Introduction To Particle Technology, 2nd Ed (Martin Rhodes)

Introduction to Particle
Technology – Second Edition
Introduction to Particle Technology, 2nd Edition Martin Rhodes

© 2008 John Wiley & Sons Ltd. ISBN: 978-0-470 -01427-1
Introduction to Particle
Technology
SECOND EDITION
Martin Rhodes
Monash University, Australia
Copyright # 2008 John Wiley & Sons Ltd, The Atrium, Southern Gate, Chichester,
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Library of Congress Cataloging-in-Publication Data
Rhodes, Martin.
Introduction to particle technology / Martin Rhodes. – 2nd ed.
p. cm.
Includes bibliographical references and index.
ISBN 978-0-470-01427-1 (cloth) – ISBN 978-0-470-01428-8 (pbk.)
1. Particles. I. Title.
TP156.P3R48 2008
6200 .43–dc22 2007041699
British Library Cataloguing in Publication Data
A catalogue record for this book is available from the British Library
ISBN 978-0-470-01427-1 (Cloth) ISBN 978-0-470-01428-8 (Paper)
Typeset in 10/12 pt Palatino by Thomson Digital, India.
Printed and bound in Great Britain by Antony Rowe Ltd, Chippenham, Wiltshire.
Contents
About the Contributors xiii

Preface to the Second Edition xv
Preface to the First Edition xvii
Introduction xxi
1 Particle Size Analysis 1
1.1 Introduction 1
1.2 Describing the Size of a Single Particle 1
1.3 Description of Populations of Particles 4
1.4 Conversion Between Distributions 5
1.5 Describing the Population by a Single Number 7
1.6 Equivalence of Means 10
1.7 Common Methods of Displaying Size Distributions 11
1.7.1 Arithmetic-normal Distribution 11
1.7.2 Log-normal Distribution 11
1.8 Methods of Particle Size Measurement 12
1.8.1 Sieving 12
1.8.2 Microscopy 13
1.8.3 Sedimentation 13
1.8.4 Permeametry 15
1.8.5 Electrozone Sensing 15
1.8.6 Laser Diffraction 16
1.9 Sampling 16
1.10 Worked Examples 17
Test Yourself 25
Exercises 25
2 Single Particles in a Fluid 29
2.1 Motion of Solid Particles in a Fluid 29
2.2 Particles Falling Under Gravity Through a Fluid 31
2.3 Non-Spherical Particles 33
2.4 Effect of Boundaries on Terminal Velocity 34
2.5 Further Reading 35
Test Yourself 44
Exercises 46
vi CONTENTS
3 Multiple Particle Systems 51

3.1 Settling of a Suspension of Particles 51
3.2 Batch Settling 53
3.2.1 Settling Flux as a Function of Suspension Concentration 53
3.2.2 Sharp Interfaces in Sedimentation 54
3.2.3 The Batch Settling Test 56
3.2.4 Relationship Between the Height – Time Curve
and the Flux Plot 59
3.3 Continuous Settling 61
3.3.1 Settling of a Suspension in a Flowing Fluid 61
3.3.2 A Real Thickener (with Upflow and Downflow Sections) 63
3.3.3 Critically Loaded Thickener 64
3.3.4 Underloaded Thickener 65
3.3.5 Overloaded Thickener 65
3.3.6 Alternative Form of Total Flux Plot 66
Test Yourself 79
Exercises 81
4 Slurry Transport 91
4.1 Introduction 91
4.2 Flow Condition 91
4.3 Rheological Models For Homogeneous Slurries 93
4.3.1 Non-Newtonian Power-law Models 94
4.3.2 Pressure Drop Prediction for Slurries Exhibiting
Power-law Rheology 96
4.3.3 Non-Newtonian Yield Stress Models 99
4.3.4 Pressure Drop Prediction for Slurries Exhibiting Bingham
Plastic Rheology 101
4.4 Heterogeneous Slurries 103
4.4.1 Critical Deposition Velocity 104
4.5 Components of a Slurry Flow System 104
4.5.1 Slurry Preparation 104
4.5.2 Pumps 105
4.5.3 Pipeline 108
4.5.4 Slurry De-watering 108
Test Yourself 114
Exercises 114
5 Colloids and Fine Particles 117

5.1 Introduction 117
5.2 Brownian Motion 118
5.3 Surface Forces 120
5.3.1 van der Waals Forces 121
5.3.2 Electrical Double Layer Forces 124
CONTENTS vii
5.3.3 Adsorbing Polymers, Bridging and Steric Forces 127

5.3.4 Other Forces 128
5.3.5 Net Interaction Force 129
5.4 Result of Surface Forces on Behaviour in Air and Water 130
5.5 Influences of Particle Size and Surface Forces on Solid/Liquid
Separation by Sedimentation 132
5.5.1 Sedimentation Rate 132
5.5.2 Sediment Concentration and Consolidation 133
5.6 Suspension Rheology 134
5.7 Influence of Surface Forces on Suspension Flow 139
5.7.1 Repulsive Forces 139
5.7.2 Attractive Forces 140
5.8 Nanoparticles 144
Test Yourself 149
Exercises 150
6 Fluid Flow Through a Packed Bed of Particles 153

6.1 Pressure Drop – Flow Relationship 153
6.1.1 Laminar Flow 153
6.1.2 Turbulent Flow 155
6.1.3 General Equation for Turbulent and
Laminar Flow 155
6.1.4 Non-spherical Particles 156
6.2 Filtration 157
6.2.1 Introduction 157
6.2.2 Incompressible Cake 157
6.2.3 Including the Resistance of the Filter Medium 159
6.2.4 Washing the Cake 159
6.2.5 Compressible Cake 160
Test Yourself 165
Exercises 165
7 Fluidization 169
7.1 Fundamentals 169
7.2 Relevant Powder and Particle Properties 172
7.3 Bubbling and Non-Bubbling Fluidization 173
7.4 Classification of Powders 174
7.5 Expansion of a Fluidized Bed 178
7.5.1 Non-bubbling Fluidization 178
7.5.2 Bubbling Fluidization 180
7.6 Entrainment 182
7.7 Heat Transfer in Fluidized Beds 186
7.7.1 Gas – Particle Heat Transfer 186
7.7.2 Bed – Surface Heat Transfer 188
viii CONTENTS
7.8 Applications of Fluidized Beds 191

7.8.1 Physical Processes 191
7.8.2 Chemical Processes 191
7.9 A Simple Model for the Bubbling Fluidized Bed Reactor 194
7.10 Some Practical Considerations 198
7.10.1 Gas Distributor 198
7.10.2 Loss of Fluidizing Gas 198
7.10.3 Erosion 199
7.10.4 Loss of Fines 199
7.10.5 Cyclones 199
7.10.6 Solids Feeders 199
Test Yourself 205
Exercises 206
8 Pneumatic Transport and Standpipes 211

8.1 Pneumatic Transport 211
8.1.1 Dilute Phase and Dense Phase Transport 212
8.1.2 The Choking Velocity in Vertical Transport 212
8.1.3 The Saltation Velocity in Horizontal Transport 214
8.1.4 Fundamentals 215
8.1.5 Design for Dilute Phase Transport 219
8.1.6 Dense Phase Transport 224
8.1.7 Matching the System to the Powder 230
8.2 Standpipes 231
8.2.1 Standpipes in Packed Bed Flow 231
8.2.2 Standpipes in Fluidized Bed Flow 232
8.2.3 Pressure Balance During Standpipe Operation 235
Test Yourself 243
Exercises 244
9 Separation of Particles from a Gas: Gas Cyclones 247

9.1 Gas Cyclones – Description 248
9.2 Flow Characteristics 249
9.3 Efficiency of Separation 249
9.3.1 Total Efficiency and Grade Efficiency 249
9.3.2 Simple Theoretical Analysis for the Gas
Cyclone Separator 250
9.3.3 Cyclone Grade Efficiency in Practice 252
9.4 Scale-up of Cyclones 253
9.5 Range of Operation 255
9.6 Some Practical Design and Operation Details 257
9.6.1 Effect of Dust Loading on Efficiency 257
9.6.2 Cyclone Types 257
9.6.3 Abrasion 257
CONTENTS ix
9.6.4 Attrition of Solids 258

9.6.5 Blockages 258
9.6.6 Discharge Hoppers and Diplegs 258
9.6.7 Cyclones in Series 259
9.6.8 Cyclones in Parallel 259
Test Yourself 262
Exercises 263
10 Storage and Flow of Powders – Hopper Design 265

10.2 Mass Flow and Core Flow 265
10.3 The Design Philosophy 268
10.3.1 Flow–No Flow Criterion 268
10.3.2 The Hopper Flow Factor, ff 269
10.3.3 Unconfined Yield Stress, sy 269
10.3.4 Powder Flow Function 269
10.3.5 Critical Conditions for Flow 270
10.3.6 Critical Outlet Dimension 270
10.3.7 Summary 271
10.4 Shear Cell Test 272
10.5 Analysis of Shear Cell Test Results 274
10.5.1 Mohr’s Circle–in Brief 274
10.5.2 Application of Mohr’s Circle to Analysis
of the Yield Locus 274
10.5.3 Determination of sy and sc 275
10.5.4 Determination of d from Shear Cell Tests 276
10.5.5 The Kinematic Angle of Friction between Powder
and Hopper Wall, w 276
10.5.6 Determination of the Hopper Flow Factor, ff 277
10.6 Summary of Design Procedure 278
10.7 Discharge Aids 281
10.8 Pressure on the Base of a Tall Cylindrical Bin 281
10.9 Mass Flow Rates 284
10.10 Conclusions 285
Test Yourself 289
Exercises 289
11 Mixing and Segregation 293

11.2 Types of Mixture 293
11.3 Segregation 294
11.3.1 Causes and Consequences of Segregation 294
11.3.2 Mechanisms of Segregation 295
11.4 Reduction of Segregation 298
11.5 Equipment for Particulate Mixing 299
x CONTENTS
11.5.1 Mechanisms of Mixing 299

11.5.2 Types of Mixer 300
11.6 Assessing the Mixture 301
11.6.1 Quality of a Mixture 301
11.6.2 Sampling 302
11.6.3 Statistics Relevant to Mixing 302
Test Yourself 309
Exercises 309
12 Particle Size Reduction 311

12.2 Particle Fracture Mechanisms 312
12.3 Model Predicting Energy Requirement and Product
Size Distribution 314
12.3.1 Energy Requirement 314
12.3.2 Prediction of the Product Size Distribution 318
12.4 Types of Comminution Equipment 320
12.4.1 Factors Affecting Choice of Machine 320
12.4.2 Stressing Mechanisms 320
12.4.3 Particle Size 326
12.4.4 Material Properties 327
12.4.5 Carrier Medium 328
12.4.6 Mode of Operation 328
12.4.7 Combination with other Operations 328
12.4.8 Types of Milling Circuit 328
Test Yourself 332
Exercises 333
13 Size Enlargement 337

13.2 Interparticle Forces 338
13.2.1 van der Waals Forces 338
13.2.2 Forces due to Adsorbed Liquid Layers 338
13.2.3 Forces due to Liquid Bridges 338
13.2.4 Electrostatic Forces 340
13.2.5 Solid Bridges 340
13.2.6 Comparison and Interaction between Forces 340
13.3 Granulation 341
13.3.2 Granulation Rate Processes 342
13.3.3 Simulation of the Granulation Process 349
13.3.4 Granulation Equipment 352
Test Yourself 357
Exercises 357
CONTENTS xi
14 Health Effects of Fine Powders 359

14.2 The Human Respiratory System 359
14.2.1 Operation 359
14.2.2 Dimensions and Flows 361
14.3 Interaction of Fine Powders with the Respiratory System 362
14.3.1 Sedimentation 362
14.3.2 Inertial Impaction 363
14.3.3 Diffusion 364
14.3.4 Interception 364
14.3.5 Electrostatic Precipitation 364
14.3.6 Relative Importance of These Mechanisms
Within the Respiratory Tract 364
14.4 Pulmonary Delivery of Drugs 367
14.5 Harmful Effects of Fine Powders 369
Test Yourself 371
Exercises 371
15 Fire and Explosion Hazards of Fine Powders 373

15.2 Combustion Fundamentals 374
15.2.1 Flames 374
15.2.2 Explosions and Detonations 374
15.2.3 Ignition, Ignition Energy, Ignition
Temperature – a Simple Analysis 374
15.2.4 Flammability Limits 377
15.3 Combustion in Dust Clouds 378
15.3.1 Fundamentals Specific to Dust Cloud Explosions 378
15.3.2 Characteristics of Dust Explosions 379
15.3.3 Apparatus for Determination of Dust Explosion
Characteristics 380
15.3.4 Application of the Test Results 382
15.4 Control of the Hazard 383
15.4.2 Ignition Sources 384
15.4.3 Venting 384
15.4.4 Suppression 385
15.4.5 Inerting 386
15.4.6 Minimize Dust Cloud Formation 386
15.4.7 Containment 386
Test Yourself 392
Exercises 393
16 Case Studies 395

16.1 Case Study 1 395
xii CONTENTS

Notation 425
References 433
Index 441
About the Contributors
Dr Karen P. Hapgood holds a BE and PhD in Chemical Engineering from the

University of Queensland, Australia. Her PhD was on granulation processes and
she continues to research in this area and related areas of powder technology.
Karen worked for Merck & Co., USA for 5 years, where she worked on designing,
troubleshooting and scaling up tablet and capsule manufacturing processes.
Karen is currently a Senior Lecturer at the Department of Chemical Engineering
at Monash University, Australia.
George Vincent Franks holds a Bachelor’s degree in Materials Science and

Engineering from MIT (1985) and a PhD in Materials Engineering from the
University of California at Santa Barbara (1997). George worked for 7 years in the
ceramic processing industry as a process development engineer for Norton
Company and Ceramic Process Systems Incorporated. His industrial work
focused mainly on near net shape forming of ceramic green bodies and non-
oxide ceramic firing. He has research and teaching experience at the Universities
of Melbourne and Newcastle in Australia. George is currently Associate Professor
in the Department of Chemical and Biomolecular Engineering at the University
of Melbourne and the recently formed Australian Mineral Science Research
Institute. His research interests include, mineral processing, particularly floccula-
tion, advanced ceramics powder processing, colloid and surface chemistry, ion
specific effects, alumina surfaces and suspension rheology.
Jennifer Sinclair Curtis received her BS degree in chemical engineering from

Purdue University and PhD in chemical engineering from Princeton University.
Jennifer has an internationally recognized research program in the development
and validation of numerical models for the prediction of particle flow phenom-
ena. Jennifer was a recipient of the NSF Presidential Young Investigator Award,
the Eminent Overseas Lectureship Award by the Institution of Engineers in
Australia and ASEE’s Sharon Keillor Award for Women in Engineering. She
currently serves on the Editorial Advisory Board of the AIChE Journal, Powder
Technology, and the Journal of Pharmaceutical Development and Technology.
Jennifer has also served as a Trustee of the non-profit Computer Aids for
Chemical Engineering Corporation and on the National Academy of Engineer-
ing’s Committee on Engineering Education. Jennifer is currently Professor and
Chair of the Chemical Engineering Department at the University of Florida.
xiv ABOUT THE CONTRIBUTORS
Martin Rhodes holds a Bachelor’s degree in chemical engineering and a PhD

in particle technology from Bradford University in the UK, industrial experience
in chemical and combustion engineering and many years experience as an
academic at Bradford and Monash Universities. He has research interests in
various aspects of gas fluidization and particle technology, areas in which he has
many refereed publications in journals and international conference proceedings.
Martin is on the editorial boards of Powder Technology and KONA and on the
advisory board of Advanced Powder Technology. Martin has a keen interest in
particle technology education and has published books and CDROM on Labora-
tory Demonstrations and directed continuing education courses for industry in
the UK and Australia. He was co-founder of the Australasian Particle Technology
Society. Martin has a Personal Chair in the Department of Chemical Engineering
at Monash University, Australia, where he is presently Head of Department.
Preface to the Second Edition
It is 10 years since the publication of the first edition of Introduction to Particle

Technology. During that time many colleagues from around the world have
provided me with comments for improving the text. I have taken these comments
into consideration in preparing the second edition. In addition, I have broadened
the coverage of particle technology topics – in this endeavour I am grateful to my
co-authors Jennifer Sinclair Curtis and George Franks, who have enabled the
inclusion of chapters on Slurry Transport and Colloids and Fine Particles, and
Karen Hapgood, who permitted an improved chapter on size enlargement
and granulation. I have also included a chapter on the Health Effects of Fine
Powders – covering both beneficial and harmful effects. I am also indebted
to colleagues Peter Wypych, Lyn Bates, Derek Geldart, Peter Arnold, John
Sanderson and Seng Lim for contributing case studies for Chapter 16.
Martin Rhodes
Balnarring, December 2007
Preface to the First Edition
Particle Technology
Particle technology is a term used to refer to the science and technology related to
the handling and processing of particles and powders. Particle technology is also
often described as powder technology, particle science and powder science.
Powders and particles are commonly referred to as bulk solids, particulate solids
and granular solids. Today particle technology includes the study of liquid
drops, emulsions and bubbles as well as solid particles. In this book only solid
particles are covered and the terms particles, powder and particulate solids will
be used interchangeably.
The discipline of particle technology now includes topics as diverse as the
formation of aerosols and the design of bucket elevators, crystallization and
pneumatics transport, slurry filtration and silo design. A knowledge of particle
technology may be used in the oil industry to design the catalytic cracking reactor
which produces gasoline from oil or it may be used in forensic science to link the
accused with the scene of crime. Ignorance of particle technology may result in
lost production, poor product quality, risk to health, dust explosion or storage
silo collapse.
Objective
The objective of this textbook is to introduce the subject of particle technology to

students studying degree courses in disciplines requiring knowledge of the
processing and handling of particles and powders. Although the primary target
readership is amongst students of chemical engineering, the material included
should form the basis of courses on particle technology for students studying
other disciplines including mechanical engineering, civil engineering, applied
chemistry, pharmaceutics, metallurgy and minerals engineering.
A number of key topics in particle technology are studied giving the funda-
mental science involved and linking this, wherever possible, to industrial
practice. The coverage of each topic is intended to be exemplary rather than
exhaustive. This is not intended to be a text on unit operations in powder
technology for chemical engineers. Readers wishing to know more about the
industrial practice and equipment for handling and processing are referred to the
various handbooks of powder technology which are available.
xviii PREFACE TO THE FIRST EDITION
The topics included have been selected to give coverage of broad areas within
easy particle technology: characterization (size analysis), processing (fluidized
beds granulation), particle formation (granulation, size reduction), fluid-particle-
separation (filtration, settling, gas cyclones), safety (dust explosions), transport
(pneumatic transport and standpipes). The health hazards of fine particles or
dusts are not covered. This is not to suggest in any way that this topic is less
important than others. It is omitted because of a lack of space and because the
health hazards associated with dusts are dealt with competently in the many
texts on Industrial or Occupational Hygiene which are now available. Students
need to be aware however, that even chemically inert dusts or ‘nuisance dust’ can
be a major health hazard. Particularly where products contain a significant
proportion of particles under 10 mm and where there is a possibility of the
material becoming airborne during handling and processing. The engineering
approach to the health hazard of fine powders should be strategic wherever
possible; aiming to reduce dustiness by agglomeration, to design equipment for
containment of material and to minimize exposure of workers.
The topics included demonstrate how the behaviour of powders is often quite
different from the behaviour of liquids and gases. Behaviour of particulate solids
may be surprising and often counter-intuitive when intuition is based on our
experience with fluids. The following are examples of this kind of behaviour:
When a steel ball is placed at the bottom of a container of sand and the container
is vibrated in a vertical plane, the steel ball will rise to the surface.
A steel ball resting on the surface of a bed of sand will sink swiftly if air is passed
upward through the sand causing it to become fluidized.
Stirring a mixture of two free-flowing powders of different sizes may result in

segregation rather than improved mixture quality.
Engineers and scientists are use to dealing with liquids and gases whose
properties can be readily measured, tabulated and even calculated. The boiling
point of pure benzene at one atmosphere pressure can be safely relied upon to
remain at 80.1 C. The viscosity of water at 20 C can be confidently predicted to
be 0.001 Pa s. The thermal conductivity of copper at 100 C is 377 W/m K. With
particulate solids, the picture is quite different. The flow properties of sodium
bicarbonate powder, for example, depends not only on the particle size distribu-
tion, the particle shape and surface properties, but also on the humidity of
atmosphere and the state of the compaction of the powder. These variables are
not easy to characterize and so their influence on the flow properties is difficult to
predict with any confidence.
In the case of particulate solids it is almost always necessary to rely on
performing appropriate measurements on the actual powder in question rather
than relying on tabulated data. The measurements made are generally measure-
ments of bulk properties, such as shear stress, bulk density, rather than measure-
ments of fundamental properties such as particle size, shape and density.
Although this is the present situation, in the not too distant future, we will be
able to rely on sophisticated computer models for simulation of particulate
PREFACE TO THE FIRST EDITION xix
systems. Mathematical modelling of particulate solids behaviour is a rapidly

developing area of research around the world, and with increased computing
power and better visualization software, we will soon be able to link fundamental
particle properties directly to bulk powder behaviour. It will even be possible to
predict, from first principles, the influence of the presence of gases and liquids
within the powder or to incorporate chemical reaction.
Particle technology is a fertile area for research. Many phenomena are still
unexplained and design procedures rely heavily on past experience rather than on
fundamental understanding. This situation presents exciting challenges to
researchers from a wide range of scientific and engineering disciplines around
the world. Many research groups have websites which are interesting and in-
formative at levels ranging from primary schools to serious researchers. Students
are encouraged to visit these sites to find out more about particle technology. Our
own website at Monash University can be accessed via the Chemical Engineering
Department web page at http://www.eng.monash.edu.au/chemeng/
Martin Rhodes
Mount Eliza, May 1998
Introduction
Particulate materials, powders or bulk solids are used widely in all areas of the
process industries, for example in the food processing, pharmaceutical, biotech-
nology, oil, chemical, mineral processing, metallurgical, detergent, power gen-
eration, paint, plastics and cosmetics industries. These industries involve many
different types of professional scientists and engineers, such as chemical engi-
neers, chemists, biologists, physicists, pharmacists, mineral engineers, food
technologists, metallurgists, material scientists/engineers, environmental scientists/
engineers, mechanical engineers, combustion engineers and civil engineers. Some
figures give an indication of the significance of particle technology in the world
economy: for the DuPont company, whose business covers chemicals, agricul-
tural, pharmaceuticals, paints, dyes, ceramics, around two-thirds of its products
involve particulate solids (powders, crystalline solids, granules, flakes, disper-
sions or pastes); around 1% of all electricity generated worldwide is used in
reducing particle size; the impact of particulate products to the US economy was
estimated to be US$ 1 trillion.
Some examples of the processing steps involving particles and powder
include particle formation processes (such as crystallization, precipitation,
granulation, spray drying, tabletting, extrusion and grinding), transportation
processes (such as pneumatic and hydraulic transport, mechanical conveying
and screw feeding) and mixing, drying and coating processes. In addition,
processes involving particulates require reliable storage facilities and give rise to
health and safety issues, which must be satisfactorily handled. Design and
operation of these many processes across this wide range of industries require a
knowledge of the behaviour of powders and particles. This behaviour is often
counterintuitive, when intuition is based on our knowledge of liquids and gases.
For example, actions such as stirring, shaking or vibrating, which would result
in mixing of two liquids, are more likely to produce size segregation in a mixture
of free-flowing powders of different sizes. A storage hopper holding 500 t of
powder may not deliver even 1 kg when the outlet valve is opened unless the
hopper has been correctly designed. When a steel ball is placed at the bottom of a
container of sand and the container is vibrated in the vertical plane, the steel ball
will rise to the surface. This steel ball will then sink swiftly to the bottom again if
air is passed upwards through the sand causing it to be fluidized.
Engineers and scientists are used to dealing with gases and liquids, whose
properties can be readily measured, tabulated or even calculated. The boiling
xxii INTRODUCTION
point of pure benzene at atmospheric pressure can be safely assumed to remain

at 80.1 C. The thermal conductivity of copper can always be relied upon to be
377 W/m K at 100 C. The viscosity of water at 20 C can be confidently expected
to be 0.001 Pa s. With particulate solids, however, the situation is quite different.
The flow properties of sodium bicarbonate powder, for example, depend not only
of the particle size distribution, but also on particle shape and surface properties,
the humidity of the surrounding atmosphere and the state of compaction of the
powder. These variables are not easy to characterize and so their influence on the
flow properties of the powder is difficult to predict or control with any
confidence. Interestingly, powders appear to have some of the behavioural
characteristics of the three phases, solids, liquids and gases. For example, like
gases, powders can be compressed; like liquids, they can be made to flow, and
like solids, they can withstand some deformation.
The importance of knowledge of the science of particulate materials (often
called particle or powder technology) to the process industries cannot be over-
emphasized. Very often, difficulties in the handling or processing powders are
ignored or overlooked at the design stage, with the result that powder-related
problems are the cause of an inordinate number of production stoppages.
However, it has been demonstrated that the application of even a basic under-
standing of the ways in which powders behave can minimize these processing
problems, resulting in less downtime, improvements in quality control and
environmental emissions.
This text is intended as an introduction to particle technology. The topics
included have been selected to give coverage of the broad areas of particle
technology: characterization (size analysis), processing (granulation, fluidiza-
tion), particle formation (granulation, size reduction), storage and transport
(hopper design, pneumatic conveying, standpipes, slurry flow), separation
(filtration, settling, cyclones), safety (fire and explosion hazards, health hazards),
engineering the properties of particulate systems (colloids, respirable drugs,
slurry rheology). For each of the topics studied, the fundamental science involved
is introduced and this is linked, where possible, to industrial practice. In each
chapter there are worked examples and exercises to enable the reader to practice
the relevant calculations and and a ‘Test Yourself’ section, intended to highlight
the main concepts covered. The final chapter includes some case studies–real
examples from the process industries of problems that arose and how they were
solved.
A website with laboratory demonstrations in particle technology, designed to
accompany this text, is available. This easily navigated resource incorporates
many video clips of particle and powder phenomena with accompanying
explanatory text. The videos bring to life many of the phenomena that I have
tried to describe here in words and diagrams. For example, you will see:
fluidized beds (bubbling, non-bubbling, spouted) in action; core flow and
mass flow in hoppers, size segregation during pouring, vibration and rolling;
pan granulation of fine powders, a coal dust explosion; a cyclone separator in
action; dilute and dense phase pneumatic conveying. The website will aid the
reader in understanding particle technology and is recommended as a useful
adjunct to this text.
1
Particle Size Analysis
1.1 INTRODUCTION
In many powder handling and processing operations particle size and size
distribution play a key role in determining the bulk properties of the powder.
Describing the size distribution of the particles making up a powder is therefore
central in characterizing the powder. In many industrial applications a single
number will be required to characterize the particle size of the powder. This can
only be done accurately and easily with a mono-sized distribution of spheres or
cubes. Real particles with shapes that require more than one dimension to fully
describe them and real powders with particles in a range of sizes, mean that in
practice the identification of single number to adequately describe the size of the
particles is far from straightforward. This chapter deals with how this is done.
1.2 DESCRIBING THE SIZE OF A SINGLE PARTICLE
Regular-shaped particles can be accurately described by giving the shape and a

number of dimensions. Examples are given in Table 1.1.
The description of the shapes of irregular-shaped particles is a branch of
science in itself and will not be covered in detail here. Readers wishing to know
more on this topic are referred to Hawkins (1993). However, it will be clear to the
reader that no single physical dimension can adequately describe the size of
an irregularly shaped particle, just as a single dimension cannot describe the
shape of a cylinder, a cuboid or a cone. Which dimension we do use will in
practice depend on (a) what property or dimension of the particle we are able to
measure and (b) the use to which the dimension is to be put.
If we are using a microscope, perhaps coupled with an image analyser, to view
the particles and measure their size, we are looking at a projection of the shape of
the particles. Some common diameters used in microscope analysis are statistical
diameters such as Martin’s diameter (length of the line which bisects the particle

2 PARTICLE SIZE ANALYSIS
Table 1.1 Regular-shaped particles

Shape Sphere Cube Cylinder Cuboid Cone
Dimensions Radius Side length Radius and Three side Radius and
height lengths height
image), Feret’s diameter (distance between two tangents on opposite sides of the
particle) and shear diameter (particle width obtained using an image shearing
device) and equivalent circle diameters such as the projected area diameter (area
of circle with same area as the projected area of the particle resting in a stable
position). Some of these diameters are described in Figure 1.1. We must
Figure 1.1 Some diameters used in microscopy

DESCRIBING THE SIZE OF A SINGLE PARTICLE 3
Figure 1.2 Comparison of equivalent sphere diameters
remember that the orientation of the particle on the microscope slide will affect
the projected image and consequently the measured equivalent sphere diameter.
If we use a sieve to measure the particle size we come up with an equivalent
sphere diameter, which is the diameter of a sphere passing through the same
sieve aperture. If we use a sedimentation technique to measure particle size then
it is expressed as the diameter of a sphere having the same sedimentation
velocity under the same conditions. Other examples of the properties of
particles measured and the resulting equivalent sphere diameters are given in
Figure 1.2.
Table 1.2 compares values of these different equivalent sphere diameters used to
describe a cuboid of side lengths 1, 3, 5 and a cylinder of diameter 3 and length 1.
The volume equivalent sphere diameter or equivalent volume sphere diameter
is a commonly used equivalent sphere diameter. We will see later in the chapter
that it is used in the Coulter counter size measurements technique. By definition,
the equivalent volume sphere diameter is the diameter of a sphere having the
same volume as the particle. The surface-volume diameter is the one measured
when we use permeametry (see Section 1.8.4) to measure size. The surface-
volume (equivalent sphere) diameter is the diameter of a sphere having the same
surface to volume ratio as the particle. In practice it is important to use the method of
Table 1.2 Comparison of equivalent sphere diameters

Sphere passing Sphere Sphere having Sphere having the
the same sieve having the same surface the same surface to
Shape aperture, xp same volume, xv area, xs volume ratio, xsv
Cuboid 3 3.06 3.83 1.95
Cylinder 3 2.38 2.74 1.80
size measurement which directly gives the particle size which is relevant to the situation
or process of interest. (See Worked Example 1.1.)
1.3 DESCRIPTION OF POPULATIONS OF PARTICLES
A population of particles is described by a particle size distribution. Particle size

distributions may be expressed as frequency distribution curves or cumulative
curves. These are illustrated in Figure 1.3. The two are related mathematically in
that the cumulative distribution is the integral of the frequency distribution; i.e. if
the cumulative distribution is denoted as F, then the frequency distribution
dF=dx. For simplicity, dF=dx is often written as fðxÞ: The distributions can be by
number, surface, mass or volume (where particle density does not vary with size,
the mass distribution is the same as the volume distribution). Incorporating this
information into the notation, fN ðxÞ is the frequency distribution by number, fS ðxÞ
is the frequency distribution by surface, FS is the cumulative distribution by
Figure 1.3 Typical differential and cumulative frequency distributions

CONVERSION BETWEEN DISTRIBUTIONS 5
Figure 1.4 Comparison between distributions
surface and FM is the cumulative distribution by mass. In reality these distribu-

tions are smooth continuous curves. However, size measurement methods often
divide the size spectrum into size ranges or classes and the size distribution
becomes a histogram.
For a given population of particles, the distributions by mass, number and
surface can differ dramatically, as can be seen in Figure 1.4.
A further example of difference between distributions for the same population
is given in Table 1.3 showing size distributions of man-made objects orbiting the
earth (New Scientist, 13 October 1991).
The number distribution tells us that only 0.2% of the objects are greater than
10 cm. However, these larger objects make up 99.96% of the mass of the
population, and the 99.3% of the objects which are less than 1.0 cm in size
make up only 0.01% of the mass distribution. Which distribution we would use is
dependent on the end use of the information.
1.4 CONVERSION BETWEEN DISTRIBUTIONS
Many modern size analysis instruments actually measure a number distribution,

which is rarely needed in practice. These instruments include software to
Table 1.3 Mass and number distributions for man-made objects orbiting the earth
Size (cm) Number of objects % by number % by mass

10–1000 7000 0.2 99.96
1–10 17 500 0.5 0.03
0.1–1.0 3 500 000 99.3 0.01
Total 3 524 500 100.00 100.00
convert the measured distribution into more practical distributions by mass,

surface, etc.
Relating the size distributions by number, fN ðxÞ, and by surface, fS ðxÞ for a
population of particles having the same geometric shape but different size:
Fraction of particles in the size range
x to x þ dx ¼ fN ðxÞdx
Fraction of the total surface of particles in the size range
x to x þ dx ¼ fS ðxÞdx
If N is the total number of particles in the population, the number of particles in

the size range x to x þ dx ¼ NfN ðxÞdx and the surface area of these particles
¼ ðx2 aS ÞNfN ðxÞdx, where aS is the factor relating the linear dimension of the
particle to its surface area.
Therefore, the fraction of the total surface area contained on these particles
[fS ðxÞdx] is:
ðx2 aS ÞNfN ðxÞdx

S
where S is the total surface area of the population of particles.

