346 SIZE ENLARGEMENT

distribution and binder viscosity. The granule porosity e, and the liquid level w,
control the granule saturation s, which is the fraction of pore space filled with
liquid:
wrs ð1
eÞ
s¼ ð13:8Þ
rl e

where rs is the solid density and rl is the liquid density. The saturation increases
as the porosity decreases, and once the saturation exceeds 100%, further con-
solidation pushes liquid to the granule surface, making the surface wet. Surface
wetness causes dramatic changes in granule growth rates (see below).

Growth

For two colliding primary granules to coalesce their kinetic energy must be
dissipated and the strength of the resulting bond must be able to resist the external
forces exerted by the agitation of the powder mass in the granulator. Granules
which are able to deform readily will absorb the collisional energy and create
increased surface area for bonding. As granules grow so do the internal forces
trying to pull the granule apart. It is possible to predict a critical maximum size of
granule beyond which coalescence is not possible during collision (see below).
Ennis and Litster (1997) suggest a rationale for interpreting observed granule
growth regimes in terms of collision physics. Consider collision between two
rigid granules (assume low deformability) of density rg, each coated with a layer
of thickness h of liquid of viscosity m, having a diameter x and approach velocity
Vapp . The parameter which determines whether coalescence will occur is a Stokes
number Stk:
rg Vapp x
Stk ¼ ð13:9Þ
16m

This Stokes number is different from that used in cyclone scale-up in Chapter 9.
The cyclone scale-up Stokes number Stk50 incorporates the dimensionless ratio
of particle size to cyclone diameter, i.e.:

rvx250 x50  rvx50

Stk50 ¼ ¼
18mD D 18m

where v is the characteristic gas velocity.

The Stokes number is a measure of the ratio of collisional kinetic energy to

energy dissipated through viscous dissipation. For coalescence to occur the
Stokes number must be less than a

criticalvalue

 Stk*, given by:
 1 h
Stk ¼ 1 þ ln ð13:10Þ
e ha