Powder Technology最新文献

{"title":"Workflow based on GANs and CNNs towards a digital twin for the 3D morphological characterization of latex aggregates","authors":"L. Théodon ,&nbsp;C. Coufort-Saudejaud ,&nbsp;J. Debayle","doi":"10.1016/j.powtec.2025.121286","DOIUrl":"10.1016/j.powtec.2025.121286","url":null,"abstract":"<div><div>This paper presents a workflow for estimating the 3D morphological characteristics of latex aggregates from 2D in-situ images using deep learning and stochastic geometry models. The method includes automatic image segmentation using a Convolutional Neural Network (CNN), 3D object generation using a Generative Adversarial Network (GAN), and estimation of 3D characteristics. Validation with synthetic datasets shows effective size, shape, and texture characterization, with the Mean Absolute Percentage Error (MAPE) for morphological characteristics of generated objects being around 5% at most. Application to real in-situ images demonstrates feasibility and consistency with experimental observations, successfully generating a digital twin of the latex aggregate population. The method’s flexibility and efficiency make it suitable for real-time industrial applications, offering potential for process monitoring and quality control. Future work will focus on enhancing model performance and adapting to different particle types for broader applicability in various industrial settings.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121286"},"PeriodicalIF":4.5,"publicationDate":"2025-07-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144536022","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Suppression characteristics of modified fly ash-based explosion suppressants for high-density polyethylene dust: From the perspective of explosion pressure, flame behavior, thermal stability, and solid residues","authors":"Dawei Ding ,&nbsp;Lijun Wei ,&nbsp;Mingqing Su ,&nbsp;Bingyou Jiang ,&nbsp;Sining Chen ,&nbsp;Yingquan Duo ,&nbsp;Jingjing Li ,&nbsp;Mengning Chen","doi":"10.1016/j.powtec.2025.121330","DOIUrl":"10.1016/j.powtec.2025.121330","url":null,"abstract":"<div><div>Dust explosions present a considerable risk in industrial settings, especially during the handling of high-density polyethylene (HDPE) and similar polymers. In this investigation, fly ash (FA) was utilized as the base matrix to develop inhibitors named MFA-1, MFA-2, and MFA-2@APP via calcination, acid-base activation, surface modifications, and solvent-antisolvent methods. The ability of these materials to suppress HDPE dust explosions was tested in a 20 L spherical apparatus, establishing the critical addition amounts of each suppressant. Experimentally, FA, MFA-1, MFA-2, and MFA-2@APP variably lowered the maximum explosion pressure (<em>P</em>_max), the maximum rate of pressure rise ((d<em>P</em>/d<em>t</em>)_max), and the flame propagation speed, with critical addition amounts of 720 %, 640 %, 620 %, and 180 %, respectively. In addition to the considerable enhancement in apparent activation energy, the nanostructured clusters and the resultant carbonized and oxidized layers in the explosion residues significantly inhibited oxidation and curtailed the release of flammable gases. The modified FA demonstrated its suppressive capacity through several mechanisms: dilution, endothermic absorption, and radical scavenging, with MFA-2@APP exhibiting the most pronounced synergistic effects. This research underscores the significance of safely managing HDPE dust and the potential of FA for developing cost-effective, eco-friendly suppressants.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121330"},"PeriodicalIF":4.5,"publicationDate":"2025-06-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144536107","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of column height, particle size, and reagent dosages on phosphate rock flotation","authors":"Ricardo C. Santana,&nbsp;Carlos H. Ataíde,&nbsp;Marcos A.S. Barrozo","doi":"10.1016/j.powtec.2025.121324","DOIUrl":"10.1016/j.powtec.2025.121324","url":null,"abstract":"<div><div>The main objective of this study was to analyze the influence of mineral particle size, flotation column height, and collector and depressant dosages on the flotation of apatite in column. For this purpose, five column heights were selected within each particle size range (coarse, intermediate, and fine), for which full factorial designs were performed, considering reagent dosages as variables. Based on the experimental results, a global statistical analysis was conducted to quantify and better visualize the effects of the investigated variables. Regression techniques have been used to obtain prediction equations and determine the conditions required to achieve target levels of phosphorus content and apatite recovery in the concentrate. In general, apatite recovery, unlike phosphorus content, tended to increase with higher collector dosages and with reductions in particle size, column height, and depressant dosage in the pulp. For coarse particles (105–297 μm), shorter columns (h/d = 12.5–25) with high collector dosages (360 g/t) produced the best results. The intermediate fraction (44–105 μm) showed optimal performance with intermediate column heights (h/d = 25–50) and various reagent dosages, achieving P₂O₅ content of 33 % or higher and apatite recovery exceeding 60 %. Fine particles (&lt;44 μm) presented high recovery but low grade due to entrainment, with little sensitivity to column height.