For a given population of particles, the total number of particles, N, and the
total surface area, S are constant. Also, assuming particle shape is independent of
size, aS is constant, and so
fS ðxÞ / x2 fN ðxÞ or fS ðxÞ ¼ kS x2 fN ðxÞ ð1:1Þ
where
aS N
kS ¼
S
Similarly, for the distribution by volume
fV ðxÞ ¼ kV x3 fN ðxÞ ð1:2Þ
where
aV N
kV ¼
V
where V is the total volume of the population of particles and aV is the factor
relating the linear dimension of the particle to its volume.
DESCRIBING THE POPULATION BY A SINGLE NUMBER 7
And for the distribution by mass
fm ðxÞ ¼ km rp x3 fN ðxÞ ð1:3Þ
where
aV r p N
km ¼
V
assuming particle density rp is independent of size.

The constants kS , kV and km may be found by using the fact that:
ð1
fðxÞdx ¼ 1 ð1:4Þ
0
Thus, when we convert between distributions it is necessary to make assump-

tions about the constancy of shape and density with size. Since these assumptions
may not be valid, the conversions are likely to be in error. Also, calculation errors
are introduced into the conversions. For example, imagine that we used an
electron microscope to produce a number distribution of size with a measure-
ment error of 2%. Converting the number distribution to a mass distribution we
triple the error involved (i.e. the error becomes 6%). For these reasons,
conversions between distributions are to be avoided wherever possible. This
can be done by choosing the measurement method which gives the required
distribution directly.
1.5 DESCRIBING THE POPULATION BY A SINGLE NUMBER
In most practical applications, we require to describe the particle size of a

population of particles (millions of them) by a single number. There are many
options available; the mode, the median, and several different means including
arithmetic, geometric, quadratic, harmonic, etc. Whichever expression of central
tendency of the particle size of the population we use must reflect the property or
properties of the population of importance to us. We are, in fact, modelling the
real population with an artificial population of mono-sized particles. This section
deals with calculation of the different expressions of central tendency and
selection of the appropriate expression for a particular application.
The mode is the most frequently occurring size in the sample. We note,
however, that for the same sample, different modes would be obtained for
distributions by number, surface and volume. The mode has no practical
significance as a measure of central tendency and so is rarely used in practice.
The median is easily read from the cumulative distribution as the 50% size; the
size which splits the distribution into two equal parts. In a mass distribution, for
example, half of the particles by mass are smaller than the median size. Since the
Table 1.4 Definitions of means

gðxÞ Mean and notation
x arithmetic mean, xa
x2 quadratic mean, xq
x3 cubic mean, xc
log x geometric mean, xg
1=x harmonic mean, xh
median is easily determined, it is often used. However, it has no special

significance as a measure of central tendency of particle size.
Many different means can be defined for a given size distribution; as pointed
out by Svarovsky (1990). However, they can all be described by:
Ð1 ð1 ð1
gðxÞdF
gðxÞ ¼ 0
Ð1 but dF ¼ 1 and so gðxÞ ¼ gðxÞdF ð1:5Þ
0 dF 0 0
where x is the mean and g is the weighting function, which is different for each
mean definition. Examples are given in Table 1.4.
Equation (1.5) tells us that the mean is the area between the curve and the FðxÞ
axis in a plot of FðxÞ versus the weighting function gðxÞ (Figure 1.5). In fact,
graphical determination of the mean is always recommended because the
distribution is more accurately represented as a continuous curve.
Each mean can be shown to conserve two properties of the original population
of particles. For example, the arithmetic mean of the surface distribution
conserves the surface and volume of the original population. This is demon-
strated in Worked Example 1.3. This mean is commonly referred to as the
surface-volume mean or the Sauter mean. The arithmetic mean of the number
Figure R1.5 Plot of cumulative frequency against weighting function gðxÞ. Shaded area is
1
gðxÞ ¼ 0 gðxÞ dF
DESCRIBING THE POPULATION BY A SINGLE NUMBER 9
distribution xaN conserves the number and length of the original population and
is known as the number-length mean xNL :
Ð1
x dFN
number-length mean; xNL ¼ xaN ¼ Ð0 1 ð1:6Þ
0 dFN
As another example, the quadratic mean of the number distribution xqN con-
serves the number and surface of the original population and is known as the
number-surface mean xNS :
Ð1
x2 dFN
number-surface mean; x2NS ¼ x2qN ¼ 0Ð 1 ð1:7Þ
0 dFN
A comparison of the values of the different means and the mode and median for
a given particle size distribution is given in Figure 1.6. This figure highlights two
points: (a) that the values of the different expressions of central tendency can vary
significantly; and (b) that two quite different distributions could have the same
Figure 1.6 Comparison between measures of central tendency. Adapted from Rhodes
(1990). Reproduced by permission
arithmetic mean or median, etc. If we select the wrong one for our design
correlation or quality control we may be in serious error.
So how do we decide which mean particle size is the most appropriate one for
a given application? Worked Examples 1.3 and 1.4 indicate how this is done.
For Equation (1.8), which defines the surface-volume mean, please see Worked
Example 1.3.
1.6 EQUIVALENCE OF MEANS
Means of different distributions can be equivalent. For example, as is shown

below, the arithmetic mean of a surface distribution is equivalent (numerically
equal to) the harmonic mean of a volume (or mass) distribution:
Ð1
x dFS
arithmetic mean of a surface distribution; xaS ¼ Ð0 1 ð1:9Þ
0 dFS
The harmonic mean xhV of a volume distribution is defined as:

Ð1 1
dFV
1 0 x
¼ Ð1 ð1:10Þ
xhV
0 dFV
From Equations (1.1) and (1.2), the relationship between surface and volume
distributions is:
kv
dFv ¼ x dFs ð1:11Þ
ks
hence

Ð 1 1 kv
x dFs Ð1
1 0 x ks dFs
¼ Ð ¼ Ð 10 ð1:12Þ
xhV 1 kv
0 x dFs
0 x k dFs
s
(assuming ks and kv do not vary with size)

and so
Ð1
x dFs
xhV ¼ Ð0 1
0 dFs
which, by inspection, can be seen to be equivalent to the arithmetic mean of the

surface distribution xaS [Equation (1.9)].
Recalling that d Fs ¼ x2 kS d FN , we see from Equation (1.9) that
Ð1 3
x dFN

xaS ¼ Ð01
0 x dFN
2
which is the surface-volume mean, xSV [Equation (1.8) - see Worked Example 1.3].
COMMON METHODS OF DISPLAYING SIZE DISTRIBUTIONS 11
Summarizing, then, the surface-volume mean may be calculated as the

arithmetic mean of the surface distribution or the harmonic mean of the volume
distribution. The practical significance of the equivalence of means is that it
permits useful means to be calculated easily from a single size analysis.
The reader is invited to investigate the equivalence of other means.
1.7 COMMON METHODS OF DISPLAYING SIZE DISTRIBUTIONS
1.7.1 Arithmetic-normal Distribution
In this distribution, shown in Figure 1.7, particle sizes with equal differences
from the arithmetic mean occur with equal frequency. Mode, median and
arithmetic mean coincide. The distribution can be expressed mathematically by:
" #
dF 1 ðx xÞ2
¼ pffiffiffiffiffiffi exp ð1:13Þ
dx s 2p 2s2
where s is the standard deviation.

To check for a arithmetic-normal distribution, size analysis data is plotted on
normal probability graph paper. On such graph paper a straight line will result if
the data fits an arithmetic-normal distribution.
1.7.2 Log-normal Distribution
This distribution is more common for naturally occurring particle populations.

An example is shown in Figure 1.8. If plotted as dF=dðlog xÞ versus x, rather than
dF=dx versus x, an arithmetic-normal distribution in log x results (Figure 1.9). The
mathematical expression describing this distribution is:
" #
dF 1 ðz zÞ2
¼ pffiffiffiffiffiffi exp ð1:14Þ
dz sz 2p 2s2z
Figure 1.7 Arithmetic-normal distribution with an arithmetic mean of 45 and standard

deviation of 12
Figure 1.8 Log-normal distribution plotted on linear coordinates
where z ¼ log x, z is the arithmetic mean of log x and sz is the standard deviation
of log x.
To check for a log-normal distribution, size analysis data are plotted on log-
normal probability graph paper. Using such graph paper, a straight line will
result if the data fit a log-normal distribution.
1.8 METHODS OF PARTICLE SIZE MEASUREMENT
1.8.1 Sieving
Dry sieving using woven wire sieves is a simple, cheap method of size analysis
suitable for particle sizes greater than 45 mm. Sieving gives a mass distribution and a
size known as the sieve diameter. Since the length of the particle does not hinder its
passage through the sieve apertures (unless the particle is extremely elongated), the
sieve diameter is dependent on the maximum width and maximum thickness of the
Figure 1.9 Log-normal distribution plotted on logarithmic coordinates

METHODS OF PARTICLE SIZE MEASUREMENT 13
particle. The most common modern sieves are in sizes such that the ratio of adjacent
sieve sizes is the fourth root of two (eg. 45, 53, 63, 75, 90, 107 mm). If standard
procedures are followed and care is taken, sieving gives reliable and reproducible
size analysis. Air jet sieving, in which the powder on the sieve is fluidized by a jet or
air, can achieve analysis down to 20 mm. Analysis down to 5 mm can be achieved by
wet sieving, in which the powder sample is suspended in a liquid.
1.8.2 Microscopy
The optical microscope may be used to measure particle sizes down to 5 mm. For
particles smaller than this diffraction causes the edges of the particle to
be blurred and this gives rise to an apparent size. The electron microscope
may be used for size analysis below 5 mm. Coupled with an image analysis
system the optical microscope or electron microscope can readily give number
distributions of size and shape. Such systems calculate various diameters from
the projected image of the particles (e.g. Martin’s, Feret’s, shear, projected area
diameters, etc.). Note that for irregular-shaped particles, the projected area
offered to the viewer can vary significantly depending on the orientation of the
particle. Techniques such as applying adhesive to the microscope slide may be
used to ensure that the particles are randomly orientated.
1.8.3 Sedimentation
In this method, the rate of sedimentation of a sample of particles in a liquid is

followed. The suspension is dilute and so the particles are assumed to fall at their
single particle terminal velocity in the liquid (usually water). Stokes’ law is
assumed to apply ðRep < 0:3Þ and so the method using water is suitable only for
particles typically less than 50 mm in diameter. The rate of sedimentation of the
particles is followed by plotting the suspension density at a certain vertical
position against time. The suspension density is directly related to the cumulative
undersize and the time is related to the particle diameter via the terminal
velocity. This is demonstrated in the following:
Referring to Figure 1.10, the suspension density is sampled at a vertical
distance, h below the surface of the suspension. The following assumptions are
made:
The suspension is sufficiently dilute for the particles to settle as individuals (i.e.
not hindered settling – see Chapter 3).
Motion of the particles in the liquid obeys Stokes’ law (true for particles
typically smaller than 50 mm).
Particles are assumed to accelerate rapidly to their terminal free fall velocity UT
so that the time for acceleration is negligible.
Figure 1.10 Size analysis by sedimentation
Let the original uniform suspension density be C0 . Let the suspension density
at the sampling point be C at time t after the start of settling. At time t all those
particles travelling faster than h=t will have fallen below the sampling point. The
sample at time t will therefore consist only of particles travelling a velocity h=t.
Thus, if C0 is representative of the suspension density for the whole population,
then C represents the suspension density for all particles which travel at a
velocity h=t, and so C=C0 is the mass fraction of the original particles which
travel at a velocity h=t. That is,
C
cumulative mass fraction ¼
C0
All particles travel at their terminal velocity given by Stokes’ law [Chapter 2,
Equation (2.13)]:
x2 ðrp rf Þg
UT ¼
18 m
Thus, equating UT with h=t, we determine the diameter of the particle travelling
at our cut-off velocity h=t. That is,
" #1=2
18 mh
x¼ ð1:15Þ
tðrp rf Þg
Particles smaller than x will travel slower than h=t and will still be in suspension
at the sampling point. Corresponding values of C=C0 and x therefore give us the
cumulative mass distribution. The particle size measured is the Stokes’ diameter,
i.e. the diameter of a sphere having the same terminal settling velocity in the
Stokes region as the actual particle.
METHODS OF PARTICLE SIZE MEASUREMENT 15
A common form of this method is the Andreason pipette which is capable of

measuring in the range 2–100 mm. At size below 2 mm, Brownian motion causes
significant errors. Increasing the body force acting on the particles by centrifu-
ging the suspension permits the effects of Brownian motion to be reduced so that
particle sizes down to 0:01 mm can be measured. Such a device is known as a
pipette centrifuge.
The labour involved in this method may be reduced by using either light
absorption or X-ray absorption to measure the suspension density. The
light absorption method gives rise to a distribution by surface, whereas the
X-ray absorption method gives a mass distribution.
1.8.4 Permeametry
This is a method of size analysis based on fluid flow through a packed bed
(see Chapter 6). The Carman–Kozeny equation for laminar flow through a
randomly packed bed of uniformly sized spheres of diameter x is [Equation 6.9]:
ðpÞ ð1 eÞ2 mU
¼ 180
H e3 x2
where ðpÞ is the pressure drop across the bed, e is the packed bed void fraction,
H is the depth of the bed, m is the fluid viscosity and U is the superficial fluid
velocity. In Worked Example 1.3, we will see that, when we are dealing with non-
spherical particles with a distribution of sizes, the appropriate mean diameter for
this equation is the surface-volume diameter xSV , which may be calculated as the
arithmetic mean of the surface distribution, xaS :
In this method, the pressure gradient across a packed bed of known voidage is
measured as a function of flow rate. The diameter we calculate from the
Carman–Kozeny equation is the arithmetic mean of the surface distribution
(see Worked Example 6.1 in Chapter 6).
1.8.5 Electrozone Sensing
Particles are held in supension in a dilute electrolyte which is drawn through a

tiny orifice with a voltage applied across it (Figure 1.11). As particles flow
through the orifice a voltage pulse is recorded.
The amplitude of the pulse can be related to the volume of the particle passing
the orifice. Thus, by electronically counting and classifying the pulses according
to amplitude this technique can give a number distribution of the equivalent
volume sphere diameter. The lower size limit is dictated by the smallest practical
orifice and the upper limit is governed by the need to maintain particles in
suspension. Although liquids more viscous than water may be used to reduce
sedimentation, the practical range of size for this method is 0.3–1000 mm. Errors
are introduced if more that one particle passes through the orifice at a time and so
dilute suspensions are used to reduce the likelihood of this error.
Figure 1.11 Schematic of electrozone sensing apparatus
1.8.6 Laser Diffraction
This method relies on the fact that for light passing through a suspension, the
diffraction angle is inversely proportional to the particle size. An instrument
would consist of a laser as a source of coherent light of known fixed
wavelength (typically 0:63 mm), a suitable detector (usually a slice of photo-
sensitive silicon with a number of discrete detectors, and some means of
passing the sample of particles through the laser light beam (techniques are
available for suspending particles in both liquids and gases are drawing them
through the beam).
To relate diffraction angle with particle size, early instruments used the
Fraunhofer theory, which can give rise to large errors under some circumstances
(e.g. when the refractive indices of the particle material and suspending medium
approach each other). Modern instruments use the Mie theory for interaction of
light with matter. This allows particle sizing in the range 0.1–2000 mm, provided
that the refractive indices of the particle material and suspending medium are
known.
This method gives a volume distribution and measures a diameter known as
the laser diameter. Particle size analysis by laser diffraction is very common in
industry today. The associated software permits display of a variety of size
distributions and means derived from the original measured distribution.
1.9 SAMPLING
In practice, the size distribution of many tonnes of powder are often assumed
from an analysis performed on just a few grams or milligrams of sample. The
importance of that sample being representative of the bulk powder cannot be
overstated. However, as pointed out in Chapter 11 on mixing and segregation,
most powder handling and processing operations (pouring, belt conveying,
WORKED EXAMPLES 17
handling in bags or drums, motion of the sample bottle, etc.) cause particles
to segregate according to size and to a lesser extent density and shape. This
natural tendency to segregation means that extreme care must be taken in
sampling.
There are two golden rules of sampling:
1. The powder should be in motion when sampled.
2. The whole of the moving stream should be taken for many short time increments.
Since the eventual sample size used in the analysis may be very small, it is often
necessary to split the original sample in order to achieve the desired amount for
analysis. These sampling rules must be applied at every step of sampling and
sample splitting.
Detailed description of the many devices and techniques used for sampling in
different process situations and sample dividing are outside the scope of this
chapter. However, Allen (1990) gives an excellent account, to which the reader is
referred.
1.10 WORKED EXAMPLES
WORKED EXAMPLE 1.1
Calculate the equivalent volume sphere diameter xv and the surface-volume equivalent
sphere diameter xsv of a cuboid particle of side length 1, 2, 4 mm.
Solution
The volume of cuboid ¼ 1 2 4 ¼ 8 mm3
The surface area of the particle ¼ ð1 2Þ þ ð1 2Þ þ ð1 þ 2 þ 1 þ 2Þ 4 ¼ 28 mm2
The volume of sphere of diameter xv is px3v =6
Hence, diameter of a sphere having a volume of 8 mm3 ; xv ¼ 2:481 mm
The equivalent volume sphere diameter xv of the cuboid particle is therefore xv ¼ 2:481 mm
28
The surface to volume ratio of the cuboid particle ¼ ¼ 3:5 mm2 =mm3
8
The surface to volume ratio for a sphere of diameter xsv is therefore 6=xsv
Hence, the diameter of a sphere having the same surface to volume ratio as the particle ¼
6=3:5 ¼ 1:714 mm
The surface-volume equivalent sphere diameter of the cuboid, xsv ¼ 1:714 mm

WORKED EXAMPLE 1.2
Convert the surface distribution described by the following equation to a cumulative

volume distribution:
FS ¼ ðx=45Þ2 for x 45 mm
FS ¼ 1 for x > 45 mm
Solution
From Equations (1.1)–(1.3),

kv
fv ðxÞ ¼ xfs ðxÞ
ks
Integrating between sizes 0 and x:
ðx
kv
Fv ðxÞ ¼ xfs ðxÞdx
0 ks
Noting that fs ðxÞ ¼ dFs =dx, we see that
d x 2 2x
fs ðxÞ ¼ ¼
dx 45 ð45Þ2
and our integral becomes
ðx
kv 2x2
Fv ðxÞ ¼ dx
0 ks ð45Þ2
Assuming that kv and ks are independent of size,
ðx
kv 2x2
Fv ðxÞ ¼ dx
ks 0 ð45Þ2
" #
2 x3 kv
¼
3 ð45Þ2 ks
kv =ks may be found by noting that Fv ð45Þ ¼ 1; hence
90 kv kv
¼ 1 and so ¼ 0:0333
3 ks ks
Thus, the formula for the volume distribution is
Fv ¼ 1:096 105 x3 for x 45 mm

Fv ¼ 1 for x > 45 mm
WORKED EXAMPLES 19
WORKED EXAMPLE 1.3
What mean particle size do we use in calculating the pressure gradient for flow of a fluid
through a packed bed of particles using the Carman–Kozeny equation (see Chapter 6)?
Solution
The Carman–Kozeny equation for laminar flow through a randomly packed bed of
particles is:
ðpÞ ð1 eÞ2 2
¼K Sv mU
L e3
where Sv is the specific surface area of the bed of particles (particle surface area per unit
particle volume) and the other terms are defined in Chapter 6. If we assume that the bed
voidage is independent of particle size, then to write the equation in terms of a mean
particle size, we must express the specific surface, Sv , in terms of that mean. The particle
size we use must give the same value of Sv as the original population or particles. Thus
the mean diameter x must conserve the surface and volume of the population; that is,
the mean must enable us to calculate the total volume from the total surface of the
particles. This mean is the surface-volume mean xsv

av av 1
xsv ðtotal surfaceÞ ¼ ðtotal volumeÞ eg: for spheres; ¼
as as 6
ð1 ð1
kv
and therefore xsv fs ðxÞdx ¼ fv ðxÞdx
k
0
ð 1s 0
Total volume of particles; V ¼ x3 aV NfN ðxÞdx

0
ð1
Total surface area of particles; S ¼ x2 aS NfN ðxÞdx
0
Ð1
as 0 x3 av NfN ðxÞdx
Hence; xsv ¼ Ð 1 2
av 0 x as NfN ðxÞdx
Then, since aV , aS and N are independent of size, x,

Ð1 3 Ð1 3
x fN ðxÞdx x dFN
xsv ¼ Ð01 2 ¼ Ð01
0 x f N ðxÞdx 0 x dFN
2
This is the definition of the mean which conserves surface and volume, known as the
surface-volume mean, xSV .
So
Ð1 3
x dFN
xSV ¼ Ð01 ð1:8Þ
0 x dFN
2
The correct mean particle diameter is therefore the surface-volume mean as defined
above. (We saw in Section 1.6 that this may be calculated as the arithmetic mean of the
surface distribution xaS , or the harmonic mean of the volume distribution.) Then in the
Carman–Kozeny equation we make the following substitution for Sv :
1 ks
Sv ¼

xSV kv
e.g. for spheres, Sv ¼ 6=xSV:
WORKED EXAMPLE 1.4 (AFTER SVAROVSKY, 1990)
A gravity settling device processing a feed with size distribution FðxÞ and operates with
a grade efficiency GðxÞ. Its total efficiency is defined as:
ð1
ET ¼ GðxÞd FM
0
How is the mean particle size to be determined?
Solution
Assuming plug flow (see Chapter 3), GðxÞ ¼ UT A=Q where, A is the settling area, Q is
the volume flow rate of suspension and UT is the single particle terminal velocity for
particle size x, given by (in the Stokes region):
x2 ðrp rf Þg
UT ¼ ðChapter 2Þ
18 m
hence ð1
Agðrp rf Þ
ET ¼ x2 d FM
18 mQ 0
Ð1
where 0 x2 d FM is seen to be the definition of the quadratic mean of the distribution by
mass xqM (see Table 1.4).
This approach may be used to determine the correct mean to use in many
applications.
WORKED EXAMPLE 1.5
A Coulter counter analysis of a cracking catalyst sample gives the following cumulative
volume distribution:
Channel 1 2 3 4 5 6 7 8
% volume differential 0 0.5 1.0 1.6 2.6 3.8 5.7 8.7
Channel 9 10 11 12 13 14 15 16
% volume differential 14.3 22.2 33.8 51.3 72.0 90.9 99.3 100
WORKED EXAMPLES 21
(a) Plot the cumulative volume distribution versus size and determine the median size.
(b) Determine the surface distribution, giving assumptions. Compare with the volume
distribution.
(c) Determine the harmonic mean diameter of the volume distribution.
(d) Determine the arithmetic mean diameter of the surface distribution.
Solution
With the Coulter counter the channel size range differs depending on the tube in use.
We therefore need the additional information that in this case channel 1 covers the size
range 3:17 mm to 4:0 mm, channel 2 covers the range 4:0 mm to 5:04 mm and so on up to
channel 16, which covers the range 101:4 mm to 128 mm. The ratio of adjacent size range
boundaries is always the cube root of 2. For example,
p ffiffiffi 4:0 5:04 128
2¼ ¼ ¼ ; etc:
3
3:17 4:0 101:4
The resulting lower and upper sizes for the channels are shown in columns 2 and 3 of
Table 1W5.1.
Table 1W5.1 Size distribution data associated with Worked Example 1.5
1 2 3 4 5 6 7 8
Channel Lower Upper Cumulative Fv 1=x Cumulative Fs 9
number size of size of per cent area under Cumulative
range range undersize Fv versus area under
mm mm 1=x Fs versus x
1 3.17 4.00 0 0 0.2500 0.0000 0.0000 0.0000

2 4.00 5.04 0.5 0.005 0.1984 0.0011 0.0403 0.1823
3 5.04 6.35 1 0.01 0.1575 0.0020 0.0723 0.3646
4 6.35 8.00 1.6 0.016 0.1250 0.0029 0.1028 0.5834
5 8.00 10.08 2.6 0.026 0.0992 0.0040 0.1432 0.9480
6 10.08 12.70 3.8 0.038 0.0787 0.0050 0.1816 1.3855
7 12.70 16.00 5.7 0.057 0.0625 0.0064 0.2299 2.0782
8 16.00 20.16 8.7 0.087 0.0496 0.0081 0.2904 3.1720
9 20.16 25.40 14.3 0.143 0.0394 0.0106 0.3800 5.2138
10 25.40 32.00 22.2 0.222 0.0313 0.0134 0.4804 8.0942
11 32.00 40.32 33.8 0.338 0.0248 0.0166 0.5973 12.3236
12 40.32 50.80 51.3 0.513 0.0197 0.0205 0.7374 18.7041
13 50.80 64.00 72 0.72 0.0156 0.0242 0.8689 26.2514
14 64.00 80.63 90.9 0.909 0.0124 0.0268 0.9642 33.1424
15 80.63 101.59 99.3 0.993 0.0098 0.0277 0.9978 36.2051
16 101.59 128.00 100 1 0.0078 0.0278 1.0000 36.4603
Note: Based on arithmetic means of size ranges.
Figure 1W5.1 Cumulative volume distribution
(a) The cumulative undersize distribution is shown numerically in column 5 of

Table 1W5.1 and graphically in Figure 1W5.1. By inspection, we see that the median
size is 50 mm (b), i.e. 50% by volume of the particles is less than 50 mm.
(b) The surface distribution is related to the volume distribution by the expression:
fv ðxÞ ks
fs ðxÞ ¼ ðfrom ½Equationsð1:1Þ and ð1:2Þ
x kv
Recalling that fðxÞ ¼ dF=dx and integrating between 0 and x:

