A dynamic two-zone model of continuous fluidized bed layering granulation with internal product classification

A dynamic two-zone model is proposed to address the formation of granulation and drying zones in fluidized bed layering granulation processes with internal product classification. The model assumes a constant volume for the granulation zone, but a variable overall volume for the fluidized bed to account for classified product removal. The model is used to study the effect of various process parameters on dynamics and process stability. Stability is shown to depend on the separation diameter of product removal and the flow rate of the injected liquid. A lower and upper range of separation diameters with stable process behavior are found. In an intermediate range instability in the form of self-sustained oscillations is observed. The lower stability boundary is in qualitative agreement with recent experimental observations (Schmidt, Bück, & Tsotsas, 2015); the upper boundary was reported in a theoretical paper by Vreman, Van Lare, and Hounslow (2009) based on a single zone model.