{"title":"DEM analysis of the media size ratio and agitator shaft geometry effects on grinding performance in a mixed-media stirred mill","authors":"Ryo Miyazawa , Hidehiro Kamiya , Kenichi Momota , Satoshi Shiina , Kyouko Okuyama , Yuma Hatakeyama , Chiharu Tokoro","doi":"10.1016/j.apt.2025.105090","DOIUrl":"10.1016/j.apt.2025.105090","url":null,"abstract":"<div><div>The effects of media diameter ratio and agitation shaft geometry on grinding performance when using small and large media in a media stirred mill were experimentally investigated, and the mechanism and optimal configuration were elucidated through discrete element method simulations to reduce energy consumption by minimizing grinding time. The number ratio of large to small media was fixed at 1:1, the diameter of large media was fixed at 10 mm, and the diameter of small media was varied, namely 2, 3, and 5 mm. The highest grinding rate was experimentally obtained using 3 mm small media, consistent with the simulations. The simulations also showed that 2 mm small media passed through the gaps between the large media more easily and segregated at the ends of the mill, reducing both the collision energy and the grinding rate. Moreover, different agitator shaft geometries were evaluated, and the inclined agitator shaft facilitated the highest grinding rate by increasing the axial movement of the small media and the rate of high-energy collisions. Overall, the improve ratio of large to small media and an inclined agitator shaft can prevent small media segregation at both ends of the mill and thereby achieve the higher grinding rate.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105090"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145415013","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":"Parameter sensitivity in DEM of aggregates for road and construction materials","authors":"Dong Feng","doi":"10.1016/j.apt.2025.105116","DOIUrl":"10.1016/j.apt.2025.105116","url":null,"abstract":"<div><div>The discrete element method (DEM) is widely used in civil engineering and road engineering to simulate the motion and interaction of aggregate particles in pavement structures. Due to the interaction between particles, selecting or calibrating particle property input parameters is one of the critical issues in DEM implementation. The angle of repose (AOR) testing is a standard test method used to calibrate the overall behavior of simulated aggregates. In this study, AOR testing of coarse aggregate particles with SMA-11 gradation is modeled to investigate the effect of different parameters on the simulation results and to calibrate parameters. For this purpose, sensitivity analyses are performed for different factors, i.e., model object, AOR testing method, rolling friction coefficient, Young’s modulus, and surface energy. The results show that the selected Young’s modulus can be reduced by up to four orders of magnitude compared to the real Young’s modulus without affecting the simulation results. The model object, rolling friction coefficient, and surface energy are significant factors for determining the AOR, and the AOR testing method does not affect the parameter sensitivity. The conclusion indicates that investigation of sensitivity parameters facilitates the implementation of DEM applications for aggregate particles in road engineering.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105116"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145517783","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}
Peng Wang , Shaochen Yang , Wencai Wang , Zhao Cao , Xuping Li , Yongdan Cao , Zhoukang Wu , Dawei Wang
{"title":"Multi-physical field coupling analysis of the spontaneous combustion process in coal gangue hills influenced by slope profiles","authors":"Peng Wang , Shaochen Yang , Wencai Wang , Zhao Cao , Xuping Li , Yongdan Cao , Zhoukang Wu , Dawei Wang","doi":"10.1016/j.apt.2025.105111","DOIUrl":"10.1016/j.apt.2025.105111","url":null,"abstract":"<div><div>Understanding the effects of different slope profiles on the spontaneous combustion of coal gangue hills is crucial for effective prevention and control. Unlike previous studies that primarily focused on temperature variations, this study developed a multiphysics coupling model integrating seepage velocity, oxygen concentration, and temperature fields to investigate the internal evolution of multiple fields during the spontaneous combustion process. Based on thermodynamic experiments, a zoning method was proposed using characteristic temperature points to delineate spontaneous combustion risk zones within coal gangue hills. The spatial distribution and formation mechanisms of combustion-prone areas were analyzed across hills with different slope profiles. The results show that when the coal gangue temperature reaches the T<sub>2</sub> point (336.82 °C), the material enters an accelerated oxidation stage, significantly increasing the risk of spontaneous combustion. Multiphysics simulation revealed that high-risk zones are primarily located in the mid-upper slope areas, with risk severity ranked as follows: arc-shaped > planar > corner > arched slopes. Additionally, under oblique wind conditions, the overall combustion risk for all slope types was reduced. The study found that the spontaneous combustion risk of coal gangue hills increases with stacking time at a decelerating rate, while the minimum safe accumulation rate exhibits exponential growth as stacking duration extends.