ðx ðx
ks 1 dFv dFs
dx ¼ dx
kv 0 x dx 0 dx
or ðx ðx
ks 1
dFv ¼ dFs ¼ Fs ðxÞ
kv 0x 0
(assuming particle shape is invariant with size so that ks =kv is constant).
So the surface distribution can be found from the area underÐ a plot of 1=x versus Fv
x¼1
multiplied by the factor ks =kv (which is found by noting that x¼0 dFs ¼ 1).
Column 7 of Table 1W5.1 shows the area under 1=x versus Fv . The factor ks =kv is
therefore equal to 0.0278. Dividing the values of column 7 by 0.0278 gives the surface
distribution Fs shown in column 8. The surface distribution is shown graphically in
Figure 1W5.2. The shape of the surface distribution is quite different from that of the
volume distribution; the smaller particles make up a high proportion of the total surface.
The median of the surface distribution is around 35 mm, i.e. particles under 35 mm
contribute 50% of the total surface area.
(c) The harmonic mean of the volume distribution is given by:

ð1
1 1
¼ dFv
xhV 0 x
WORKED EXAMPLES 23
Figure 1W5.2 Cumulative surface distribution
This can be calculated graphically from a plot of Fv versus 1=x or numerically from the
tabulated data in column 7 of Table 1W5.1. Hence,
ð1
1 1
¼ dFv ¼ 0:0278
xhV 0 x
and so, xhV ¼ 36 mm.
We recall that the harmonic mean of the volume distribution is equivalent to the
surface-volume mean of the population.
(d) The arithmetic mean of the surface distribution is given by:

ð1
xaS ¼ x dFs
0
This may be calculated graphically from our plot of Fs versus x (Figure 1W5.2) or
numerically using the data in Table 1W5.1. This area calculation as shown in Column 9
of the table shows the cumulative area under a plot of Fs versus x and so the last figure
in this column is equivalent to the above integral.
Thus:
xas ¼ 36:4 mm
We may recall that the arithmetic mean of the surface distribution is also equivalent to
the surface-volume mean of the population. This value compares well with the value
obtained in (c) above.
WORKED EXAMPLE 1.6
Consider a cuboid particle 5:00 3:00 1:00 mm. Calculate for this particle the follow-
ing diameters:
(a) the volume diameter (the diameter of a sphere having the same volume as the
particle);
(b) the surface diameter (the diameter of a sphere having the same surface area as the
particle);
(c) the surface-volume diameter (the diameter of a sphere having the same external
surface to volume ratio as the particle);
(d) the sieve diameter (the width of the minimum aperture through which the particle
will pass);
(e) the projected area diameters (the diameter of a circle having the same area as the
projected area of the particle resting in a stable position).
Solution
(a) Volume of the particle ¼ 5 3 1 ¼ 15 mm3

px3v
Volume of a sphere ¼
6 rffiffiffiffiffiffiffiffiffiffiffiffiffiffi
3 15 6
Thus volume diameter, xv ¼ ¼ 3:06 mm
p
(b) Surface area of the particle ¼ 2 ð5 3Þ þ 2 ð1 3Þ þ 2 ð1 5Þ ¼ 46 mm2
Surface area of sphere ¼ px2s

rffiffiffiffiffiffiffiffiffiffi
46
Therefore, surface diameter, xs ¼ ¼3:83 mm
p
(c) Ratio of surface to volume of the particle ¼ 46=15 ¼ 3:0667
6
For a sphere, surface to volume ratio ¼
xsv
6
Therefore, xsv ¼ ¼ 1:96 mm
3:0667
(d) The smallest square aperture through which this particle will pass is 3 mm. Hence,
the sieve diameter, xp ¼ 3 mm
(e) This particle has three projected areas in stable positions:
area 1 ¼ 3 mm2 ; area 2 ¼ 5 mm2 ; area 3 ¼ 15 mm2

px2
area of circle ¼
4
hence, projected area diameters:
projected area diameter 1 ¼ 1:95 mm;
projected area diameter 2 ¼ 2:52 mm;
projected area diameter 3 ¼ 4:37 mm:

EXERCISES 25
TEST YOURSELF
1.1 Define the following equivalent sphere diameters: equivalent volume diameter, equiva-
lent surface diameter, equivalent surface-volume diameter. Determine the values of each
one for a cuboid of dimensions 2 mm 3 mm 6 mm.
1.2 List three types of distribution that might be used in expressing the range of particle
sizes contained in a given sample.
1.3 If we measure a number distribution and wish to convert it to a surface distribution,

what assumptions have to be made?
1.4 Write down the mathematical expression defining (a) the quadratic mean and (b) the
harmonic mean.
1.5 For a give particle size distribution, the mode, the arithmetic mean, the harmonic
mean and the quadratic mean all have quite different numberical values. How do we
decide which mean is appropriate for describing the powder’s behaviour in a given
process?
1.6 What are the golden rules of sampling?
1.7 When using the sedimentation method for determination of particle size distribution,
what assumptions are made?
1.8 In the electrozone sensing method of size analysis, (a) what equivalent sphere particle
diameter is measured and (b) what type of distribution is reported?
EXERCISES
1.1 For a regular cuboid particle of dimensions 1:00 2:00 6:00 mm, calculate the
following diameters:
(a) the equivalent volume sphere diameter;
(b) the equivalent surface sphere diameter;
(c) the surface-volume diameter (the diameter of a sphere having the same external
surface to volume ratio as the particle);
(d) the sieve diameter (the width of the minimum aperture through which the particle will
pass);
(e) the projected area diameters (the diameter of a circle having the same area as the
projected area of the particle resting in a stable position).
[Answer: (a) 2.84 mm; (b) 3.57 mm; (c) 1.80 mm; (d) 2.00 mm; (e) 2.76 mm, 1.60 mm and
3.91 mm.]
1.2 Repeat Exercise 1.1 for a regular cylinder of diameter 0.100 mm and length 1.00 mm.
[Answer: (a) 0.247 mm; (b) 0.324 mm; (c) 0.142 mm; (d) 0.10 mm; (e) 0.10 mm (unlikely to
be stable in this position) and 0.357 mm.]
1.3 Repeat Exercise 1.1 for a disc-shaped particle of diameter 2.00 mm and length 0.500 mm.
[Answer: (a) 1.44 mm; (b) 1.73 mm; (c) 1.00 mm; (d) 2.00 mm; (e) 2.00 mm and 1.13 mm
(unlikely to be stable in this position).]

1.4 1.28 g of a powder of particle density 2500 kg m3 are charged into the cell of an
apparatus for measurement of particle size and specific surface area by permeametry. The
cylindrical cell has a diameter
of 1.14 cm and the powder forms a bed of depth 1 cm. Dry
air of density 1:2 kg m3 and viscosity 18:4 106 Pa s flows at a rate of 36 cm3 min
through the powder (in a direction parallel to the axis of the cylindrical cell) and
producing a pressure difference of 100 mm of water across the bed. Determine the
surface-volume mean diameter and the specific surface of the powder sample.
(Answer: 20 mm; 120 m2 =kg:)
1.5 1.1 g of a powder of particle density 1800 kg=m3 are charged into the cell of an
apparatus for measurement of particle size and specific surface area by permeametry. The
cylindrical cell has a diameter of 1.14 cm and the powder forms a bed of depth l cm. Dry
air of density 1:2 kg=m3 and viscosity 18:4 106 Pa s flows through the powder (in a
direction parallel to the axis of the cylindrical cell). The measured variation in pressure
difference across the bed with changing air flow rate is given below:
Air flow ðcm3 =minÞ 20 30 40 50 60

Pressure difference across the bed (mm of water) 56 82 112 136 167
Determine the surface-volume mean diameter and the specific surface of the powder
sample.
(Answer: 33 mm; 100 m2 =kg:)
1.6 Estimate the (a) arithmetic mean, (b) quadratic mean, (c) cubic mean, (d) geometric
mean and (e) harmonic mean of the following distribution.
Size 2 2.8 4 5.6 8 11.2 16 22.4 32 44.8 64 89.6

cumulative 0.1 0.5 2.7 9.6 23 47.9 73.8 89.8 97.1 99.2 99.8 100
%
undersize
[Answer: (a) 13.6; (b) 16.1; (c) 19.3; (d) 11.5; (e) 9.8.]
1.7 The following volume distribution was derived from a sieve analysis
Size ðmmÞ 37–45 45–53 53–63 63–75 75–90 90–106 106–126 126–150 150–180 180–212
Volume % 0.4 3.1 11 21.8 27.3 22 10.1 3.9 0.4 0
in range
EXERCISES 27
(a) Estimate the arithmetic mean of the volume distribution.
From the volume distribution derive the number distribution and the surface distribu-
tion, giving assumptions made.
Estimate:
(b) the mode of the surface distribution;
(c) the harmonic mean of the surface distribution.
Show that the arithmetic mean of the surface distribution conserves the surface to volume
ratio of the population of particles.
[Answer: (a) 86 mm; (b) 70 mm; (c) 76 mm.]

2
Single Particles in a Fluid
This chapter deals with the motion of single solid particles in fluids. The objective
here is to develop an understanding of the forces resisting the motion of any such
particle and provide methods for the estimation of the steady velocity of the
particle relative to the fluid. The subject matter of the chapter will be used in
subsequent chapters on the behaviour of suspensions of particles in a fluid,
fluidization, gas cyclones and pneumatic transport.
2.1 MOTION OF SOLID PARTICLES IN A FLUID
The drag force resisting very slow steady relative motion (creeping motion)
between a rigid sphere of diameter x and a fluid of infinite extent, of viscosity m is
composed of two components (Stokes, 1851):
a pressure drag force; Fp ¼ pxmU ð2:1Þ

a shear stress drag force; Fs ¼ 2pxmU ð2:2Þ
Total drag force resisting motion, FD ¼ 3pxmU ð2:3Þ
where U is the relative velocity.

This is known as Stokes’ law. Experimentally, Stokes’ law is found to hold
almost exactly for single particle Reynolds number, Rep 0:1; within 9% for
Rep 0:3; within 3% for Rep 0:5 and within 9 % for Rep 1:0; where the single
particle Reynolds number is defined in Equation (2.4).
Single particle Reynolds number; Rep ¼ xUrf =m ð2:4Þ

0 1
A drag coefficient; CD is defined as CD ¼ R = rf U 2
ð2:5Þ
2
where R0 is the force per unit projected area of the particle.

30 SINGLE PARTICLES IN A FLUID
Creeping flow Inertial flow
log CD Stokes’ law Intermediate Newton’s law Boundary

layer
separation
≈0.3 ≈ 500 ≈ 2 x 105 log Rep
Figure 2.1 Standard drag curve for motion of a sphere in a fluid
Thus, for a sphere: 2

px
R0 ¼ FD ð2:6Þ
4
and, Stokes’ law, in terms of this drag coefficient, becomes:

CD ¼ 24 Rep ð2:7Þ
At higher relative velocities, the inertia of the fluid begins to dominate (the
fluid must accelerate out of the way of the particle). Analytical solution of the
Navier–Stokes equations is not possible under these conditions. However,
experiments give the relationship between the drag coefficient and the particle
Reynolds number in the form of the so-called standard drag curve (Figure 2.1).
Four regions are identified: the Stokes’ law region; the Newton’s law region in
which drag coefficient is independent of Reynolds number; an intermediate
region between the Stokes and Newton regions; and the boundary layer separa-
tion region. The Reynolds number ranges and drag coefficient correlations for
these regions are given in Table 2.1.
The expression given for CD in the intermediate region in Table 2.1 is that of
Schiller and Naumann (1933), which fits the data with an accuracy of around
7% in the intermediate range. Several correlations have been proposed for CD
Table 2.1 Reynolds number ranges for single particle drag coefficient correlations
Region Stokes Intermediate Newton’s law
Rep range < 0:3 0:3 < Rep < 500 500 < Rep < 2 105
24
CD 24/Rep ð1 þ 0:15 Re0:687 Þ 0.44
Rep p
PARTICLES FALLING UNDER GRAVITY THROUGH A FLUID 31
over the entire range; the one presented in Equation (2.8) is that of Haider and
Levenspiel (1989), which is claimed to fit the data with a root mean square
deviation of 0.024. 0 1
24 B 0:4251 C
CD ¼ 1 þ 0:1806 Re0:6459 þB
@
C ð2:8Þ
Rep p 6880:95A
1þ
Rep
2.2 PARTICLES FALLING UNDER GRAVITY THROUGH A FLUID
The relative motion under gravity of particles in a fluid is of particular interest. In

general, the forces of buoyancy, drag and gravity act on the particle:
gravity buoyancy drag ¼ acceleration force ð2:9Þ
A particle falling from rest in a fluid will initially experience a high acceleration
as the shear stress drag, which increases with relative velocity, will be small. As
the particle accelerates the drag force increases, causing the acceleration to
reduce. Eventually a force balance is achieved when the acceleration is zero
and a maximum or terminal relative velocity is reached. This is known as the
single particle terminal velocity.
For a spherical particle, Equation (2.9) becomes
px3 px3 px2

rp g rf g R0 ¼0 ð2:10Þ
6 6 4
Combining Equation (2.10) with Equation (2.5):
px3 1 px2
ðrp rf Þg CD rf UT2 ¼0 ð2:11Þ
6 2 4
where UT is the single particle terminal velocity. Equation (2.11) gives the
following expression for the drag coefficient under terminal velocity conditions:

4 gx ðrp rf Þ
CD ¼ ð2:12Þ
3 UT2 rf

Thus in the Stokes’ law region, with CD ¼ 24 Rep ; the single particle terminal
velocity is given by:
x2 ðrp rf Þg
UT ¼ ð2:13Þ
18m
Note that in the Stokes’ law region the terminal velocity is proportional to the
square of the particle diameter.
In the Newton’s law region, with CD ¼ 0:44, the terminal velocity is given by:
1=2
xðrp rf Þg
UT ¼ 1:74 ð2:14Þ
rf
Note that in this region the terminal velocity is independent of the fluid viscosity
and proportional to the square root of the particle diameter.
In the intermediate region no explicit expression for UT can be found.
However, in this region, the variation of terminal velocity with particle and fluid
properties is approximately described by:
UT / x1:1 ; ðrp rf Þ0:7 ; r0:29

f ; m0:43
Generally, when calculating the terminal velocity for a given particle or the
particle diameter for a given velocity, it is not known which region of operation is
relevant. One way around this is to formulate the dimensionless groups, CD Re2p
and CD =Rep :
To calculate UT , for a given size x. Calculate the group
4 x rf ðrp rf Þg
3
CD Re2p ¼ ð2:15Þ
3 m2
which is independent of UT
(Note that CD Re2p ¼ 43 Ar, where Ar is the Archimedes number.)
For given particle and fluid properties, CD Re2p is a constant and will therefore
produce a straight line of slope 2 if plotted on the logarithmic coordinates
(log CD versus log Rep ) of the standard drag curve. The intersection of
this straight line with the drag curve gives the value of Rep and hence UT
(Figure 2.2).
To calculate size x, for a given UT . Calculate the group
CD 4 gmðrp rf Þ
¼ ð2:16Þ
Rep 3 UT3 r2f
which is independent of particle size x.

For a given terminal velocity, particle density and fluid properties, CD =Rep is
constant and will produce a straight line of slope þ1 if plotted on the logarithmic
coordinates (log CD versus log Rep ) of the standard drag curve. The intersection
of this straight line with the drag curve gives the value of Rep and hence, x
(Figure 2.2). An alternative to this graphical method, but based on the same
approach, is to use tables of corresponding values of Rep ; CD ; CD Re2p , and CD/Rep.
For example, see Perry and Green (1984).
NON-SPHERICAL PARTICLES 33
Slope = –2
log CD (from CDRe2 = constant)
Slope = +1
(from CD/Rep = constant)
log Rep
UT
x
Figure 2.2 Method for estimating terminal velocity for a given size of particle and vice
versa (Note: Rep is based on the equivalent volume sphere diameter, xv )
2.3 NON-SPHERICAL PARTICLES
The effect of shape of non-spherical particles on their drag coefficient has proved
difficult to define. This is probably due to the difficulty in describing particle
shape for irregular particles. Engineers and scientist often require a single
number to describe the shape of a particle. One simple approach is to describe
the shape of a particle in terms of its sphericity, the ratio of the surface area of a
sphere of volume equal to that of the particle to the surface area of the particle.
For example, a cube of side one unit has a volume of 1 (cubic units) and a surface
area of 6 (square units). A sphere of the same volume has a diameter, xv of 1.24
units. The surface area of a sphere of diameter 1.24 units is 4.836 units. The
sphericity of a cube is therefore 0.806 (¼ 4.836/6).
Shape affects drag coefficient far more in the intermediate and Newton’s law
regions than in the Stokes’ law region. It is interesting to note that in the Stokes’
law region particles fall with their longest surface nearly parallel to the direction
of motion, whereas, in the Newton’s law region particles present their maximum
area to the oncoming fluid.
For non-spherical particles the particle Reynolds number is based on the equal-
volume sphere diameter, i.e. the diameter of the sphere having the same volume
as that of the particle. Figure 2.3 (after Brown et al., 1950) shows drag curves for
particles of different sphericities. This covers regular and irregular particles. The
plot should be used with caution, since sphericity on its own may not be
sufficient in some cases to describe the shape for all types of particles.
Small particles in gases and all common particles in liquids quickly accelerate
to their terminal velocity. As an example, a 100 mm particle falling from rest in
water requires 1.5 ms to reach its terminal velocity of 2 mm/s. Table 2.2 gives
104
1000
Drag coefficient, CD
100
ψ = 0.125
ψ = 0.22
8 10
6
ψ = 0.6
4
ψ = 0.806
2
1
ψ = 1.0
0.1
0.001 0.01 0.1 1 10 100 1000 104 105 106
0.4 0.8 Single particle Reynolds number, Rep

0.2 0.6
Figure 2.3 Drag coefficient CD versus Reynolds number Rep for particles of sphericity j
ranging from 0.125 to 1.0. (Note Rep and CD are based on the equivalent volume diameter)
some interesting comparisons of terminal velocities, acceleration times and

distances for sand particles falling from rest in air.
2.4 EFFECT OF BOUNDARIES ON TERMINAL VELOCITY
When a particle is falling through a fluid in the presence of a solid boundary the
terminal velocity reached by the particle is less than that for an infinite fluid. In
practice, this is really only relevant to the falling sphere method of measuring
liquid viscosity, which is restricted to the Stokes’ region. In the case of a particle
falling along the axis of a vertical pipe this is described by a wall factor, fw, the
ratio of the velocity in the pipe, UD to the velocity in an infinite fluid, U1 . The
correlation of Francis (1933) for fw is given in Equation (2.17).
x 2:25
fw ¼ 1 Rep 0:3; x=D 0:97 ð2:17Þ
D
Table 2.2 Sand particles falling from rest in air (particle density, 2600 kg=m3 )
Size Time to each 99% of UT ðsÞ UT (m/s) Distance travelled in this time (m)
30 mm 0.033 0.07 0.00185
3 mm 3.5 14 35
3 cm 11.9 44 453
WORKED EXAMPLES 35
2.5 FURTHER READING
For further details on the motion of single particles in fluids (accelerating motion, added
mass, bubbles and drops, non-Newtonian fluids) the reader is referred to Coulson and
Richardson (1991), Clift et al. (1978) and Chhabra (1993).
2.6 WORKED EXAMPLES
WORKED EXAMPLE 2.1
Calculate the upper limit of particle diameter xmax as a function of particle density
rp for gravity sedimentation in the Stokes’ law regime. Plot the results as xmax
versus rp over the range 0 rp 8000 kg=m3 for settling in water and in air at
ambient conditions. Assume that the particles are spherical and that Stokes’ law
holds for Rep 0:3.
Solution
The upper limit of particle diameter in the Stokes’ regime is governed by the upper limit
of single particle Reynolds number:
rf xmax U
Rep ¼ ¼ 0:3
m
In gravity sedimentation in the Stokes’ regime particles accelerate rapidly to their

terminal velocity. In the Stokes’ regime the terminal velocity is given by
Equation (2.13):
x2 ðrp rf Þg
UT ¼
18m
Solving these two equations for xmax we have

" #1=3
18m2
xmax ¼ 0:3
gðrp rf Þrf
" #1=3
m2
¼ 0:82
ðrp rf Þrf
Thus, for air (density 1:2 kg=m3 and viscosity 1:84 105 Pa s):
" #1=3
4 1
xmax ¼ 5:37 10
ðrp 1:2Þ
And for water (density 1000 kg=m3 and viscosity 0.001 Pa s):
" #1=3
4 1
xmax ¼ 8:19 10
ðrp 1000Þ
(a)
180.0
160.0
Particle size, xmax (mm)
140.0
120.0
100.0
Falling particles
80.0
60.0 Rising particles
40.0
20.0
0.0
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000
Particle density (kg/m3)
(b)
120.0
100.0
Particle size, xmax (mm)
80.0
60.0
40.0
20.0
0.0
0 500 1000 1500 2000 2500 3000
Particle density (kg/m3)
Figure 2W1.1 (a) Limiting particle size for Stokes’ law in water. (b) Limiting particle size
for Stokes’ law in air
These equations for xmax as a function are plotted in Figure 2W1.1 for particle densities
greater than and less than the fluid densities.
WORKED EXAMPLE 2.2
A gravity separator for the removal from water of oil droplets (assumed to behave as
rigid spheres) consists of a rectangular chamber containing inclined baffles as shown
schematically in Figure 2W2.1.
(a) Derive an expression for the ideal collection efficiency of this separator as a function
of droplet size and properties, separator dimensions, fluid properties and fluid
velocity (assumed uniform).
WORKED EXAMPLES 37
X Y
Oil out
Water +
oil in h
U h
Water
H
out
L B
X Y
Section Y-Y Section X-X
side elevation end elevation
Figure 2W2.1 Schematic diagram of oil–water separator
(b) Hence, calculate the per cent change in collection efficiency when the throughput of
water is increased by a factor of 1.2 and the density of the oil droplets changes from
750 to 800 kg=m3 .
Solution
(a) Referring to Figure 2W2.1, we will assume that all particles rising to the under
surface of a baffle will be collected. Therefore, any particle which can rise a distance h or
greater in the time required for it to travel the length of the separator will be collected.
Let the corresponding minimum vertical droplet velocity be UTmin .
Assuming uniform fluid velocity and negligible relative velocity between drops and
fluid in the horizontal direction,
drop residence time; t ¼ L=U
Then UTmin ¼ hU =L
Assuming that the droplets are small enough for Stokes’ law to apply and that the time
and distance for acceleration to terminal velocity is negligible, then droplet velocity will
be given by Equation (2.13):
x2 ðrp rf Þg
UT ¼
18m
This is the minimum velocity for drops to be collected whatever their original position
between the baffles. Thus
x2 ðrp rf Þg hU
UTmin ¼ ¼
18m L
Assuming that drops of all sizes are uniformly distributed over the vertical height of the
separator, then drops rising a distance less than h in the time required for them to travel
the length of the separator will be fractionally collected depending on their original
vertical position between two baffles. Thus for droplets rising at a velocity of 0:5UTmin
only 50% will be collected, i.e. only those drops originally in the upper half of the space
between adjacent baffles. For drops rising at a velocity of 0:25UTmin only 25% will be
collected.
actual UT for droplet
Thus; efficiency of collection; Z ¼
UTmin
and so, " #

x2 ðrp rf Þg hU
Z¼
18m L
(b) Comparing collection efficiencies when the throughput of water is increased by a

factor of 1.2 and the density of the oil droplets changes from 750 to 850 kg=m3 .
Let original and new conditions be denoted by subscripts 1 and 2, respectively.
Increasing throughput of water by a factor of 1.2 means that U2 =U1 ¼ 1:2.
Therefore from the expression for collection efficiency derived above:

Z2 rp2 rf rp1 rf
¼
Z1 U2 U1

Z2 850 1000 1
¼ ¼ 0:5
Z1 750 1000 1:2
The decrease in collection efficiency is therefore 50%.
WORKED EXAMPLE 2.3
A sphere of diameter 10 mm and density 7700 kg=m3 falls under gravity at terminal
conditions through a liquid of density 900 kg=m3 in a tube of diameter 12 mm. The
measured terminal velocity of the particle is 1:6 mm=s. Calculate the viscosity of the
fluid. Verify that Stokes’ law applies.
Solution
To solve this problem, we first convert the measured terminal velocity to the equivalent
velocity which would be achieved by the sphere in a fluid of infinite extent. Assuming
Stokes’ law we can determine the fluid viscosity. Finally we check the validity of
Stokes’ law.
Using the Francis wall factor expression [Equation (2.17)]:
UT1 1
¼ ¼ 56:34
UTD ð1 x=DÞ2:25
Thus, terminal velocity for the particle in a fluid of infinite extent,
UT1 ¼ UTD 56:34 ¼ 0:0901 m=s

WORKED EXAMPLES 39
Equating this value to the expression for UT1 in the Stokes’ regime [Equa-
tion (2.13)]:
ð10 103 Þ2 ð7700 900Þ 9:81

U T1 ¼
18m
Hence, fluid viscosity, m ¼ 4:11 Pa s.
Checking the validity of Stokes’ law:
xrf U
Single particle Reynolds number; Rep ¼ ¼ 0:197
m
Rep is less than 0.3 and so the assumption that Stokes’ law holds is valid.
WORKED EXAMPLE 2.4
A mixture of spherical particles of two materials A and B is to be separated using a

rising stream of liquid. The size range of both materials is 15–40 mm. (a) Show that a
complete separation is not possible using water as the liquid. The particle densities for
materials A and B are 7700 and 2400 kg=m3 , respectively. (b) Which fluid property must
be changed to achieve complete separation? Assume Stokes’ law applies.
Solution
(a) First, consider what happens to a single particle introduced into the centre of a pipe
in which a fluid is flowing upwards at a velocity U which is uniform across the pipe
cross-section. We will assume that the particle is small enough to consider the time
and distance for its acceleration to terminal velocity to be negligible. Referring to
Figure 2W4.1(a), if the fluid velocity is greater than the terminal velocity of the
particle UT , then the particle will move upwards; if the fluid velocity is less than UT
the particle will fall and if the fluid velocity is equal to UT the particle will remain at
the same vertical position. In each case the velocity of the particle relative to the pipe
wall is ðU UT Þ. Now consider introducing two particles of different size and
density having terminal velocities UT1 and UT2 . Referring to Figure 2W4.1(b), at low
fluid velocities ðU < UT2 < UT1 Þ, both particles will fall. At high fluid velocities
(U > UT1 > UT2 ), both particles will be carried upwards. At intermediate fluid
velocities ðUT1 > U > UT2 Þ, particle 1 will fall and particle 2 will rise. Thus we
have the basis of a separator according to particle size and density. From the analysis
above we see that to be able to completely separate particles A and B, there must be
no overlap between the ranges of terminal velocity for the particles; i.e. all sizes of
the denser material A must have terminal velocities which are greater than all sizes
of the less dense material B.
Assuming Stokes’ law applies, Equation (2.13), with fluid density and viscosity
1000 kg=m3 and 0.001 Pa s, respectively, gives
UT ¼ 545x2 ðrp 1000Þ

(a)
Increasing fluid velocity
U U U
U < UT U = UT U > UT
(Relative velocity = U - UT)
(b) Increasing fluid velocity
U U U
2
1
U > UT1
U < UT1 U < UT1
U > UT2
U < UT2 U > UT2
Figure 2W4.1 Relative motion of particles in a moving fluid
Based on this equation, the terminal velocities of the extreme sizes of particles A and B
are:
Size ðmmÞ ! 15 40
UTA ðmm=sÞ 0.82 5.84
UTB ðmm=sÞ 0.17 1.22
We see that there is overlap of the ranges of terminal velocities. We can therefore
select no fluid velocity which would completely separate particles A and B.
(b) Inspecting the expression for terminal velocity in the Stokes’ regime [Equation (2.13)]
we see that changing the fluid viscosity will have no effect on our ability to separate
the particles, since change in viscosity will change the terminal velocities of all
particles in the same proportion. However, changing the fluid density will have a
different effect on particles of different density and this is the effect we are looking for.
The critical condition for separation of particles A and B is when the terminal velocity
of the smallest A particle is equal to the terminal velocity of the largest B particle.
UTB40 ¼ UTA15
WORKED EXAMPLES 41
Hence,
545 x240 ð2400 rf Þ ¼ 545 x215 ð7700 rf Þ
From which, critical minimum fluid density rf ¼ 1533 kg=m3 .
WORKED EXAMPLE 2.5
A sphere of density 2500 kg=m3 falls freely under gravity in a fluid of density 700 kg=m3
and viscosity 0:5 103 Pa s. Given that the terminal velocity of the sphere is 0:15 m=s,
calculate its diameter. What would be the edge length of a cube of the same material
falling in the same fluid at the same terminal velocity?
Solution
In this case we know the terminal velocity, UT , and need to find the particle size x. Since
we do not know which regime is appropriate, we must first calculate the dimensionless
group CD =Rep [Equation (2.16)]:
CD 4 gmðrp rf Þ
¼
Rep 3 UT3 r2f
hence,

