wim oostra granulation - a process with many faces
TRANSCRIPT
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Granulation - a process with many faces
WIM OOSTRA
25| October | 16
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CONTENT
• Introduction
• Mechanisms of granulation
• Nucleation and wetting
• Growth and coalescence
• Breakage and attrition
• Outlook
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WHY GRANULATION
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The Science and Engineering of Granulation ProcessesBy Jim Litster, Bryan Ennis
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HOW
Dry
• Roller compaction
• Tablet compaction
• Pelletizing mills
Wet
• Drum granulators
• Disc granulators
• Planetary mixers
• High shear mixers
• Fluid bed granulators
• Extruders
• Spray drying
• Prilling
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PHARMA
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- FUTURE?
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MECHANISMS IN GRANULATION
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NUCLEATION AND WETTING
“Pour on”
• Relies on mechanical dispersion
• Short nucleation times
• Can be very reproducible for low viscous binders
Spray-on
• Use spray flux density
• Well controlled nucleation
• Lead to long nucleation times in scale up and wider distributions
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𝜓𝑎= 3 𝑉
2 𝐴𝑑𝑑
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NUCLEATION AND WETTING
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Nucleation regime maps
K.P. Hapgood, J.D. Litster, R. Smith, AIChE L, 49 (2), 350-361, 2003
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NUCLEATION AND WETTING - EXAMPLE
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5003: Penetration time of binder > 60 s5004: Penetration time of binder < 1 s
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NUCLEATION AND WETTING – EXAMPLE 2
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MECHANISMS IN GRANULATION
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CONSOLIDATION AND COALESCENCE
• Growth (pattern) observed depends on
• Strength/deformability of granules (particle size, viscosity, porosity)
• Pore saturation
• Force applied (Fluid bed vs. high shear, impeller/chopper speeds )
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CONSOLIDATION AND COALESCENCE
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CONSOLIDATION AND COALESCENCE
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Granule growth regime map
S.M. Iveson and J.D. Litster, AIChE J 44, 1510-1518 (1998)
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CONSOLIDATION AND COALESCENCE
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Layered growth
Layered growth
K. Van den Dries, Paradox of high shear granulation, PhD thesis, Utrecht, 2004
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MECHANISMS IN GRANULATION
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ATTRITION AND BREAKAGE
• Important process which affects, even, may control the PSD….
• Less understood than other phenomena
• Difficult to study/separate from other phenomena
• Various semi-quantitative theories available
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BREAKAGE
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ATTRITION AND BREAKAGE
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0.0000 0.0001 0.0010 0.0100 0.1000 1.0000 10.0000
StdefGral 10
Gral 25
Gral 75
Gral 300
Breakage
No breakage
No breakage Breakage
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MECHANISMS IN GRANULATION
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SUMMARY, OUTLOOK
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