Mass Flow Patterns Research Articles

An experimental study on pressure drop of air-oil flow in horizontal pipes using two synthetic oils

This study focuses on the frictional pressure drop in gas-liquid two-phase flow, characterized by nonlinear behavior under various flow conditions due to complex two-phase phenomena. The experimental investigation involves an air-oil mixture flowing through horizontal pipes with diameters of 20 mm and 40 mm, aiming to observe the flow patterns and quantify the pressure drop. Two oils with different thermophysical properties are used as the liquid phase. The operating temperature and pressure of the test pipes are controlled within the range of 24–44°C and 1–3 bar, respectively. Seven air-oil flow patterns are identified based on visualization results: stratified smooth, stratified wavy, annular, plug, slug, bubbly, and dispersed bubble flows. On analyzing 1043 data points from the experiment, this study explores the effects of total mass velocity, flow quality, pipe diameter, operating temperature, operating pressure, and oil type on the frictional pressure gradient. Particular attention is given to the variation of the frictional pressure gradient concerning operating pressure, and its relationship with total mass velocity, flow quality, and flow pattern is discussed. Additionally, the study examines predictions from 55 previous correlations against the current pressure drop data. The predictive capability of these correlations is evaluated for the entire dataset and its subsets, categorized by oil type, pipe diameter, operating pressure, flow condition, total mass velocity, flow quality, and flow pattern. Evaluation metrics include mean absolute errors and the proportions of data points within 30% and 50% of absolute error. In addition, average and standard deviation values are calculated for each dataset to provide a comprehensive assessment.

The flowering dynamics and breeding system in Magnolia ×soulangeana ‘Hongyun’

Magnolia soulangeana ‘Hongyun’ is an ornamental tree used for landscaping. It has an attractive shape and produces abundant showy flowers. However, the fruit set rate of ‘Hongyun’ is low under natural pollination condition. In this study, we examined the basic characteristics of its breeding system. The results showed that the flower of ‘Hongyun’ is hermaphroditic, with both pistil and stamen being fertile. The pollen-ovule ratio (P/O) ranged from 3,205.78 to 6,244.21, and the outcrossing index (OCI) was 4. Comparing with different pollination treatments, we found that there was no fruit set under direct bagging, bagging after emasculation, and no bagging and non-pollination after emasculation. Furthermore, the fruit set rate under the geitonogamy treatment was lower than that under the xenogamy treatment, indicating low self-compatibility. Therefore, when combined with the numerical value of P/O and OCI, we infer that the breeding system of ‘Hongyun’ is partially self-compatible, outcrossing, and demands pollinators. In particular, ‘Hongyun’ presents a mass-flowering pattern. Furthermore, there is the phenomenon of secondary opening and closing in the flowering process of a single flower. The stigma receptivity and pollen viability of a flower are the strongest when it is slightly blooming during the first flowering. Strangely, the anther wall dehiscence occurs during the second flowering, which may guarantee that ‘Hongyun’ maintains a morphological dichogamy status to avoid self-fertilization. Overall, the unique flowering dynamics is closely related to the type of breeding system in ‘Hongyun’. Group planting will be the best way to promote better reproductive success of ‘Hongyun’ under garden planting conditions.

Effect of Scale-Up on Mass Transfer and Flow Patterns in Liquid–Liquid Flows Using Experiments and Computations

Effect of Scale-Up on Mass Transfer and Flow Patterns in Liquid–Liquid Flows Using Experiments and Computations

Numerical simulations on effect of cooling hole diameter on the outlet temperature distribution for a gas turbine combustor