CD 4 9:81 ð0:5 103 Þ ð2500 700Þ
¼
Rep 3 0:153 7002
CD
¼ 7:12 103
ReP
This is the relationship between drag coefficent CD and single particle Reynolds number
Rep for particles of density 2500 kg=m3 having a terminal velocity of 0:15 m=s in a fluid
of density 700 kg=m3 and viscosity 0:5 103 Pa s. Since CD =Rep is a constant, this
relationship will give a straight line of slope þ1 when plotted on the log–log coordinates
of the standard drag curve.
For plotting the relationship:
Rep CD
100 0.712
1000 7.12
10 000 71.2
These values are plotted on the standard drag curves for particles of different
sphericity (Figure 2.3). The result is shown in Figure 2W5.1.
104
1000
100
ψ = 0.125
10 ψ = 0.22
ψ = 0.6
ψ = 0.806
1
ψ = 1.0
0.1
0.001 0.01 0.1 1 10 100 1000 104 105 106
sphere cube
Single particle Reynolds number, Rep
Figure 2W5.1 Drag coefficient CD versus Reynolds number Rep .
Where the plotted line intersects the standard drag curve for a sphere ðc ¼ 1Þ,
Rep ¼ 130.
The diameter of the sphere may be calculated from:
rf xv UT
Rep ¼ 130 ¼
m
Hence, sphere diameter xV ¼ 619 mm.
For a cube having the same terminal velocity under the same conditions, the same CD
versus Rep relationship applies, only the standard drag curve is that for a cube
ðc ¼ 0:806Þ.
Cube sphericity
For a cube of side 1 unit, the volume is 1 cubic unit and the surface area is 6 square
units. If xv is the diameter of a sphere having the same volume as the cube, then
px3v
¼ 1:0 which gives xv ¼ 1:24 units
6
surface area of a sphere of volume equal to the particle
Therefore; sphericity c ¼
surface area of the particle
4:836
c¼ ¼ 0:806
6
WORKED EXAMPLES 43
At the intersection of this standard drag curve with the plotted line, Rep ¼ 310.
Recalling that the Reynolds number in this plot uses the equivalent volume sphere
diameter,
310 ð0:5 103 Þ

xv ¼ ¼ 1:48 103 m
0:15 700
px3
And so the volume of the particle is v ¼ 1:66 109 m3
6
Giving a cube side length of ð1:66 109 Þ1=3 ¼ 1:18 103 mð1:18 mmÞ
WORKED EXAMPLE 2.6
A particle of equivalent volume diameter 0.5 mm, density 2000 kg=m3 and sphericity 0.6
falls freely under gravity in a fluid of density 1:6 kg=m3 and viscosity 2 105 Pa s.
Estimate the terminal velocity reached by the particle.
Solution
In this case we know the particle size and are required to determine its terminal velocity
without knowing which regime is appropriate. The first step is, therefore, to calculate
the dimensionless group CD Re2p :

4 x3 rf rp rf g
CD Re2p ¼
3 m2
"
3 #
4 0:5 103 1:6 ð2000 1:6Þ 9:81
¼
3 ð2 105 Þ2
¼ 13069
This is the relationship between drag coefficient CD and single particle Reynolds number
Rep for particles of size 0.5 mm and density 2000 kg=m3 falling in a fluid of density
1:6 kg=m3 and viscosity 2 105 Pa s. Since CD Re2p is a constant, this relationship will
give a straight line of slope 2 when plotted on the log–log coordinates of the standard
drag curve.
For plotting the relationship:
Rep CD
10 130.7
100 1.307
1000 0.013
These values are plotted on the standard drag curves for particles of different sphericity
(Figure 2.3). The result is shown in Figure 2W6.1.
104
1000
100
ψ = 0.125
10 ψ = 0.22
ψ = 0.6
ψ = 0.806
1
ψ = 1.0
0.1
0.001 0.01 0.1 1 10 100 1000 104 105 106
Single particle Reynolds number, Rep
Figure 2W6.1 Drag coefficient CD versus Reynolds number Rep .
Where the plotted line intersects the standard drag curve for a sphericity of 0:6ðc ¼ 0:6Þ,
Rep ¼ 40.
The terminal velocity UT may be calculated from
rf xv UT
Rep ¼ 40 ¼
m
Hence, terminal velocity, UT ¼ 1:0 m=s.
TEST YOURSELF
2.1 The total drag force acting on a particle is a function of:
(a) the particle drag coefficient;
(b) the projected area of the particle;
(c) both (a) and (b);
(d) none of the above.
2.2 The particle drag coefficient is a function of:
(a) the particle Reynolds number;
(b) the particle sphericity;

TEST YOURSELF 45
2.3 Stokes drag assumes:
(a) the drag coefficient is constant;
(b) the particle Reynolds number is constant;
(c) the drag force is constant;
2.4 The particle Reynolds number is not a function of:
(a) the particle density;
(b) the pipe diameter;
2.5 The force on a particle due to buoyancy depends on:
(b) the particle size;
2.6 The force on a particle due to gravity depends on:
(b) the particle size;
2.7 The particle Reynolds number is dependent on:
(b) the fluid density;

2.8 For particle in suspension in a fluid flowing in a pipe, as the pipe size increases (all
other things held constant), the particle Reynolds number:
(a) increases;
(b) decreases;
(c) remains the same.
2.9 The particle Reynolds number does not depend on:
(a) particle density;
(b) velocity;
(c) viscosity;
2.10 The units of viscosity are:
(a) length;
(b) mass/length;
(c) mass length/time;
EXERCISES
2.1 The settling chamber, shown schematically in Figure 2E1.1, is used as a primary
separation device in the removal of dust particles of density 1500 kg=m3 from a gas of
density 0:7 kg=m3 and viscosity 1:90 105 Pa s.
(a) Assuming Stokes’ law applies, show that the efficiency of collection of particles of size
x is given by the expression
x2 gðrp rf ÞL
collection efficiency; Zx ¼
18mHU
where U is the uniform gas velocity through the parallel-sided section of the chamber.
State any other assumptions made.
EXERCISES 47
Gas U Gas Gas

inlet exit exit H
X Collection W
surface
L
Elevation Section X-X
Dimensions:
H=3m
L = 10 m
W=2m
Figure 2E1.1 Schematic diagram of settling chamber
(b) What is the upper limit of particle size for which Stokes’ law applies?
(c) When the volumetric flow rate of gas is 0:9 m3 =s , and the dimensions of the chamber
are those shown in Figure 2E1.1, determine the collection efficiency for spherical
particles of diameter 30 mm [Answer: (b) 57 mm; (c) (86%).]
2.2 A particle of equivalent sphere volume diameter 0.2 mm, density 2500 kg=m3 and
sphericity 0.6 falls freely under gravity in a fluid of density 1:0 kg=m3 and viscosity
2 105 Pa s. Estimate the terminal velocity reached by the particle. (Answer: 0.6 m/s.)
2.3 Spherical particles of density 2500 kg=m3 and in the size range 20–100 mm are fed
continuously into a stream of water (density, 1000 kg=m3 and viscosity, 0.001 Pa s) flowing
upwards in a vertical, large diameter pipe. What maximum water velocity is required to
ensure that no particles of diameter greater than 60 mm are carried upwards with water?
(Answer: 2.9 mm/s.)
2.4 Spherical particles of density 2000 kg=m3 and in the size range 20–100 mm are fed
continuously into a stream of water (density, 1000 kg=m3 and viscosity, 0.001 Pa s) flowing
upwards in a vertical, large diameter pipe. What maximum water velocity is required to
ensure that no particles of diameter greater than 50 mm are carried upwards with the water?
(Answer: 1.4 mm/s.)
2.5 A particle of equivalent volume diameter 0.3 mm, density 2000 kg=m3 and sphericity
0.6 falls freely under gravity in a fluid of density 1:2 kg=m3 and viscosity 2 105 Pa s .
Estimate the terminal velocity reached by the particle.
(Answer: 0.67 m/s.)
2.6 Assuming that a car is equivalent to a flat plate 1.5 m square, moving normal to the
airstream, and with a drag coefficient, CD ¼ 1:1, calculate the power required for steady motion
at 100 km/h on level ground. What is the Reynolds number? For air assume a density of
1:2 kg=m3 and a viscosity of 1:71 105 Pa s. (Cambridge University)
(Answer: 32.9 kW; 2:95 106 .)
2.7 A cricket ball is thrown with a Reynolds number such that the drag coefficient is 0.4
ðRe 105 Þ.
(a) Find the percentage change in velocity of the ball after 100 m horizontal flight in air.
(b) With a higher Reynolds number and a new ball, the drag coefficient falls to 0.1. What
is now the percentage change in velocity over 100 m horizontal flight?
(In both cases take the mass and diameter of the ball as 0.15 kg and 6.7 cm, respectively,
and the density of air as 1:2 kg=m3 .) Readers unfamiliar with the game of cricket may
substitute a baseball. (Cambridge University) [Answer: (a) 43.1%; (b) 13.1%.]
2.8 The resistance F of a sphere of diameter x, due to its motion with velocity u through a fluid
of density r and viscosity m, varies with Reynolds number ðRe ¼ rux=mÞ as given below:
log10Re 2.0 2.5 3.0 3.5 4.0

F
CD ¼ 1 2 ðpx2 =4Þ
1.05 0.63 0.441 0.385 0.39
2 ru
Find the mass of a sphere of 0.013 m diameter which falls with a steady velocity of 0.6 m/s
in a large deep tank of water of density 1000 kg=m3 and viscosity 0.0015 Pa s. (Cambridge
University)
(Answer: 0.0021 kg.)
2.9 A particle of 2 mm in diameter and density of 2500 kg/m3 is settling in a stagnant fluid
in the Stokes’ flow regime.
(a) Calculate the viscosity of the fluid if the fluid density is 1000 kg/m3 and the particle
falls at a terminal velocity of 4 mm/s.
(b) What is the drag force on the particle at these conditions?
(c) What is the particle drag coefficient at these conditions?
(d) What is the particle acceleration at these conditions?
(e) What is the apparent weight of the particle?
2.10 Starting with the force balance on a single particle at terminal velocity, show that:
" #
4 gx rp rf
CD ¼
3 UT2 rf
where the symbols have their usual meaning.

EXERCISES 49
2.11 A spherical particle of density 1500 kg=m3 has a terminal velocity of 1 cm/s in a fluid
of density 800 kg/m3 and viscosity 0.001 Pa s. Estimate the diameter of the particle.
2.12 Estimate the largest diameter of spherical particle of density 2000 kg/m3
which would be expected to obey Stokes’ law in air of density 1:2 kg=m3 and viscosity
18 106 Pa s.
3
Multiple Particle Systems
3.1 SETTLING OF A SUSPENSION OF PARTICLES
When many particles flow in a fluid in close proximity to each other the motion
of each particle is influenced by the presence of the others. The simple analysis
for the fluid particle interaction for a single particle is no longer valid but can be
adapted to model the multiple particle system.
For a suspension of particles in a fluid, Stokes’ law is assumed to apply but an
effective suspension viscosity and effective average suspension density are
used:
effective viscosity; me ¼ m=fðeÞ ð3:1Þ

average suspension density; rave ¼ erf þ ð1 eÞrp ð3:2Þ
where e is the voidage or volume fraction occupied by the fluid. The effective
viscosity of the suspension is seen to be equal to the fluid viscosity, m modified by
a function fðeÞ of the fluid volume fraction.
The drag coefficient for a single particle in the Stokes’ law region was shown in
Chapter 2. to be given by CD ¼ 24=Rep . Substituting the effective viscosity and
average density for the suspension, Stokes’ law becomes
24 24me
CD ¼ ¼ ð3:3Þ
Rep Urel rave x

1
where CD ¼ R0 = rave Urel
2
and Urel is the relative velocity of the particle to the
2
fluid.

52 MULTIPLE PARTICLE SYSTEMS
Under terminal velocity conditions for a particle falling under gravity in a

suspension, the force balance,
drag force ¼ weight upthrust
becomes
2 3
px 1 px
rave Urel
2
CD ¼ ðrp rave Þ g ð3:4Þ
4 2 6
giving
x2 g
Urel ¼ ðrp rave Þ ð3:5Þ
18me
Substituting for average density rave and effective viscosity me of the suspension,
we obtain the following expression for the terminal falling velocity for a particle
in a suspension:
x2 g
UrelT ¼ ðrp rf Þ efðeÞ ð3:6Þ
18m
Comparing this with the expression for the terminal free fall velocity of a single
particle in a fluid [Equation (2.13)], we find that
UrelT ¼ UT efðeÞ ð3:7Þ
UrelT is known as the particle settling velocity in the presence of other particles or
the hindered settling velocity.
In the following analysis, it is assumed that the fluid and the particles are
incompressible and that the volume flowrates, Qf and Qp , of the fluid and the
particles are constant.
We define Ufs and Ups as the superficial velocities of the fluid and particles,
respectively:
Qf
superficial fluid velocity; Ufs ¼ ð3:8Þ
A
Qp
superficial particle velocity; Ups ¼ ð3:9Þ
A
where A is the vessel cross-sectional area.

Under isotropic conditions the flow areas occupied by the fluid and the
particles are:
flow area occupied by the fluid; Af ¼ eA ð3:10Þ

flow area occupied by the particles; Ap ¼ ð1 eÞA ð3:11Þ
BATCH SETTLING 53
And so continuity gives:
for the fluid : Qf ¼ Ups A ¼ Uf Ae ð3:12Þ

for the particles : Qp ¼ Ups A ¼ Up Að1 eÞ ð3:13Þ
hence the actual velocities of the fluid and the particles, Uf and Up are given by:
actual velocity of the fluid; Uf ¼ Ufs =e ð3:14Þ

actual velocity of the particles; Up ¼ Ups =ð1 eÞ ð3:15Þ
3.2 BATCH SETTLING
3.2.1 Settling Flux as a Function of Suspension Concentration
When a batch of solids in suspension are allowed to settle, say in a measuring

cylinder in the laboratory, there is no net flow through the vessel and so
Qp þ Qf ¼ 0 ð3:16Þ
hence
Up ð1 eÞ þ Uf e ¼ 0 ð3:17Þ
and
ð1 eÞ
Uf ¼ Up ð3:18Þ
e
In hindered settling under gravity the relative velocity between the particles and
the fluid ðUp Uf Þ is UrelT . Thus using the expression for UrelT found in Equation
(3.7), we have
Up Uf ¼ UrelT ¼ UT efðeÞ ð3:19Þ
Combining Equation (3.19) with Equation (3.18) gives the following expression
for Up , the hindered settling velocity of particles relative to the vessel wall in
batch settling:
Up ¼ UT e2 fðeÞ ð3:20Þ
The effective viscosity function, fðeÞ, was shown theoretically to be
fðeÞ ¼ e2:5 ð3:21Þ
for uniform spheres forming a suspension of solid volume fraction less than
0:1½ð1 eÞ 0:1.
Richardson and Zaki (1954) showed by experiment that for Rep < 0:3 (under
Stokes’ law conditions where drag is independent of fluid density),
Up ¼ UT e4:65 ½giving fðeÞ ¼ e2:65 ð3:22Þ
and for Rep > 500 (under Newton’s law conditions where drag is independent of
fluid viscosity)
Up ¼ UT e2:4 ½giving fðeÞ ¼ e0:4 ð3:23Þ
In general, the Richardson and Zaki relationship is given as:
Up ¼ UT en ð3:24Þ
Khan and Richardson (1989) recommend the use of the following correlation for
the value of exponent n over the entire range of Reynolds numbers:
x 0:27
4:8 n
¼ 0:043Ar0:57 1 2:4 ð3:25Þ
n 2:4 D
where Ar is the Archimedes number ½x3 rf ðrp rf Þg=m2 and x is the particle
diameter and D is the vessel diameter. The most appropriate particle diameter to
use here is the surface-volume mean.
Expressed as a volumetric solids settling flux, Ups , Equation (3.24) becomes
Ups ¼ Up ð1 eÞ ¼ UT ð1 eÞen ð3:26Þ
or, dimensionless particle settling flux,
Ups
¼ ð1 eÞen ð3:27Þ
UT
Taking first and second derivates of Equation (3.27) demonstrates that a plot of
dimensionless particle settling flux versus suspension volumetric concentration,
1 e has a maximum at e ¼ n=ðn þ 1Þ and an inflection point at
e ¼ ðn 1Þ=ðn þ 1Þ. The theoretical form of such a plot is therefore that shown
in Figure 3.1.
3.2.2 Sharp Interfaces in Sedimentation
Interfaces or discontinuities in concentration occur in the sedimentation or

settling of particle suspensions.
In the remainder of this chapter, for convenience, the symbol C will be used to
represent the particle volume fraction 1 e. Also for convenience the particle
volume fraction will be called the concentration of the suspension.
BATCH SETTLING 55
U ps/UT
Maximum
Inflection
0.177 0.35
Volumetric suspension concentration, 1-ε (or C)
Figure 3.1 Variation of dimensionless settling flux with suspension concentration, based
on Equation (3.27) (for Rep < 0:3, i.e. n ¼ 4:65)
Consider Figure 3.2, which shows the interface between a suspension of

concentration C1 containing particles settling at a velocity Up1 and a suspension
of concentration C2 containing particles settling at a velocity Up2 .
The interface is falling at a velocity Uint . All velocities are measured relative to
the vessel walls. Assuming incompressible fluid and particles, the mass balance
over the interface gives
ðUp1 Uint ÞC1 ¼ ðUp2 Uint ÞC2
hence
Up1 C1 Up2 C2
Uint ¼ ð3:28Þ
C1 C2
or, since Up C is particle volumetric flux, Ups , then:
Ups1 Ups2
Uint ¼ ð3:29Þ
C1 C2
Up1 C1
Uint
C2
Up2
Figure 3.2 Concentration interface in sedimentation

where Ups1 and Ups2 are the particle volumetric fluxes in suspensions of
concentration C1 and C2 , respectively. Thus,
Ups
Uint ¼ ð3:30Þ
C
dUps
and; in the limit as C ! 0; Uint ¼ ð3:31Þ
dC
Hence, on a flux plot (a plot of Ups versus concentration):
(a) The gradient of the curve at concentration C is the velocity of a layer of

suspension of this concentration.
(b) The slope of a chord joining two points at concentrations C1 and C2 is the
velocity of a discontinuity or interface between suspensions of these concen-
trations.
This is illustrated in Figure 3.3.
3.2.3 The Batch Settling Test
The simple batch settling test can supply all the information for the design of a
thickener for separation of particles from a fluid. In this test a suspension of
particles of known concentration is prepared in a measuring cylinder. The
cylinder is shaken to thoroughly mix the suspension and then placed upright
to allow the suspension to settle. The positions of the interfaces which form are
monitored in time. Two types of settling occur depending on the initial concen-
tration of the suspension. The first type of settling is depicted in Figure 3.4 (Type
1 settling). Three zones of constant concentration are formed. These are: zone A,
U ps
Slope = velocity of layer of
concentration C4
Slop = Uint , 12 = velocity of interface
between clear liquid (C1 = 0) and
suspension of concentration O 2.
Slope = U int, 23
U ps2
Slop = Uint , 23 = velocity of interface
between uspension of concentration O 2
and settled bed of concentration O 3.
Slope = U int, 12
U ps1 (=0)
C1 (=0) C4 C2 C3
Suspension concentration, C
Settled bed
Figure 3.3 Determination of interface and layer velocities from a batch flux plot
BATCH SETTLING 57
h h h
A
B A
B
S S
C C C
CA=0 CA=0
CB CB CS
CS
Start of test End of test
Figure 3.4 Type 1 batch settling. Zones A, B and S are zones of constant concentration.
Zone A is a clear liquid; zone B is a suspension of concentration equal to the initial
suspension concentration; zone S is a suspension of settled bed or sediment concentration
clear liquid ðC ¼ 0Þ; zone B, of concentration equal to the initial suspension

concentration ðCB Þ; and zone S, the sediment concentration ðCS Þ. Figure 3.5 is a
typical plot of the height of the interfaces AB, BS and AS with time for this type of
settling. On this plot the slopes of the lines give the velocities of the interfaces. For
example, interface AB descends at constant velocity, interface BS rises at constant
velocity. The test ends when the descending AB meets the rising BS forming an
interface between clear liquid and sediment (AS) which is stationary.
In the second type of settling (Type 2 settling), shown in Figure 3.6, a zone of
variable concentration, zone E, is formed in addition to the zones of constant
concentration (A, B and S). The suspension concentration within zone E varies
with position. However, the minimum and maximum concentrations within this
zone, CEmin and CEmax , are constant. Figure 3.7 is a typical plot of the height of the
interfaces AB, BEmin , Emax S and AS with time for this type of settling.
Height of
interface, h
AB
AS
BS
Time, t
Figure 3.5 Change in positions of interface AB, BS and AS with time in Type 1 batch
settling (e.g. AB is the interface between zone A and zone B; see Figure 3.4)
h h h h
A A
B B A
E
E
S S B
C C C
CA=0 CA=0
CB CA=0
CS
CEmax
CS CS
range of CE
Start of test end of test
Figure 3.6 Type 2 batch settling. Zones A, B and S are zones of constant concentration.
Zone A is clear liquid; zone B is a suspension of concentration equal to the initial
suspension concentration; zone S is a suspension of settled bed concentration. Zone E is
a zone of variable concentration
The occurrence of Type 1 or Type 2 settling depends on the initial concentra-

tion of the suspension, CB. In simple terms, if an interface between zone B and a
suspension of concentration greater than CB but less that CS rises faster than the
interface between zones B and S then a zone of variable concentration will form.
Examination of the particle flux plot enables us to determine which type of
settling is occurring. Referring to Figure 3.8, a tangent to the curve is drawn
through the point (C ¼ CS , Ups ¼ 0). The concentration at the point of tangent is
CB2 . The concentration at the point of intersection of the projected tangent with
the curve is CB1 . Type 1 settling occurs when the initial suspension concentration
is less than CB1 and greater than CB2 . Type 2 settling occurs when the initial
suspension concentration lies between CB1 and CB2 . Strictly, beyond CB2 , Type 1
settling will again occur, but this is of little practical significance.
Height of
interface, h
AB
AS
BEmin
Emax S
Time, t
Figure 3.7 Change in positions of interface AB, BEmin , Emax S and AS with time in Type 2
batch settling (e.g. AB is the interface between zone A and zone B. BEmin is the interface
between zone B and the lowest suspension concentration in the variable zone E; see
Figure 3.6)
BATCH SETTLING 59
Ups
C
CB1 CB2 CS
Type 1 Type 2
Figure 3.8 Determining if settling will be Type 1 or Type 3. A line through CS tangent to
the flux curve gives CB1 and CB2 . Type 2 settling occurs when initial suspension
concentration is between CB1 and CB2
3.2.4 Relationship Between the Height–Time Curve and the Flux Plot
Following the AB interface in the simple batch settling test gives rise to the
height–time curve shown in Figure 3.9 (Type 1 settling). In fact, there will be a
family of such curves for different initial concentrations. The following analysis
permits the derivation of the particle flux plot from the height–time curve.
Referring to Figure 3.9, at time t the interface between clear liquid and
suspension of concentration C is at a height h from the base of the vessel and
velocity of the interface is the slope of the curve at this time:
dh h1 h
velocity of interface ¼ ¼ ð3:32Þ
dt t
Height of
interface with
clear liquid
h1
t
Time
Figure 3.9 Analysis of batch settling test

This is also equal to Up , the velocity of the particles at the interface relative to the
vessel wall. Hence,
h1 h
Up ¼ ð3:33Þ
t
Now consider planes or waves of higher concentration which rise from the
base of the vessel. At time t a plane of concentration C has risen a distance h from
the base. Thus the velocity at which a plane of concentration C rises from the base
is h=t. This plane or wave of concentration passes up through the suspension. The
velocity of the particles relative to the plane is therefore:
h
velocity of particles relative to plane ¼ Up þ ð3:34Þ
t
As the particles pass through the plane they have a concentration, C (refer to
Figure 3.10). Therefore, the volume of particles which have passed through this
plane in time t is
¼ area velocity of particles concentration time

h
¼ A Up þ Ct ð3:35Þ
t
But, at time t this plane is interfacing with the clear liquid, and so at this time all
the particles in the test have passed through the plane.
The total volume of all the particles in the test ¼ CB h0 A ð3:36Þ
where h0 is the initial suspension height.
Figure 3.10 Analysis of batch settling; relative velocities of a plane of concentration C and
the particles in the plane
CONTINUOUS SETTLING 61
Therefore,

h
CB h0 A ¼ A Up þ Ct ð3:37Þ
t
hence, substituting for Up from Equation (3.33), we have
C B h0
C¼ ð3:38Þ
h1
3.3 CONTINUOUS SETTLING
3.3.1 Settling of a Suspension in a Flowing Fluid
We will now look at the effects of imposing a net fluid flow on to the particle
settling process with a view to eventually producing a design procedure for a
thickener. This analysis follows the method suggested by Fryer and Uhlherr (1980).
Firstly, we will consider a settling suspension flowing downwards in a vessel.
A suspension of solids concentration ð1 eF Þ or CF is fed continuously into the
top of a vessel of cross-sectional area A at a volume flow rate Q (Figure 3.11): The
suspension is drawn off from the base of the vessel at the same rate. At a given
axial position, X, in the vessel let the local solids concentration be ð1 eÞ or C and
the volumetric fluxes of the solids and the fluid be Ups and Ufs , respectively. Then
assuming incompressible fluid and solids, continuity gives
Q ¼ ðUps þ Ufs ÞA ð3:39Þ
At position X, the relative velocity between fluid and particles, Urel is given by
Ups Ufs
Urel ¼ ð3:40Þ
1e e
Our analysis of batch settling gave us the following expression for this relative
velocity:
Urel ¼ UT efðeÞ ð3:7Þ
Q
(1-εF)
X 1-ε
Ups Ufs
Figure 3.11 Continuous settling; downflow only

and so, combining Equations (3.39), (3.40) and (3.7) we have
Qð1 eÞ
Ups ¼ þ UT e2 ð1 eÞfðeÞ ð3:41Þ
A
or
total solids flux ¼ flux due to bulk flow þ flux due to settling
We can use this expression to convert our batch flux plot into a continuous total
downward flux plot. Referring to Figure 3.12, we plot a line of slope Q/A through
the origin to represent the bulk flow flux and then add this to the batch flux plot
to give the continuous total downward flux plot. Now, in order to graphically
determine the solids concentration at level X in the vessel we apply the mass
balance between feed and the point X. Reading up from the feed concentration CF
to the bulk flow line gives the value of the volumetric particle flux fed to the
vessel, QCF =A. By continuity this must also be the total flux at level X or any level
in the vessel. Hence, reading across from the flux of QCF =A to the continuous
total flux curve, we may read off the particle concentration in the vessel during
downward flow, which we will call CB . (The subscript B will eventually refer to
the ‘bottom’ section of the continuous thickener.) In downward flow the value of
CB will always be lower than the feed concentration CF, since the solids velocity is
greater in downward flow than in the feed ðconcentration velocity ¼ fluxÞ.
A similar analysis applied to upward flow of a particle suspension in a vessel
gives total downward particle flux,
Qð1 eÞ
Ups ¼ UT e2 fðeÞ ð3:42Þ
A
Ups
Continuous total
downward flux
Bulk flow
Slope Q/A
Ups =
QC F/A
Batch setting
flux
CB C
Feed
concentration, CF
Figure 3.12 Total flux plot for settling in downward flow

Batch setting
Ups flux Total
continuous total
downward flux
CF CT
0
C
Ups =
QCF/A
Bulk flow
slope Q/A
Figure 3.13 Total flux plot for settling in upward flow

or
total solids flux ¼ flux due to settling flux due to bulk flow
Hence, for upward flow, we obtain the continuous total flux plot by subtracting
the straight line representing the flux due to bulk flow from the batch flux curve
(Figure 3.13). Applying the material balance as we did for downward flow, we
are able to graphically determine the particle concentration in the vessel during
upward flow of fluid, CT. (The subscript T refers to the ‘top’ section of the
continuous thickener.) It will be seen from Figure 3.13 that the value of particle
concentration for the upward-flowing suspension, CT, is always greater than the
feed concentration, CF. This is because the particle velocity during upward flow is
always less than that in the feed.
3.3.2 A Real Thickener (with Upflow and Downflow Sections)
Consider now a real thickener shown schematically in Figure 3.14. The feed
suspension of concentration CF is fed into the vessel at some point intermediate
between the top and bottom of the vessel at a volume flow rate, F. An ‘under-
flow’ is drawn off at the base of the vessel at a volume flow rate, L, and
concentration CL. A suspension of concentration CV overflows at a volume
flow rate V at the top of the vessel (this flow is called the ‘overflow’). Let the
mean particle concentrations in the bottom (downflow) and top (upflow)
sections be CB and CT, respectively. The total and particle material balances
over the thickener are:
Total:
F¼VþL ð3:43Þ
Feed
F, CF
CT Overflow
V, CV
CB
Underflow
L, CL
Figure 3.14 A real thickener, combining upflow and downflow (F, L and V are volume
flows; CF , CL and CV are concentrations)
Particle:
FCF ¼ VCV þ LCL ð3:44Þ
These material balances link the total continuous flux plots for the upflow and
downflow sections in the thickener.
3.3.3 Critically Loaded Thickener
Figure 3.15 shows flux plots for a ‘critically loaded’ thickener. The line of slope F/A
represents the relationship between feed concentration and feed flux for a
volumetric feed rate, F. The material balance equations [Equations (3.43) and
(3.44)] determine that this line intersects the curve for the total flux in the down-
flow section when the total flux in the upflow section is zero. Under critical loading
conditions the feed concentration is just equal to the critical value giving rise to a
feed flux equal to the total continuous flux that the downflow section can deliver at
that concentration. Thus the combined effect of bulk flow and settling in the
downflow section provides a flux equal to that of the feed. Under these conditions,
since all particles fed to the thickener can be dealt with by the downflow section,
the upflow flux is zero. The material balance then dictates that the concentration in
the downflow section, CB, is equal to CF and the underflow concentration, CL is
FCF =L. The material balance may be performed graphically and is shown in
Figure 3.15. From the feed flux line, the feed flux at a feed concentration, CF is
Ups ¼ FCF =A. At this flux the concentration in the downflow section is CB ¼ CF .
The downflow flux is exactly equal to the feed flux and so the flux in the upflow
section is zero. In the underflow, where there is no sedimentation, the underflow
flux, LCL =A, is equal to the downflow flux. At this flux the underflow concentra-
tion, CL is determined from the underflow line.
Figure 3.15 indicates that under critical conditions there are two possible solutions
for the concentration in the upflow section, CT . One solution, the obvious one, is
CT ¼ 0; the other is CT ¼ CB . In this second situation a fluidized bed of particles at
concentration CB with a distinct surface is observed in the upflow section.
Below feed
Ups
Downward Feed flux
flux below line,
feed slope F/A
Ups =
FCF/A=
LCL/A
slope L/A
Batch
flux
C
CF = CB CL
Downward
Ups flux above
feed
Above feed
Ups =
VCV/A=0 C
CT
CT
Overflow flux
line,
slope-V/A
Figure 3.15 Total flux plot for a thickener at critical loading
3.3.4 Underloaded Thickener
When the feed concentration CF is less than the critical concentration the
thickener is said to be underloaded. This situation is depicted in Figure 3.16.
Here the feed flux, FCF =A, is less than the maximum flux due to bulk flow and
settling which can be provided by the downflow section. The flux in the upflow
section is again zero ðCT ¼ CV ¼ 0; VCV =A ¼ 0Þ. The graphical mass balance
shown in Figure 3.16 enables CB and CL to be determined (feed
flux ¼ downflow section flux ¼ underflow flux).
3.3.5 Overloaded Thickener
When the feed concentration CF is greater than the critical concentration, the
thickener is said to be overloaded. This situation is depicted in Figure 3.17. Here
Below feed
Ups
Downward Feed flux
flux below link line,
feed slope F/A
Ups = Underflow
FCF/A = flux,slope L/A
LCL/A
Batch
flux
CB CF CL C
Downward
Ups flux above
feed Above feed
Ups =
VCv/A=0 C
CT
Overflow flux
line,
slope-V/A
Figure 3.16 Total flux plot for an underloaded thickener
the feed flux, FCF =A, is greater than the maximum flux due to bulk flow and
settling provided by the downflow section. The excess flux must pass through the
upflow section and out through the overflow. The graphical material balance is
depicted in Figure 3.17. At the feed concentration CF, the difference between the
feed flux and the total flux in the downflow section gives the excess flux which
must pass through the upflow section. This flux applied to the upflow section
graph gives the value of the concentration in the upflow section, CT , and the
overflow concentration, CV (upflow section flux ¼ overflow flux).
3.3.6 Alternative Form of Total Flux Plot
A common form of continuous flux plot is that exhibiting a minimum total flux
shown under critical conditions in Figure 3.18. With this alternative flux plot the
critical loading condition occurs when the feed concentration gives rise to a flux
excess flux Below feed

