The effect of the operating conditions of three continuous high shear granulators on the internal structure and strength of granules has been investigated and the possibility of seeded granulation has been explored. In a recently concluded programme of research on the scale-up of a high shear granulator, Cyclomix (manufactured by Hosokawa Micron B.V., The Netherlands), a novel method of granulation called seeded granulation was introduced, where each granule contained, at its core, a large particle from the upper tail end of the feed particle size distribution. Seeded granulation is particularly useful for process control of continuous granulators as there is the potential to control granulation by the flow rate of the seed particles. Hence, the performance of three different types of continuous granulators in terms of granule strength and structure has been evaluated here; these are Extrudomix, Modulomix (manufactured by Hosokawa Micron, UK and The Netherlands, respectively) and the Nica M6 Turbine continuous granulator (manufactured by GEA, UK). Calcium carbonate (Durcal 65) powder was granulated using an aqueous solution of polyethylene glycol (PEG) as binder in the same ratio as used previously in our batch granulation, to allow comparison between the continuous and batch processes. The crushing strength was characterised by quasi-static side crushing between two platens using a mechanical testing machine. The internal structure and morphology were evaluated by scanning electron microscopy and the extent of seeding quantified. Granules produced in all the three continuous granulators were significantly weaker than those of the batch granulator tested previously. Among the continuous granulators only the Modulomix granulator produced some seeded granules. It is considered that longer residence time is necessary to produce seeded granules.

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The fluid bed granulation is a well-established method how to improve such properties of powders as flowability and increase content uniformity of the tablets. In this thesis, there was evaluated a granulation process on a lab scale fluid Glatt bed granulator and optimized for highest possible yield. Product yield in the size range of 80-90 % of granules and process reproducibility were stated as most effective. The product was analysed for its particle size distribution, the API distribution within the different particle size fractions and the flowability of the final granules. For process optimization, the most critical parameters such as spraying rate, particle size of raw materials and fluid bed pressure were identified and evaluated. As the highest-yielding dosage for the powder binder was found the spraying rate of 9 g/min. Changes in bed fluid pressure and nozzle pressure showed no significant improvement. Different grades of caffeine were compared for their impact on the granulation properties. Sieved caffeine enhanced yield of the product and reproducibility compared to bulk or disagglomerated caffeine.

Detta examensarbete har ämnat konstruktionen av en strimlare för att sönderdela kasserad PLA-plast från 3d-skrivarna i verkstaden på Mälardalens universitet. Målet med detta arbete var att underlätta återvinning men även möjliggöra återbruk av materialet genom att skapa nytt filament av den sönderdelade plasten som åter kan användas av 3d-skrivarna och därmed minska behovet av att köpa in nytt filament. För att planera detta arbete har projektgruppen använt sig av ett Gantt schema som skapades under arbetets tidiga fas.   Projektgruppens arbete har bestått av att utvärdera befintliga lösningar så som en granulator och strimlare för att sedan välja ut den bäst lämpade maskinen att konstruera för ändamålet. Under arbete utfördes även en fallstudie för att skapa en uppfattning om hur stor kraft som behövs för att sönderdela PLA-plast.   I detta uppdrag har projektgruppen använt sig av utvärderingsmetoden FMEA tillsammans med föreskrifter från arbetsmiljöverket för att konstruera bort eller minimera risker som kan orsaka skada på maskin och användare.   För att verifiera den framtagna konstruktionens hållbarhet har FEM analys använts i ett flertal fall med syftet att undersöka säkerhetsfaktorer och spänningsfördelningar under belastning.   Resultatet av detta arbete presenteras som en CAD modell i formen av en strimlare med tillhörande elektronik. Till största del möter den slutliga konstruktionen de förbestämda kraven specificerade av kunden med ett undantag gällande den önskade vikten som överskreds på grund utav den tunga snäckväxeln som implementerades i konstruktionen för att möta det utmätta kraftbehovet. Arbetet anses har skapat en grund för fortsatt arbete att byggare vidare på och vidareutveckla med nya idéer och lösningar. / This thesis consists of the construction of a shredder to shred discarded PLA-plastic from the 3d-printers in the workshop at Mälardalens University. The aim of this assignment was to ease the recycling process, but also enable the possibility to reuse the shredded plastic to make new filament that can be used by the 3d-printers and thereby decrease the need to purchase new filament.  To plan this project, the project group used a Gantt chart that was created during the project's infancy.   The work has consisted of evaluating existing solutions such as a granulator and a shredder in order to pick the best-suited machine to construct. During the assignment, a case study was also conducted with the aim of creating an understanding of how much force is needed to shred PLA-plastic.   In this assignment, the project group has used the evaluation method FMEA together with regulations from The Swedish Work Environment Authority to remove or minimize risks that can cause damage the machine or harm the user.   To verify the durability of the machine, FEM analysis was implemented in multiple cases with the purpose of examining safety factors and material stress under load.   The result for the work produced is presented as a CAD model in the form of a shredder together with the electronics. For the most part, the finished machine meets the pre-determined requirements except for the desired weight, which was exceeded because of the heavy worm gear that got implemented in the construction to meet the measured power demands. The work is considered to have created a foundation to develop further with innovative ideas and solutions.