The outlet temperature distribution characteristics of a gas turbine combustor are critical to the durability and lifetime of the turbine. Regarding to an advanced high-temperature-rise combustor, the air flow rate for swirling increases while the volume of air used to cool the wall and control the outlet temperature field decreases, causing severe challenges in effectively regulating the outlet temperature field, consequently. In the present work, with a focus on regulating the outlet temperature field under conditions of low cooling and mixed gas volume, numerical simulations of a single-sector centrally-staged combustor are carried out. The effusion cooling structure of multi-inclined cooling holes with 30° inlet angle are used on the liner wall. The impact of liner wall cooling holes with different diameters on the outlet temperature distribution characteristics is analyzed, while the variation in relative areas and distribution shapes of low-temperature regions near the outlet wall and hot streaks are obtained. The results suggest that under a constant inlet mass flow rate, both pattern factor (PF) and radial pattern factor (RPF) of the combustor increase with the increment of cooling hole diameter. Compared to the 0.5 mm hole diameter, when the diameter of each single cooling hole is doubled to 1.0 mm, the PF and RPF increase respectively by 1.14 times and 1.83 times, meanwhile, the combustion efficiency decreases from 99.97% to 97.74%, and the pressure drop reduces from 4.3% to 2.4%. Increasing the diameter of cooling holes enhances the cooling film thickness on the liner wall, resulting in the expansion of low-temperature regions near the outlet wall. Furthermore, in comparison with the smaller diameter, the larger diameter forces the combustion reaction zone to shift toward the outlet, leading to the expansion of hot streaks and a deterioration in the uniformity of the outlet temperature field. The combustor corresponding to the design scheme of multi-inclined cooling holes with 0.5 mm diameter has the most uniform outlet temperature field and the highest combustion efficiency, showing the optimum performance.

Blooming characteristics and breeding system of an invasive plant Gaura parviflora.

The invasiveness and dissemination of exotic species are strongly influenced by its sexual reproduction characteristics, including blooming characteristics and breeding system. Exploring the association of these sexual reproductive traits with invasiveness would be helpful for revealing the mechanism of its successful invasion. We examined the blooming characteristics and breeding system of Gaura parviflora based on field observations, out-crossing index (OCI) estimation, and hand-pollination experiments. The results showed flowering duration of the G. parviflora population (flowering period) was short (more than 3 months). The life span of single flower (floral longevity) was 40.46 h. Its flower diameter was 3.99 mm. Over seven flowers in bloom per inflorescence and most individuals often bloomed synchronously, which showed a 'mass-flowering pattern'. The changing trend of pollen and stigma vitality was relatively similar, but the duration of stigma vitality was 2 h longer than that of pollen. The stigma and the anthers were close to each other at the initial flowering stage, but the stigma removed from the anthers at the full-blooming stage with the style curving downwards. Many pollinators visited flowers in late full-blooming stage, which were mainly Apis mellifera and Syrphidae spp. Their average visiting frequency was 9.8 times·m-2·h-1. The fruit set in natural pollination after emasculation treatment (insect or wind pollination) was signi-ficantly higher than that in bagged and emasculation treatment, and the treatment of emasculated and bagged with nylon net (excluding insect pollination) could also bear fruits, indicating possible existence of ambophily in G. parviflora. The results of pollen ovule ratio (P/O) mensuration, OCI estimation and hand-pollination experiments showed that its mating system type belonged to additive mixed mating system. So, its characteristics, such as smaller flower size, shorter floral longevity and flowering period, were conducive to allocating more resources to plant growth and seed development, which would help improve its total fitness. The changes of spatial position of male and female organs not only avoided interference between male and female functions, but also created opportunities for stigmas to receive outcross pollen. In addition, the 'mass-flowering pattern' was conducive to attracting pollinators. The pollination mechanism of ambophily was helpful to ensure cross-pollination. The additive mixed mating system could provide double reproductive assurance for this species. These reproductive characteristics were significant for the successful invasion and expansion of G. parviflora.

