Summary

This joint project shall provide models, methods and implementations for realization of autonomous structure formation processes in spray fluidized beds. This will be achieved by a combination of novel multi-rate soft-sensors to assess the development of agglomerate structure online and advanced process control schemes that allow adjustment of defined agglomerate structures. Structural and morphological models are a key part towards this goal, providing the required links between process inputs, measurable quantities and agglomerate structure. By this approach, the project addresses all central research areas of the priority program. In the first period of the project (three years), the focus will be on structure formation of homo-agglomerates; i.e. agglomerates consisting of single-material primary particles. The major objectives in the first period of the project are: 1) Development of novel models to describe the temporal evolution of structure and morphology of homo-agglomerates in continuously-operated fluidized bed spray agglomeration (with and without recycle); 2) Investigation of structure formation dynamics, experimentally and in process simulations; 3) Elucidation of process-structure and material-structure relationships by comprehensive characterization of agglomerate structure; 4) Development and implementation of a novel multi-rate model-based soft-sensor for assessment of structure development during SFB agglomeration; 5) Development of real-time capable and control-oriented process models, applying hybrid and surrogate modelling; 6) Development, implementation and evaluation of different process control schemes for autonomous structure formation of homo-agglomerates in SFB agglomeration processes. Cooperation is sought throughout the partners of the priority program, especially in the areas of process modelling, online measurement methods, model order reduction, optimization and process control. The second project period sees the extension of models, methods and implementation to hetero-aggregates; i.e. adding additional complexity and design opportunity by allowing primary particles to consist of different materials.