A comprehensive review of the application of DEM in the investigation of batch solid mixers

Powder mixing is a vital operation in a wide range of industries, such as food, pharmaceutical, and cosmetics. Despite the common use of mixing systems in various industries, often due to the complex nature of mixing systems, the effects of operating and design parameters on the mixers' performance and final blend are not fully known, and therefore optimal parameters are selected through experience or trial and error. Experimental and numerical techniques have been widely used to analyze mixing systems and to gain a detailed understanding of mixing processes. The limitations associated with experimental techniques, however, have made discrete element method (DEM) a valuable complementary tool to obtain comprehensive particle level information about mixing systems. In the present study, the fundamentals of solid-solid mixing, segregation, and characteristics of different types of batch solid mixers are briefly reviewed. Previously published papers related to the application of DEM in studying mixing quality and assessing the influence of operating and design parameters on the mixing performance of various batch mixing systems are summarized in detail. The challenges with regards to the DEM simulation of mixing systems, the available solutions to address those challenges and our recommendations for future simulations of solid mixing are also presented and discussed.

Automated summary

Powder mixing is a crucial process in various industries, but due to the complexity of mixing systems, the optimal parameters for mixer performance and final blend are not fully understood. This study reviews the fundamentals of solid-solid mixing, characteristics of different batch solid mixers, and the application of discrete element method (DEM) in studying mixing quality and assessing the influence of operating and design parameters on mixing performance. The challenges and recommended solutions for DEM simulation of mixing systems are also discussed.