Finite element modeling of biomass hopper flow

Hoppers are widely used biomass handling devices that channel bulk biomass from storage to subsequent handling equipment. Jenike’s longstanding approach, based on the Mohr-Coulomb model, has been successfully used to design hoppers handling cohesionless granular materials such as grains and other agricultural produces. However, designing a hopper to ensure reliable biomass flow is found to be challenging due to cohesion, irregular particle shape, and bulk material elastoplasticity. This study aims to address the biomass handling engineering challenge with alternative constitutive material models concerning the flow behavior of bulk solids. Finite element modeling is an approach that allows for implementation of different material models, whose underlying constitutive theories assist in investigating the origin and manifestation of bulk mechanical behavior of granular materials. This study focuses on the incipient gravity hopper flow of two types of biomass feedstocks, i.e., ground corn stover and Douglas fir wood. Three widely used constitutive material models, i.e., Mohr-Coulomb model, modified Cam-Clay model, and Drucker-Prager/Cap model, are implemented. Using the flow pattern represented by the volume of biomass exhibiting more than 7% of axial strain (Kamath and Puri, 1999), the finite element model predicts that the bulk corn stover particulate material forms an arch, which represents a hampered transition from the static state to the dynamic flow-state out of the hopper, whereas bulk Douglas fir wood particulate material develops a reliable mass flow pattern. A laboratory scale hopper was used to experimentally determine the biomass flow conditions, which were subsequently compared with the predicted onset of flow by a finite element model (FEM). The developed FEM was found to correctly predict the initiation of mass flow for the milled Douglas fir wood, whereas corn stover was predicted to establish a strong core flow suggesting an unreliable handling characteristic. This observation aligns with the reported poor handling of milled corn stover.

Seasonal variability in size-resolved hygroscopicity of sub-micron aerosols over the Western Ghats, India: Closure and parameterization

Hygroscopicity of atmospheric aerosol primarily depends on the size and chemical composition of the particle and is important for estimating anthropogenic aerosol radiative forcing. There is limited information exists over the Indian region on size segregated aerosol hygroscopicity (κ) in different seasons. This study presents ‘κ’ as derived from a Humidified Tandem Differential Mobility Analyzer (HTDMA) over a High Altitude Cloud Physics Laboratory (HACPL) in the Western Ghats, India for more than a year (from May 2019 to May 2020). The average hygroscopicity values of aerosol particles of diameters 32, 50, 75, 110, 150, 210 and 260 nm at 90 % RH condition are 0.19, 0.18, 0.16, 0.17, 0.18, 0.20, 0.21 respectively during the entire observation period. κ was observed to decrease with an increase in size in the Aitken mode regime (32–75 nm) and an increase in the accumulation mode (110–260 nm). Seasonal variation of hygroscopicity for a wide range of particle diameters is reported which is highly demanding as there is a change in the air mass flow pattern in each of the seasons. The diurnal cycle of hygroscopicity showed a prominent peak during the midnight to early morning hours followed by a decrease in the forenoon hours and a secondary peak in the afternoon hours. κ is found to be higher in pre-monsoon compared to winter season as Chl is approximately 3 % higher in pre-monsoon and NH4Cl is highly hygroscopic among the assumed chemical composition. Hygroscopicity derived through chemical speciation observations assuming internal and external mixing of aerosols i.e. κinter and κexter are overestimating as compared to κHTDMA. However, the bias between kexter and kHTDMA is relatively lower as external mixing type of aerosol is evident through the growth factor data sets measured by HTDMA. Utilizing the hygroscopicity measurements available for discrete diameters by HTDMA, a parameterization of hygroscopicity with the dry diameter of sub-micron particles is developed.

