Integral Process Modeling and Simulation of Spray Processes for Powder Production in the SPP "Process-Spray"

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Spray processes for the production of solid particles can be represented by a continuous simulation model. The nozzle, the primary break-up and the spray behavior influence the product quality. This influence in the spray process is mainly caused by solidification and form giving processes. These are the topic of projects in the SPP.The aim of this project is the development of models for solid particle producing spray processes based on the model of the SPP projects. Therefore, surface models simulate primary break-up of jets while secondary break-up is covered by multiphase models. To determine the interaction between droplets and particles a simulation is executed. Thus, regimes for coalescence and bouncing in case of two droplets and impact efficiency and adhering and penetration probability in case of particle-droplet are defined.In the second period these interaction models are integrated in a continuous simulation model. Afterwards, the models are combined to achieve a global model for the spray process. This model is to be validated against experimental data obtained in the SPP projects pilot plants.In a second model approach, the complete spray is simulated based on sheets, thus allowing an inverse engineering procedure from product properties to process conditions. In the end, the continuous model is used to produce data for the integral recursive process model. In addition, the results of the other SPP projects are taken into account. The aim is to construct a fully executable process model.