Purpose The purpose of this paper is to investigate the effect of different heating approaches during thermal rounding of polymer powders on powder bulk properties such as particle size, shape and flowability, as well as on the yield of process. Design/methodology/approach This study focuses on the rounding of commercial high-density polyethylene polymer particles in two different downer reactor designs using heated walls (indirect heating) and preheated carrier gas (direct heating). Powder bulk properties of the product obtained from both designs are characterized and compared. Findings Particle rounding with direct heating leads to a considerable increase in process yield and a reduction in powder agglomeration compared to the design with indirect heating. This subsequently leads to higher powder flowability. In terms of shape, indirect heating yields not only particles with higher sphericity but also entails substantial agglomeration of the rounded particles. Originality/value Shape modification via thermal rounding is the decisive step for the success of a top-down process chain for selective laser sintering powders with excellent flowability, starting with polymer particles from comminution. This report provides new information on the influence of the heating mode (direct/indirect) on the performance of the rounding process and particle properties.

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The present work focuses on investigating the residence time behavior of microparticles in a concurrent downer reactor through experiments and numerical simulations. For the numerical simulations, a three-dimensional multiphase model was developed using the Euler-Lagrange approach. The experiments were performed in a 0.8 m-long steel reactor with gravitational particle injection. The effects of different operating conditions, e.g., the sheath gas velocity on the particle residence time distribution were assessed. An increase in the sheath gas flow rate led to a decrease in the peak residence time, although the maximum residence time increased. Regarding the lowest sheath gas flow rate, the particles’ peak residence time was twice as high compared to the peak residence time within the highest flow rate. The particles’ residence time curves presented a broad distribution coinciding with the size distribution of the powder. The numerical results agreed with the experimental data; thus, this study presents a numerical model for predicting the particle residence time behavior in a concurrent downer reactor. Furthermore, the numerical simulations contributed to a better understanding of the particle residence time behavior inside a concurrent downer reactor which is essential for optimizing thermal rounding processes. Dimensionless correlations for the observed effects are developed.