Effects of Duct Height and Fire Location on Fire Phenomena of Enclosure with Two Horizontal Vents Installed on Ceiling

The effects of duct height (DH) and fire location (FL) in an enclosure on the mass flow rate and flow pattern of horizontal vent (HV) flow and temperature distribution in the enclosure were investigated through numerical simulations under the condition that two HVs were installed on the ceiling of the enclosure. To evaluate the effect of DH, DHs of HV1 were set to 0.19 m (HV1_DH0.19) and 0.05 m (HV1_DH0.05) under the condition that DH of HV2 was 0.05 m (HV2_DH0.05). The effect of FL was evaluated in three cases where the fire sources were located in the center of the floor (F LC), below HV1 (F L1), and below HV2 (F L2). With respect to the DH effect, the total mass flow rate of the vent flow was slightly higher and temperature was slightly lower in the case of HV1_DH0.19 than that in the case of HV1_DH0.05. However, considering the error bars, the effect of DH in this numerical simulation condition was considered to be insignificant. Furthermore, bidirectional flow patterns appeared in HV1 and HV2 in both DH conditions. Meanwhile, with respect to the FL effect, a bidirectional flow dominated by the mass flow rate of outflow occurred in the HV where the fire source was located, and a unidirectional inflow dominated by the mass flow rate of inflow occurred in the HV where the fire source was not located. The total mass flow rates of FL1 and FL2 conditions were similar, which were higher than those of FLC condition. The temperature was higher in FLC than those in FL1 and FL2. This was due to the small mass flow rate through the HV in the FLC. Meanwhile, an increasing trend of the temperature with the rising measurement height from the floor was observed at most of the temperature measurement points. However, when the fire source was located below HV1 and HV2, as the height from the floor increased, the temperature decreased and the overall temperature was low at the temperature measurement points below the vent where the fire source was not located. This trend was attributed to the occurrence of a strong unidirectional inflow wherein a large volume of low-temperature air flowed into the enclosure from the HV where the fire source was not located.

Phase separation of two-phase ammonia in horizontal T-junction at low mass velocity

Phase separation of a two-phase working fluid accompanies the thermal-hydraulic process in every system and device, with at least one T-junction used in a two-phase line. Adequate qualitative and quantitative prediction of phase separation in T-junction is critical for successful designing, e.g., refrigeration, thermal control, and fluid transport systems. Three simple T-junctions with different inlet and side diameters were tested in the horizontal position on two-phase ammonia at a saturation level of 40÷60 °C and mass velocities of 25÷150 kg·m−2s−1. Based on test data, it has been revealed that at the relative side branch mass flow rate above 0.6, the phase separation behaviour does not depend on inlet mass velocity, vapour quality, void fraction, flow patterns (stratified, slug and annular) and relative side branch diameter. A simplified empirical correlation has been proposed describing the ammonia test points with an error margin of ±15%.

Discharge of elongated grains in silos under rotational shear.

The discharge of elongated particles from a silo with rotating bottom is investigated numerically. The introduction of a slight transverse shear reduces the flow rate Q by up to 70% compared with stationary bottom, but the flow rate shows a modest increase by further increasing the external shear. Focusing on the dependency of flow rate Q on orifice diameter D, the spheres and rods show two distinct trends. For rods, in the small-aperture limit Q seems to follow an exponential trend, deviating from the classical power-law dependence. These macroscopic observations are in good agreement with our earlier experimental findings [Phys. Rev. E 103, 062905 (2021)2470-004510.1103/PhysRevE.103.062905]. With the help of the coarse-graining methodology we obtain the spatial distribution of the macroscopic density, velocity, kinetic pressure, and orientation fields. This allows us detecting a transition from funnel to mass flow pattern caused by the external shear. Additionally, averaging these fields in the region of the orifice reveals that the strong initial decrease in Q is mostly attributed to changes in the flow velocity, while the weakly increasing trend at higher rotation rates is related to increasing packing fraction. Similar analysis of the grain orientation at the orifice suggests a correlation of the flow rate magnitude with the vertical orientation and the packing fraction at the orifice with the order of the grains. Lastly, the vertical profile of mean acceleration at the center of the silo denotes that the region where the acceleration is not negligible shrinks significantly due to the strong perturbation induced by the moving wall.

