Scale-up effects on flow patterns in the high shear mixing of cohesive powders

Processing of granular material often requires mixing steps in order to blend cohesive powders, distribute viscous liquids into powder beds or create agglomerates from a wet powder mass. For this reason, using bladed, high-speed mixers is frequently considered a good solution by many types of industry. However, despite the importance of such mixers in powder processing, the granular flow behavior inside the mixer bowl is generally not totally understood. In this work extensive experimentation was performed comparing the behavior of a lab-scale mixer (1.9. l vessel volume) to that of a pilot-scale mixer (65. l vessel volume) with a mixture of some pharmaceutical excipients (e.g. lactose, cellulose). The aim was to propose a new and more detailed method for describing the complex powder rheology inside an high shear mixer using impeller torque, current consumption and particle image velocimetry (PIV) analysis. Particularly, a new dimensionless torque number is proposed for the torque profile analysis in order to isolate the contributions of mass fill and blade clearance at the vessel base. Impeller torque and motor current consumption were integrated with PIV to obtain more detailed information about the surface velocity and flow pattern changes in the pilot-scale mixer. Mass fill resulted to be one of the most critical variables, as predicted by the torque model, strongly affecting the powder flow patterns. An additional mixing regimes was furthermore defined according to the observation of the surface velocity of the powder bed.