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Coating powder beds with liquids and foams based on viscous formulations using a twin screw mixer:A continuous process study

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Particuology 2024年第10期93卷 364-376页

作者： Mohamed S.Manga dimitrios kontziampasis Mustafa Al-Maqdad Sean Clifford Serafim Bakalis David W.York School of Chemical and Process Engineering Faculty of Engineering and Physical SciencesUniversity of LeedsLeedsLS29JTUK School of Mechanical Engineering Faculty of Engineering and Physical SciencesUniversity of LeedsLeedsLS29JTUK School of Science and Engineering University of DundeeDD14HNDundeeScotlandUK Dundee International Institute of Central South University Tongzipo RoadCentral South UniversityChangshaHunan410013China Department of Chemical Engineering School of EngineeringUniversity of NewcastleNewcastleNE17RUUK School of Chemical Engineering University of BirminghamBirminghamB152TTUK Department of Chemical Engineering Faculty of EngineeringUniversity of NottinghamNG72RDUK

Coating with viscous formulations has been essential in numerous industries as it can be a means for providing functionalization, additional properties, as well as other benefits. However, there have been scarce studies that have investigated and proposed methodologies in literature. Continuous coating of powders with viscous liquids poses as a promising technology, which has been mentioned in some studies, but has not yet been thoroughly investigated. This paper employs the use of image processing and analysis, in combination with statistical analysis of particles to evaluate the effectiveness of foams and liquids as a means of coating powder beds. Two different sizes of twin screw mixers that are working in continuous operation are employed, and a new continuous foaming device is fabricated and used for the experiments of coating. The effect of materials and process parameters (as for example rotational speed, and flowrate) on the quality of coating are investigated. Image analysis is used to assess the coating quality. The results clearly showcase the potential of using twin screw mixers for coating purposes and not only for mixing. The hypothesis that using large bubble foams to improve the coating of viscous liquids on particles is proven correct, as they provide higher quality coatings compared to their equivalent liquids, when used in the twin screw mixer. Surprisingly, using a larger scale twin screw mixer, does not show a substantial effect on the mixing, regarding quality, however there is still a requirement for mix optimization for achieving scale-up of this process. These results provide a new pathway for coating powders with viscous formulations in industrial applications, requiring less energy and effort in this process, and can pave the way towards introducing more sustainable industrial methodologies for coating.

关键词： Powder coating Continuous processing Viscous liquid Foam Image analysis Positron emission particle traking(PEPT)

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Coating particles using liquids and foams based on viscous formulations with industrial mixers: Batch operation

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Particuology 2020年第3期18卷 13-24页

作者： D.kontziampasis M.S.Manga D.W.York School of Chemical and Process Engineering Faculty of EngineeringUniversity of LeedsLS29JTLeedsW.YorkshireUK

Particle or powder coating with viscous liquids has been essential in industry for surface modification purposes to induce and enhance specific *** paper evaluates the performance of using foams (of different bubble diameters) versus liquids as a means of coating powder beds based on viscous liquid *** with viscous liquids present numerous industrial challenges and therefore preparing foam equivalents can render the liquid component weak enough (through pre shearing to form the foam),to allow it to break up and coat particles under the shear forces exerted in a mixing *** this study,two shear mixers are used;the first type consists of paddles in different configurations attached to a single rotating shaft,whilst the second type is a commercial twin screw mixer (TSM).The quality of coating achieved on the bulk powder bed using liquids and foams (stained with a dye) is assessed by image analysis to determine the homogeneity of the color *** addition,scanning electron microscopy provides a tool to further investigate the coating quality of individual particles from the bulk *** results show that large bubble (centimeter size) foams are much more effective at distributing within the fluidized powder bed compared to the starting viscous liquid and small bubble foams (submillimeter size).Furthermore,there is a maximum ratio of foam to powder beyond which agglomeration occurs and is insufficient to fully coat the *** of individual particles is achieved in the case of the TSM,whereas SEM proves that the single shaft paddle mixer crushes the particles and subsequently granulates them together to form granules of a size comparable to the size of coated particles seen after coating with the TSM.

关键词： Powder coating Viscous liquid Foam Image analysis Foam rheology Surface modification

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