Modeling of High-Density Compaction of Pharmaceutical Tablets Using Multi-Contact Discrete Element Method

The purpose of this work is to simulate the powder compaction of pharmaceutical materials at the microscopic scale in order to better understand the interplay of mechanical forces between particles, and to predict their compression profiles by controlling the microstructure. For this task, the new framework of multi-contact discrete element method (MC-DEM) was applied. In contrast to the conventional discrete element method (DEM), MC-DEM interactions between multiple contacts on the same particle are now explicitly taken into account. A new adhesive elastic-plastic multi-contact model invoking neighboring contact interaction was introduced and implemented. The uniaxial compaction of two microcrystalline cellulose grades (Avicel® PH 200 (FMC BioPolymer, Philadelphia, PA, USA) and Pharmacel® 102 (DFE Pharma, Nörten-Hardenberg, Germany) subjected to high confining conditions was studied. The objectives of these simulations were: (1) to investigate the micromechanical behavior; (2) to predict the macroscopic behavior; and (3) to develop a methodology for the calibration of the model parameters needed for the MC-DEM simulations. A two-stage calibration strategy was followed: first, the model parameters were directly measured at the micro-scale (particle level) and second, a meso-scale calibration was established between MC-DEM parameters and compression profiles of the pharmaceutical powders. The new MC-DEM framework could capture the main compressibility characteristics of pharmaceutical materials and could successfully provide predictions on compression profiles at high relative densities.

Stress Path Analysis of the Depleted Middle Miocene Clastic Reservoirs in the Badri Field, Gulf of Suez Rift Basin, Egypt

The purpose of this study is to evaluate the reservoir geomechanics and stress path values of the depleted Miocene sandstone reservoirs of the Badri field, Gulf of Suez Basin, in order to understand the production-induced normal faulting potential in these depleted reservoirs. We interpreted the magnitudes of pore pressure (PP), vertical stress (Sv), and minimum horizontal stress (Shmin) of the syn-rift and post-rift sedimentary sequences encountered in the studied field, as well as we validated the geomechanical characteristics with subsurface measurements (i.e. leak-off test (LOT), and modular dynamic tests) (MDT). Stress path (ΔPP/ΔShmin) was modeled considering a pore pressure-horizontal stress coupling in an uniaxial compaction environment. Due to prolonged production, The Middle Miocene Hammam Faraun (HF) and Kareem reservoirs have been depleted by 950-1000 PSI and 1070-1200 PSI, respectively, with current 0.27-0.30 PSI/feet PP gradients as interpreted from initial and latest downhole measurements. Following the poroelastic approach, reduction in Shmin is assessed and reservoir stress paths values of 0.54 and 0.59 are inferred in the HF and Kareem sandstones, respectively. As a result, the current rate of depletion for both Miocene reservoirs indicates that reservoir conditions are stable in terms of production-induced normal faulting. Although future production years should be paid more attention. Accelerated depletion rate could have compelled the reservoirs stress path values to the critical level, resulting in depletion-induced reservoir instability. The operator could benefit from stress path analysis in future planning of infill well drilling and production rate optimization without causing reservoir damage or instability.

On the Relation Between Pressing Energy and Green Strength at Compaction of Hard Metal Powders

The relation between pressing energy and green strength is examined experimentally and numerically using a commercially available design of experiment (DOE) software, at compaction of five hard metal powder materials. This is of substantial practical importance, in particular at pressing of complicated geometries when high values on the green strength is necessary. The compaction energy is here experimentally determined at uniaxial compaction of a cylindrical die, filled with powder material, by measuring punch force and compression. The corresponding measurements of the resulting green strength are performed using standard three-point bend (3PB) testing. The statistical analysis of the results shows that the relation between the two properties, pressing energy and green strength, is very close to a linear fit with the coefficient of determination R2 taking on the value 0.92. This suggests that the pressing energy is an important quantity for reaching a target value on the green strength and the linear relation is certainly convenient in particular when compaction of similar materials is at issue. In parallel with the experimental work finite element calculations are performed in order to evaluate the effect from friction between the powder and the die wall, and it was found that this feature has a limited effect on the pressing energy when similar materials are at issue and is not detrimental for the usefulness of the present correlation approach.

Preliminary analyses of synthetic carbonate plugs: consolidation, petrophysical and wettability properties

Synthetic plugs are available to understand oilfield properties and the behavior of oil in reservoirs where natural plugs cannot be extracted. Specifically, in cases where it is necessary to reproduce representative mineralogical and petrophysical characteristics from carbonate reservoirs, it is evident that there is a lack of publications focusing on synthetic plug construction. In this work, a methodology to construct synthetic carbonate plugs is proposed using disintegrated carbonate rock with controlled particle size, mixed in different weight fraction, uniaxial compaction with controlled load force velocity, pH, temperature, and bonding materials. Preliminary analysis of consolidation (basic consolidation and consolidation by water immersion test), wettability (contact angle measurements) and petrophysical properties (nitrogen expansion porosimetry measurements and theoretical porosity calculation) are reported in this study to determine which composition of the synthetic samples provides similar properties compared to that expected for natural rocks from carbonate reservoirs. Two compositions are recommended to construct synthetic samples: Composition 1 with a total quantity of 100 g of base material (50% w/w of <20 μm, 50% w/w of 20–74 μm) + 5% w/w of amide wax (relative to 100 g of base material) + 6% w/w (relative to 100 g of base material) of pH 3 hydrochloric acid solution; and Composition 2 with a total quantity of 100 g of base material (50% w/w of 150–300 μm, 50% w/w of 300–600 μm) + 5% w/w (relative to 100 g of base material) of amide wax + 6% w/w (relative to 100 g of base material) of pH 3 hydrochloric acid solution. In addition to the compositions, it is necessary to follow the reported procedure based on the uniaxial compaction with controlled load force (200 kN) and velocity (25 mm/min) and the sample’s drying temperature of 100 °C for 1 h aiming to obtain similar samples. These preliminary results will guide further dedicated petrophysical and wettability analysis to deeply understanding these sample’s properties and enhance the construction of synthetic samples more similar to the natural rocks from carbonate reservoirs.

Effect of Yttrium Oxide on Mechanical and Physical Properties of Fe–10%Cu Composite

Iron-based composites have found a lot of industrial applications such as bearings, camshafts, connecting rods, pulleys, various valves, oil pump gears and many other applications in the automotive and other industries due to their low cost, availability, and high strength. The present study aims to prepare Fe-10 vol.% Cu - (0 – 5) wt.% nano Y2O3 composites by powder metallurgy technique and studying their physical and mechanical properties. The powders were mixed into ball mill for 30 minutes, followed by room temperature uniaxial compaction at 700 MPa for 3 minutes. The green specimens were sintered at 1000 oC for 1 hour. The results of the present study showed that nano yttrium oxide has significant effects on both physical and mechanical properties of Fe-10%Cu composite. The bulk density was increased by 0.92% and the true porosity was decreased by 6.4% on increasing the nano oxide content from 0% to 3% respectively. Vickers microhardness was increased by 5.9% on increasing Y2O3 up to 1% followed by gradual decrease on further increase above 1%. Wear rate was decreased by 21% on increasing the nano oxide content from 0% to 3%. On the other hand, the compressive strength was decreased by 47% on increasing Y2O3 up to 5%