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105111"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145517790","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":"Composite fiber of polyvinyl alcohol/activated carbon from corn cob prepared by electrospinning as a sustainable adsorbent for efficient rhodamine B adsorption","authors":"Adhi Setiawan, Sugeng Winardi, W. Widiyastuti","doi":"10.1016/j.apt.2025.105093","DOIUrl":"10.1016/j.apt.2025.105093","url":null,"abstract":"<div><div>Rhodamine B (RB) is a synthetic dye commonly used in the textile industry, but its presence poses risks to health and the environment. Mitigating water pollution caused by synthetic dyes necessitates effective wastewater treatment methods. Therefore, this study aims to develop a simple, cost-effective, and environmentally friendly approach to synthesizing adsorbents by combining polyvinyl alcohol (PVA) and corn cob (CC)-based activated carbon (AC) through an electrospinning process to form PVA/AC composite fibers. The results showed that the increase in AC content in the composite fiber led to an enhancement in the adsorption performance against RB. PVA/AC composite fiber containing 10 % AC had a maximum adsorption capacity 5.41 times higher than PVA fiber and got a maximum 96.02 % RB removal efficiency. Adsorption isotherm analysis demonstrated compliance with the Langmuir model. Kinetic studies show that the pseudo-first-order (PFO) model best explains the adsorption process. Thermodynamic analysis also indicated that the adsorption was spontaneous and exothermic (ΔH° = −57.23 kJ/mol). Based on reusability tests, the adsorbent maintained a high removal efficiency, with RB removal decreasing marginally from 96.35 % to 78.93 % after five cycles. These results underscore the potential of PVA/AC composite fiber as an effective adsorbent for addressing water pollution caused by synthetic dyes.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105093"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145464002","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":"A comprehensive strategy for enhanced thermoelectric properties of ZnO ceramics by doped Fe and composite C","authors":"Yan Peng , Shuoying Liu , Xueli Du","doi":"10.1016/j.apt.2025.105130","DOIUrl":"10.1016/j.apt.2025.105130","url":null,"abstract":"<div><div>Znic oxide (ZnO) is a promising environmentally friendly thermoelectric material, however, its commercial applications are constrained by low electrical conductivity and high thermal conductivity. This study adopted a simple and scalable hydrothermal method to synthesize Fe-doped and C-coated (acetylene black as carbon source) ZnO powders, which were then sintered in an argon atmosphere at 1000 ℃ to fabricate ZnO-based composite ceramics with enhanced thermoelectric performance. Experimental results demonstrate that the doped Fe and coated C enhanced electrical transport, and reduced the thermal conductivity of ZnO, the highest figure of merit (<em>ZT</em><sub>max</sub>) 0.91 at 800 K was obtained from Zn<sub>0.997</sub>Fe<sub>0.003</sub>O/0.3 at %C. Hall effect measurements confirm that Fe and C effectively increased the carrier concentration. Additionally, the coated C improved the connection between matrix grains, and enhanced carrier mobility. Photoluminescence analysis of pure ZnO and ZnO/C particles reveals that the coated C effectively quenched the oxygen vacancies on the ZnO grain surface, thus released the trapped electrons. Furthermore, the sample Zn<sub>0.997</sub>Fe<sub>0.003</sub>O/0.3 at %C exhibits a notable low thermal conductivity about 2.85 Wm<sup>-1</sup>K<sup>−1</sup> at 800 K. Overall, this is a practical method to optimize the thermoelectric properties of ZnO materials.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105130"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145615132","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}
Fenqiang Li , Jiawei Shu , Qianting Wang , Xin Xu , Xinyu Chen , Jun Zhao
{"title":"Process analysis and densification for magnetic pulse radial compaction of w-cu mixed powder using multi-particle finite element method","authors":"Fenqiang Li , Jiawei Shu , Qianting Wang , Xin Xu , Xinyu Chen , Jun Zhao","doi":"10.1016/j.apt.2025.105092","DOIUrl":"10.1016/j.apt.2025.105092","url":null,"abstract":"<div><div>Magnetic pulse radial compaction (MPRC) is a high-speed powder consolidation technique capable of producing high-density green compacts. In this study, the MPRC process of W-Cu mixed powder was systematically investigated using a three-dimensional multi-particle finite element method. The influence of key process parameters — including discharge voltage, copper content and interfacial friction — on the densification behavior was quantitatively analyzed. The particle deformation mechanisms and pore closure behavior were also thoroughly examined. The results indicate that the MPRC densification process occurs in three distinct stages. In the initial stage, intense impact forces induce simultaneous particle rearrangement and elastoplastic deformation. This is followed by a second stage characterized by dominant large-scale plastic deformation with minimal further rearrangement. In the final stage, local vibrations and magnetic-induced expansions result in a slight reduction in relative density. It was found that both the uniformity of powder mixing and the evolution of force chain networks significantly affect densification. The rigid structure of tungsten particles tends to retain porosity, whereas the highly deformable copper particles promote densification through effective pore filling. Additionally, the radial density distribution of the compact is governed by the interaction between the incident stress wave from the outer shell and the reflected wave from the inner mandrel. Increasing the discharge voltage and Cu content leads to higher relative density, while higher friction coefficients impede densification. These findings provide theoretical insights into the design and optimization of MPRC processes for fabricating high-performance W-Cu composite components.