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In the early stages of development of a new Active Pharmaceutical Ingredient (API), insufficient material quantity is available for addressing processing issues, and it is highly desirable to be able to assess processability issues using the smallest possible powder sample quantity. A good example is milling of new active pharmaceutical ingredients. For particle breakage that is sensitive to strain rate, impact testing is the most appropriate method. However, there is no commercially available single particle impact tester for fine particulate solids. In contrast, dry powder dispersers, such as the Scirocco disperser of the Malvern Mastersizer 2000, are widely available, and can be used for this purpose, provided particle impact velocity is known. However, the distance within which the particles can accelerate before impacting on the bend is very short and different particle sizes accelerate to different velocities before impact. As the breakage is proportional to the square of impact velocity, the interpretation of breakage data is not straightforward and requires an analysis of particle velocity as a function of size, density and shape. We report our work using an integrated experimental and CFD modelling approach to 2 evaluate the suitability of this device as a grindability testing device, with the particle sizing being done immediately following dispersion by laser diffraction. Aspirin, sucrose and -lactose monohydrate are tested using narrow sieve cuts in order to minimise variations in impact velocity. The tests are carried out at eight different air nozzle pressures. As intuitively expected, smaller particles accelerate faster and impact the wall at a higher velocity compared to the larger particles. However, for a given velocity the extent of breakage of larger particles is larger. Using a numerical simulation based on CFD, the relationship between impact velocity and particle size and density has been established assuming a spherical shape, and using one-way coupling, as the particle concentration is very low. Taking account of these dependencies, a clear unification of the change in the specific surface area as a function of particle size, density and impact velocity is observed, and the slope of the fitted line gives a measure of grindability for each material. The trend of data obtained here matches the one obtained by single particle impact testing. Hence aerodynamic dispersion of solids by the Scirocco disperser can be used to evaluate the ease of grindability of different materials.

Abstract:The particle residence time in counter-current spray drying towers has a significant influence on the moisture content of the powder exiting the tower. Therefore, the reliability of predictions of residence time by numerical methods is highly desirable. A combined experimental and computational fluid dynamics investigation is reported for the prediction of the residence time distributions of glass beads with a narrow size range of 300-425 m in a counter-current tower with isothermal swirling flows of air. The particle-wall collision is taken into account using a rough-wall collision model. Overall, a reasonably good agreement is obtained between the measurements and predictions. Consideration of wall roughness results in greater axial dispersion of particles in the tower compared to a smooth wall assumption. The rough particle-wall collision is important for a reliable prediction of residence time distributions. In addition, analysis of the results infers that the clustering effect of particles on drag and particle-particle interactions are important and should be investigated in a future study.

A steady-state, three-dimensional, multiphase CFD modelling of a pilot-plant counter-current spray drying tower is carried out to study the drying behavior of detergent slurry droplets. The software package ANSYS Fluent is employed to solve the heat, mass and momentum transfer between the hot gas and the polydispersed droplets/particles using the Eulerian-Lagrangian approach. The continuous phase turbulence is modelled using the differential Reynolds stress model. The drying kinetics is modelled using a single droplet drying model [1] which is incorporated into the CFD code using user-defined functions. Heat loss from the insulated tower wall to the surrounding is modelled by considering thermal resistances due to deposits on the inside surface, wall, insulation and outside convective film. For the particle-wall interaction, the restitution coefficient is specified as a constant value as well as a function of particle moisture content. It is found that the variation in the value of restitution coefficient with moisture causes significant changes in the velocity, temperature and moisture profiles of the gas as well as the particles. Overall, a reasonably good agreement is obtained between the measured and predicted powder temperature, moisture content and gas temperature at the bottom and top outlets of the tower; considering the complexity of the spray drying process, simplifying assumptions made in both the CFD and droplet drying models and the errors associated with the measurements.2

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