V-blender segregation patterns for free-flowing materials: effects of blender capacity and fill level.

Stable segregation patterns are shown to form in V-blenders over a wide range of vessel capacities, fill levels, and rotation rates. Slight changes in either rotation rate or fill level induce changes in pattern formation. Trajectory segregation in two regions of the flow, accumulating over many flow periods, drives segregation pattern formation. Scaling criteria derived to relate particle velocities to vessel size and rotation rate in rotating cylinders successfully predict the rotation rate for the transition between patterns across V-blenders of 0.8-26.5 quart total capacity. This agreement suggests that pattern formation is governed by the magnitude of particle velocities. Regardless of vessel size, when particle velocities at specific regions of the blender are below a certain value, one particular pattern appears, and when they increase beyond that speed (i.e. by changing the rotation rate or the vessel size), a different pattern emerges. A scaling relation between segregation pattern formation and blender fill level was not identified because the complex flow patterns in the V-blender (the length of the flowing layer and the mixture center of mass relative to the blender are constantly oscillating) preclude the determination of a relationship between blender fill level and particle velocities.