Optimization of product characteristics of porous carbon agglomerates using a design of experiments in fluidized bed agglomeration (Open Access)--颗粒学报PARTICUOLOGY

Oelofse, M., Rack, R., Hilden, M., & Langguth, P. (2024). Optimization of product characteristics of porous carbon agglomerates using a design of experiments in fluidized bed agglomeration. Particuology, 89, 258-269. https://doi.org/10.1016/j.partic.2023.10.017

Optimization of product characteristics of porous carbon agglomerates using a design of experiments in fluidized bed agglomeration (Open Access)

Martin Oelofse^{a b}, Robert Rack^b, Marcelle Hilden^b, Peter Langguth ^a *

a Department of Pharmaceutical Technology and Biopharmaceutics, Johannes Gutenberg University, Mainz, Germany
b Carbon Advanced Solutions GmbH, Heuchelheim, Germany

10.1016/j.partic.2023.10.017

Volume 89, June 2024, Pages 258-269

Received 12 July 2023, Revised 27 September 2023, Accepted 20 October 2023, Available online 18 November 2023, Version of Record 14 December 2023.

E-mail: langguth@uni-mainz.de

Highlights

• A novel carbon granules formulation based on carbon and peroxide powder was developed.

• Influence of spraying parameters during agglomeration was understood and optimized.

• Through spraying parameters, a defined pore and volume structure in agglomerates and carbon tablets was achieved.

• Particle agglomeration was monitored throughout agglomeration cycle time.

• Through design of experiments, optimum carbon tablet strength was achieved based on spraying parameters.

Abstract

Spraying parameters during particle agglomeration processes can affect the agglomeration kinetics and particle growth. This study was conducted to better understand the influence of the spraying parameters in a fluidized bed wet agglomeration process, and the influence on the stability characteristics of carbon tablets. A formulation based on fine carbon and peroxide powder, as well as carboxymethyl cellulose as a binder, was used to produce agglomerates in a first production step. Thereafter in a second production step carbon tablets with a high porosity were molded for the customer goods industry. The optimization of the compressive strength of these carbon tablets was the goal of the trials. Carbon agglomerates were produced with a laboratory scale granulator called “ProCell” and were compressed with a five-cavity mechanical press. The screening of the agglomeration process parameters and their influence on the agglomerates quality, as well as the performance characteristics of the carbon tablets, were investigated using a multilevel factorial design. The experimental runs were done by varying atomized air pressure and feed rate of the fluid. This was determined by the design model. The findings of the statistical trials showed that low atomized air pressure and a low feed rate lead to a higher tablet compressive strength.

Graphical abstract

Keywords

Wet agglomeration; Fluidized bed; Design of experiments; Carbon agglomerates and tablets

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