Liquid Transport Rates during Binary Collisions of Unequally-sized Particles

In this paper, we study the liquid transport between particles of different sizes, as well as build a dynamic liquid bridge model to predict liquid transport between these two particles. Specifically, the drainage process of liquid adhering to two unequally-sized, non-porous wet particles is simulated using direct numerical simulations (DNS). Same as in our previous work (Wu et al., AIChE Journal, 2016, 62:1877–1897), we first provide an analytical solution of a proposed dynamic liquid bridge model. We find that such an analytical solution also describes liquid transport during collisions of unequally-sized particles very well. Finally, we show that our proposed model structure is sufficient to collapse all our direct numerical simulation data. Our model is hence able to predict liquid transport rates in size-polydisperse systems for a wide range of parameter

Numerical study on the effect of particle shape on mixers

Homogenization of particulate systems is a critical part in the processing of particulate materials to achieve consistency and ensure product quality. Homogenization is achieved by mixing, the aim is to obtain a final mixture that is homogeneous when mixing individual particulate constituents, in the sense of a uniform spatial mass distribution. Although there is always some measure of heterogeneity in a mixture this can be quantified by Gys sampling theory. This is critical for pharmaceutical industries in which it is essential that the variance of the active ingredients between tablets are within specified bounds. Although there have been numerous numerical studies on mixing using the Discrete Element Method (DEM), most studies to date have incorporated significant simplifications to reduce the computational time such as using mono-disperse size distributions, scaling up of particle size and spherical estimations of shape. The development of GPU based DEM simulations in the past few years significantly increased the number of spherical particles however most often at the expense of simplifying the physical interaction between particles. This oversimplification of particle shape has much wider primary implications as primary contact mechanisms such as angularity and locking are omitted. This is important in the pharmaceutical industry where the feed powders are often made from crystalline solids in which the shape of the individual particles are polyhedral. As this study demonstrates, this is significant in that the underlining dynamics of polyhedral particles is vastly different to that of spherical particles, resulting in tighter packing fractions different flow patterns, and percolation. In this paper we use the GPU based DEM code BlazeDEM3D-GPU to study and quantify the effect of particle shape in a high shear blade mixer

Review of sensing technologies for measuring powder density variations during pharmaceutical solid dosage form manufacturing

Oral solid dosage forms, the most widely used pharmaceutical products, are typically manufactured through a series of processes that transform a blend of drug and excipient particles into a densified product with consistent quality attributes. While the densification of powder during processing is crucial and directly impacts the quality of the drug product, there is still scarcity of non-destructive and fast sensor systems that provide access to the powder density at critical process stages. This review discusses methods for monitoring density variations of particulate matter by describing their principles and presenting application examples. The techniques discussed range from common in-line methods such as near-infrared spectroscopy, acoustic emission and ultrasonic methods as well as techniques with potential to be more frequently applied in a pharmaceutical manufacturing line, i.e., terahertz spectroscopy and imaging, microwave technique, electrical tomography and X-ray based methods. This review also compares these techniques in terms of measurement and data processing time, resolution and its ability to be integrated in a process

Characterization of the coating and tablet core roughness by means of 3D optical coherence tomography

This study demonstrates the use of optical coherence tomography (OCT) to simultaneously characterize the roughness of the tablet core and coating of pharmaceutical tablets. OCT is a high resolution non-destructive and contactless imaging methodology to characterize structural properties of solid dosage forms. Besides measuring the coating thickness, it also facilitates the analysis of the tablet core and coating roughness. An automated data evaluation algorithm extracts information about coating thickness, as well as tablet core and coating roughness. Samples removed periodically from a pan coating process were investigated, on the basis of thickness and profile maps of the tablet core and coating computed from about 480,000 depth measurements (i.e., 3D data) per sample. This data enables the calculation of the root mean square deviation, the skewness and the kurtosis of the assessed profiles. Analyzing these roughness parameters revealed that, for the given coating formulation, small valleys in the tablet core are filled with coating, whereas coarse features of the tablet core are still visible on the final film-coated tablet. Moreover, the impact of the tablet core roughness on the coating thickness is analyzed by correlating the tablet core profile and the coating thickness map. The presented measurement method and processing could be in the future transferred to in-line OCT measurements, to investigate core and coating roughness during the production of film-coated tablets

At-line validation of optical coherence tomography as in-line/at-line coating thickness measurement method

Optical Coherence Tomography (OCT) is a promising technology for monitoring of pharmaceutical coating processes. However, the pharmaceutical development and manufacturing require a periodic validation of the sensor's accuracy. For this purpose, we propose polyethylene terephthalate (PET) films as a model system, to periodically validate the measurements during manufacturing. This study proposes a new approach addressing the method validation requirement in the pharmaceutical industry and presents results for complementary methods. The methods investigated include direct measurement of the layer thickness using a micrometer gauge as reference, X-ray micro computed tomography, transmission and reflectance terahertz pulsed imaging, as well as 1D- and 3D-OCT. To quantify the significance of OCT for pharmaceutical coatings, we compared the OCT results for commercial Thrombo ASS and Pantoloc tablets with direct measurements of coating thickness via light microscopy of microtome cuts. The results of both methods correlate very well, indicating high intra- and inter-tablet variations in the coating thickness for the commercial tablets. The light microscopy average measured coating thickness of Thrombo ASS (Pantoloc) was 71.0 µm (83.7 µm), with an inter-coating variability of 8.7 µm (6.5 µm) and an intra-coating variability of 2.3 µm to 9.4 µm (2.1 µm to 6.7 µm)