Ups Downward
flux below (to section
above feed) Feed flux
feed line,
Ups = slope F/A
FCF/A
LCL/A
slope L/A
Batch
flux C
CF = CB CL
Ups Downward
flux above
feed
CV CT
0
Ups = C
-VCV/A
Overflow flux
line, Above feed
slope -V/A
Figure 3.17 Total flux plot for an overloaded thickener
equal to this minimum in the total flux curve. The downflow section cannot
operate in a stable manner above this flux. Under critical conditions the upflow
flux is again zero and the graphical material balance depicted in Figure 3.18 gives
the values of CB and CL. It will be noted that under these conditions there are two
possible values of CB; these may coexist in the downflow section with a
discontinuity between them at any position between the feed level and the
underflow.
Figure 3.19 shows this alternative flux plot in an overloaded situation. For the
graphical solution in this case, the excess flux must be read from the flux axis of
the downflow section plot and applied to the upflow section plot in order to
determine the value of CT and CV. Note that in this case although there are
theoretically two possible values of CB, in practice only the higher value can
stably coexist with the higher concentration region, CT, above it.
Ups Downward Below feed

flux below
feed Feed flux line,
slope F/A
Ups =
FCF/A=
LCL/A
=Upsmax
Underflow flux line,

slope L/A
Batch flux
C
CB CF CB=Cmax CL
Ups Downward
flux above
feed Above feed
0
C
Overflow flux
line,
slope-V/A
Figure 3.18 Alternative total flux plot shape; thickener at critical loading
3.4 WORKED EXAMPLES
WORKED EXAMPLE 3.1
A height–time curve for the sedimentation of a suspension, of initial suspension

concentration 0.1, in vertical cylindrical vessel is shown in Figure 3W1.1. Determine:
(a) the velocity of the interface between clear liquid and suspension of concentration 0.1;
(b) the velocity of the interface between clear liquid and a suspension of concentration
0.175;
WORKED EXAMPLES 69
excess flux
(to section
Ups Downward Below feed
above feed)
flux below
feed Feed flux line,
slope F/A
Ups =
FCF/A
LCL/A
(=Upsmax)
Underflow flux line,

slope L/A
Batch flux
CB CF CB=Cmax CL
Ups Downward
flux above
feed
CV CT
0
C
Ups =
-VCv/A Above feed
Overflow flux
line,
slope-V/A
Figure 3.19 Alternative total flux plot shape; overloaded thickener
(c) the velocity at which a layer of concentration 0.175 propagates upwards from the
base of the vessel;
(d) the final sediment concentration.
Solution
(a) Since the initial suspension concentration is 0.1, the velocity required in this question
is the velocity of the AB interface. This is given by the slope of the straight portion of
the height–time curve.
20 40
Slope ¼ ¼ 1:333 cm=s
15 0
Figure 3W1.1 Batch settling test; height–time curve

(b) We must first find the point on the curve corresponding to the point at which a
suspension of concentration 0.175 interfaces with the clear suspension. From
Equation (3.38), with C ¼ 0:175, CB ¼ 0:1 and h0 ¼ 40 cm, we find:
0:1 40
h1 ¼ ¼ 22:85 cm
0:175
A line drawn through the point t ¼ 0, h ¼ h1 tangent to the curve locates the point on the
curve corresponding to the time at which a suspension of concentration 0.175 interfaces
with the clear suspension (Figure 3W1.2). The coordinates of this point are t ¼ 26 s,
h ¼ 15 cm. The velocity of this interface is the slope of the curve at this point:
15 22:85
slope of curve at 26 s; 15 cm ¼ ¼ 0:302 cm=s
26 0
downward velocity of interface¼ 0:30 cm=s
(c) From the consideration above, after 26 s the layer of concentration 0.175 has just
reached the clear liquid interface and has travelled a distance of 15 cm from the base
of the vessel in this time.
h 15
Therefore, upward propagation velocity of this layer ¼ ¼ ¼ 0:577 cm=s
t 16
(d) To find the concentration of the final sediment we again use Equation (3.38). The value
of h1 corresponding to the final sediment ðh1s Þ is found by drawing a tangent to the
part of the curve corresponding to the final sediment and projecting it to the h axis.
In this case h1S ¼ 10 cm and so from Equation (3.38),

C0 h0 0:1 4:0
final sediment concentration; C ¼ ¼ ¼ 0:4
h1S 10
WORKED EXAMPLES 71
Height of interface of suspension with clear liquid (cm) 40
30 Slope = –1.333 cm/s
Slope = –0.302 cm/s
20
h1 = 22.85 cm
h = 15 cm
10
h1S = 10 cm
Tangent to curve
at sediment
t = 26 s concentration
0
0 25 50 75 100 125
Time from start of test (s)
Figure 3W1.2 Batch settling test
WORKED EXAMPLE 3.2
A suspension in water of uniformly sized sphere (diameter 150 mm, density 1140 kg/m3
has a solids concentration of 25% by volume. The suspension settles to a bed of solids
concentration of 55% by volume. Calculate:
(a) the rate at which the water/suspension interface settles;
(b) the rate at which the sediment/suspension interface rises (assume water properties:
density, 1000 kg=m3 ; viscosity, 0.001 Pa s).
Solution
(a) Solids concentration of initial suspension, CB ¼ 0:25
Equation (3.28) allows us to calculate the velocity of interfaces between suspensions of

different concentrations.
The velocity of the interface between initial suspension (B) and clear liquid (A) is
therefore:
UpA CA UpB CB
Uint;AB ¼
CA CB
Since CA ¼ 0, the equation reduces to
Uint;AB ¼ UpB
UpB is the hindered settling velocity of particles relative to the vessel wall in batch
settling and is given by Equation (3.24):
Up ¼ UT en
Assuming Stokes’ law applies, then n ¼ 4:65 and the single particle terminal velocity is
given by Equation (2.13) (see Chapter 2):
x2 ðrp rf Þg
UT ¼
18m
9:81 ð150 106 Þ2 ð1140 1000Þ
UT ¼
18 0:001
¼ 1:717 103 m=s
To check that the assumption of Stokes’ law is valid, we calculate the single particle
Reynolds number:
ð150 106 Þ 1:717 103 1000

Rep ¼
0:001
¼ 0:258, which is less than the limiting value for Stokes’ law (0.3) and so the assumption
is valid.
The voidage of the initial suspension, eB ¼ 1 CB ¼ 0:75
hence; UpB ¼ 1:717 103 0:754:65

¼ 0:45 103 m=s
Hence, the velocity of the interface between the initial suspension and the clear liquid is
0:45 mm=s. The fact that the velocity is positive indicates that the interface is moving
downwards.
(b) Here again we apply Equation (3.28) to calculate the velocity of interfaces between
suspensions of different concentrations.
The velocity of the interface between initial suspension (B) and sediment (S) is
therefore
UpB CB UpS CS
Uint; BS ¼
CB CS
With CB ¼ 0:25 and CS ¼ 0:55 and since the velocity of the sediment, UpS is zero, we
have:
UpB 0:25 0
Uint;BS ¼ ¼ 0:833UpB
0:25 0:55
And from part (a), we know that UpB ¼ 0:45mm/s, and so Uint;BS ¼ 0:375 mm=s.
The negative sign signifies that the interface is moving upwards. So, the interface between
initial suspension and sediment is moving upwards at a velocity of 0.375 mm/s.
WORKED EXAMPLES 73
0.02
Solids flux, Ups(mm/s)
0.01
0
0.1 0.2 0.3 0.4
Volume fraction of solids, C
Figure 3W3.1 Batch flux plot
WORKED EXAMPLE 3.3
For the batch flux plot shown in Figure 3W3.1, the sediment has a solids concentration of
0.4 volume fraction of solids.
(a) Determine the range of initial suspension concentrations over which a zone of
variable concentration is formed under batch settling conditions.
(b) Calculate and plot the concentration profile after 50 min in a batch settling test of a
suspension with an initial concentration 0.1 volume fraction of solids, and initial
suspension height of 100 cm.
(c) At what time will the settling test be complete?
Solution
(a) Determine the range of initial suspension concentrations by drawing a line through
the point C ¼ CS ¼ 0:4, Ups ¼ 0 tangent to the batch flux curve. This is shown as line XCS
in Figure 3W3.2. The range of initial suspension concentrations for which a zone of
variable concentration is formed in batch settling (Type 2 settling) is defined by CBmin
and CBmax . CBmin is the value of C at which the line XCS intersects the settling curve and
CBmax is the value of C at the tangent. From Figure 3W3.2, we see that CBmin ¼ 0:036 and
CBmax ¼ 0:21.
(b) To calculate the concentration profile we must first determine the velocities of the
interfaces between the zones A, B, E and S and hence find their positions after 50 min.
The line AB in Figure 3W3.2 joins the point representing A the clear liquid (0, 0) and the
point B representing the initial suspension (0.1, Ups ). The slope of line AB is equal to the
0.02
Slope = velocity B
of AB interface
Slope = velocity of interface
of B with Emin
Solids flux, Ups (mm/s)
0.01
Slope = velocity of
interface of Emax with S
0
0 0.1 0.2 0.3 0.4
A
CB CB CE CE CB CS
min min max max
Volume fraction of solids, C
Figure 3W3.2 Graphical solution to batch settling problem in Worked Example 3.3
velocity of the interface between zones A and B. From Figure 3W3.2,

Uint; AB ¼ þ0:166 mm=s or þ1:00 cm=min.
The slope of the line from point B tangent to the curve is equal to the velocity of the
interface between the initial suspension B and the minimum value of the variable
concentration zone CEmin .
From Figure 3W3.2,
Uint; BEmin ¼ 0:111 mm=s or 0:66 cm=min
The slope of the line tangent to the curve and passing through the point representing the
sediment (point C ¼ CS ¼ 0:4, Ups ¼ 0) is equal to the velocity of the interface between
the maximum value of the variable concentration zone CEmax and the sediment.
From Figure 3W3.2,
Uint; Emax S ¼ 0:0355 mm=s or 0:213 cm=min
Therefore, after 50 min the distances travelled by the interfaces will be:
AB interface 50:0 cmð1:00 50Þdownwards

BEmin interface 33:2 cm upwards
Emax S interface 10:6 cm upwards
Therefore, the positions of the interfaces (distance from the base of the test vessel) after
50 min will be
AB interface 50:0 cm
BEmin interface 33:2 cm
Emax S interface 10:6 cm
WORKED EXAMPLES 75
Figure 3W3.3 Sketch of concentration profile in batch settling test vessel after 50 min
From Figure 3W3.2 we determine the minimum and maximum values of suspension
concentration in the variable zone
CEmin ¼ 0:16
CEmax ¼ 0:21
Using this information we can plot the concentration profile in the test vessel 50 min
after the start of the test. A sketch of the profile is shown in Figure 3W3.3. The shape of
the concentration profile within the variable concentration zone may be determined by
the following method. Recalling that the slope of the batch flux plot (Figure 3W3.1) at a
value of suspension concentration C is the velocity of a layer of suspension of that
concentration, we find the slope at two or more values of concentration and then
determine the positions of these layers after 50 min:
. Slope of batch flux plot at C ¼ 0:18 is 0:44 cm= min upwards.
Hence, position of a layer of concentration 0.18 after 50 min is 22.0 cm from the base.
. Slope of batch flux plot at C ¼ 0:20 , is 0:27 cm= min upwards.
Hence, position of a layer of concentration 0.20 after 50 min is 13.3 cm from the base.
These two points are plotted on the concentration profile in order to determine the shape
of the profile within the zone of variable concentration.
Figure 3W3.4 is a sketched plot of the height–time curve for this test constructed from
the information above. The shape of the curved portion of the curve can again be
Figure 3W3.4 Sketch of height–time curve for the batch settling test in Worked Example 3.3
determined by plotting the positions of two or more layers of suspension of different

concentration. The initial suspension concentration zone (B) ends when the AB line
intersects the BEmin line, both of which are plotted from a knowledge of their slopes.
The time for the end of the test is found in the following way. The end of the test is when
the position of the Emax S interface coincides with the height of the final sediment. The
height of the final sediment may be found using Equation (3.38) [see part (d) of Worked
Example 3.1]:
CS hS ¼ CB h0
where hS is the height of the final sediment and h0 is the initial height of the suspension
(at the start of the test). With CS ¼ 0:4, CB ¼ 0:1 and h0 ¼ 100 cm, we find that
hS ¼ 25 cm. Plotting hS on Figure 3W3.4, we find that the Emax S line intersects the final
sediment line at about 120 min and so the test ends at this time.
WORKED EXAMPLE 3.4
Using the flux plot shown in Figure 3W4.1:
(a) Graphically determine the limiting feed concentration for a thickener of area
100 m2 handling a feed rate of 0:019 m3 =s and an underflow rate of 0:01 m3 =s.
Under these conditions what will be the underflow concentration and the overflow
concentration?
WORKED EXAMPLES 77
Ups(mm/s)
0.03
0.02
0.01
Batch
flux C
0
0 0.1 0.2 0.3
Figure 3W4.1 Batch flux plot
(b) Under the same flow conditions as above, the feed concentration is increased to 0.2.
Estimate the solids concentration in the overflow, in the underflow, in the upflow
section and in the downflow section of the thickener.
Solution
(a) Feed rate, F ¼ 0:019 m3 =s
Underflow rate, L ¼ 0:01 m3 =s
Material balance gives, overflow rate, V ¼ F L ¼ 0:009 m3 =s
Expressing these flows as fluxes based on the thickener area ðA ¼ 100 m2 Þ:
F
¼ 0:19 mm=s
A
L
¼ 0:10 mm=s
A
V
¼ 0:09 mm=s
A
The relationships between bulk flux and suspension concentration are then:

F
Feed flux ¼ CF
A

L
Flux in underflow ¼ CL
A

V
Flux in overflow ¼ CV
A
Lines of slope F/A, L/A and V/A drawn on the flux plot represent the fluxes in the
feed, underflow and overflow, respectively (Figure 3W4.2). The total flux plot for the
section below the feed point is found by adding the batch flux plot to the underflow flux
line. The total flux plot for the section above the feed point is found by adding the batch
Figure 3W4.2 Total flux plot: solution to part (a) of Worked Example 3.4
flux plot to the overflow flux line (which is negative since it is an upward flux). These
plots are shown in Figure 3W4.2.
The critical feed concentration is found where the feed flux line intersects the plot of
total flux in the section below the feed (Figure 3.W4.2). This gives a critical feed flux of
0:0335 mm=s. The downflow section below the feed point is unable to take a flux greater
than this. The corresponding feed concentration is CFcrit ¼ 0:174.
The concentration in the downflow section, CB is also 0.174.
The corresponding concentration in the underflow is found where the critical flux line
intersects the underflow flux line. This gives CL ¼ 0:33.
(b) Referring now to Figure 3W4.3, if the feed flux is increased to 0.2, we see that the
corresponding feed flux is 0:038 mm=s. At this feed concentration the downflow section
TEST YOURSELF 79
Figure 3W4.3 Solution to part (b) of Worked Example 3.4
is only able to take a flux of 0:034 mm=s and gives an underflow concentration,
CL ¼ 0:34. The excess flux of 0:004 mm=s passes into the upflow section. This flux in
the upflow section gives a concentration, CT ¼ 0:2 and a corresponding concentration,
CV ¼ 0:044 in the overflow.
TEST YOURSELF
3.1 The particle settling velocity in a fluid–particle suspension:

(a) increases with increasing ratio of particle diameter to characteristic system dimension;
(b) increases with increasing particle concentration;

(c) increases with increasing fluid viscosity;
3.2 The terminal velocity of a particle settling in a stagnant fluid:
(a) increases with increasing ratio of particle diameter to characteristic system dimension;
(b) increases with increasing solids concentration;
3.3 In an overloaded thickener, the concentration in the bottom section of the thickener is
equal to (when the total flux plot does not go through a minimum):
(a) the feed concentration;
(b) the overflow concentration;
3.4 In an underloaded thickener, the concentration in the bottom section of the thickener
is (when the total flux plot does not go through a minimum):
(a) greater than the feed concentration;
(b) less than the feed concentration;
(c) equal to the feed concentration.
3.5 In an underloaded thickener, the concentration in the overflow is (when the total flux
plot does not go through a minimum):
(a) greater than the feed concentration;
(b) less than the feed concentration;
(c) equal to the feed concentration.
3.6 In an underloaded thickener, the concentration in the underflow is (when the total
flux plot does not go through a minimum):
(a) greater than the concentration in the bottom section;
(b) less than the concentration in the bottom section;
(c) equal to the concentration in the bottom section.

EXERCISES 81
3.7 When a particle reaches terminal velocity:
(a) the particle acceleration is constant;
(b) the particle acceleration is zero;
(c) the particle acceleration equals the apparent weight of the particle;
3.8 Which of the following do not influence hindered settling velocity?
(a) particle density;
(b) particle size;
(c) particle suspension concentration;
EXERCISES
3.1 A suspension in water of uniformly sized spheres of diameter 100 mm and density
1200 kg=m3 has a solids volume fraction of 0.2. The suspension settles to a bed of
solids volume fraction 0.5. (For water, density is 1000 kg=m3 and viscosity is
0.001 Pa s.)
The single particle terminal velocity of the spheres in water may be taken as 1:1 mm=s.
Calculate:
(a) the velocity at which the clear water/suspension interface settles;
(b) the velocity at which the sediment/suspension interface rises.
[Answer: (a) 0:39 mm=s; (b) 0:26 mm=s.]
3.2 A height–time curve for the sedimentation of a suspension in a vertical cylindrical

vessel is shown in Figure 3E2.1. The initial solids concentration of the suspension is
150 kg=m3 .
Determine:
(a) the velocity of the interface between clear liquid and suspension of concentration
150 kg=m3 ;
(b) the time from the start of the test at which the suspension of concentration
240 kg=m3 is in contact with the clear liquid;
(c) the velocity of the interface between the clear liquid and suspension of concentra-
tion 240 kg=m3 ;
75
Height of suspension/clear liquid interface (cm)
50
25
0
0 25 50 75 100 125
Time (s)
Figure 3E2.1 Batch settling test results. Height–time curve for use in Exercises 3.2 and 3.4
(d) the velocity at which a layer of concentration 240 kg=m3 propagates upwards from
the base of the vessel;
(e) the concentration of the final sediment.
[Answer: (a) 2:91 cm=s; (b) 22 s; (c) 0:77 cm=s downwards; (d) 1:50 cm=s upwards; (e)
600 kg=m3 .]

1100 kg=m3 has a solids volume fraction of 0.2. The suspension settles to a bed of solids
volume fraction 0.5. (For water, density is 1000 kg=m3 and viscosity is 0:001 Pa s.)
The single particle terminal velocity of the spheres in water may be taken as 0:44 mm=s.
Calculate:
(a) the velocity at which the clear water=suspension interface settles;
(b) the velocity at which the sediment=suspension interface rises.
[Answer: (a) 0:156 mm=s; (b) 0:104 mm=s.]

200 kg=m3 .
EXERCISES 83
Determine:
200 kg=m3 ;
tion 400 kg=m3 ;
[Answers: (a) 2.9 cm/s downwards; (b) 32.5 s; (c) 0.40 cm/s downwards; (d) 0.846 cm/s
upwards; (e) 800 kg/m3.]
3.5
(a) Spherical particles of uniform diameter 40 mm and particle density 2000 kg=m3 form
a suspension of solids volume fraction 0.32 in a liquid of density 880 kg=m3 and
viscosity 0:0008 Pa s. Assuming Stokes’ law applies, calculate (i) the sedimentation
velocity and (ii) the sedimentation volumetric flux for this suspension.
(b) A height–time curve for the sedimentation of a suspension in a cylindrical vessel is

shown in Figure 3E5.1. The initial concentration of the suspension for this test is
0:12 m3 =m3 .
50
Height of suspension/clear liquid interface (cm)
25
0
0 25 50 75
Time (s)
Figure 3E5.1 Batch settling test results. Height–time curve for use in Exercise 3.5
Calculate:
(i) the velocity of the interface between clear liquid and a suspension of concentration,
0:12 m3 =m3 ;
(ii) the velocity of the interface between clear liquid and a suspension of concentration
0:2 m3 =m3 ;
(iii) the velocity at which a layer of concentration, 0:2 m3 =m3 propagates upwards from
(iv) the concentration of the final sediment;
(v) the velocity at which the sediment propagates upwards from the base.
[Answer: (a)(i) 0:203 mm=s, (ii) 0:065 mm=s, (b)(i) 1:11 cm=s downwards, (ii) 0:345 cm=s
downwards, (iii) 0:514 cm=s upwards, (iv) 0.4, (v) 0:30 cm=s upwards.]

100 kg=m3 .
Determine:
100 kg=m3 ;
Height of interface between suspension and clear liquid (cm)
75
50
25
0
0 100 200 300 400 500
Time (s)
Figure 3E6.1 Batch settling test results. Height–time curve for use in Exercises 3.6 and 3.8
EXERCISES 85
tion 200 kg=m3 ;
[Answer: (a) 0:667 cm=s downwards; (b) 140 s; (c) 0:0976 cm=s downwards; (d) 0:189 cm=s
upwards; (e) 400 kg=m3 .]

1300 kg=m3 has a solids volume fraction of 0.10. The suspension settles to a bed of solids
volume fraction 0.4. (For water, density is 1000 kg=m3 and viscosity is 0:001 Pa s.)
The single particle terminal velocity of the spheres under these conditions is 1:0 mm=s.
Calculate:
(a) the velocity at which the clear water=suspension interface settles;
(b) the velocity at which the sediment/suspension interface rises.
[Answer: (a) 0:613 mm=s; (b) 0:204 mm=s.]

125 kg=m3 .
Determine:
125 kg=m3 ;
tion 200 kg=m3 ;
[Answer: (a) 0:667 cm=s downwards; (b) 80 s; (c) 0:192 cm=s downwards; (d) 0:438 cm=s
upwards; (e) 500 kg=m3 .]
0.03
0.02
Ups (mm/s)
0.01
0
0 0.1 0.2 0.3 0.4 0.5
C (volume fraction)
Figure 3E9.1 Batch flux plot for use in Exercise 3.9
3.9 Use the batch flux plot in Figure 3E9.1 to answer the following questions. (Note that
the sediment concentration is 0.44 volume fraction.)
(a) Determine the range of initial suspension concentration over which a variable
concentration zone is formed under batch settling conditions.
(b) For a batch settling test using a suspension with an initial concentration 0.18 volume
fraction and initial height 50 cm, determine the settling velocity of the interface
between clear liquid and suspension of concentration 0.18 volume fraction.
(c) Determine the position of this interface 20 min after the start of this test.
(d) Produce a sketch showing the concentration zones in the settling test 20 min after
the start of this test.
[Answer: (a) 0.135 to 0.318; (b) 0:80 cm= min; (c) 34 cm from base; (d) BE interface is 12.5 cm
from base.]
3.10 Consider the batch flux plot shown in (Figure 3W3.1). Given that the final sediment
concentration is 0.36 volume fraction:
(a) determine the range of initial suspension concentration over which a variable
concentration zone is formed under batch settling conditions;
(b) calculate and sketch the concentration profile after 40 min of the batch settling test
with an initial suspension concentration of 0.08 and an initial height of 100 cm;
(c) estimate the height of the final sediment and the time at which the test is complete.
[Answers: (a) 0.045 to 0.20; (c) 22.2 cm; 83 min.]

EXERCISES 87
Continuous flux plot

solids flux, (downflow section)
Ups (mm/s)
0.04
0.03
0.02
Batch flux plot

0.01
0.0
0.0 0.1 0.2 0.3
solids volume fraction, C
solids flux,
Ups (mm/s)
0.02
0.01
solids volume fraction, C

0.0
0.0 0.1 0.2 0.3
Continuous flux plot

(upflow section)
Figure 3E11.1 Total flux plot for use in Exercise 3.11
3.11 The batch and continuous flux plots supplied in Figure 3E11.1 are for a thickener of
area 200 m2 handling a feed rate of 0:04 m3 =s and an underflow rate of 0:025 m3 =s.
(a) Using these plots, graphically determine the critical or limiting feed concentration
for this thickener.
(b) Given that if the feed concentration is 0:18 m3 =m3 , determine the solids concentra-
tions in the overflow, underflow, in the regions above and below the feed well.
(c) Under the same flow rate conditions in the same thickener, the feed concentration
increases to 0.24. Estimate the new solids concentration in the overflow and the
underflow once steady state has been reached.
[Answer: (a) 0.21; (b) CV ¼ 0, CT ¼ 0, CL ¼ 0:29, CB ¼ 0:087; (c) CV ¼ 0:08, CL ¼ 0:34.]

Table 3E12.1 Batch flux test data

C 0.01 0.02 0.04 0.06 0.08 0.10 0.12 0.14 0.16 0.18 0.20
Flux, mm/sð103 Þ 5.0 9.1 13.6 15.7 16.4 16.4 15.7 13.3 10.0 8.3 7.3
C 0.22 0.24 0.26 0.28 0.30 0.32 0.34 0.36 0.38 0.40
Flux, mm/sð103 Þ 7.7 5.6 5.1 4.5 4.2 3.8 3.5 3.3 3.0 2.9
3.12
(a) Using the batch flux plot data given in Table 3E12.1, graphically determine the
limiting feed concentration for a thickener of area 300 m3 handling a feed rate of
0:03 m3 =s and with an underflow rate of 0:015 m3 =s. Determine the underflow
concentration and overflow concentration under these conditions. Sketch a possible
concentration profile in the thickener clearly indicating the positions of the overflow
launder, the feed well and the point of underflow withdrawal (neglect the conical base
of the thickener).
(b) Under the same flow conditions as above, the concentration in the feed increases to
110% of the limiting value. Estimate the solids concentration in the overflow, in the
underflow, in the section of the thickener above the feed well and in the section
below the feed well.
[Answer: (a) CFcrit ¼ 0:17; CB ¼ 0:05, CB ¼ 0:19 (two possible values); CL ¼ 0:34; (b)
CV ¼ 0:034; CL ¼ 0:34; CT ¼ 0:19; CB ¼ 0:19.]
3.13 Uniformly sized spheres of diameter 50 mm and density 1500 kg/m3 are uniformly
suspended in a liquid of density 1000 kg/m3 and viscosity 0.002 Pa s. The resulting
suspension has a solids volume fraction of 0.30.
The single particle terminal velocity of the spheres in this liquid may be taken as 0.00034 m/s
(Rep < 0:3). Calculate the velocity at which the clear water/suspension interface settles.
3.14 Calculate the settling velocity of glass spheres having a diameter of 155 mm in
water at 293K. The slurry contains 60 wt % solids. The density of the glass spheres is
2467 kg/m3.
How does the settling velocity change if the particles have a sphericity of 0.3 and an
equivalent diameter of 155 mm?
3.15 Develop an expression to determine the time it takes for a particle settling in a liquid
to reach 99% of its terminal velocity.
3.16 A suspension in water of uniformly sized spheres (diameter 150 mm and density
1140 kg/m3) has a solids concentration of 25% by volume. The suspension settles to a bed
of solids concentration 62% by volume. Calculate the rate at which the spheres settle in the
suspension. Calculate the rate at which the settled bed height rises.
EXERCISES 89
Height
100
(cm)
50
10 20 30 40
Time
(s)
Figure 3E18.1 Plot of height of clear liquid interface versus time during settling test for
use in Exercise 3.18
3.17 If 20 mm particles with a density of 2000 kg/m3 are suspended in a liquid with a
density of 900 kg/m3 at a concentration of 50 kg/m3, what is the solids volume fraction of
the suspension? What is the bulk density of the suspension?
3.18 Given Figure 3E18.1 for the height–time curve for the sedimentation of a
suspension in a vertical cylindrical vessel with an initial uniform solids concentration
of 100 kg/m3:
(a) What is the velocity at which the sediment/suspension interface rises?
(b) What is the velocity of the interface between the clear liquid and suspension of
concentration 133 kg/m3?
(c) What is the velocity at which a layer of concentration 133 kg/m3 propagates
upwards from the base of the vessel?
(d) At what time does the sediment/suspension interface start rising?
(e) At what time is the concentration of the suspension in contact with the clear liquid
no longer 100 kg/m3?
3.19 Given Figure 3E19.1 for the fluxes below the feed in a thickener of area 300 m2 and a
feed solids volume concentration of 0.1:
(a) What is the concentration of solids in the top section of the thickener?
(b) What is the concentration of solids in the bottom section of the thickener?
Downward flux
below feed
U PS Feed flux
mm/s
0.03
0.02
Underflow flux
0.01
0.1 0.2 0.3 0.4 C
Figure 3E19.1 Total flux plot for use in Exercise 3.19
(c) What is the concentration of solids exiting the thickener?
(d) What is the flux due to bulk flow below the feed?
(e) What is the flux due to settling below the feed?

