Undesired agglomeration in agitated filter dryers: A critical review

IF 4.6 2区工程技术 Q2 ENGINEERING, CHEMICAL

Powder Technology Pub Date : 2025-07-26 DOI:10.1016/j.powtec.2025.121425

Suruthi Gnanenthiran , Christopher Hewitt , Pari Rao , Kate Pitt , James Litster , Rachel Smith

{"title":"Undesired agglomeration in agitated filter dryers: A critical review","authors":"Suruthi Gnanenthiran , Christopher Hewitt , Pari Rao , Kate Pitt , James Litster , Rachel Smith","doi":"10.1016/j.powtec.2025.121425","DOIUrl":null,"url":null,"abstract":"<div><div>Agitated filter dryers (AFDs) are commonly used in many industries, however the mechanisms driving undesired agglomeration remain poorly understood. Undesired agglomeration can have several consequences, including out of specification product, equipment damage, additional downstream processing and increased cycle times and cost. This review explores the influence of key material and process parameters on agglomeration in AFDs, highlighting the lack of mechanistic understanding that has hindered the development of accurate predictive models.</div><div>To address this, insights from wet granulation are applied to propose a novel mechanism consisting of three rate processes governing agglomeration during agitated drying: (1) formation of loosely bound agglomerates, (2) consolidation and coalescence, and (3) solidification of liquid bridges. The review examines how various parameters influence each rate process in this mechanism, offering a more predictive framework for agglomeration behaviour.</div><div>Additionally, existing modelling efforts for AFDs are reviewed, revealing that many studies focus on heat transfer while neglecting agglomeration. Comparisons with wet granulation models highlight opportunities to integrate established agglomeration and scale-up approaches into AFD models. By advancing the mechanistic understanding, this work aims to improve prediction, control, and scalability of agglomeration in agitated drying.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"466 ","pages":"Article 121425"},"PeriodicalIF":4.6000,"publicationDate":"2025-07-26","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Powder Technology","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0032591025008204","RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q2","JCRName":"ENGINEERING, CHEMICAL","Score":null,"Total":0}

引用次数: 0

Abstract

Agitated filter dryers (AFDs) are commonly used in many industries, however the mechanisms driving undesired agglomeration remain poorly understood. Undesired agglomeration can have several consequences, including out of specification product, equipment damage, additional downstream processing and increased cycle times and cost. This review explores the influence of key material and process parameters on agglomeration in AFDs, highlighting the lack of mechanistic understanding that has hindered the development of accurate predictive models.

To address this, insights from wet granulation are applied to propose a novel mechanism consisting of three rate processes governing agglomeration during agitated drying: (1) formation of loosely bound agglomerates, (2) consolidation and coalescence, and (3) solidification of liquid bridges. The review examines how various parameters influence each rate process in this mechanism, offering a more predictive framework for agglomeration behaviour.

Additionally, existing modelling efforts for AFDs are reviewed, revealing that many studies focus on heat transfer while neglecting agglomeration. Comparisons with wet granulation models highlight opportunities to integrate established agglomeration and scale-up approaches into AFD models. By advancing the mechanistic understanding, this work aims to improve prediction, control, and scalability of agglomeration in agitated drying.

Abstract Image

查看原文本刊更多论文

搅拌过滤干燥机中不希望的结块：一个重要的回顾

搅拌过滤干燥机（afd）通常用于许多行业，然而，驱动不希望团聚的机制仍然知之甚少。不希望出现的结块会产生多种后果，包括不符合规格的产品、设备损坏、额外的下游处理以及周期时间和成本的增加。本文探讨了关键材料和工艺参数对afd中团聚的影响，强调缺乏对机理的理解，这阻碍了准确预测模型的发展。为了解决这个问题，我们应用湿造粒的见解，提出了一种新的机制，包括在搅拌干燥过程中控制团聚的三个速率过程：(1)松散结合的团聚体的形成，(2)固结和聚结，以及(3)液体桥的凝固。该综述考察了各种参数如何影响该机制中的每个速率过程，为团聚行为提供了更具预测性的框架。此外，对现有的afd建模工作进行了回顾，揭示了许多研究侧重于传热而忽略了团聚。与湿造粒模型的比较突出了将已建立的团聚和放大方法整合到AFD模型中的机会。通过推进机理的理解，本工作旨在改善搅拌干燥中团聚的预测、控制和可扩展性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

求助全文

约1分钟内获得全文求助全文

来源期刊

Powder Technology 工程技术-工程：化工

CiteScore

9.90

自引率

15.40%

发文量

1047

审稿时长

46 days

期刊介绍： Powder Technology is an International Journal on the Science and Technology of Wet and Dry Particulate Systems. Powder Technology publishes papers on all aspects of the formation of particles and their characterisation and on the study of systems containing particulate solids. No limitation is imposed on the size of the particles, which may range from nanometre scale, as in pigments or aerosols, to that of mined or quarried materials. The following list of topics is not intended to be comprehensive, but rather to indicate typical subjects which fall within the scope of the journal's interests: Formation and synthesis of particles by precipitation and other methods. Modification of particles by agglomeration, coating, comminution and attrition. Characterisation of the size, shape, surface area, pore structure and strength of particles and agglomerates (including the origins and effects of inter particle forces). Packing, failure, flow and permeability of assemblies of particles. Particle-particle interactions and suspension rheology. Handling and processing operations such as slurry flow, fluidization, pneumatic conveying. Interactions between particles and their environment, including delivery of particulate products to the body. Applications of particle technology in production of pharmaceuticals, chemicals, foods, pigments, structural, and functional materials and in environmental and energy related matters. For materials-oriented contributions we are looking for articles revealing the effect of particle/powder characteristics (size, morphology and composition, in that order) on material performance or functionality and, ideally, comparison to any industrial standard.