Groundwater flow numerical model to evaluate the water mass balance and flow patterns in Groundwater Circulation Wells (GCW) with varying aquifer parameters

Groundwater Circulation Wells (GCW) can be an effective in-situ remediation option allowing high mass recovery of contaminants in cases where contamination hotspots are located in saturated soil having low hydraulic conductivity. Traditional treatment options such as Pump&Treat, Air Sparging (AS)/Soil Vapor Extraction (SVE) and Multi Phase Extraction (MPE) typically require long operation times and significant costs for long-term plume management. GCWs induce meaningful changes in the groundwater flow introducing vertical flows both downward and upward, generating a “circulation cell”, which facilitates contaminant desorption from the soil. This study aims to understand the effects of a GCW on an aquifer in terms of both groundwater flow directions and water balance. A groundwater numerical model was built using MODFLOW-2005 to simulate the effect of the hydraulic parameters of the aquifer on the hydraulic circulation pattern of the GCW. The use of particle tracking simulated by MODPATH 7 showed the circulation cells and the impact on groundwater directions induced by different configurations of hydraulic parameters. The water flowing into the cell comes from both the injection well and the surrounding aquifer and the model shows how the hydraulic parameters of the aquifer, in particular the horizontal and vertical hydraulic conductivity, have a paramount influence in determining the shape and dimension of the circulation cell. A water mass balance analysis was carried out. It allowed to predict the groundwater flows exchanges between the GCW system and the surrounding aquifer, and to verify the sensitivity of the water budget to specific aquifer parameters. The results of this study are useful for further understanding the hydraulics of a GCW remediation system in order to support the design and to predict its performance.

Study on solid-liquid transition behaviors of cohesive powders and predict the critical arch-breaking gas flow rate

Cohesive powders cannot flow freely in the silo and even behave like solid, which brings a great challenge to the powder handling process. Aeration is an effective method used to break the arch structure formed above the silo outlet and to promote the powder flow. However, it is difficult to determine the solid-liquid transition behaviors and to predict the critical arch-breaking gas flow rate in the aerated discharge systems. In this paper, cohesive powders including alumina (Al2O3), pulverized coal (COAL) and calcium carbonate (CaCO3) were used as experimental materials. Powder flow properties were characterized by conducting shear test, permeability test, and aerated discharge experiment. Unconfined yield strength of powders under zero pre-consolidated stress was obtained based on using a linear extrapolation procedure of shear parameters. Aerated discharge characteristics of cohesive powders were determined and, the critical condition corresponding to the transition from solid-like to liquid-state and the stable condition distinguishing the funnel flow pattern and mass flow pattern were defined, respectively. The Brown and Richards model, and the flow/no-flow criterion of Jenike were modified to describe the powder flow state and to predict the solid mass flow rate under the action of aeration by introducing the positive gas pressure gradient. A logical algorithm was proposed to predict the critical arch-breaking gas flow rate by assuming the same gas distribution coefficient under different aeration conditions. As a precondition, the critical solid mass flow rate was calculated by an iterative algorithm giving the same order of magnitude of that from the experiment, which was further related to the stable solid mass flow rate and the powder permeability index. This simplification provided us with satisfactory results for all the powders producing errors generally less than 30%, a more easy-to-operate method to determine the critical arch-breaking gas flow rate.

A design method of hopper shape optimization with improved mass flow pattern and reduced particle segregation

A shape optimization method is presented in this paper to re-design hopper shapes for improving the flow patterns in silos. This method combines a continuum model of granular matter based on the Eulerian Finite Element Method, the optimization algorithms of genetic algorithm and the gradient descent method. Starting from a classic conical shape, the optimization method searches for the optimal shape of the hopper under given geometrical constraints. An optimized curve design can increase the mass flow zone in the hopper by more than 90%. The sensitivity of this method suggests that the shape optimization is of particular significance for initially funnel flow hoppers and granular materials with high internal friction. The optimized design was further characterized by using the Discrete Element Method. The DEM results demonstrate that the optimized hopper can also dramatically reduce particle segregation by around 70% during hopper discharge.