4
Slurry Transport
Jennifer Sinclair Curtis
4.1 INTRODUCTION
A slurry is a mixture of a liquid and solid particles. The term ‘sludge’ typically
refers to a highly concentrated slurry containing fine particulate material. Each
year, vast tonnages of slurries are pumped. Slurries are often used to transport
coal, phosphates and minerals. Dredging of sand and silt in the maintenance of
waterways is another example of solids handled in slurry form. In most slurries,
the liquid phase is water. However, coal–oil and coal–methanol fuels are
examples of slurries made up with liquids other than water.
The mixture density of a slurry, rm , in terms of the volume fraction of solids Cv
is given by:
rm ¼ Cv rs þ ð1 Cv Þrf ð4:1Þ
where rf is the density of the liquid and rs is the density of the solid particles. In
terms of the weight or mass fraction of solids Cw , the mixture density is
equivalently expressed as:
1 Cw 1 Cw
¼ þ ð4:2Þ
rm rs rf
4.2 FLOW CONDITION
In general, the flow behaviour of slurries or slurry transport can be classified into
the following flow conditions:

92 SLURRY TRANSPORT
(a) Homogeneous flow. In homogeneous flow, the particles are uniformly

distributed over the pipeline cross-section. The particles settle very slowly
and remain in suspension. The solids markedly influence the flow properties
of the carrying liquid. Homogeneous flow is encountered in slurries of high
concentration and finer particle sizes (typically less than 75 mm). For a given
fine particle size, a liquid-particle mixture with higher solids concentration is
more likely to result in a homogeneous suspension. This is due to the
hindered settling effect (Chapter 3). Homogeneous slurries are also referred
to as ‘non-settling slurries’. Typical slurries that show minimal tendency to
settle are sewage sludge, drilling muds, detergent slurries, fine coal slurries,
paper pulp suspensions, and concentrated suspensions of fine limestone
which are fed to cement kilns.
(b) Heterogeneous flow. In heterogeneous flow, there is a pronounced concen-

tration gradient across the pipeline cross-section. Heterogeneous slurries
range from fine particles fully suspended, but with significant concentration
gradients, to rapidly settling large particles. Slurries in heterogeneous flow
show a marked tendency to settle. In addition, the presence of the solid
particles has a minimal effect on the flow properties of the carrying liquid.
Examples include slurries consisting of coarse coal, potash or rocks.
(c) Saltation regime. In this regime of flow, particles begin to slide, roll and/or
jump along the pipe bottom. This saltating layer of particles may accumulate
and a moving bed of particles then develops along the pipe bottom. A liquid
flow layer, separate from the solid particles, exists above the moving bed of
particles.
The pressure drop required to pump slurries in pipelines is of prime concern to

engineers. The pressure gradient required to pump a slurry of a given concen-
tration for varying operating conditions is usually expressed in the form of
graph. Such a graph is often referred to as the hydraulic characteristic of the
slurry and displays a log–log plot of pressure drop versus superficial velocity,
defined as volumetric flowrate divided by the cross-sectional area of the pipe.
The hydraulic characteristic is similar to the Zenz diagram used to display the
flow behaviour of gas–solid flows (Chapter 8). The hydraulic characteristic,
shown in Figure 4.1, illustrates the modes of flow occurring in settling and
non-settling slurries.
For settling slurries, at relatively high velocities the particles are carried in
suspension and the flow behaviour approximates that of a homogeneous suspen-
sion. As long as the velocity is maintained above the ‘standard velocity’, the
particle concentration gradient is minimized. As the superficial velocity is
reduced below this transition or standard velocity, particle concentration gradi-
ents develop and the flow becomes heterogeneous.
The minimum point on the hydraulic characteristic curve for a settling slurry
corresponds to the ‘critical deposition velocity’. This is the flow velocity when
particles begin to settle out. Good slurry transport design dictates that the pipe
diameter and/or pump are selected so that the velocity in the pipeline over the
RHEOLOGICAL MODELS FOR HOMOGENEOUS SLURRIES 93
)
us
neo (Settling slurry)
ge
o mo
(H (Non-settling slurry)
Log (pressure gradient)
us)
(Saltation) (Heterogeneo
)
nt
le
bu
ur
(T
ar)
(Lamin
Critical Standard
deposition velocity
velocity
Log (superficial slurry velocity)
Figure 4.1 Examples of hydraulic characteristics for settling and non-settling slurries
range of operating conditions prevents the solid particles from settling out.
Hence, the velocity is to be maintained just above the critical deposition velocity.
As the velocity is decreased below the critical deposition velocity, a sliding,
rolling or moving bed of deposited particles accumulates and this causes a steady
increase in the pressure drop.
Non-settling, homogeneous slurries can be pumped through a pipeline either
in laminar or turbulent flow. The hydraulic characteristic of a non-settling slurry
typically exhibits a change of slope of the characteristic, reflecting the transition
from laminar to turbulent flow as the superficial velocity is increased. Settling
slurries typically do not show such an abrupt change in pressure drop with
increasing velocity.
4.3 RHEOLOGICAL MODELS FOR HOMOGENEOUS SLURRIES
Although no slurry is ever perfectly homogeneous or non-settling, the

homogeneous condition is a limiting form of flow behaviour that actual
slurries can approach. The solid particles settle so slowly that continuum
fluid models can be used to describe the flow behaviour of slurries. Like
liquids, non-settling slurries may exhibit either Newtonian or non-Newtonian
flow behaviour. At higher solids concentration, homogeneous slurry mixtures
behave essentially as single-phase liquids with flow properties markedly
different from that of the original liquid (before the solids are added).
Viscometric techniques can generally be employed to analyse the flow proper-
ties of non-settling slurries in much the same way as these techniques are
applied to single-phase liquids.
94 SLURRY TRANSPORT
In Newtonian fluids, a linear relationship exists between the shear stress and
the shear rate in laminar flow.
t ¼ m_g ð4:3Þ
where t is the shear stress (units of force F per unit area A, e.g. Pa), g_ is the shear
rate or velocity gradient (units of inverse time t, e.g. s1 ) and m is the Newtonian
viscosity (units of Ft=A, e.g. Pa s). The slope of the line on a plot of shear stress
versus shear rate is equal to the viscosity of the liquid m. In addition, any finite
amount of stress will initiate flow.
The viscosity of a slurry can be measured if the particles settle slowly. For
dilute suspensions of fine particles, slurries may exhibit Newtonian behaviour. In
this case, the viscosity of a very dilute suspension (solids volume fraction less
than 2%) of uniform, spherical particles can be described by the theoretical
equation derived by Einstein (Einstein, 1906). Einstein’s equation is:
mm
mr ¼ ¼ 1 þ 2:5Cv ð4:4Þ
mf
where mr is the relative viscosity or the ratio of the slurry viscosity mm to that of
the single-phase fluid mf . When the particles are non-spherical or the particle
concentration increases, the factor 2.5 typically increases. In fact, deviations from
Equation (4.4) can be quite pronounced in these cases.
At high particle concentrations, slurries are often non-Newtonian. For non-
Newtonian fluids, the relationship between the shear stress and shear rate,
which describes the rheology of the slurry, is not linear and/or a certain
minimum stress is required before flow begins. The power-law, Bingham plastic
and Herschel–Bulkley models are various models used to describe the flow
behaviour of slurries in which these other types of relationships between the
shear stress and shear rate exist. Although less common, some slurries also
display time-dependent flow behaviour. In these cases, the shear stress can
decrease with time when the shear rate is maintained constant (thixotropic fluid)
or can increase with time when the shear rate is maintained constant (rheopectic
fluid). Milk is an example of a non-settling slurry which behaves as a thixotropic
liquid.
4.3.1 Non-Newtonian Power-law Models
In power-law fluids, the relationship between the shear stress and shear rate is
nonlinear and a finite amount of stress will initiate flow. The mathematical model
(sometimes called the Ostwald-de-Waele equation)
t ¼ k_gn ð4:5Þ
describes the relationship between the shear stress and shear rate where k and n
are constants. Note that the units of the consistency index k (N sn/m2 in SI units)
depend on the value of the dimensionless flow behaviour index n, which

indicates the amount of deviation from Newtonian behaviour. For Newtonian
fluids, n ¼ 1, and k is equal to the Newtonian viscosity.
In power-law fluids, an ‘apparent viscosity’, mapp , is defined in a similar
manner to a Newtonian fluid,
t
mapp ¼ ¼ k_gn1 ð4:6Þ
g_
The apparent viscosity, mapp , is equal to the slope of a line from the origin to a
point on the shear stress–shear rate curve; it decreases or increases as the shear
rate increases. Hence, the term ‘viscosity’ for a non-Newtonian fluid has no
meaning unless the shear rate is specified. In shear-thinning (or pseudoplastic)
slurries, the apparent viscosity decreases as the shear rate increases and the value
for n is less than one. In shear-thickening (or dilatant) slurries the apparent
viscosity increases as the shear rate increases and the value of n is greater than 1
(Figure 4.2).
In shear-thinning slurries, since the apparent viscosity decreases as the shear
rate increases, the velocity profile in a pipe becomes increasingly blunt, tending
towards a plug flow profile as n decreases. In shear-thickening slurries, the
velocity profile becomes more pointed, with larger velocity gradients through-
out the flow domain. For extreme dilatant fluids ðn ! 1Þ, the velocity varies
almost linearly with the radial position in the pipe. This is illustrated in
Figure 4.3.
Most slurries are shear-thinning. It is hypothesized that this shear-thinning
behaviour is due to the formation of particulate aggregates which provide a
lower resistance to flow than fully dispersed particles.
Pseudoplastic, n <1
Newtonian, n =1
Shear stress ,τ
Dilatant , n >1
Shear rate , g
Figure 4.2 Power-law models of non-Newtonian fluids

96 SLURRY TRANSPORT
n =1
r
z decreasing n
Pseudoplastic
vz = 0 Shear-thinning slurry
r
increasing n
z n =1
Dilatant
vz = 0 Shear-thickening slurry
Figure 4.3 Velocity profiles for slurries exhibiting power-law rheology
4.3.2 Pressure Drop Prediction for Slurries Exhibiting

Power-law Rheology
Laminar flow
The fluid momentum balance applied to the case of laminar, fully developed flow
of a power-law fluid in a horizontal pipe of diameter D yields the following
expression for the relationship between the pressure drop, P=L, and the average
flow velocity, vAV :
1
Dn DP =n
vAV ¼ ð4:7Þ
2ð3n þ 1Þ 4kL
or rearranged equivalently as

P 4k 2vAV ð3n þ 1Þ n
¼ ð4:8Þ
L D Dn
Note that for n ¼ 1 and k ¼ m, Equations (4.7) and (4.8) reduce to the familiar
Hagen–Poiseuille equation which describes the pressure drop–velocity relation-
ship for the laminar flow of a Newtonian fluid.
P 32mvAV
¼ ð4:9Þ
L D2
Friction factor method – Laminar and Turbulent flow
The friction factor method can also be used to determine the pressure drop
for homogeneous slurries. It is applied in the same way as for Newtonian
fluids but the friction factor depends on a new definition for the Reynolds
number.
Since the friction factor in a horizontal pipeline is related to the friction head
loss, hf (units of length), by
2
L vAV
hf ¼ 2ff ð4:10Þ
D g
and the pressure drop in a horizontal pipeline is related to the friction head loss by
the modified Bernoulli equation,
P
hf ¼ ð4:11Þ
rm g
then the relationship between pressure drop and friction factor is as follows:

L 2
P ¼ 2ff rm v ð4:12Þ
D AV
In these equations, ff is the Fanning friction factor.

For a more general case of vertical flow in a pipeline network with varying
pipe cross-sectional area and head losses and gains due to pumps (positive head),
turbines (negative head), valves and fittings (negative head), the modified
Bernoulli equation gives:
X X 2
P v
H hf ¼ þ z þ AV ð4:13Þ
rm g 2g
98 SLURRY TRANSPORT
where z ¼ z2 P z1 is the vertical height difference between the exit (2) and the
entrance (1) and H is the sum of all head (units of length) owing to pumps,
turbines, valves or fittings in the pipeline network.
The generalized Reynolds number is defined in terms of an effective visco-
sity, me
rm DvAV
Re ¼ ð4:14Þ
me
In order to define the effective viscosity for a power-law fluid, the expression for
the viscosity of a Newtonian fluid is extended to a non-Newtonian fluid. For a
Newtonian fluid, rearranging the Hagen–Poiseuille equation gives

DP 8vAV 8vAV
m¼ ¼ t0 ð4:15Þ
4L D D
where to is the shear stress at the pipe wall. The power-law effective viscosity, me ,
is defined in a similar manner,

8vAV
me ¼ to ð4:16Þ
D
and, the wall shear stress for a power-law fluid is given by rearranging Equation
(4.8):

PD 2vAV ð3n þ 1Þ n kð3n þ 1Þn 8vAV n
t0 ¼ ¼k ¼ ð4:17Þ
4L Dn ð4nÞn D
Thus, combining Equations (4.16) and (4.17), the power-law effective viscosity is
given by:

kð3n þ 1Þn 8vAV n1
me ¼ ð4:18Þ
ð4nÞn D
and the generalized Reynolds number for a power-law fluid is:

n
8rm Dn v2n n
Re ¼ AV
ð4:19Þ
k ð6n þ 2Þ
For slurries exhibiting power-law fluid rheology, the transition velocity from
laminar to turbulent flow is governed by the flow behaviour index n of the slurry.
The equation proposed by Hanks and Ricks (1974) gives an estimate of this
transition velocity in terms of the generalized Reynolds number Re .
2þn 2n
6464n 1
Retransition ¼ ð2 þ nÞ 1þn ð4:20Þ
ð1 þ 3nÞn 1 þ 3n
For Newtonian fluids and n ¼ 1, the generalized Reynolds Re* is 2100 at the
transition between laminar and turbulent flow.
For laminar flow,
16
ff ¼
Re
For turbulent flows, Dodge and Metzner (1959) developed the following equation
for the power-law fluids in smooth pipes based on a semitheoretical analysis:
1 4 qffiffiffiffiffiffiffiffiffi 0:4
pffiffiffi ¼ 0:75 logðRe ff2n Þ pffiffiffi ð4:21Þ
ff n n
In turbulent flow, the Fanning friction factor ff for the slurry described by a
power-law fluid model depends on both the generalized Reynolds number Re
and the flow behaviour index n.
4.3.3 Non-Newtonian Yield Stress Models
Some slurries require a minimum stress, ty, before flow initiates. This minimum
stress is known as the yield stress for the slurry. For example, freshly poured
concrete does not flow along an inclined surface until a specific angle relative to
the horizontal is reached. Other examples of slurries which exhibit a yield stress
include paints and printing inks. In these cases, there is a critical film thickness
below which these slurries will not flow under the action of gravity.
The behaviour of slurries which exhibit a yield stress can be represented by a
model in which the relationship between the effective stress t ty and the shear
rate is either linear, as in Newtonian fluids (Bingham plastic model), or follows a
power-law, as in pseudoplastic or dilatant fluids (Herschel–Bulkley model or
yield power-law model). The shear stress–shear rate relationship for these
models is shown in Figure 4.4.
In the Bingham plastic model, the yield stress ty and the plastic viscosity mp (the
slope of the line on the shear stress–shear rate plot in Figure 4.4) characterize the
slurry.
t ¼ ty þ mp g_ ð4:22Þ
Since
t ty
mp ¼ ð4:23Þ
g_
the apparent viscosity of a Bingham fluid is

t ty
mapp ¼ ¼ mp þ ð4:24Þ
g_ g_
100 SLURRY TRANSPORT
τ = τ y + kγ n
Herschel–Bulkley
τ = τ y + μ pγ
Shear stress , τ
Bingham plastic
Slope = μ p (plastic viscosity)
Yield stress, τ y
Shear rate, γ
Figure 4.4 Bingham plastic and Herschel–Bulkley models of non-Newtonian fluids
In the Herschel–Bulkley model, the yield stress, consistency index k, and the flow
behaviour index n characterize the slurry.
t ¼ ty þ k_gn ð4:25Þ
The apparent viscosity is
ty
mapp ¼ þ k_gn1 ð4:26Þ
g_
Hence, the Bingham plastic model is a special case of the Hershel–Bulkley model
when n ¼ 1. Slurries following the Bingham plastic model will be discussed in
more detail in the next section.
In pipe flow, the shape of the velocity profile for slurries exhibiting yield
stress is more complex than that for slurries exhibiting power-law rheology
(Figure 4.5). A plug flow region, where dvz =dr ¼ 0, exists between r ¼ 0 and
r ¼ R , where 0 < R < R. In this central region of the pipe, the shear stress trz
is lower than the yield stress value ty . Outside of this central region, where
R < r < R, the shear stress trz is greater than the yield stress ty , trz > ty . At the
wall, the wall shear stress trz jr¼R is given by the same relationship as New-
tonian fluids.
PR
trz jr¼R ¼ t0 ¼ ð4:27Þ
2L
r=R
} τ rz > τ y
r=R
*
τ rz < τ y
z r =0
vz = 0
Figure 4.5 Velocity profile for slurries with a yield stress
4.3.4 Pressure Drop Prediction for Slurries Exhibiting Bingham

Plastic Rheology
Laminar flow
As with slurries following a power-law flow model, it is necessary to reliably

predict the pressure drop in a horizontal pipe of diameter D under laminar, fully
developed flow conditions. A fundamental analysis of the Bingham plastic model
yields the following expression for the mean velocity in terms of the yield stress
ty and the wall shear stress t0 .
" #
Rt0 4 ty 1 ty 4
vAV ¼ 1 þ ð4:28Þ
4mp 3 t0 3 t0
If the ratio ty =t0 is small, as it often is, the mean velocity for the Bingham slurry
can be approximated by the linear expression

D 4
vAV t0 ty ð4:29Þ
8mp 3
By expressing t0 in terms of P and rearranging, the relationship between the

pressure drop and the average velocity can be obtained
P 32mp vAV 16ty

¼ þ ð4:30Þ
L D2 3D
In the case of zero yield stress, ty ¼ 0, the Hagen–Poiseuille equation results.
Turbulent flow
For turbulent flows in smooth pipes, the Fanning friction factor depends on both
the Reynolds number, defined in terms of the plastic viscosity mp ,
rm DvAV
Re ¼ ð4:31Þ
mp
and the dimensionless Hedstrom number He
rm D2 ty
He ¼ ð4:32Þ
m2p
.
The Hedstrom number is the product of the Reynolds number and the ratio of the
internal strain property of the fluid ðty =mp Þ to the shear strain conditions
prevailing in the pipe vAV =D.
Hence, estimation of the pressure drop in turbulent, horizontal slurry flow in a
pipe, based on the method developed by Hedstrom, involves using the friction
factor chart given in Figure 4.6 and Equation (4.12).
For a Bingham plastic slurry, the transition from laminar to turbulent flow
depends on the Hedstrom number. The critical Reynolds number, which allows
Figure 4.6 Friction factor as a function of Reynolds number and Hedstrom number for
slurries exhibiting Bingham plastic rheology
HETEROGENEOUS SLURRIES 103
Figure 4.7 Transition Reynolds number as a function of Hedstrom number for slurries
exhibiting Bingham plastic rheology
the calculation of the average velocity of the slurry at transition, is estimated by

an empirical relationship given in Figure 4.7.
4.4 HETEROGENEOUS SLURRIES
When slurries exhibit non-homogeneous flow behaviour, prediction of the

critical deposition velocity is an essential component of pipeline design. If a
pipeline is operated at or below the critical deposition velocity, pipeline
blockage can result as particles settle and form a stationary bed on the
bottom of a horizontal pipe. In addition to maintaining the operating velocity
greater than the deposition velocity, pipeline design requires prediction of
the pressure gradient. Since both of these – the critical deposition velocity
and the pressure drop – depend on a host of variables including particle size,
pipe diameter, particle concentration, particle density, etc., the deposition
velocity and pressure drop are estimated via correlations that summarize the
results of experimental investigations. Because many of these correlations are
based on experiments that do not report all relevant variables, the values
obtained by these correlations should be regarded as estimates and one
should not expect their predictive ability to be much better than 20%. In
addition, caution should be employed in the use of any correlation due to
limitations in the database on which the correlation was derived. In the case
of heterogeneous slurry flow, the majority of the published experimental data
are for pipe sizes less than 150 mm (significantly smaller than modern
industrial practice), fairly monodispersed particle mixtures, and for water-
based slurries at ambient temperature. Hence, for other flow situations, pilot
plant test results or prior experience with similar slurries are used to estimate
the deposition velocity and pressure drop.
4.4.1 Critical Deposition Velocity
The most widely used form for the correlation yielding an estimate of the critical
deposition velocity is based on the early work of Durand and Condolios (1954).
They found the following simple relationship well described the critical deposi-
tion velocity VC :
vffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
!ffi
u
u r
VC ¼ FtgD s 1
rf
where the dimensionless factor F was presented as a function of particle diameter

and solids concentration by Wasp et al. (1977)
x
1=6
F ¼ 1:87C0:186
v
D
More recently, Gillies et al. (2000) have shown that F is best represented in terms
of the particle Archimedes number Ar ½Ar ¼ 43 x3 rf ðrs rf Þg=m2f
80 < Ar < 160 F¼ 0:197 Ar0:4

160 < Ar < 540 F¼ 1:19 Ar0:045
Ar > 540 F¼ 1:78 Ar0:019
It should be emphasized that the above relationships between F and the particle
Archimedes number do not include the influence of variables such as particle
shape or particle concentration so the correlation yields only an approximate
value for the deposition velocity VC .
For Archimedes number less than 80, the correlation of Wilson and Judge
(1976) should be used.

pffiffiffi x
Ar < 80 F ¼ 2 2 þ 0:3 log10
DCD
5 x
1 10 < < 1 103
DCD
4.5 COMPONENTS OF A SLURRY FLOW SYSTEM
The main elements of a slurry transport system are shown in Figure 4.8.
4.5.1 Slurry Preparation
Initially the slurry must be prepared by physical and/or chemical processing in

order to achieve the proper slurry characteristics for effective transport. Slurry
COMPONENTS OF A SLURRY FLOW SYSTEM 105
SLURRY MAIN INTERMEDIATE DE-WATERING

PREPARATION PUMP PUMP OF SLURRY
Pipeline Pipeline
RECYCLE OF CARRIER LIQUID

(OR TO WASTE)
Figure 4.8 Components of a slurry conveying system
preparation involves slurrification, or addition of the liquid phase to the dry

solids. In addition, chemical treatment for corrosion inhibition, or modification of
slurry rheology by particle size reduction, are often aspects of slurry preparation.
In the grinding process, the desired particle size is small enough such that the
generated slurry is homogeneous and easily transported, but not too small that
the slurry is difficult to dewater. If the particle size is too coarse, a heterogeneous
slurry will result necessitating higher pumping velocities and, consequently,
higher energy costs. In addition, higher pipeline wear rates are associated with
larger particles. Size reduction of larger bulk solids is typically accomplished by
crushing or grinding, such as with jaw crushers (Chapter 12), until the particle
size is about 2 mm. Further particle size reduction is then performed in rod mills
or ball mills (Chapter 12). If significant size reduction of the solid is required, the
cost of slurry preparation can be one of the two largest components (rivaling the
pumping cost) of the total cost of slurry transport.
The typical practice is to add the liquid phase to the solids in agitated tanks,
forming a slurry with a slightly higher concentration than the ultimate pipeline
concentration. Final adjustments to the slurry concentration are then made by the
addition of more liquid as the slurry enters the pipeline.
4.5.2 Pumps
Several types of pumps are useful for handling slurries. The selection of a pump
for a specific slurry transport line is based on the discharge pressure requirement
and the particle characteristics (particle size and abrasivity). The pumps that are
used are either positive displacement pumps or centrifugal (rotodynamic)
pumps.
For discharge pressures under approximately 45 bar, centrifugal pumps offer
an economic advantage over positive displacement pumps. Due to the lower
working pressure, the application of centrifugal pumps is generally restricted to
shorter distances; they are typically used for in-plant transportation of slurries.
The efficiency of a centrifugal pump is low due to the robust nature of the
impeller design; the impellers and casings have wide flow passages. Efficiencies
of 65% are common for centrifugal pumps compared with efficiencies of 85–90%
for positive displacement pumps. The wide flow passages, however, enable the
transport of very large particles, even up to 150 mm in size, in centrifugal pumps.
In contrast, for positive displacement pumps, the maximum particle size is

typically on the order of 2 mm. In order to minimize wear, centrifugal pumps
for coarse-particle slurries are lined with rubber or wear-resistant metal alloys.
The head versus flow characteristic for a centrifugal slurry pump is relatively
flat. Therefore, if the flow resistance of the system increases and the flow rate
drops below the critical velocity, a fixed bed of deposited solids, potentially
developing into a plugged pipeline, can result. To prevent this situation from
occurring, most centrifugal pumps have variable speed drives to maintain the
flow rate.
For slurry transport systems requiring discharge pressures greater than 45 bar,
only positive displacement or reciprocating pumps are technically feasible. These
pumps fall into two main categories: plunger type and piston type. The choice of
which type to employ depends upon the abrasivity of the slurry. The plunger
pump and the piston pump are similar in construction in that both have a
plunger or a piston that is being caused to pass back and forth in a chamber. In
plunger pumps, the plunger reciprocates through packing, displacing liquid
through cylinders in which there is considerable radial clearance (Figure 4.9). The
two valves alternate open and closed as the plunger moves up and down.
Plunger-type pumps are always ‘single-acting’ in that only one end of the
plunger is used to drive the fluid. For slurry applications, the plunger is
continuously flushed with clear liquid during the suction stroke to greatly reduce
internal wear.
PACKING
PLUNGER
FLUSH
LIQUID
VALVE
MOTION
FLOW
Figure 4.9 Vertical plunger pump

COMPONENTS OF A SLURRY FLOW SYSTEM 107
Figure 4.10 Single-acting piston pump
Piston pumps may be either single- or double-acting (Figures 4.10 and 4.11). In
double-acting piston pumps, both sides of the piston are used to move the fluid.
In piston pumps, as in plunger pumps, the valves (two for single-acting and four
for double-acting) alternate open and closed as the piston moves back and forth.
In double-acting piston pumps, both suction and discharge are accomplished
with the movement of the piston in a single direction. Since the throughput of
positive displacement pumps is much lower than centrifugal pumps, these
Figure 4.11 Double-acting piston pump

pumps are often arranged in parallel in a slurry line for transporting solids over
long distances at high volumetric flow rates. Another characteristic of positive
displacement pumps is that throughput is a function of piston or plunger speed,
and is relatively independent of discharge pressure. Therefore, a constant-speed
pump that moves 20 m3/h at 30 bar will handle very nearly 20 m3/h at 200 bar.
4.5.3 Pipeline
The most important considerations when specifying the pipeline are that the pipe
material should be able to withstand the applied pressure and that the pipe
material should be wear-resistant. Erosive wear is likely to be a problem for
transporting abrasive particles at higher velocities ð> 3 m=sÞ. Based on these
considerations, pipe materials generally fall into the broad categories of hardened
metals, elastomers (rubbers and urethanes), and ceramics.
Steel is the most widely used material; linings of rubber or plastic are often
used with steel pipes when handling abrasive slurries. Cost savings can be
realized when installing the pipeline if pipe sections of reduced wall thickness
are used where the pipeline pressure is lower.
Rubber and urethane tend to wear better than metals. However, high tem-
peratures or the presence of oils or chemicals may render this option not feasible.
Ceramics are the most wear resistant materials, but they are low in toughness and
impact strength. In addition, ceramic pipelines are typically the most costly. For
this reason, ceramics are often used as liners, particularly in localized areas of
high wear, such as pipe bends or in centrifugal pumps.
4.5.4 Slurry De-watering
The capital and operating costs of de-watering a slurry at the discharge end of a
pipeline can be the deciding factor in a slurry pipeline feasibility study. In
addition, the difficulty of de-watering the slurry will often dictate whether to
transport the solids in a coarse or finely ground state. In a slurry conveying
systems, the common de-watering processes are:
1. particle sedimentation by gravity or assisted by a centrifugal field;
2. filtration by gravity, assisted by a centrifugal field, pressure or vacuum;
3. thermal drying.
In one slurry conveying system, all three methods of de-watering may even be
used.
Particle sedimentation techniques can involve the use of a screen if the particle
size is relatively large. For smaller particles, the particles in the slurry can settle
naturally due to the gravity in large tanks. For continuous settling operations, a
WORKED EXAMPLES 109
thickener (Chapter 3) is employed. Solids settle into the conical bottom and are
directed to a central outlet using a series of revolving rakes. Clear liquid is
discharged from the top of the thickener.
Hydrocyclones are also used for liquid–solid separation. Hydrocyclones are
similar in design and operation to gas cyclones; the slurry is fed tangentially to
the hydrocyclone under pressure. The resulting swirling action subjects particles
to high centrifugal force. The overflow of the hydrocyclone will carry predomi-
nantly clear liquid and the underflow will contain the remaining liquid and the
solids. Some small fraction of the particles will be discharged in the overflow; this
fraction will depend on the particle size range in the slurry and the cut size of the
hydrocyclone.
4.6 FURTHER READING
For further reading on slurry flow, the reader is referred to the following:
Brown, N.P. and N.I. Heywood (1991), Slurry Handling Design of Solid-Liquid Systems,
Elsevier Applied Science, London.
Shook, C.A. and M.C. Roco (1991), Slurry Flow: Principles and Practice, Butterworth-
Heinemann, Boston.
Wilson, K.C., Addie, G.R. and R. Clift (1992), Slurry Transport Using Centrifugal Pumps,
Elsevier Applied Science, London.
4.7 WORKED EXAMPLES
WORKED EXAMPLE 4.1
A slurry exhibiting power-law flow behaviour is flowing through 15 m of pipe having

an inside diameter of 5 cm at an average velocity of 0.07 m/s. The density of the slurry is
1050 kg/m3 and its flow index and consistency index are n ¼ 0:4 and k ¼ 13:4 N s0:4 =m2 ,
respectively. Calculate the pressure drop in the pipeline.
Solution
First we check to see if the flow is laminar or turbulent by calculating the generalized
Reynolds number Re for the specified flow conditions. We then compare this Reynolds
number to the generalized Reynolds number at which the transition from laminar to
turbulent flow occurs.
From Equation (4.20)

20:4
6464 0:4 1
ð2 þ 0:4Þð1þ0:4Þ
2þ0:4
Retransition ¼
½1 þ 3ð0:4Þ0:4 1 þ 3ð0:4Þ
Retransition ¼ 2400
The generalized Re for the flow conditions in the pipe is found from Equation (4.19),

8 1050 kg=m3 ð0:05 mÞ0:4 ð0:07 m=sÞ1:6 0:4 0:4
Re ¼
13:4N s0:4 =m2 4:4

Re ¼ 1:03 < 2400 ) flow is laminar
The pressure drop can then be calculated using Equation (4.8).