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121324"},"PeriodicalIF":4.5,"publicationDate":"2025-06-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144536106","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Numerical simulation and experimental investigation of anisotropic reduction in iron ore pellets using X-ray micro-computed tomography","authors":"Dejin Qiu ,&nbsp;Abdallah A. Elsherbiny ,&nbsp;Jie Ren ,&nbsp;Manqing Li ,&nbsp;Yuandong Xiong ,&nbsp;Su Cao ,&nbsp;Yaowei Yu","doi":"10.1016/j.powtec.2025.121321","DOIUrl":"10.1016/j.powtec.2025.121321","url":null,"abstract":"<div><div>Direct reduced iron (DRI) provides a promising pathway for the iron and steel industry to achieve carbon neutrality in response to global decarbonization goals. Iron ore pellets are critical feedstocks for the DRI process; however, existing studies typically adopt overly simplified models, failing to accurately represent the complex reduction behaviors occurring in actual pellets. This study investigates the anisotropic reduction behaviors of pellets at various stages under a hydrogen (H₂) atmosphere by employing interrupted reduction experiments, X-ray micro-computed tomography (micro-CT), and computational fluid dynamics (CFD). The results show that pellet morphology and porosity significantly influence the heterogeneous distribution of H₂, resulting in pronounced anisotropic reduction behaviors. At 973 K, the outer region of the pellet achieved homogeneous H₂ concentration and metallization within 50 and 35 s, respectively, whereas the core required 210 s. At 1273 K, the outer region homogenized within 10 s, with the core achieving similar conditions after 100 s. Gas flow distribution and internal pore structures notably affected this anisotropic behavior. Micro-CT analyses revealed new pore formation during pellet reduction, especially prominent in the α₂ and α₃ stages, facilitating H₂ diffusion and promoting faster and more uniform reduction at higher temperatures. The porosity increased by up to 38 % at 1273 K, compared to an 8.45 % increase at 973 K. This research provides insights that could enhance efficiency in industrial-scale iron ore pellet reduction processes.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121321"},"PeriodicalIF":4.5,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144522742","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Synchronous positive flotation separation of magnesite, dolomite, and quartz","authors":"Xueming Yin ,&nbsp;Jin Yao ,&nbsp;Xiufeng Gong ,&nbsp;Wanzhong Yin ,&nbsp;Yaowen Cao ,&nbsp;Xin Wang","doi":"10.1016/j.powtec.2025.121322","DOIUrl":"10.1016/j.powtec.2025.121322","url":null,"abstract":"<div><div>Herein, single-mineral flotation and artificially mixed-ore flotation of magnesite, quartz, and dolomite in sodium oleate (NaOL) were conducted under different conditions. By regulating slurry pH and adding inhibitors, the synchronous positive flotation desilication and decalcification of magnesite was achieved. At pH 9, 2-phosphate-1,2,4-tricarboxylic acid (PBTCA) facilitated excellent flotation separation and recovered 88.34 % and 8.93 % of magnesite and dolomite, respectively. Moreover, MgO and CaO grades of 46.21 % and 0.91 %, respectively, were achieved. Under these conditions, 3.18 % of quartz was recovered and a SiO₂ grade of 0.45 % was achieved. PBTCA considerably reduced the contact angle and adsorption capacity of dolomite in NaOL, slightly reduced the contact angle and adsorption capacity of magnesite in NaOL. Ca²⁺ and Mg²⁺ did not affect the contact angle of quartz at pH 9, whereas they considerably increased the contact angle at pH 11. Moreover, PBTCA weakly adsorbed on the magnesite surface and did not impact NaOL adsorption therein, strongly adsorbed on the dolomite surface, which was not conducive to NaOL adsorption on the same surface. Ca²⁺ and Mg²⁺ increased the surface electrical properties of quartz and activated its flotation. PBTCA strongly acts on the Ca sites on dolomite surface through chemical adsorption, hindering the adsorption of NaOL on dolomite surface and inhibiting its flotation. It has weaker adsorption on magnesite surface, while NaOL can act on magnesite surface through chemical adsorption and collect magnesite. Among the dissolved components of Ca²⁺ and Mg²⁺, CaOH⁺ and MgOH⁺ were the dominant components for activating quartz flotation and their concentrations were relative to the high flotation recovery of quartz.