Integral Process Modelling and Simulation for Solid-Particle-Forming Spray Processes

Abstract

Solid particles are formulated in spray processes by atomization of a slurry or melt and successive solidification or drying of the droplets. The inter-correlations between the spray process conditions (atomizer types, raw material properties, operation conditions, etc.) and the powder product properties (particle size, morphology, structure, etc.) in spray processing of solid particles through integral process modelling and simulation are to be derived. A multiphase CFD-Continuum Model integrates different sub-process models dealing with various nozzle arrangements, liquid atomization, droplet spray, and particle consolidation phenomena. For quantitative descriptions of particle–droplet interactions in spray processes, particle–droplet collision model, and particle penetration model are developed based on numerical simulations. The integrative models are validated based on melt atomization process (two-phase) and spray process for composite-particle production (three-phase). The integral process model may be inverted to derive proper feed and process conditions for tailored particle production in a recursive design.