A geometrical criterion for the dynamic snap-off event of a non-wetting droplet in a rectangular pore–throat microchannel

In porous media, non-wetting phase droplets snapping off in a constricted microchannel are one of the most common phenomena in two-phase flow processes. In this paper, the application range of the classic quasi-static criterion in rectangular cross section microchannels is obtained. For three different droplet breakup phenomena—total breakup, partial breakup, and non-breakup—observed in experiments when a non-wetting phase droplet passes through a microchannel constriction, the breakup is caused by the droplet neck snapping off in a channel constriction. A critical criterion for the dynamic snap-off event in a two-phase flow is proposed considering the effect of viscous dissipation by mechanical analysis, energy dissipation analysis, and many microfluidic experiments. When the droplet front flows out of the constriction, snap-off will occur if the surface energy release exceeds the required energy for viscous dissipation and kinetic energy conversion. The unique partial breakup phenomenon is affected by droplet surfactant distribution and the acceleration effect in the constriction center. This partial breakup phenomenon in experiments is an essential evidence for the non-uniform distribution of surfactants in the droplet surface. The results of this study contribute to understanding pore-scale mass transfer and flow pattern changes within porous media.

A State-of-the-Art Review on Two-Phase Flow-Induced Noise in Expansion Devices

This paper presents a state-of-the-art review of the literature concerning flow-induced noise in expansion devices. The topics covered are theoretical natural frequency models of bubbles with spherical and cylindrical shapes and flow-induced noise in capillary tubes, such as orifice, thermal and electric expansion valve. Several parametric conditions affect the flow-induced noise in capillary tubes, such as outlet capillary geometry, capillary inner diameter and length, flow orientation, outlet vapor quality, mass velocity, pressure drop, in/outlet flow pattern, evaporation temperature, and refrigeration cycle operational conditions. Despite the broad use of orifice, there is a lack of knowledge in the literature of flow-induced noise in these devices. The flow-induced noise seems primarily a function of mass velocity, vapor quality, and flow pattern. It seems that outlet intermittent flow patterns lead to significant noise in capillary tubes and expansion valves. In general, for the noise evaluated outside the expansion device, electric expansion valves exhibited higher sound pressure levels than capillary tubes. Furthermore, the present literature review indicates that efforts should be made to perform tests for a wide range of conditions evaluating the noise within and outside the expansion device, device wall acceleration and flow topology for current and new refrigerants, simultaneously.

Modeling of water mass flow patterns at the Mahakam River and its sub-river of the Karang Mumus River

Modeling of water mass flow patterns at the Mahakam River and its sub-river of the Karang Mumus River

Flow characterization of compressible biomass particles using multiscale experiments and a hypoplastic model

Poor flowability of compressible biomass particles poses severe handling challenges in all processes of biorefineries, which results in poor energy-yielding in conversion. This paper presents the characterization of the flow behavior of a widely used compressible biomass material (ground loblolly pine) using a combination of physical characterization and numerical simulation. An advanced hypoplastic model with implementation and validation in Abaqus VUMAT is adopted. A workflow is established to calibrate material parameters directly from index tests, an oedometer test, and a Schulze ring shear test, and indirectly from numerical simulations of those tests. The finite element simulation of axial shear tests and hopper flow tests using the calibrated hypoplastic model is shown to capture key flow attributes, such as the maximum shear stress in shear tests, as well as the mass flow rate and flow pattern in hopper. The results demonstrate that a subset of the laboratory tests needs to allow large strains for adequate characterization of compressible granular flow, and numerical models developed for non-compressible materials can accurately predict the flow behavior of compressible biomass material, even though strain magnitudes are not scaled correctly. This study provides a potent tool to decipher and resolve material handling upsets in biorefineries and other energy industries that utilize forest products.