Results of a study of the influence of impeller speed on the strength, structure and morphology of granules produced in a type of high shear mixer granulators are reported. Calcium carbonate particles (Durcal 65) have been granulated in a Cyclomix with a capacity of 5 L. An aqueous solution of polyethylene glycol was used as the binder. The granules produced have been dried and their structure visualized using X-ray micro-tomography equipment, Nanotom, with a resolution of less than 1 μm. It is shown that the operation of the granulator at high impeller tip speeds produces granules with a higher strength and lower porosity than those produced at medium and low impeller speeds. Two different granule micro-structures and morphologies are produced at high and low impeller speeds. Structure descriptors such as phase volume fraction (as representative of porosity), chord length distribution and auto-correlation function (as indices of homogeneity of structure) are used to quantify the internal structure of granules in 3D, which in turn affects the granule strength.

Results of a study on the influence of process parameters such as impeller speed, granulation time and binder viscosity on granule strength and properties are reported. A high shear granulator (Cyclomix manufactured by Hosokawa Micron B.V., The Netherlands) has been used to produce granules. Calcium carbonate (Durcal) was used as feed powder and aqueous polyethylene glycol (PEG) as the binder. The dried granules have been analysed for their strength, density and size distribution. The results show that increasing the granulation time has a great affect on granules strength, until an optimum time has been reached. The underlying cause is an increase in granule density. Granules are consolidated more at higher impeller speeds. Moreover, the granule size distribution seems not to be affected significantly by an increase in impeller speed. Granules produced with high binder viscosity have a considerably lower strength, wide strength distribution due to poor dispersion of binder on the powder bed. Binder addition methods have showed no considerable effect on granule strength or on granule size distribution.

A novel method for manufacturing granules with a large particle at their core, referred to as seeded granules, is presented. As an example, calcium carbonate powders (Durcal) of different grades are used as primary particles and polyethylene glycol (PEG) as liquid binder in high shear granulators of different scales (Cyclomix, manufactured by Hosokawa Micron B.V., The Netherlands). The conditions giving rise to seeded granulations are specified in the form of an operational regime map. It is found that the seeded structure is strongly dependent on the impeller speed and the primary particles size distribution. It is shown that a Stokes number of around 0.1 represents the optimal dynamic conditions in the given example for producing seeded granules, regardless of the scale of the granulator.

Yes / The effect of screw configuration on granule size distribution (GSD) using gPROMS FormulatedProduct (gFP) software to perform optimization, estimation of complex processes, and analyses is evaluated. Twin-screw granulation modeling was used to investigate the contribution of screw configuration and liquid-to-solid (L/S) ratio on GSD. Lactose and Avicel were the granulating materials. Twelve different configurations were investigated under three feed rates as consistent with literature and at various L/S ratios. Results indicate that kneading elements promote the recovery of 100–1000 µm granules while reducing the production of oversized granules. Higher feed rates support the production of fines and agglomerates, while a low feed rate produces 100–1000 µm granules. / Ghana Scholarship Secretariat

Recycling of plastics always plays an important role in keeping our environment better and safe. With the rise in usage of plastics and industrialization, the need for recycling the plastics has become a big business and is getting bigger. This thesis work was done for a company called Rapid Granulator AB, which works with the recycling of plastics as a big trade in Sweden. Like all the industries across the globe are trying to be economical in every way, Rapid Granulator AB wanted to develop an economical design of their high quality granulating knife. For achieving the economical design, they wanted to study the behaviour of the rotating knife during the process of producing plastic granules. The granulator cutting process was simulated and numerical analysis was done on the rotating knife of a plastic granulator machine by using the finite element code ABAQUS with 3D stress elements to find out the critical stresses and forces acting on the rotating knife. The bolt preload was applied by Abaqus/Standard, and the results of implicit analysis were imported to Abaqus/Explicit for the impact analysis where the flow of stresses on the rotating knife during the impact with materials were simulated and studied. The study was done on knife models of different thickness to see if the thickness of the current knife model can be reduced. Analysis were done also on a knife model assembly with a double sided cutting edge knife to see if the knife model can be used to its full extent. The simulation models and analysis results were given to the company to develop a more economical knife model.

Yes / Numerical simulation of wet granulation in a continuous granulator is carried out using Discrete Element Method (DEM) to discover the possibility of formation of seeded granules in a continuous process with the aim of reducing number of experimental trials and means of process control. Simple and scooped drum granulators are utilized to attain homogenous seeded granules in which the effects of drum rotational speed, particles surface energy, and particles size ratio are investigated. To reduce the simulation time a scale-up scheme is designed in which a dimensionless number (Cohesion number) is defined based on the work of cohesion and gravitational potential energy of the particles. Also a mathematical/numerical method along with a MATLAB code is developed by which the percentage of surface coverage of each granule is predicted precisely. The results show that use of continuous granulator is promising provided that a high level of shear is considered in the granulator design, e.g. it is observed that using baffles inside the drum granulators is essential for producing seeded granules. It is observed, moreover, that the optimum surface energy for scooped granulator with rotational speed of 50 rpm is 3 J/m2 which is close to the number predicted by Cohesion number. It is also shown that increasing the seed/fine size ratio enhances the seeded granulation both quantitatively (60% increase in seeds surface coverage) and qualitatively (more homogeneous granules).