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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： Manga, Mohamed S. Kontziampasis, Dimitrios Al-Maqdad, Mustafa Clifford, Sean Bakalis, Serafim York, David W. Univ Leeds Fac Engn & Phys Sci Sch Chem & Proc Engn Leeds LS2 9JT England Univ Leeds Sch Mech Engn Fac Engn & Phys Sci Leeds LS2 9JT England Univ Dundee Sch Sci & Engn Dundee DD1 4HN Scotland Cent South Univ Dundee Int Inst Tongzipo Rd Changsha 410013 Hunan Peoples R China Univ Newcastle Sch Engn Dept Chem Engn Newcastle Upon Tyne NE1 7RU England Univ Birmingham Sch Chem Engn Birmingham B15 2TT England Univ Nottingham Fac Engn Dept Chem Engn Nottingham NG7 2RD England

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. (c) 2024 Chinese Society of Particuology and Institute of Process Engineering, Chinese Academy of Sciences. Published by Elsevier B.V. Thi

关键词： Powder coating Continuous processing Viscous liquid Foam Image analysis Positron emission particle traking (PEPT) emission particle tracking GROWTH REGIME MAP WET GRANULATION ENCAPSULATION PENETRATION NUCLEATION

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