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This study focuses on the effects of bed-height and number of revolutions on the granular mixing performance with an objective to derive a mathematical relationship between mixing performance and number of revolutions. The simulations were carried out in a rectangular box in which three fill-levels and up to 15 blade revolutions were used. Blade forces were observed to have a direct relationship with the fill-level while mixing performance had an inverse relation and decreased with the increase in fill-level or bed-height. Mixing performance increased with the increase in the number of revolutions almost exponentially in the beginning. After around 12 blade-passes, the change in mixing performance was not significant, i.e., the mixing index value reached an asymptotic value. A mathematical relationship was derived for a quick estimate of mixing performance after given number of revolutions. The findings are significant and have direct industrial applications as they can best predict the mixing efficiency and residence times for the mixer. The proposed mathematical relationship can be effectively used for any industrial batch mixer employing blade movement or rotation and reduce the mixing costs by a significant factor.

Development of a mathematical relationship for prediction of mixing quality in industrial convective batch mixers