The size segregation of binary mixtures of spherical nickel pellets flowing into a packed bed was investigated with Discrete Element Method (DEM) simulations and physical experiments in 30 cm and 60 cm wide rectangular test cells. Each test cell approximates a vertical slice of a cylindrical packed bed, with a rising feed tube on one side of the cell representing the stationary frame of reference in the packed bed. As the feed tube is raised, the pellets flow laterally into the test cell to form a sloping surface inclined to the horizontal by the angle of repose. The lateral flow of pellets is confined near the surface of the packed bed, and was intermittent in character (i.e. surging). Velocity vectors show the detailed flow field in the simulated test cells. The smaller pellets were found to be concentrated near the core of the granular assembly, and the larger pellets segregate to the outer wall farthest from the feed tube. The degree of segregation, or coefficient of variation (variance/mean), is proportional to the diameter ratio alpha of the pellets and the length of the surface, and inversely proportional to the mass fraction of the smaller pellets within the range of parameters studied. The DEM simulations had an average deviation in mass fraction of 0.07 and maximum deviation of 0.22 from the experimental data. (C) 2009 Elsevier B.V. All rights reserved.