P 4 13:4 N s0:4 =m2 2 0:07 m=s 2:2 0:4
¼
15 m 0:05 m ð0:05 m 0:4Þ
P ¼ 48 000 N=m2
Using the friction factor method,
16 16
ff ¼ ¼ ¼ 15:53
Re 1:03
and from Equation (4.12)
15 m
P ¼ 2 15:53 1050 kg=m3 ð0:07 m=sÞ2
0:05 m
P ¼ 48 000 N=m2
Therefore, the pipeline pressure drop is 48 kPa.
WORKED EXAMPLE 4.2
A slurry with a density of 2000 kg=m3 , a yield stress of 0:5 N=m2 , and a plastic viscosity
of 0.3 Pa s is flowing in a 1.0 cm diameter pipe which is 5 m long. A pressure driving
force of 4 kPa is being used. Calculate the flow rate of the slurry. Is the flow laminar or
turbulent?
Solution
We will first assume that the flow is laminar and then go back and check this
assumption. For laminar flow of a Bingham plastic fluid,
" #
Rt0 4 ty 1 ty 4
vAV ¼ 1 þ
4mp 3 t0 3 t0
where the wall shear stress t0
PR
t0 ¼
2L
4000 N=m2 ð0:005 mÞ
t0 ¼ ¼ 2:0 N=m2
2ð5:0 mÞ
WORKED EXAMPLES 111
Then,
" #
0:005 m 2:0 N=m2 4 0:5 1 0:5 4
vAV ¼ 1 þ
4 0:3 N s=m2 3 2:0 3 2:0
vAV ¼ 0:0056 m=s
And,
pD2 hp i
Q ¼ vAV ¼ ð0:0056 m=sÞ ð0:01 mÞ2
4 4
Q ¼ 4:37 107 m3 =s
Now check to see if the flow is laminar by computing Re and He.
rm DvAV ð2000 kg=m3 Þð0:01 mÞð0:0056 m=sÞ

Re ¼ ¼
mp 0:3 kg=m=s
Re ¼ 0:37
rm D2 ty ð2000 kg=m3 Þð0:01 mÞ2 ð0:5 kg=m=s2 Þ
He ¼ ¼
m2p ð0:3 kg=m=sÞ2
He ¼ 1:1
Given this He and Re, the flow is laminar.
WORKED EXAMPLE 4.3
The following rheology test results were obtained for a mineral slurry containing 60%
solids by weight. Which rheological model describes this slurry, and what are the
appropriate rheological properties for this slurry?
Shear rate ðs1 Þ Shear stress (Pa)

0 5.80
0 5.91
0 6.00
1 6.06
10 6.52
15 6.76
25 7.29
40 8.00
45 8.24
Solution
The shear stress at zero shear rate is 6.00 Pa. Hence there is a yield stress equal to 6.00 Pa.
In order to determine whether the slurry behaves as a Bingham fluid or if it follows the
Herschel–Bulkley model, we need to plot t ty versus shear rate.
t ty (Pa) Shear rate ðs1 Þ

0.06 1
0.52 10
0.76 15
1.29 25
2.00 40
2.24 45
This plot yields a straight line with slope equal to 0.05 Pa s which is the value of the
plastic viscosity mp .
WORKED EXAMPLE 4.4
A coal–water slurry with 65% volume fraction coal (coal specific gravity ¼ 2.5) is
pumped at a rate of 3.41 m3/h from a storage tank through a 50 m long, 1.58 cm inside
diameter horizontal pipe to a boiler. The storage tank is at 1 atm pressure and the slurry
must be fed to the boiler at a gauge pressure of 1.38 bar. If this slurry behaves as a
Bingham plastic fluid with a yield stress of 80 Pa and a plastic viscosity of 0.2 Pa s, what
is the required pumping power?
Solution
First check to see if flow is laminar or turbulent by computing Re and He. Compute
mixture density rm
rm ¼ Cw rs þ ð1 Cw Þrf
rm ¼ ð0:65Þð2500 kg=m3 Þ þ ð0:35Þð1000 kg=m3 Þ
rm ¼ 1975 kg=m3
Compute the velocity vAV given the volumetric flow rate Q.
D2 3:41 1
Q ¼ vav p ; so vAV ¼ ¼ 4:83 m=s
4 3600 p ð0:0158Þ2
4
Calculate the Reynolds number
rm DvAV ð1975 kg=m3 Þð0:0158 mÞð4:83 m=sÞ

Re ¼ ¼ ¼ 754
mp ð0:2 kg=m=sÞ
WORKED EXAMPLES 113
Calculate the Hedstrom number He
rm D2 ty 1975 0:01582 80
He ¼ ¼ ¼ 986
m2p 0:22
Given Re ¼ 754 and He ¼ 986, the flow is laminar.
‘1’
Storage tank
Boiler
‘2’
‘3’
Pump
Figure 4W4.1
Applying Equation (4.13) to the process between points ‘1’ and ‘2’ (Figure 4W4.1)
p2 p1 v2AV
Hgained by pump hf ¼ þ
rm g 2g
The head loss due to friction in the pipeline alone is related to the pressure drop
between points ‘3’ and ‘2’

p3 p2 1 32mp vAV L 16ty L
hf ¼ ¼ þ
rm g rm g D2 3D
So:

1 32 0:2 4:83 50 16 80 50
hf ¼ þ ¼ 390 m
1975 9:81 0:01582 3 0:0158
1:38 ð1:013 105 Þ 4:832
Hgained by pump ¼ 390 þ þ ¼ 398 m
1975 9:81 2 9:81
Head gained by pump is related to the power required W_
W_
Hgained by pump ¼ ¼ 398 m
rm gQ
Therefore; W_ ¼ 1975 9:81 ð3:41 3600Þ 398 ¼ 7300 J=s
Therefore, pumping power required is 7.3 kW.

TEST YOURSELF
4.1 What are the chief distinguishing characteristics of homogeneous flow and hetero-
geneous flow in slurries?
4.2 What is meant by the term ‘critical deposition velocity’ in reference to a setting slurry?
4.3 Name three models that might describe the rheological behaviour of non-setting
supensions at high concentrations.
4.4 What is a chief characteristic of a thixotropic fluid?
4.5 Sketch a plot of shear stress versus strain rate for (a) a dilatant fluid and (b) a
pseudoplastic fluid.
4.6 Sketch fluid radial velocity profiles within a pipeline carrying a shear-thinning fluid.
4.7 Outline the steps in the procedure for predicting pipeline pressure drop for slurries
exhibiting power-law rheology.
4.8 How might one distinguish between a slurry behaving as a Bingham plastic fluid and
a Herschel–Bulkley fluid?
4.9 Define the Hedstrom number. How is this number used in prediction of pipeline
pressure drop for slurries exhibiting Bingham plastic rheology?
4.10 What steps might be typically involved in preparation of a slurry for transport by
pipeline?
4.11 What type of pump would be used in pipeline transport for an abrasive, non-settling
slurry requiring pressures up to 60 bar?
4.12 How is erosive wear in slurry pipelines combated?
EXERCISES
4.1 Samples of a phosphate slurry mixture are analysed in a lab. The following data
describe the relationship between the shear stress and the shear rate:
Shear rate, g_ ðs1 Þ Shear stress, tðPaÞ

25 38
75 45
125 48
175 51
225 53
325 55.5
425 58
525 60
625 62
725 63.2
825 64.3
EXERCISES 115
The slurry mixture is non-Newtonian. If it is considered a power-law slurry, what is the

relationship of the viscosity to the shear rate?
(Answer: t ¼ 23:4_g0:15 .)
4.2 Verify Equation (4.7).
4.3 Verify Equation (4.28).
4.4 A slurry behaving as a pseudoplastic fluid is flowing through a smooth round tube
having an inside diameter of 5 cm at an average velocity of 8.5 m/s. The density of the
slurry is 900 kg/m3 and its flow index and consistency index are n ¼ 0:3 and
k ¼ 3:0 N s0:3 =m2 . Calculate the pressure drop for (a) 50 m length of horizontal pipe and
(b) 50 m length of vertical pipe with the flow moving against gravity.
(Answer: (a) 338 kPa; (b) 779 kPa.)
4.5 The concentration of a water-based slurry sample is to be found by drying the slurry in
an oven. Determine the slurry weight concentration given the following data:
Weight of container plus dry solids 0.31 kg

Weight of container plus slurry 0.48 kg
Weight of container 0.12 kg
Determine the density of the slurry if the solid specific gravity is 3.0.
(Answer: 1546 kg/m3.)
4.6 A coal-water slurry has a specific gravity of 1.3. If the specific gravity of coal is 1.65,
what is the weight percent of coal in the slurry? What is the volume percent coal?
(Answer: 58.6%, 46%.)
4.7 The following rheology test results were obtained for a mineral slurry containing 60%
solids by weight. Which rheological model describes the slurry and what are the
appropriate rheological properties for this slurry?
Shear rate ðs1 Þ Shear stress (Pa)

0 4.0
0.1 4.03
1 4.2
10 5.3
15 5.8
25 6.7
40 7.8
45 8.2
(Answer: Herschel–Bulkley model: k ¼ 0:20, n ¼ 0:81.)

4.8 A mud slurry is drained from a tank through a 15.24 m long horizontal plastic hose.
The hose has an elliptical cross-section, with a major axis of 101.6 mm and a minor axis of
50.8 mm. The open end of the hose is 3.05 m below the level in the tank. The mud is a
Bingham plastic with a yield stress of 10 Pa, a plastic viscosity of 50 cp, and a density of
1400 kg/m3.
(a) At what velocity will water drain from the hose?
(b) At what velocity will the mud drain from the hose?
(Answer: (a) 3.65 m/s; (b) 3.20 m/s.)
4.9 A coal slurry is found to behave as a power-law fluid with a flow index 0.3, a specific
gravity 1.5, and an apparent viscosity of 0.07 Pa s at a shear rate 100 s1 .
(a) What volumetric flow rate of this fluid would be required to reach turbulent flow in a
12.7 mm inside diameter smooth pipe which is 4.57 m long?
(b) What is the pressure drop (in Pa) in the pipe under these conditions?
(Answer: (a) 0.72 m3/h; (b) 19.6 kPa.]
4.10 A mud slurry is draining from the bottom of a large tank through a 1 m long vertical
pipe with a 1 cm inside diameter. The open end of the pipe is 4 m below the level in the
tank. The mud behaves as a Bingham plastic with a yield stress of 10 N/m2, an apparent
viscosity of 0.04 kg/m/s, and a density of 1500 kg/m3. At what velocity will the mud
slurry drain from the hose?
(Answer: 3.5 m/s.)
4.11 A mud slurry is draining in laminar flow from the bottom of a large tank through a 5
m long horizontal pipe with a 1 cm inside diameter. The open end of the pipe is 5 m below
the level in the tank. The mud is a Bingham plastic with a yield stress of 15 N/m2, an
apparent viscosity of 0.06 kg/m/s, and a density of 2000 kg/m3. At what velocity will the
mud slurry drain from the hose?
(Answer: 0.6 m/s.)

5
Colloids and Fine Particles
George V. Franks
5.1 INTRODUCTION
The importance of colloids and fine particles has been the focus of increased
attention with the emergence of nanotechnology and microfluidics although it
has historically been very important in many fields including paints, ceramics,
foods, minerals, paper, biotechnology and other industries. The primary factor
that distinguishes colloids and fine particles from larger particles is that the ratio
of surface area to mass is very large for the small particles. The behaviour of fine
particles is dominated by surface forces rather than body forces. Colloids are very
fine particles with one or more linear dimension between about 1 nm and 10 mm
suspended in a fluid. The dominance of surface forces is exhibited in the cohesive
nature of fine particles, high viscosity of concentrated suspensions and slow
sedimentation of dispersed colloidal suspensions.
The ratio of the surface area to the volume of a spherical particle can be
calculated from the diameter of the sphere as follows (where x is the particle
diameter):
Surface Area px2 6

¼p 3¼ ð5:1Þ
Volume 6x x
The mass of a particle is directly related to its volume by its density. As particle
size decreases the influence of surface forces (described in Section 5.3) dominate
the behaviour of the powders and suspensions relative to body forces which
depend on the particles’ mass. Body forces are easy to understand because they
are simply a result of Newton’s laws of motion, where the force depends on the
mass and acceleration via F ¼ ma. The quintessential example of a body force is
that of a particle settling under the influence of gravity ðF ¼ mgÞ as described in
Chapter 2.

118 COLLOIDS AND FINE PARTICLES
The mass of a 10 nm diameter silica particle is 1:4 1021 kg. Because the mass
of fine particles and colloids is so small, the magnitude of their body forces is less
than the magnitude of the forces acting between their surfaces. These surface
forces are the result of a number of physico-chemical interactions such as van der
Waals, electrical double layer, bridging and steric forces, which will be described
in detail in the following sections. It is these forces that control the behaviour of
fine powders and colloidal suspensions which are discussed in detail in the
sections that follow. The understanding of these forces is not as simple as body
forces since they depend upon specific chemical interactions at the surface of the
particles. A basic understanding of this specialist information is described in
Section 5.3 and detailed knowledge is available in the colloid and surface
chemistry textbooks (Hiemenz and Rajagopolan, 1997; Hunter, 2001; Israelechvili,
1992).
Surface forces may result in either attraction or repulsion between two particles
depending on the material of which the particles are composed, the fluid type
and the distance between the particles. Generally, if nothing is done to control the
interaction between particles, they will be attracted to each other due to van der
Waals forces which are always present. (The few rare cases where the van der
Waals forces are repulsive are described in Section 5.3.1.) The dominance of
attraction is the reason why fine powders in air are usually cohesive.
Another result of the small mass of colloidal particles is that they behave
somewhat like molecules when dispersed in liquids. For example, they diffuse
through the liquid and move randomly due to the phenomenon known as
Brownian motion.
5.2 BROWNIAN MOTION
When colloids are dispersed in a liquid they are influenced by hydrodynamic

body forces as described in Chapter 2. They also experience a phenomenon
known as Brownian motion. Thermal energy from the environment causes the
molecules of the liquid to vibrate. These vibrating molecules collide with each
other and with the surface of the particles. The random nature of the collisions
causes the particles to move in a random walk as shown in Figure 5.1. The
phenomenon is named after Robert Brown who first observed the behaviour in
the motion of pollen grains in water in 1827 (Perrin, 1913).
A simple application of a kinetic model allows us to determine the influence
of key parameters on the average velocity of particles in suspension. Consider
that the thermal energy of the environment is transferred to the particles as
kinetic energy. The average thermal energy is ¯˜ kT (where k is Boltzmann’s
constant ¼ 1:381 1023 J=K and T is the temperature in Kelvin). If one ignores
drag, collisions and other factors, the average velocity v of the particle can be
estimated by equating the kinetic energy ½ mv2 (where m is the mass of the
particle) with the thermal energy as follows:
rffiffiffiffiffiffiffiffi
3kT
v ¼ ð5:2Þ
m
BROWNIAN MOTION 119
Figure 5.1 Illustration of the random walk of a Brownian particle. The distance the
particle has moved over a period of time is L
This simple analysis cannot be used to determine the actual distance of the
particle from its original position because it does not move in a straight line (see
Figure 5.1 and below), but, it does show that either increasing temperature or
decreasing the particles mass increases Brownian motion.
Thermodynamic principles dictate that the lowest free energy state (greatest
entropy) of a suspension is a uniform distribution of particles throughout the
volume of the fluid. Thus, the random walk of a particle due to Brownian motion
provides a mechanism for the particles to arrange themselves uniformly through-
out the volume of the fluid. The result is diffusion of particles from regions of
high concentration to regions of lower concentration. Einstein and Smoluchowski
used statistical analysis of the one-dimensional random walk to determine the
average (root mean square) distance that a Brownian particle moves as a function
of time (Einstein, 1956).
pffiffiffiffiffiffiffi
L ¼ 2at ð5:3Þ
where a is the diffusion coefficient. Einstein further developed a relationship for

the diffusion coefficient that accounted for the hydrodynamic frictional drag on a
spherical particle:
af ¼ kT ð5:4Þ
where the frictional coefficient f is defined as FD/U, where U is the relative

velocity between the particle and fluid. Then for creeping laminar flow we find
from Stokes’ law [Equation (2.3)] that f ¼ 3pxm so that:
a ¼ kT=3pxm ð5:5Þ
and
sffiffiffiffiffiffiffiffiffiffiffiffiffi
2kT
L¼ t ð5:6Þ
3pxm
Thus the average distance that a particle will move over a period of time can be
determined. Increasing temperature increases the distance travelled over a
period of time while increasing particle size and fluid viscosity reduce the
distance travelled. Note that the distance scales with the square root of time
rather than linearly with time.
Note that Equations (5.3)–(5.6) have been derived for the case of the one-
dimensional random walk. This is because these equations will be used later in
analysis of sedimentation under gravity where motion only in one direction (one
dimension) is of interest. Only motion of particles in the direction of the applied
gravitational force field is of interest in sedimentation; lateral motion in the other
two orthogonal directions is not. In the case of the three-dimensional
pffiffiffiffiffiffi
ffi random
walk, the analogy to Equation (5.3) would be L ¼ 6at.
5.3 SURFACE FORCES
Surface forces ultimately arise from the summation of intermolecular interaction

forces between all the molecules (or atoms) in the particles acting across the
intervening medium. The intermolecular (and interatomic) forces are manifesta-
tions of electromagnetic interactions between the atoms of the material
(Israelechvili, 1991). Comprehensive understanding of such forces is described
in great detail in colloid and surface chemistry texts (Hiemenz and Rajagopolan,
1997; Hunter, 2001; Israelechvili, 1992). Discussion here is limited to a few of the
forces with most technological significance.
In general, the force between two particles (F) may be either attractive or
repulsive. The force depends upon the surface to surface separation distance (D)
between the particles and the potential energy (V) at that separation distance. The
relationship between the force and potential energy is that the force is the
negative of the gradient of the potential energy with respect to distance.
dV
F¼ ð5:7Þ
dD
Typical potential energy and force versus separation distance relationships for
fine particles are shown schematically in Figure 5.2. Thermodynamics dictates
that the pair of particles move to the separation distance that results in the lowest
energy configuration. A force between the particles will result if the particles are
at any other separation distance. There is always a strong repulsive force at zero
separation distance that prevents the particles from occupying the same space.
When there is attraction (at all other separation distances), the particles reside in
a potential energy well (minimum in energy) at an equilibrium separation
distance (in contact) [Figure 5.2 (a) and (b)]. In some cases, a repulsive potential
energy barrier exists that prevents the particles from moving to the minimum
energy separation because they do not have enough thermal or kinetic energy to
surmount the barrier. (In terms of force, there is not enough force applied to the
particles to exceed the repulsive force field.) In this case the particles cannot
touch each other and reside at a separation distance greater than the extent of the
SURFACE FORCES 121
V (a) V (c)
D
D
F (b) F (d)
D D
Figure 5.2 Schematic representations of interparticle potential energy (V) and force (F)
versus particle surface to surface separation distance (D). (a) Energy versus separation
distance curve for an attractive interaction. The particles will reside at the separation
distance where the minimum in energy occurs. (b) Force versus separation distance for the
attractive potential shown in (a). (The convention used in this book is that positive
interparticle forces are repulsive.) The particles feel no force if they are at the equilibrium
separation distance. An applied force greater than a maximum is required to pull the
particles apart. (c) Energy versus separation distance curve for a repulsive interaction.
When the potential energy barrier is greater than the available thermal and kinetic energy
the particles cannot come in contact and move away from each other to reduce their
energy. (d) Force versus separation distance for the repulsive potential shown in (c). There
is no force on the particles when they are very far apart. There is a maximum force that
must be exceeded to push the particles into contact
repulsive barrier which is usually at least several nanometres or more [Figure 5.2
(c) and (d)].
The relationships between force and distance as well as the underlying
physical and chemical mechanisms responsible for those forces are described
below for several of the forces with the most technological significance.
5.3.1 van der Waals Forces
van der Waals forces is the term commonly used to refer to a group of
electrodynamic interactions including Keesom, Debye and London dispersion
interactions that occur between the atoms in two different particles. The domi-
nant contribution to the van der Waals interaction between two particles is from
the dispersion force. The dispersion force is a result of Columbic interactions
between correlated fluctuating instantaneous dipole moments within the atoms
+ _
attraction
_ +
Figure 5.3 Schematic representation of the dipole–dipole attraction that exists between
the instantaneous dipoles of two atoms in two particles. The þ represents the nucleus of
the atom and the represents the centre of the electron density. Because the centre of
electron density is typically not coincident with the nucleus, a dipole moment exists
between the two separated opposite charges in each atom. Application of Coulomb’s law
between the charges indicates that the lowest free energy configuration is as shown in the
figure. The resulting position of positive and negative charges leads to an attraction
between the two atoms, again due to Coulomb’s law
that comprise the two particles. To understand this concept, imagine that each
atom in a material contains a positively charged nucleus and orbiting negative
electrons. The nucleus and the electrons are separated by a short distance, on the
order of an Ångstrom ð1010 mÞ. At any instant in time, a dipole moment exists
between the nucleus and the centre of electron density. This dipole moment
fluctuates very rapidly with time, revolving around the nucleus as the electrons
orbit. The dipole moment of each atom creates an electric field that emanates
from the atom and is felt by all other atoms in both particles. In order to lower the
overall energy of the system, the dipole moments of all the atoms in both particles
correlate their dipole moments (i.e. they align themselves like a group of
choreographed pairs of dancers in a musical, who remain ‘in sync’ although
they are always moving). When the two particles are composed of the same
material, the lowest energy configuration of the correlated dipoles is such that
there is attraction between the dipoles as shown in Figure 5.3. The combined
attraction between all the dipoles in the two particles results in an overall
attraction between the particles. In general the van der Waals interaction can
be attractive or repulsive depending on the dielectric properties of the two
particles and the medium between the particles.
Pairwise summation of the interactions between all atoms in both particles
results in a surprisingly simple equation for the overall interaction between two
spherical particles of the same size when the distance between the particles (D) is
much less than the diameter of the particles (x).
VvdW ¼ Ax=24D ð5:8aÞ
and
FvdW ¼ Ax=24D2 ð5:8bÞ

SURFACE FORCES 123
material 2
material1
material 1 material3
material 3
Figure 5.4 Notation used to indicate the type of material for each particle and the
intervening medium
where VvdW is the van der Waals interaction energy and FvdW is the van der
Waals force. More complicated relationships arise if the particles are not the same
size or are small relative to the distance between them. The sign and magnitude
of the interaction for a particular pair of particles interacting in a given medium is
expressed as the numerical value of the Hamaker constant (A). When the
Hamaker constant is greater than zero the interaction is attractive and when
the Hamaker constant is less than zero the interaction is repulsive. Figure 5.4
shows the configuration of two particles (materials 1 and 3) and an intervening
medium (material 2). The Hamaker constant can be calculated from the dielectric
properties of the three materials. Table 5.1 shows the Hamaker constants for
several combinations of particles and intervening media. Note that oil droplets in
emulsions and bubbles in foams may be considered particles in the sense of
understanding interaction forces and the stability of the emulsions and foams.
Table 5.1 Hamaker constants of some common material combinations

Hamaker
constant
Material 1 Material 2 Material 3 (approximate) (J) Example
Alumina Air Alumina 15 1020 Oxide minerals in air are
strongly attractive and cohesive
Silica Air Silica 6:5 1020
Zirconia Air Zirconia 20 1020
Titania Air Titania 15 1020
Alumina Water Alumina 5:0 1020 Oxide minerals in water are
attractive but less so than in air
Silica Water Silica 0:7 1020
Zirconia Water Zirconia 8:0 1020
Titania Water Titania 5:5 1020
Metals Water Metals 40 1020 Conductivity of metals makes
them strongly attractive
Air Water Air 3:7 1020 Foams
Octane Water Octane 0:4 1020 Oil in water emulsions
Water Octane Water 0:4 1020 Water in oil emulsions
Silica Water Air 0:9 1020 Particle bubble attachment in
mineral flotation, weak
repulsion
When materials 1 and 3 are the same, the van der Waals interaction is always
attractive, for example, the mineral oxides interacting across water or air shown
in Table 5.1. Note the van der Waals interaction is reduced when the particles are
in water compared with air. Thus it is easier to separate (disperse) fine particles
in liquids than in air. When materials 1 and 3 are different materials, repulsion
will result between the two particles if the dielectric properties of the intervening
medium are between that of the two particles, such as for silica particles and air
bubbles interacting across water.
5.3.2 Electrical Double Layer Forces
When particles are immersed in a liquid they may develop a surface charge by
any one of a number of mechanisms. Here, consider the case of oxide particles
immersed in aqueous solutions. The surface of a particle is comprised of atoms
that have unsatisfied bonds. In vacuum, these unfulfilled bonds result in an equal
number of positively charged metal ions and negatively charged oxygen ions as
shown in Figure 5.5(a). When exposed to ambient air (which usually has at least
15 % relative humidity) or immersed in water, the surface reacts with water to
produce surface hydroxyl groups (denoted M-OH) as shown in Figure 5.5(b).
The surface hydroxyl groups react with acid and base at low and high pH,
respectively, via surface ionization reactions as follows (Hunter, 2001):
M-OH þ Hþ K!
a
M-OHþ
2 ð5:9aÞ
Kb
M-OH þ OH ! M-O þ H2 O ð5:9bÞ
(a) vacuum (b) water (at IEP)

H
H -
+ - + -
+
+ O H
O H
O
- O M O - H2 H M O M O M H H
+ M M O O O
O O + O
M M M M
(c) low pH (d) high pH

+ +
H2 + H2 + H H
-
O H2 -
+ O H2 O - O -
H 2 H M O M O M H2 + H + - - O O M O
H
O -
O O O O 2 O O M M
O O
M M M M
Figure 5.5 Schematic representation of the surface of metal oxides (a) in vacuum.
Unsatisfied bonds lead to positive and negative sites associated with metal and oxygen
atoms, respectively. (b) The surface sites react with water or water vapour in the
environment to form surface hydroxyl groups (M-OH). At the isoelectric point (IEP) the
neutral sites dominate, and the few positive and negative sites present exist in equal
numbers. (c) At low pH the surface hydroxyl groups react with Hþ in solution to create a
positively charged surface composed mainly of ðM-OHþ 2 Þ species. (d) At high pH the
surface hydroxyl groups react with OH in solution to create a negatively charged surface
composed mainly of (M-O ) species
SURFACE FORCES 125
M-OH2+ M-O
–
Number of sites per unit area

