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The effects of air and particle density difference on segregation of powder mixtures during die filling

This paper presents the first numerical study on air-induced segregation during die filling, a typical unit operation in manufacturing particulate products. A robust coupled discrete element method with computational fluid dynamics (DEM-CFD) model is developed and used to investigate how the presence of air can affect the flow behaviour of powder mixtures during die filling. It is found that air can play an important role in determining powder segregation during die filling. The DEM-CFD model developed can be used to optimise formulations so that detrimental segregation phenomena can be minimised in pharmaceutical, fine chemical, agrochemical and other industries.