporal resolution to visualize water penetration through the porous network of immediate-release tablets. We couple liquid penetration due to capillary pressure described by the Lucas-Washburn theory with the first-order swelling kinetics of the excipients to provide a physical interpretation of the experimental observations. From the mechanistic understanding of the water penetration kinetics using the micro-CT tests, we propose a two-stage mechanistic ROM, which is comprised of (i) a mechanistic dissolution model of the active pharmaceutical ingredient (API) that solves a population balance model (PBM) for a given API crystal size distribution and dissolution rate coefficient, and (ii) a tablet wetting function that estimates the rate at which the API is exposed to the buffer solution. These two sub-models are coupled by means of convolution in time to capture the start time of the API dissolution process as water uptake, swelling, and disintegration take place. Finally, we demonstrate the versatility and the capability of the mechanistic API dissolution model and the two-stage tablet dissolution ROM to represent the dissolution profile of different pharmaceutical formulations and its connection with CMAs, CPPs, and other CQAs, namely initial API crystal size distribution, porosity, composition, and dimensions of the tablet. In all of the cases considered in this work, the estimations of the model are in good agreement with experimental data. </p>

Kansanshi mine sulphide ore circuit did not achieve target flotation recovery in 2016, hence it was deemed necessary to carry out a research aimed at optimizing this circuit. The objective of the research was to optimise the Kansanshi milling and flotation circuit processing a copper sulphide ore. In line with this, samples were obtained around the circuit and processed in the laboratory for moisture content, slurry concentration, particle size distribution, and flotation response. This information was then used to build a computer-based model of the Kansanshi milling and flotation circuit. This was done in MODSIM®, a software package specialising in the design and simulation of mineral processing operations. After careful appraisal, appropriate models were selected for the semi autogenous grinding (SAG) and ball mills, SAG mill discharge screen, hydrocyclones, pebble crusher, and the flotation cells. The calibrated model was then used to simulate the effects of key operating parameters on flotation recovery. Analysis using the attainable region technique revealed that the SAG mill feed-rate should be adjusted from 1719 tph to 2090 tph. This would lead to a better utilisation of the pebble crusher that can process 358 tph of pebbles from the current 198 tph. From the simulation work, it was established that rougher flotation recovery can be improved from the current 80.0 % to 82.3 %. The technoeconomic benefits of the proposition are yet to be investigated. Findings from the research concluded that the milling circuit optimum operating parameter; which generated a final product falling predominantly in the range - 150 +38 μm were SAG and ball mills conditions of ball sizes 200 and 40mm respectively, ball mill ball filling 32% and rotational speed between 75 and 80% for both SAG and ball mills. The optimum hydrocyclone feed slurry concentration was found to be 62% solids. Additionally, the SAG mill discharge screen aperture size of 6 mm was the optimum. It must be noted that slurry concentration did not show any impact on both the SAG and ball mills performance. The SAG mill ball filling did not show any significant improvement on performance. / College of Engineering, Science and Technology / M. Tech. (Chemical Engineering)