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121322"},"PeriodicalIF":4.5,"publicationDate":"2025-06-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144522743","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Prediction of particle mixing process in a rotating drum based on convolutional neural network","authors":"Wenjie Wu,&nbsp;Chuanlei Li,&nbsp;Yanjie Li,&nbsp;Changchun Zhang","doi":"10.1016/j.powtec.2025.121311","DOIUrl":"10.1016/j.powtec.2025.121311","url":null,"abstract":"<div><div>The Discrete Element Method (DEM) has been widely used to analyze particle mixing processes. However, in chemical industry applications, mixing often involves billions of particles, making DEM simulations computationally expensive due to the intensive processes of contact detection and force calculation. Convolutional Neural Network (CNN) leverages images from DEM simulations as input, maintaining computational efficiency regardless of particle number, thus offering an effective solution to reduce computational costs. To balance accuracy and efficiency, we propose a Convolutional Neural Network with a Multi-Branch Block (CNNMB), which integrates convolutional kernels of different sizes through skip connections to extract global features. The performance of CNNMB was evaluated using three key metrics. Results show that across 24 DEM test cases, the predicted mixing index achieved an R² greater than 0.998, the predicted dynamic angle of repose reached an accuracy exceeding 98.4 %, and the predicted average particle height yielded an R² above 0.96. Furthermore, to capture the time-sequential characteristics of the mixing index, we developed a hybrid architecture by coupling CNNMB with a Long Short-Term Memory (LSTM) network—referred to as the Convolutional Neural Memory Network (CNMN). Results indicate that CNMN achieved a prediction accuracy of over 82 % across simulation cases with varying parameters. Additionally, a large-scale simulation involving one million particles was conducted, demonstrating that CNMN reduced computational time by approximately 97-fold compared to DEM simulations, highlighting its potential for efficient predicting.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121311"},"PeriodicalIF":4.5,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144523560","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Gas phase synthesis of mixed Cu1.8S-ZnS particles and the terminal phases in the reducing atmosphere","authors":"Suman Pokhrel ,&nbsp;Muhammad Ali Martuza ,&nbsp;Jan Derk Groeneveld ,&nbsp;Marco Schowalter ,&nbsp;Andreas Rosenauer ,&nbsp;Johannes Birkenstock ,&nbsp;Lutz Mädler","doi":"10.1016/j.powtec.2025.121318","DOIUrl":"10.1016/j.powtec.2025.121318","url":null,"abstract":"<div><div>The synthesis of Cu₁.₈S, ZnS, and Cu₁.₈S-ZnS composite nanoparticles is achieved <em>via</em> reactive spray combustion, wherein rapid vaporization of thiophene initiates micro-explosions that promote high-temperature vapor-phase reactions under reducing conditions. High-resolution transmission electron microscopy (HRTEM) and X-ray diffraction (XRD) analyses reveal that the synthesized nanoparticles consist of agglomerated spherical primary crystallites, with average sizes of 12.2 nm for Cu₁.₈S, 10 nm for ZnS, and 10.8 nm for the Cu₁.₈S-ZnS composite. Elemental analysis <em>via</em> energy-dispersive X-ray spectroscopy (EDX) coupled with scanning transmission electron microscopy (STEM) confirms homogeneous spatial distribution of Cu and S in Cu₁.₈S, elevated surface oxygen content in ZnS attributed to physisorption, and substantial Cu incorporation into the ZnS lattice within the Cu₁.₈S-ZnS composite system. Structural analysis indicates that the contrast features observed in Cu₁.₈S, ZnS, and Cu-Zn mixed sulfides are consistent with their respective crystallographic symmetries, where sulfur atoms adopt well-ordered lattice positions, while copper exhibits partial site occupancy and electron density disorder attributed to the comparable ionic radii of Cu²⁺ and Zn²⁺ ions. This study underscores the efficacy of oxygen-deficient, reducing flame environments in facilitating the synthesis of binary and mixed-metal sulfide nanomaterials, enabling the formation of metastable phases providing a scalable, cost-effective route for producing advanced functional materials with broad application potential.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121318"},"PeriodicalIF":4.5,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518708","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Determining flow regimes in gradient-controlled magnetically fluidized beds via CFD-DEM modelling","authors":"Balamurugan Deivendran ,&nbsp;Hamed Hoorijani ,&nbsp;Zhiheng Fan ,&nbsp;Casper De Somer ,&nbsp;Annelies Coene ,&nbsp;Luc Dupre ,&nbsp;Vladimir V. Galvita ,&nbsp;Hilde Poelman ,&nbsp;Kevin M. Van Geem ,&nbsp;Geraldine Heynderickx","doi":"10.1016/j.powtec.2025.121312","DOIUrl":"10.1016/j.powtec.2025.121312","url":null,"abstract":"<div><div>Magnetically fluidized beds (MFBs) have become a prominent field of study, given their recent application in industry. MFB operational phase diagrams, locating the boundaries between fluidization regimes, are needed to support process intensification studies. A CFD-DEM model is developed to study magnetic fluidization of mixtures of magnetic and non-magnetic Geldart D particles, and construct operational phase diagrams for MFBs, operated in magnetic first and magnetic last mode, with upward acting and downward acting magnetic field gradients. Different flow regimes, including fixed bed, partially and completely segregated bed, magnetically stabilized bed, and magnetically bubbling bed, are identified by analysing variations in minimum fluidization velocities, minimum bubbling velocities, and segregation indices for a range of operating conditions. Additionally, the effect of magnetic particles' mass fraction on particle distribution is determined to establish its potential for process intensification.