Discrete element method simulation of binary blend mixing of cohesive particles in a high-intensity vibration system

The effects of processing intensity, time, and particle surface energy on mixing of binary cohesive powder blends in high-intensity vibration system were investigated via discrete element method simulations. The mixedness was quantified by the coefficient of variation, C_v; lower being better. The mixing rate, which is the speed at which homogeneity was achieved, was inversely proportional to the mixing Bond number, defined as the ratio of particle cohesion to the shear force resulting from the mixing intensity. Results show that both increasing processing intensity and reducing surface energy led to a faster mixing rate. However, the mixedness improved initially as mixing action (the product of mixing rate and mixing time) increased, but later deteriorated upon its further increase. Thus, both mixing rate and mixing intensity need to be tuned for optimum mixing performance depending on the cohesion level of particles; too high or too low mixing action should be avoided.