Powders, Volume 3, Issue 4 (December 2024) – 5 articles

The creation of highly specific particle systems in the nano- and micrometer size range is a challenging task. The demand for particle systems with narrowly distributed properties is increasing in many applications, especially for use in high-tech products. Conventional separation techniques often reach their limits in the micrometer size range or become (labor-)intensive, which makes them economically or ecologically unsustainable. In addition, sorting based on several properties is rarely feasible in just one separator. Dielectrophoretic processes can be a viable option for complex sorting tasks like this, given their ability to address several particle properties and their high degree of selectivity. In this paper, we summarize the progress of a project in which the capability of dielectrophoretic methods for multidimensional sorting of microparticles was investigated. We were able to develop an operation mode for multidimensional sorting of microparticles using dielectrophoresis as well as a scalable electrically switchable filter. This creates a basis for high-throughput and multi-target sorting of technical microparticles using dielectrophoretic processes. Full article

In this study, a two-dimensional separation of microparticles based on their settling velocity and triboelectric charge ability is achieved using an air classifier for size fractionation and simultaneous charging, followed by an electrostatic separator. In the first part, considerations for enhancing particle classification with high sharpness and low-pressure drops are discussed through improvements in blade design investigated with CFD simulations and validated experimentally. Blades with extended lengths towards the center of the classifier prevent the formation of high-velocity vortices, thereby minimizing the back-mixing of particles and enhancing separation sharpness. This approach also reduces pressure drops associated with these flow vortices. In the second part of the study, the modified blades within the classifier are utilized for two-dimensional separation. Powders from two different materials are fed into the classification system, where particles become triboelectrically charged, mainly through collisions with the walls of the classification system components. Coarse particles are rejected at the wheel and exit the classifier, while differently charged fine particles of the two materials are directed into an electrostatic separator for material sorting. An enrichment of approximately 25–35% for both materials has been achieved on the electrodes of the separator. Full article

Chemical and physical properties of nanoparticles (NPs) are strongly influenced not only by the crystal structure of the respective material, including crystal structure defects but also by the NP size and shape. Contemporary transmission electron microscopy (TEM) can describe all these NP characteristics, however typically with a different statistical relevance. While the size and shape of NPs are frequently determined on a large ensemble of NPs and thus with good statistics, the characteristics on the atomic scale are usually quantified for a small number of individual NPs and thus with low statistical relevance. In this contribution, we present a TEM-based characterization technique, which can determine relevant characteristics of NPs in a scale-bridging way—from the crystal structure and crystal structure defects up to the NP size and morphology—with sufficient statistical relevance. This technique is based on a correlative multi-scale TEM approach that combines information on atomic scale obtained from the high-resolution imaging with the results of the low-resolution imaging assisted by a semi-automatic segmentation routine. The capability of the technique is illustrated in several examples, including Au NPs with different shapes, Au nanorods with different facet configurations, and multi-core iron oxide nanoparticles with a hierarchical structure. Full article

The homogenized lattice Boltzmann method (HLBM) has emerged as a flexible computational framework for studying particulate flows, providing a monolithic approach to modeling pure fluid flows and flows through porous media, including moving solid and porous particles, within a unified framework. This paper presents a thorough review of HLBM, elucidating its underlying principles and highlighting its diverse applications to particle-laden flows in various fields as reported in literature. These include studies leading to new fundamental knowledge on the settling of single arbitrarily shaped particles as well as application-oriented research on wall-flow filters, hindered settling, and evaluation of the damage potential during particle transport. Among the strengths of HLBM are its monolithic approach, which allows seamless simulation of different fluid-solid interactions, and its ability to handle arbitrary particle shapes, including irregular and concave geometries, while resolving surface interactions to capture local forces. In addition, its parallel scheme based on the lattice Boltzmann method (LBM) results in high computational efficiency, making it suitable for large-scale simulations, even though LBM requires small time steps. Important future development needs are identified, including the addition of a lubrication force correction model, performance enhancements, such as support for hybrid parallelization and GPU, and the extension of compatible contact models to accommodate concave shapes. These advances promise expanded capabilities for HLBM and broader applicability for solving complex real-world problems. Full article

Background: Precise continuous feeding of active pharmaceutical ingredients (APIs) and excipients is crucial in a continuous powder-to-tablet manufacturing setup, as any inconsistency can affect the final tablet quality. Method: This study investigated the impact of various materials on the performance of a continuous twin-screw loss-in-weight (LIW) feeder. The materials tested included spray-dried lactose, anhydrous lactose, granulated lactose, microcrystalline cellulose (MCC), an MCC–lactose preblend (50%:50% w/w ratio), and a co-processed excipient (lactose–lactitol at a 95%:5% w/w ratio). The feeding performance of these excipients was systematically assessed, focusing on powder densification and screw layering within the LIW feeder. Results: The results demonstrated densification for the spray-dried lactose and preblend. Densification was more pronounced during the initial feeding cycles for spray-dried lactose, but decreased gradually over time. In contrast, the densification remained relatively constant throughout the feeding process for the preblend. Notably, minor screw layering was observed for both spray-dried lactose and anhydrous lactose, with the extent of this issue reducing over time for the spray-dried lactose. Interestingly, granulated lactose grades did not show screw layering, making them preferable for blending with APIs prone to severe screw layering. The LIW feeder control system successfully managed powder densification and minor screw layering, maintaining the mass flow rate at the set point for all investigated materials. Conclusions: These findings inform the selection of optimal excipients, appropriate tooling for LIW feeders, and the enhancement of control strategies to shorten startup times. By addressing these factors, the precision and reliability of continuous feeding processes can be improved. Full article