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Volume 105
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Numerical analysis of particle agglomeration in a continuous pan granulator using DEM
Gisele M. de Souza, Rondinelli M. Lima, Claudio R. Duarte, Marcos A.S. Barrozo *
School of Chemical Engineering, Federal University of Uberlândia, Bloco K, Campus Santa Mônica, 38400-902, Uberlandia, MG, Brazil
10.1016/j.partic.2025.07.022
Volume 105, October 2025, Pages 140-154
Received 17 June 2025, Revised 22 July 2025, Accepted 29 July 2025, Available online 13 August 2025, Version of Record 21 August 2025.
E-mail: masbarrozo@ufu.br
Highlights

• DEM analysis with cohesive contact force models is compared with experimental data.

• Combination of Easo capillarity model and SJKR adhesion model is proposed.

• RTD curves reveal short-circuit effect in all cohesive granular beds.

• A new methodology to quantify particle agglomeration in DEM analysis is presented.

• Larger agglomerates are observed in rolling and cascading regimes.


Abstract

Pan granulators are widely used in granulation processes; however, the relationship between particle dynamics within the equipment and the underlying agglomeration mechanisms remains not fully understood. To address this, the present study conducted numerical simulations using the Discrete Element Method (DEM) with cohesive contact force models. Various models were evaluated and compared with experimental data to determine the one that best represented the behavior of the granular bed. The selected model, which incorporates the Easo capillarity model for particle-particle interactions and the SJKR adhesion model for particle-wall interactions, yielded satisfactory results. The numerical findings highlighted significant changes in granular flow dynamics when cohesive forces were taken into account. Additionally, the influence of cohesive forces and rotational speeds on residence time distributions (RTD) was analyzed, revealing the presence of a short-circuit effect in all cohesive granular beds. Finally, a new methodology was developed to quantify particle agglomeration. Larger and more numerous agglomerates were observed when the pan granulator operated in rolling or cascading regimes, conditions that were associated with longer residence times and an increased number of particle contacts.

Graphical abstract
Keywords
Pan granulator; Discrete element method; Liquid bridge force; Agglomeration; Cohesive contact forces
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