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Dynamic Simulation of Roller Compaction

By shsu

Purdue University

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A dynamic model for roller compaction process is derived based on Johanson’s rolling theory and material balance. Johanson’s rolling theory is used to predict the stress and density profiles during the compaction and the material balance equation describes the roll gap change. The proposed model considers the relationship between the process parameters, so it becomes possible to design, optimize, and control the process using the model-based approach. Currently, the operating conditions are mostly found by trial and error. The simulation case studies show the model can predict the ribbon density and gap width while varying roll pressure, feed speed and roll speed. The roll pressure influences the ribbon density much more than other two input variables, and the roll gap is affected by all three inputs. If the ratio of feed speed to roll speed is kept constant, neither ribbon density nor gap width change, but the production rate.


NSF Engineering Research Center for Structured Organic Particulate Systems (ERC-SOPS)


Bindhumadhavan, G., Seville, J. P. K., Adams, M. J., Greenwood, R. W., and Fitzpartrick, S. (2005). "Roll compaction of a pharmaceutical excipient: experimental validation of rolling theory for granular solids." Chemical Engineering Science, 60, 3891-3897

Hsu, S.-H., Joglekar, G., Reklaitis, G. V., and Venkatasubramanian, V. (2007). "Model Predictive Control on Roller Compaction for Pharmaceutical Manufacturing." AIChE 2007 annual meeting, Salt Lake City, UT.

Hsu, Shuo-Huan; (2008), "Dynamic Roller Compactor",

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  • shsu (2008), "Dynamic Simulation of Roller Compaction,"

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