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121312"},"PeriodicalIF":4.5,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144518709","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"The effect of irregular particle shape and surface deformation on particle bounce, Part I: Characterizing particle geometries and induced plastic deformation on surfaces","authors":"Alix M. Ehlers ,&nbsp;Brandon J. Weindorf ,&nbsp;Mark J. Caddick ,&nbsp;K. Todd Lowe ,&nbsp;Wing Ng ,&nbsp;Jim Loebig ,&nbsp;Rory Clarkson","doi":"10.1016/j.powtec.2025.121315","DOIUrl":"10.1016/j.powtec.2025.121315","url":null,"abstract":"<div><div>Erosion of in-engine machinery from the ingestion of atmospheric particulates has been a longstanding problem in the aviation industry. Minerals comprise most atmospheric particles, but their complex characteristics make reproducing and interpreting in-engine particle-driven erosion challenging. Crushed quartz is a commonly used impactor material in engine durability tests, but its jagged morphology renders its dynamical behavior difficult to reproduce in computational and analytical models. This work demonstrates that in the case of a particle-surface impact, the many global-scale geometric parameters of a jagged particle can be reduced to one unifying robust metric that is derived from its local geometric features. We additionally introduce a methodology to semi-quantitatively measure characteristics of particle-induced plastic deformation of flat surfaces. This was implemented on a series of particle impact experiments conducted using a free jet rig in which quartz-laden air was accelerated toward coupons of five different metal alloys at nominal speeds of <span><math><mn>60</mn><mspace></mspace><mi>m</mi><mo>/</mo><mi>s</mi></math></span> and <span><math><mn>120</mn><mspace></mspace><mi>m</mi><mo>/</mo><mi>s</mi></math></span>, with two impact angles of <span><math><msup><mn>30</mn><mo>°</mo></msup></math></span> and <span><math><msup><mn>90</mn><mo>°</mo></msup></math></span>. This was done such that the extent of impact-induced erosion could be analyzed for a unique particle speed, angle of impingement, and target material combination. Correlations of average crater volume show that particle-induced plastic deformation is inversely proportional to the coupon's compressive yield strength. We further show a correlation between particle incidence angle, impact velocity, and crater volume, which is consistent between each material type. The proposed methodology and data are ideal for validating particle bounce models, which is demonstrated in this study's companion paper.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121315"},"PeriodicalIF":4.5,"publicationDate":"2025-06-25","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144536108","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Patterned slip boundaries modulate microswimmer dynamics in two-dimensional superhydrophobic microchannels","authors":"Geng Guan,&nbsp;Tongxiao Jiang,&nbsp;Yuxiang Ying,&nbsp;Jianzhong Lin","doi":"10.1016/j.powtec.2025.121309","DOIUrl":"10.1016/j.powtec.2025.121309","url":null,"abstract":"<div><div>This study investigates how patterned slip conditions on superhydrophobic microchannel walls affect the near-wall dynamics of microswimmers. Using a two-dimensional lattice Boltzmann method, we simulate the motion of neutral, puller, and pusher-type squirmers near walls with alternating no-slip and slip segments. By systematically varying the surface pattern length scale (<em>R</em>) and slip ratio (<em>φ</em>), we reveal how these parameters modulate swimmer trajectories, retention distances, and escape angles. Notably, puller and pusher microswimmers exhibit distinct wall-induced behaviors—including sliding, large-amplitude oscillations, and trapping modes—depending on the wall configuration. Our results demonstrate that the key mechanism underlying these transitions is the swimmer's transient exposure to different boundary types during its near-wall interaction. These findings provide mechanistic insights into microswimmer–wall interactions and offer theoretical guidance for designing microfluidic surfaces for controlled swimmer navigation, sorting, and trapping.</div></div>","PeriodicalId":407,"journal":{"name":"Powder Technology","volume":"465 ","pages":"Article 121309"},"PeriodicalIF":4.5,"publicationDate":"2025-06-24","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"144522741","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}