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105092"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145415011","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":"A thermal-fluid model coupling VOSET-IBM-DEM method for simulating nucleate boiling in particle-laden fluids","authors":"Xin Chen, Bifeng Yin, Xiaoxiang Li, Ying Zhang, Sheng Xu, Fei Dong","doi":"10.1016/j.apt.2025.105086","DOIUrl":"10.1016/j.apt.2025.105086","url":null,"abstract":"<div><div>This paper presents a coupled VOSET-IBM-DEM method on a hybrid Eulerian-Lagrangian framework to simulate particle-laden pool boiling. Combination of an interface capturing method (VOSET) and Lee mass transfer model is implemented to track the vapor–liquid interface during phase change in the Eulerian frame. An immersed boundary method is adopted to describe the interactions between fluids and particles. A discrete element method is coupled to solve the motion of the dispersed particle in the Lagrangian frame. An “extension” equation is incorporated into VOSET to achieve the contact-angle boundary condition. To ensure that the heat flux at the fluid–solid interface satisfies the thermal relation, an interfacial heat conduction model is incorporated into the energy equation. Several validation tests were conducted, demonstrating good agreement with theoretical, prior simulation, and experimental results. The model was then applied to simulate particle-laden pool boiling, investigating the effect of particle deposition. When the density ratio <em>k<sub>ρ</sub></em> ≥ 2, particle deposition leads to a reduction in nucleation sites and a decrease in boiling intensity. The heat conduction effect induced by particle deposition is greater than the evaporation effect caused by liquid–vapor phase change. As particle density increases, the particle deposition effect becomes more pronounced, resulting in a decrease in the average temperature of the heated surface and an increase in the average heat flux during the steady stage.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105086"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145374613","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}
Camila Ottonelli Calgaro , Mirian Dosolina Fuzinatto , Shayla Santos Lopes , Taliana Tronco , Diego Gil de los Santos , Daniel Assumpção Bertuol , Pedro José Sanches Filho
{"title":"Evaluation of the use of silica extracted from industrial waste with an ultrasonic bath and modifications to the aging stage in the synthesis of ZSM-5 and its application in pyrolysis","authors":"Camila Ottonelli Calgaro , Mirian Dosolina Fuzinatto , Shayla Santos Lopes , Taliana Tronco , Diego Gil de los Santos , Daniel Assumpção Bertuol , Pedro José Sanches Filho","doi":"10.1016/j.apt.2025.105098","DOIUrl":"10.1016/j.apt.2025.105098","url":null,"abstract":"<div><div>Rice husk ash is an industrial residue composed essentially of silica that can be used as an alternative source of silica for the synthesis of ZSM-5 zeolite. This study aimed to obtain ZSM-5 zeolite without organic structure-directing agents, evaluating the use of silica extracted from industrial rice husks using an ultrasonic bath. The effect of ultrasound was also evaluated in the aging stage of the zeolite. The catalytic potential of the synthesized zeolite was measured in the pyrolysis of rice husks. XRF, XRD, BET, and SEM-EDS characterization were performed on the synthesized zeolites. It was possible to obtain the ZSM-5 zeolite under all the synthesis conditions studied. Still, the silica extraction method and the aging method were decisive for the formation of the crystalline phase and the surface area of the synthesized zeolite. The use of silica extracted with an ultrasonic bath promoted the most crystalline ZSM-5 phase in the samples and the highest surface areas. The ZU3 zeolite had the highest BET surface area of 277.5 m<sup>2</sup>/g, which was attributed to the use of ultrasound. The application of ZU3 zeolite increased the gas phase production in rice husk pyrolysis to 45 % due to its action in cracking reactions.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 12","pages":"Article 105098"},"PeriodicalIF":4.2,"publicationDate":"2025-12-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145463943","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":"Quality and process-performance monitoring in the pharmaceutical continuous manufacturing of oral solid dosage forms with statistical control from process variables and near-infrared spectroscopy","authors":"Toshiki Yamaoka , Hideo Takashima , Kohei Tahara","doi":"10.1016/j.apt.2025.105075","DOIUrl":"10.1016/j.apt.2025.105075","url":null,"abstract":"<div><div>We developed a statistical control approach combining process variables and near-infrared (NIR) spectroscopy to detect deviations in the continuous manufacturing of oral solid dosage forms. Multivariate statistical process control (MSPC) models were independently developed for process variables during wet granulation and drying, as well as for NIR spectral data. Data obtained from a laboratory-scale continuous manufacturing unit (ConsiGma™-1) were used to construct principal component analysis based MSPC models, enabling identification of abnormal batches via calculated Hotelling’s T<sup>2</sup> and Q statistics. The combined use of NIR and process variable monitoring for the MSPC technique enabled the accurate detection of process deviations and product quality defects, demonstrating its effectiveness. In batches with altered formulation ratios, defects were successfully detected through an MSPC chart from NIR spectra, highlighting the sensitivity of NIR-based analyses. In batches with intentional changes in the process variable settings, deviations were identified by the MSPC of the process variables. This paper presents a robust framework for ensuring the consistent quality of drug products and process performance in continuous manufacturing by leveraging the complementary strengths of NIR and process variable monitoring for MSPC. The proposed method addresses the limitations of traditional batch monitoring and offers improved sensitivity in variation detection.</div></div>","PeriodicalId":7232,"journal":{"name":"Advanced Powder Technology","volume":"36 11","pages":"Article 105075"},"PeriodicalIF":4.2,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145262439","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}