Local Heat Transfer Analysis in a Single Microchannel with Boiling DI-Water and Correlations with Impedance Local Sensors

Determination of local heat transfer coefficient at the interface of channel wall and fluid was the main goal of this experimental study in microchannel flow boiling domain. Flow boiling heat transfer to DI-water in a single microchannel with a rectangular cross section was experimentally investigated. The rectangular cross section dimensions of the experimented microchannel were 1050 μm × 500 μm and 1500 μm × 500 μm. Experiments under conditions of boiling were performed in a test setup, which allows the optical and local impedance measurements of the fluids by mass fluxes of 22.1 kg·m−2·s−1 to 118.8 kg·m−2·s−1 and heat fluxes in the range of 14.7 kW·m−2 to 116.54 kW·m−2. The effect of the mass flux, heat flux, and flow pattern on flow boiling local heat transfer coefficient and pressure drop were investigated. Experimental data compared to existing correlations indicated no single correlation of good predictive value. This was concluded to be the case due to the instability of flow conditions on one hand and the variation of the flow regimes over the experimental conditions on the other hand. The results from the local impedance measurements in correlation to the optical measurements shows the flow regime variation at the experimental conditions. From these measurements, useful parameters for use in models on boiling like the 3-zone model were shown. It was shown that the sensing method can shed a precise light on unknown features locally in slug flow such as residence time of each phases, bubble frequency, and duty cycle.

The Effect of External Geometry Factors on the Characteristics of Flow Profiles and Segregation in a Vertical Sinter Cooling Bed

Good particle flow patterns and uniform particle velocity distributions enhance the performance of heat transfer and smooth flow processes in vertical sinter cooling beds (VSCBs). The effect of three typical geometries, conical, curved and rectangular, on the performance of flow profiles and segregation in a VSCB is investigated comparatively and quantitatively based on the discrete element method (DEM). The evolution of flow profiles and particle segregation directly influence the evenly distributed sinter layers and the efficiency of heat exchange in VSCBs. In this research, a 3D packed bed model is established for the three geometry types to quantitatively and qualitatively investigate the influence of structural parameters on the evolution of flow patterns and segregation. The comparison of the effect of the three geometry types on the particle flow process showed that the curved geometry types greatly improve the performance of the flow pattern and size segregation. The height of the mass flow pattern for the curved geometry varies with the structural parameters by 1.5-fold that of the flow pattern for the other two geometry types. The curved geometry dramatically reduces the magnitude of the segregation index (SI) near the sidewall, while this magnitude fluctuates near 1.0 in the central flow passage of the VSCB.

Theoretical and Experimental Evaluation of Flow Pattern of Pharmaceutical Powder Blends Discharged From Intermediate Bulk Containers (IBCs).

The purpose of this study is to assess the prevalence of funnel flow pattern for common pharmaceutical powder blends, upon discharging from modern intermediate bulk containers (IBCs) in drug product manufacturing. The estimation was built upon Jenike's original radial stress field theory. It was modified to account for the stress-dependence of wall friction angle commonly observed in pharmaceutical powders. A total of 260 flow pattern estimations, based on 20 real-life IBCs and 13 investigational powder blends, were made. The estimated results showed that the mass flow pattern is present in less than 5% of all cases. Funnel flow pattern is clearly prevalent among pharmaceutical powder blends. The prevalence of funnel flow stems from several factors: 1) relatively shallow hopper section shared by all IBCs, 2) the common transition-type geometry, leading to even shallower hopper inclination at the edge of the hopper section, and 3) relatively high wall friction angles resulting from low wall normal stresses. This conclusion was verified through at-scale experiments, by discharging multiple pharmaceutical powder blends from a representative IBC. In general, our study suggests that, unless the powder wall friction can be substantially reduced, pharmaceutical powders are likely to discharge under funnel flow from modern IBCs.