The combined effect of H2O and SO2 on the simultaneous calcination/sulfation reaction in CFBs

The combined effect of H2O and SO2 on the reaction kinetics and pore structure of limestone during simultaneous calcination/sulfation reactions under circulating fluidized bed (CFB) conditions was first studied in a constant‐temperature reactor. H2O can accelerate the sulfation reaction rate in the slow‐sulfation stage significantly but has a smaller effect in the fast‐sulfation stage. H2O can also accelerate the calcination of CaCO3, and should be considered as a catalyst, since the activation energy for the calcination reaction was lower in the presence of H2O. When the limestone particles are calcining, SO2 in the flue gas can react with CaO on the outer particle layer and the resulting CaSO4 blocks the CaO pores, increases the diffusion resistance of CO2 and, in consequence, decreases the calcination rate of CaCO3. Here, gases containing 15% H2O and 0.3% SO2 are shown to increase the calcination rate. This means that the accelerating effect of 15% H2O on CaCO3 decomposition is stronger than the impeding effect caused by 0.3% SO2. The calcination rate of limestone particles was controlled by both the intrinsic reaction and the CO2 diffusion rate in the pores, but the intrinsic reaction rate played a major role as indicated by the effectiveness factors determined in this work. This may explain the synergic effect of H2O and SO2 on CaCO3 decomposition observed here. Finally, the effect of H2O and SO2 on sulfur capture in a 600 MWe CFB boiler burning petroleum coke is also analyzed. The sulfation performance of limestone evaluated by simultaneous calcination/sulfation is shown to be much higher than that by sulfation of CaO. Based on our calculations, a novel use of the wet flue gas recycle method was put forward to improve the sulfur capture performance for high‐sulfur, low‐moisture fuels such as petroleum coke

Predicting capsule fill weight from in-situ powder density measurements using terahertz reflection technology

The manufacturing of the majority of solid oral dosage forms is based on the densification of powder. A good understanding of the powder behavior is therefore essential to assure high quality drug products. This is particularly relevant for the capsule filling process, where the powder bulk density plays an important role in controlling the fill weight and weight variability of the final product. In this study we present a novel approach to quantitatively measure bulk density variations in a rotating container by means of terahertz reflection technology. The terahertz reflection probe was used to measure the powder density using an experimental setup that mimics a lab-scale capsule filling machine including a static sampling tool. Three different grades of α-lactose monohydrate excipients specially designed for inhalation application were systematically investigated at five compression stages. Relative densities predicted from terahertz reflection measurements were correlated to off-line weight measurements of the collected filled capsules. The predictions and the measured weights of the powder in the capsules were in excellent agreement, where the relative density measurements of Lactohale 200 showed the strongest correlation with the respective fill weight (R 2 =0.995). We also studied how the density uniformity of the powder bed was impacted by the dosing process and the subsequent filling of the holes (with excipient powder), which were introduced in the powder bed after the dosing step. Even though the holes seemed to be filled with new powder (by visual inspection), the relative density in these specific segments were found to clearly differ from the undisturbed powder bed state prior to dosing. The results demonstrate that it is feasible to analyze powder density variations in a rotating container by means of terahertz reflection measurements and to predict the fill weight of collected capsules

Crystal shape modification via cycles of growth and dissolution in a tubular crystallizer

Besides size and polymorphic form, crystal shape takes a central role in engineering advanced solid materials for pharmaceutical and chemical industry. This work demonstrates how multiple cycles of growth and dissolution can manipulate the habit of an acetylsalicylic acid crystal population. Considerable changes of the crystal habit could be achieved within minutes due to rapid cycling, i.e., up to 25 cycles within <10 min. The required fast heating and cooling rates were facilitated using a tubular reactor design allowing for superior temperature control. The face specific interactions between solvent and the crystals’ surface result in face specific growth and dissolution rates and hence alterations of the final shape of the crystals in solution. Accurate quantification of the crystal shapes was essential for this work, but is everything but easy. A commercial size and shape analyser had to be adapted to achieve required accuracy. Online size, and most important shape, analysis was achieved using an automated microscope equipped with a flow-through cell, in combination with a dedicated image analysis routine for particle tracking and shape analysis. Due to the implementation of this analyser, capable of obtaining statistics on the crystals’ shape while still in solution (no sampling and manipulation required), the dynamic behaviour of the size shape distribution could be studied. This enabled a detailed analysis of the solvent’s effect on the change in crystal habit

Designing attractive models via automated identification of chaotic and oscillatory dynamical regimes

Chaos and oscillations continue to capture the interest of both the scientific and public domains. Yet despite the importance of these qualitative features, most attempts at constructing mathematical models of such phenomena have taken an indirect, quantitative approach, for example, by fitting models to a finite number of data points. Here we develop a qualitative inference framework that allows us to both reverse-engineer and design systems exhibiting these and other dynamical behaviours by directly specifying the desired characteristics of the underlying dynamical attractor. This change in perspective from quantitative to qualitative dynamics, provides fundamental and new insights into the properties of dynamical systems