Efficient and clean separation of residual plastic mulch film is the primary bottleneck hindering its resource-oriented reutilization. Currently, the field faces critical technical challenges, most notably the elusive motion mechanisms of flexible materials and the inherent difficulty of film–impurity separation. To address these issues, this study investigates a drum-type mulch-film impurity-removal unit by modeling the throw-off motion mechanism of the material stream, followed by comprehensive multiphysics simulation and optimization. First, to overcome the simulation hurdles typical of flexible materials, “Meta-particles” and the “Bonding V2” contact model were implemented on the EDEM platform to establish a discrete element method (DEM) framework. The resulting analysis revealed a non-linear transport trajectory and morphological evolution within the drum flow field, characterized by a “wall-adhering–slipping–throwing” sequence. These findings were further quantified through MATLAB-based numerical calculations to determine collision frequency and axial residence behavior. Second, ANSYS modal analysis verified the dynamic stability of the frame structure, confirming that the operating frequency (2.37 Hz) remains well below the first natural frequency (6.77 Hz). Furthermore, Box–Behnken response surface methodology (RSM) was employed to elucidate the coupled effects of key process parameters. The results demonstrated that separation efficiency and impurity-removal mass are predominantly governed by the quadratic terms of the inclination angle and rotational speed, respectively. After multi-objective optimization and engineering refinement, the optimal operating parameters were established: a film length of 220 mm, an inclination angle of 3°, and a drum rotational speed of 25 r/min. Bench tests indicated that, under these optimal conditions, the impurity-removal rate stabilized between 71.5% and 72.4%, satisfying the design requirement (≥70%). By elucidating the drum’s throw-off screening mechanism, this study achieves a coordinated improvement in both impurity-removal mass and separation efficiency, resolving long-standing engineering uncertainties regarding film–impurity trajectories and providing a theoretical foundation for the clean treatment of waste mulch film.
Pei et al. (Sat,) studied this question.