M-OH
IEP
pH
Figure 5.6 Number density per unit area of neutral (M-OH), positive ðM OHþ
2 Þ and
negative (M-O ) surface sites as a function of pH
resulting in either a positively charged surface ðM-OHþ 2 Þ as in Figure 5.5(c), or a

negatively charged surface ðM O Þ as in Figure 5.5(d). The value of the surface
ionization reaction constants (Ka and Kb) depend upon the particular type of
material (for example SiO2, Al2O3 and TiO2). For each type of material, there is a
pH known as the isoelectric point (IEP), where the majority of surface sites are
neutral (M-OH) and the net charge on the surface is zero. At a pH below or above
the IEP, the particle’s surfaces become positively ðM-OHþ 2 Þ or negatively (M-O )

þ
charged due to the addition of either acid (H ) or base (OH ), respectively.
Figure 5.6 shows how the concentration of surface sites changes with pH.
Table 5.2 contains a listing of the IEPs of some common materials.
For each charged surface site there is a counterion of opposite charge in
solution. For example, the counterion for a positive surface site is a Cl anion
in the case when HCl is used to reduce the pH and the counterion for a negative
surface site is a Naþ cation if NaOH is used to increase the pH. The entire system
is electrically neutral. The separation of charge between the surface and the bulk
solution results in a potential difference known as the surface potential ð0 Þ.
Table 5.2 Isoelectric points of some

common materials
Material pH of IEP
Silica 2–3
Alumina 8.5–9.5
Titania 5–7
Zirconia 7–8
Hematite 7–9
Calcite 8
Oil 3–4
Air 3–4
The counterions form a diffuse cloud that shrouds each particle in order to
maintain electrical neutrality of the system. When two particles are forced
together their counterion clouds begin to overlap and increase the concentration
of counterions in the gap between the particles. If both particles have the same
charge, this gives rise to a repulsive potential due to the osmotic pressure of the
counterions which is known as the electrical double layer (EDL) repulsion. If the
particles are of opposite charge an EDL attraction will result. It is important to
realize that EDL interactions are not simply determined by the Columbic
interaction between the two charged spheres, but are due to the osmotic pressure
(concentration) effects of the counterions in the gap between the particles.
A measure of the thickness of the counterion cloud (and thus the range of the
repulsion) is the Debye length ðk1 Þ where the Debye screening parameter ðkÞ,
for monovalent salts is (Israelachvili,1992):
pffiffiffiffiffi
k ¼ 3:29 ½c ðnm1 Þ ð5:10Þ
where [c] is the molar concentration of monovalent electrolyte. When the Debye
length is large (small counterion concentration) the particles are repulsive at large
separation distances so that the van der Waals attraction is overwhelmed as in
Figure 5.2(c) and (d). The electrical double layer is compressed (Debye length is
reduced) by adding a salt, which increases the concentration of the counterions
around the particle. When sufficient salt is added, the range of the EDL repulsion
is decreased sufficiently to allow the van der Waals attraction to dominate at
large separation distances. At this point, an attractive potential energy well as
shown in Figure 5.2(a) and (b) results.
An approximate expression for the EDL potential energy (VEDL) versus the
surface to surface separation distance (D) between two spherical particles of
diameter (x) with the same surface charge is (Israelachvili,1992):
VEDL ¼ peeo x20 ekD ð5:11Þ
where 0 is the surface potential (created by the surface charge), e the relative
permittivity of water, not voidage as frequently used in other parts of the book, e0
the permittivity of free space which is 8:854 1012 C2 =J=m, and k the inverse
Debye length. This expression is valid when the surface potential is constant and
below about 25 mV and the separation distance between the particles is small
relative to their size (Israelachvili, 1992).
Because a layer of immobile ions and water molecules exists at the surface of
the particle it is not easy to directly measure the surface potential of particles.
Instead, a closely related potential known as the zeta potential is usually
measured. The zeta potential can be determined by measuring the particle’s
velocity in an electric field. The zeta potential is the potential at the plane of shear
between the immobilized surface layer and the bulk solution. This plane is
typically located only a few Angstroms from the surface so that there is little
difference between the zeta potential and the surface potential. In practice, the
zeta potential can be used in place of the surface potential in Equation (5.11) to
predict the interparticle forces as a function of separation distance with little
SURFACE FORCES 127
100
0.01 M
alumina in KCl solution
80
0.1 M
60
Zeta potential (mV)
0.3 M
40
20 1.0 M
0
3 4 5 6 7 8 9 10 11 12 13
-20
-40
-60
-80
pH
Figure 5.7 Zeta potential of alumina particles as a function of pH and salt concentration.
(Data from Johnson et al., 2000)
error. Addition of salt to a suspension reduces the magnitude of the zeta potential
as well as compressing the range of the double layer (reducing Debye length) as
described above. Figure 5.7 is an example of how pH and salt concentration
influence the zeta potential of alumina particles.
5.3.3 Adsorbing Polymers, Bridging and Steric Forces
Another method that is useful in controlling surface forces between particles in

suspensions is through the addition of soluble polymer to the solution. Consider
the situation where the polymer has affinity for the particle’s surface and tends to
adsorb on the particles’ surfaces. Either attraction by polymer bridging or
repulsion due to steric interactions can result depending on the polymer
molecular weight and amount adsorbed as shown in Figure 5.8.
Bridging flocculation (Gregory, 2006; Hiemenz and Rajagopolan, 1997) is a
method in which polymer that adsorbs onto the particle’s surface is added in a
quantity that is less than sufficient to fully cover the surface. The polymer chains
adsorbed onto one particle’s surface can then extend and adsorb on another
particle’s surface and hold them together. The optimum amount of polymer to
add is usually just enough to cover half of the total particle surface area. The best
bridging flocculation is usually found with polymers of high to very high
molecular weight (typically 1 106 20 106 g/mol) so that they can easily
bridge between particles. Commercial polymeric flocculants are typically
charged or nonionic copolymers of polyacrylamide. They are used extensively
in the water treatment, waste water, paper and mineral processing industries to
aid in solid/liquid separation. They operate by creating attraction between the
fine particles resulting in the formation of aggregates known as flocs. The flocs’
mass is much greater than the individual particle’s mass so that body forces
(a) (b)
Figure 5.8 Schematic representation of (a) bridging flocculation and (b) steric repulsion
become important in controlling the behaviour of the floc and gravity sedimenta-
tion dominates relative to the randomizing effect of Brownian motion that
dominates the individual particle’s behaviour.
The addition of polymers can also create repulsion between particles by a steric
mechanism. Steric repulsion occurs when the particle’s surfaces are completely
covered with a thick layer of polymer. The polymer must adsorb to the surfaces
of the particles and extend out into solution. In a good solvent, as the separation
distance becomes less than twice the extent of the adsorbed polymer, the polymer
layers begin to overlap and a strong repulsion results as shown in Figure 5.2(c)
and (d). The polymers that work best in creating steric repulsion are typically low
to moderate molecular weight (typically less than 1 106 g/mol) and the surfaces
of the particles should be completely covered. When the solvent quality is poor,
the steric interaction can be attractive at moderate to long range. This can occur
when a poorly soluble polymer is adsorbed to the particle’s surface. Electrosteric
stabilization occurs when the polymer is a charged polyelectrolyte such that both
EDL and steric repulsion are active. Steric and electrosteric stabilization are
commonly used in the processing of ceramics to control suspension stability and
viscosity.
5.3.4 Other Forces
There are several other mechanisms that may lead to forces between particles. In
very dry air static charge may result in Columbic interactions between particles.
Columbic interactions are usually of little significance in ambient air which is
usually humid enough that the static charge dissipates rapidly. In solution, non-
adsorbing polymers can result in another type of weak attraction called depletion
attraction. Layers of solvent molecules on particles’ surfaces, such as water on
SURFACE FORCES 129
strongly hydrated surfaces, can result in short range repulsion. These short
ranged repulsions are known as hydration or structural forces. Hydrophobic
surfaces (poorly wetted), when immersed in water exhibit a special kind of
strong attraction. The so called hydrophobic force causes oil droplets to coalesce
and hydrophobic particles to aggregate.
5.3.5 Net Interaction Force
In the 1940s Derjaguin, Landau, Verwey and Overbeek (DLVO), developed the
hypothesis that the total particle interaction could be determined by simply
summing the contributions from the van der Waals interaction and the EDL
interaction. In the meantime, the DLVO theory has been widely verified experi-
mentally. Furthermore, it has been found that many other forces may be
combined in the same way to determine the overall interparticle interaction.
Examples of some net interparticle interaction forces are shown in Figure 5.9.
2.0
(a)
pH 4.3
1.5
pH 5.5
1.0
Force (nN)
pH 6.0
pH 6.4
0.5
pH 6.8
0.0
0 2 4 6 8 10
pH 9
van der Waals only
-0.5
Separation distance (nm)
Figure 5.9 (a) Force versus distance curves for alumina at different pH values calculated
from Equations (5.8) and (5.11) with parameters as detailed in Franks et al. (2000). At pH 9
the van der Waals attraction dominates. As pH is decreased the range and magnitude of
the EDL repulsion increases as zeta potential increases (see Figure 5.8). At very small
separation distances the van der Waals attraction always dominates the EDL repulsion. (b)
Force versus distance curves for silica particles interacting with an adsorbed polymer
(Zhou et al., 2008). Upon approach, the adsorbed polymer provides a weak steric
repulsion. Upon separation (retraction) the polymer creates a strong long range attraction
because chains are adsorbed on both surfaces. The van der Waals only interaction is shown
for comparison
0.5
steric repulsion
on approach
0.0
0 5 10 15 20 25
van der Waals only
for comparison
-0.5
Force (nN)
bridging attraction
on retraction
-1.0
-1.5
(b)
-2.0
Separation distance (nm)
Figure 5.9 ðContinuedÞ
5.4 RESULT OF SURFACE FORCES ON BEHAVIOUR

IN AIR AND WATER
From the equations for van der Waals forces [Equation (5.8)] and EDL repulsion
[Equation (5.11)] one can see that the magnitude of surface forces increases
linearly with particle size. Body forces which depend on the mass of the particle,
however, increase with the cube of the particle size (since the mass is related to
the volume multiplied by the density and volume depends upon the cube of the
particle size). It is the relative values of body forces and interparticle surface forces
that are important. Although, small particles have very small interparticle surface
forces compared with big particles, relative to the body forces, the interparticle
surface forces are large for small particles. This effect occurs because of the much
stronger dependence of body forces on size than the surface forces.
When particles’ surfaces interact across air, such as in dry fine powders, the
dominant interaction is attraction due either to van der Waals interactions or
capillary bridges (see Chapter 13). In air, other gases and vacuum the only
mechanism which could generate repulsion is electrostatic charging (for example
due to friction). If the charge on particles is the same sign, repulsion will result
due to Coulomb’s law while attraction would result between oppositely charged
particles. Electrostatic interaction, although possible is usually not of significance
if the relative humidity is greater than about 45 % because the charge rapidly
dissipates at room temperature in humid air.
The result is that fine powders in air are cohesive due to van der Waals and
capillary attraction. Attraction between particles results in cohesive behaviour of
RESULT OF SURFACE FORCES ON BEHAVIOUR 131
the powder. The strong cohesion of the particles is the reason why fine particles
are difficult to fluidize (Geldart’s Group C powders described in Chapter 7). The
strong cohesion is also the cause of the high unconfined yield stresses of powders
described in Chapter 10. The high unconfined yield stress of these powders
means that the powders are not free flowing and will require a larger dimension
hopper opening relative to free flowing powders of the same bulk density. Either
larger primary particles or granules of the fine powder will have greater mass so
that body forces (rather than adhesive surface forces) will dominate behaviour of
these bigger particles and free flowing powders will result.
The influence of attractive forces between fine dry powders is observed as the
effect of particle size on bulk density. As the particle size decreases the loose
packed and tapped bulk densities tend to decrease. This is because as the particle
size becomes smaller, the influence of the attractive surface forces becomes
stronger than the body forces. Consolidation is aided by body forces (such as
gravity) which allow the particles to rearrange into denser packing structures.
The attractive surface forces between fine particles hinder their rearrangement
into dense packing structures. Note this may seem counterintuitive to some
readers (who may think that attractive forces would increase packing density).
This is not the case because attractive forces create strong bonds that hinder
rearrangement of particles into more dense packing structures.
One difference between dry fine powders and colloids in liquids is that the low
viscosity of air (and other gases) make hydrodynamic drag forces minimal for
dry powders in many instances, except when the particles have very low density
(such as dust and smoke) or the gas velocity is very high. However, fine particles
in liquids are strongly influenced by hydrodynamic drag forces as described in
Chapter 2 because the viscosity of liquids is much greater than that of gases.
When fine particles are suspended or dispersed in liquids, such as water, we
are able to control the interaction forces by prudent choice of the solution
chemistry. This control of interaction forces is of significant technological
importance because we can thus control the suspension behaviour such as
stability, sedimentation rate, viscosity, and sediment density. Additives such as
acids, bases, polymers and surfactants can easily be used in formulations to
develop the range and magnitude of either repulsion or attraction as demon-
strated in Figure 5.9. When fine particles are suspended or dispersed in liquids,
such as water, there are several mechanisms that can produce repulsive forces
between particles that can overwhelm the attractive van der Waals interaction
between like particles if we want to keep the particles dispersed. One example of
a situation where dispersed particles are desirable is in ceramic processing. In
this application, the low viscosity of dispersed particles is desirable as well as the
uniform and dense packing of particles in the shaped ceramic component
afforded by the repulsion. However, suspended particles with high magnitude
zeta potential with strong repulsion between them may be made to aggregate by
development of an attractive interaction so that they settle rapidly to increase
efficiency of solid/liquid separation. This application of bridging polymers is
discussed in Section 5.5.
In general, as shown in Figure 5.10, suspension behaviour depends upon the
interparticle forces which in turn depend upon the solution conditions. The
Low zeta potential (near IEP) High zeta potential (away from IEP)
High salt (coagulation) Low salt
Bridging polymers Polymer cushions (steric repulsion)
Attraction Repulsion
V V
D
D
Flocculated Dispersed
or aggregated or stabilized
Aggregation Individual particles

Rapid sedimentation Slow settling
Low density sediments (high moisture) Dense sediments ( low moisture)
High viscosity and yield stress Low viscosity
Figure 5.10 The top section of the figure gives examples of how the solution conditions
influence the forces between particles. The bottom section shows how attractive and
repulsive forces influence some behaviour of suspensions
suspension behaviour of interest such as stability, sedimentation, sediment

density, particle packing and rheological (flow) behaviour are discussed in the
following sections.
5.5 INFLUENCES OF PARTICLE SIZE AND SURFACE FORCES

ON SOLID/LIQUID SEPARATION BY SEDIMENTATION
The two primary factors that influence the efficiency of solid/liquid separation
by gravity are the rate of sedimentation and the moisture content (solids
concentration) of sediment. The rate of sedimentation should be maximized
while the moisture content of the sediment should be minimized.
5.5.1 Sedimentation Rate
The time frame for the stability of a colloidal suspension against gravity depends
upon the ratio of the sedimentation flux to the Brownian flux. The sedimentation
flux tends to move particles denser than the fluid downward and particles less
dense than the fluid upward. The Brownian flux tends to randomize the position
of the particles. It is possible to estimate the time frame of stability from the
particle and fluid properties assuming that the suspension is stable for the period
of time that the average distance travelled by a particle due to Brownian motion
is greater than the distance it settles over the same time period. This can be
determined by equating Equation (5.6) with a rearranged Stokes’ settling law
INFLUENCES OF PARTICLE SIZE AND SURFACE FORCES 133
(see Chapter 2) such that:

sffiffiffiffiffiffiffiffiffiffiffiffiffi
2kT ðrp rf Þx2 g
L¼ t¼ t ð5:12Þ
3pxm 18m
Solving for (non-zero) time:

216kTm
t¼ ð5:13Þ
pg2 ðrp rf Þ 2 x 5
Because the Brownian distance depends upon the square root of time and the
distance settled depends linearly on time, given enough time all suspensions will
eventually settle out. The time frame of stability is important when the engineer-
ing objective is solid/liquid separation because it is typically only economically
viable to conduct solid/liquid separation by sedimentation in a unit operation
such as a thickener when the residence times are on the order of hours rather
than on the order of weeks or months.
In order to increase the sedimentation rate of colloidal suspensions which
would otherwise remain stable for days or weeks, a polymeric flocculant which
produces bridging attraction is typically added to the suspension. The attraction
between particles results in the formation of aggregates which are larger than
the primary particles. The larger aggregates then have sedimentation velocities
that exceed the randomizing effect of Brownian motion so that economical
solid/liquid separation is possible in conventional thickeners by gravity
sedimentation.
5.5.2 Sediment Concentration and Consolidation
The moisture content of the sediment and how the sediment consolidates in
response to an applied consolidation pressure (by for instance the weight of the
sediment above it or during filtration) depends upon the interparticle forces.
During batch sedimentation, given enough time, the sediment/supernatant
interface will stop moving downward and a final equilibrium sediment concen-
tration will result. In fact the concentration will vary from the top to the bottom of
the sediment due to the local solids pressure because fine particles and colloids
typically produce compressible sediments. Although the sedimentation rate is
slow when repulsion and Brownian motion dominate, the sediment bed that
eventually forms is quite concentrated and approaches a value near random
dense packing of monodisperse spheres ½fmax ¼ ð1 eÞmax ¼ 0:64. (Note, here e
refers to the voidage and f is the volume fraction of solids.) This is because the
repulsive particles joining the sediment bed are able to rearrange into a lower
energy (lower height) position as illustrated in Figure 5.11(a). Attractive particles
(and aggregates), however, form sediments that are quite open and contain high
levels of residual moisture. This is because the strong attraction between particles
creates a strong bond between individual particles that prevents rearrangement
into a compact sediment structure as shown in Figure 5.11(b).
(a) (b)
Stable Stable
suspension suspension
repulsion repulsion
add flocculant
Stable Aggregated
repulsion attraction
after long time after short time
Stable Aggregated
repulsion attraction
dense loose
sediment sediment
Figure 5.11 (a) Repulsive colloidal particles result in stable dispersions that only form
sediments after extended periods. The sediment is quite concentrated. (b) When a
flocculant is added to a stable dispersion, the resulting attraction causes aggregation of
the particles and rapid sedimentation of the flocs. The sediment in this case is quite open
A pressure may be applied to a particle network in a number of ways including

direct application of pressure as in a filter press or centrifuge and by the weight
of the particles sitting above a particular level in a sediment. The response of the
particle network to the applied pressure depends upon the interparticle force
between individual particles. The difference between repulsive particles and
attractive particles is demonstrated in Figure 5.12. The repulsive particles (dis-
persed suspensions) easily pack to near the maximum random close packing
limit at all consolidation pressures. Strongly attractive particles have the lowest
packing densities at a particular applied pressure and weakly attractive particles
have intermediate behaviour.
One can see the dilemma in solid/liquid separation where it appears rapid
sedimentation and low sediment moisture are mutually exclusive. Current
research in improving solid/liquid separation focuses on controlling the inter-
particle interaction to be optimized for each step of the separation process; that is,
attraction when rapid sedimentation is required and repulsion when consolida-
tion is desired. The approach by the author of this chapter is to use stimulant
responsive flocculants to achieve this outcome.
5.6 SUSPENSION RHEOLOGY
Rheology is the study of flow and deformation of matter (Barnes et al., 1989). It
encompasses a wide range of mechanical behaviour from Hookian elastic
SUSPENSION RHEOLOGY 135
0.62
0.6
pH 4, dispersed
0.58
0.56
Volume fraction solids
0.54
0.52 pH 5
1.0 M salt
0.5 weakly aggregated
pH 9
0.48 strongly aggregated
at the IEP
0.46
0.44
0.42
0.1 1 10 100
Consolidation pressure (MPa)
Figure 5.12 Equilibrium volume fraction as a function of consolidation pressure in a filter

press (data from Franks and Lange, 1996) for 200 nm diameter alumina. At pH 4 the strong
repulsion between particles results in consolidation to high densities over a wide range of
pressures. At pH 9, the IEP of the powder, the strong attraction produces difficult to
consolidate and pressure-dependent filtration behaviour. The weak attraction at pH 5,
with added salt results in intermediate behaviour
behaviour to Newtonian fluid behaviour. Suspensions of particles can exhibit this

entire range of behaviour from Newtonian liquids with viscosities near water to
high yield stress and high viscosity pastes such as mortar or toothpaste. The
parameters that mainly influence the rheological behaviour of suspensions are
the volume fraction of solids, the viscosity of the fluid, surface forces between
particles, particle size and particle shape.
First, in this section, the influence of volume fraction of particles is discussed in
the case where there are no surface forces between particles. Only hydrodynamic
forces and Brownian motion are considered in this case, which is known as the
non-interacting hard sphere model. The influence of surface forces is considered
in the following section.
Consider a molecular liquid with Newtonian behaviour (see Chapter 4) such as
water, benzene, alcohol, decane, etc. The addition of a spherical particle to the
liquid will increase its viscosity due to the additional energy dissipation related
to the hydrodynamic interaction between the liquid and the sphere. Further
addition of spherical particles increases the viscosity of the suspension linearly.
Einstein developed the relationship between the viscosity of a dilute suspension
and the volume fraction of solid spherical particles as follows (Einstein, 1906):
ms ¼ ml ð1 þ 2:5fÞ ð5:14Þ
1.05
1.04
Relative viscosity
1.03
1.02
1.01
1
0 0.005 0.01 0.015 0.02
Volume fraction
Figure 5.13 Relative viscosity ðms =ml Þ of hard sphere silica particle suspensions (black
circles) and Einstein’s relationship (line). (Data from Jones et al., 1991)
where ms is the suspension viscosity, ml is the liquid viscosity and f is the volume
fraction of solids (f ¼ 1 e where e is the voidage). Note that the viscosity of the
suspension remains Newtonian and follows Einstein’s prediction when the
volume fraction of solids is less than about 7%. This relationship has been
verified extensively. Figure 5.13 shows the relationship as measured by Jones
et al., (1991) for silica spheres.
Einstein’s analysis was based on the assumption that the particles are far
enough apart so that they do not influence each other. Once the volume fraction
of solids reaches about 10%, the average separation distance between particles is
about equal to their diameter. This is when the hydrodynamic disturbance of the
liquid by one sphere begins to influence other spheres. In this semi-dilute
concentration regime (about 7–15 vol% solids), the hydrodynamic interactions
between spheres results in positive deviation for Einstein’s relationship. Batch-
elor (1977) extended the analysis to include higher order terms in volume fraction
and found that the suspension viscosities are still Newtonian but increase with
volume fraction according to:
ms ¼ ml ð1 þ 2:5f þ 6:2f2 Þ ð5:15Þ
At even higher concentrations of particles, the particle–particle hydrodynamic

interactions become even more significant and the suspension viscosity increases
even faster than predicted by Batchelor and the suspension rheology becomes
shear thinning (see Chapter 4) rather than Newtonian.
Brownian motion dominates the behaviour of concentrated suspensions at rest
and at low shear rate such that a random particle structure results that produces a
SUSPENSION RHEOLOGY 137
100
random structure
Suspension viscosity (Pa s)
10
shear thinning
behaviour of typical
concentrated suspension
1
preferred flow structure
0.1
0.01 0.1 1 10 100 1000
-1
Shear rate (s )
Figure 5.14 The transition from Brownian dominated random structures to preferred
flow structures as shear rate is increased is the mechanism for the shear thinning
behaviour of concentrated suspensions of hard sphere colloids
viscosity dependent upon the particle volume fraction. As shown in Figure 5.14
there is typically a range of low shear rates over which the viscosity is independent
of shear rate. This region is commonly referred to as the low shear rate Newtonian
plateau. At high shear rates, hydrodynamic interactions are more significant than
Brownian motion and preferred flow structures such as sheets and strings of
particles develop as in Figure 5.14. The viscosity of suspensions with such
preferred flow structures is much lower than the viscosity of the same volume
fraction suspension with randomized structure. The preferred flow structure that
minimizes the particle–particle hydrodynamic interaction develops naturally as
the shear rate is increased. There is typically a range of high shear rates where the
viscosity reaches a plateau. The shear thinning behaviour observed in concentrated
hard sphere suspensions is the transition from the randomized structure of the low
shear rate Newtonian plateau to the fully developed flow structure of the high
shear rate Newtonian plateau as illustrated in Figure 5.14.
As the volume fraction of particles continues to increase, the viscosities of
suspensions continue to increase and diverge to infinity as the maximum packing
fraction of the powder is approached. Although there is currently no first
principles model that is able to predict the rheological behaviour of concentrated
suspensions, there are a number of semi-empirical models that are useful in
describing concentrated suspension behaviour. The Kreiger–Dougherty model
(Kreiger and Dougherty, 1959) takes the form:

f ½Zfmax
ms ¼ ml 1 ð5:16Þ
fmax
where ms can represent either the low shear rate Newtonian plateau viscosity or
the high shear rate Newtonian plateau viscosity. The parameter fmax is a fitting
parameter that is considered an estimate of the maximum packing faction of the
powder. ½Z is known as the intrinsic viscosity and represents the dissipation of a
single particle. Its value is 2.5 for spherical particles and increases for particles of
non-spherical geometry. (It is not a coincidence that the value 2.5 is found in
Einstein’s relationship.) For real powders, the exact values of fmax and ½Z are not
easy to determine and since fmax ½Zð2:5 0:64Þ is close to 2, a simpler version
of the Kreiger–Dougherty model developed by Quemada (1982) is often used.

f 2
ms ¼ ml 1 ð5:17Þ
fmax
Figure 5.15 shows the good correlation of the Quemada model with
fmax ¼ 0:631 to the experimental results of low shear rate viscosity of Jones
et al. (1991) for silica hard sphere suspensions.
When the volume fraction of solid particles is very near the maximum packing
fraction, and the shear rate is high, the preferred flow structures that have
developed become unstable. The large magnitude hydrodynamic interactions
push particles together into clusters that do not produce good flow structures. In
fact, these hydrodynamic clusters can begin to jam the entire flowing suspension
and result in an increase in viscosity. Depending on the conditions, this shear
100 000 5
4
Relative viscosity
10 000
3
Relative viscosity
1 000
2
100 1
0 0.1 0.2 0.3 0.4
Volume fraction
10
1
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Volume fraction
Figure 5.15 Relative viscosity ðms =ml Þ at low shear rate of hard sphere silica suspensions
(circles). Quemada’s model (solid line) with fmax ¼ 0:631; Batchelor’s model (dashed line)
and Einstein’s model (dotted line). (Data from Jones et al., 1991)
INFLUENCE OF SURFACE FORCES ON SUSPENSION FLOW 139
1000
≈ 55 vol %
shear thinning shear thickening
100 region region
10
low shear rate ≈ 50 vol %
Newtonian plateau
1
≈ 45 vol %
0.1 high shear rate
Newtonian plateau
< ≈ 40 vol %
0.01
0.01 0.1 1 10 100 1000 10000
–1
Shear rate (s )
Figure 5.16 Map of typical rheological behaviour of hard sphere suspensions as a

function of shear rate for suspensions with volume fractions between about 40 and 55
vol % solid particles. The dashed lines indicate the approximate location of the boundaries
between Newtonian and non-Newtonian behaviour
thickening (increase in viscosity with shear rate) or dilatancy may be gradual or

abrupt. Strictly speaking, the term dilatancy means that the suspension volume
must increase (dilate) for particles to be able to flow past one another, but the
term dilatancy is commonly used interchangeably with shear thickening (any
increase in viscosity with increasing shear rate). Figure 5.16 shows the behaviour
of typical hard sphere suspensions over a wide range of particle concentrations
and shear rates.
Note that for hard spheres, surprisingly there is no influence of the particle size
on the viscosity. The only concern about particle size in hard sphere suspensions
is that if the particles are too big they will settle out. If the particles are neutrally
buoyant sedimentation issues are not significant.
5.7 INFLUENCE OF SURFACE FORCES ON SUSPENSION FLOW
The second factor to influence fine particle and colloidal suspension rheology is
the interaction force between the particles. (The first factor being the volume
fraction of particles.) The sense (attractive or repulsive), range and magnitude of
the surface forces all influence the suspension rheological behaviour.
5.7.1 Repulsive Forces
Particles that interact with long range repulsive forces behave much like hard
spheres when the distance between the particles is larger than the range of the
repulsive force. This is usually the case when the volume fraction is low (average
distance between the particles is large) and/or when the particles are relatively
large (so that the range of the repulsion is small compared with the particles’
size). If the volume fraction is high, the repulsive force fields of the particles
overlap and the viscosity of the suspension is increased compared with hard
spheres. If the particles are very small (typically 100 nm or less) the average
distance between the particles (even at moderate volume fraction) is on order of
the range of the repulsion so the repulsive force fields overlap and viscosity is
increased.
Even dilute suspensions of repulsive particles will have slightly greater
viscosity than hard spheres because of the additional viscous dissipation related
to the flow of fluid through the repulsive region around the particle. For particles
with EDL repulsion this is known as the primary electro-viscous effect (Hunter,
2001). The total drag on the particle and the double layer is greater than the drag
on a hard sphere. The increase in viscosity due to the primary electro-viscous
effect is typically minimal.
Concentrated suspensions can have significantly elevated viscosities (relative
to hard spheres at the same volume fraction) due to the interaction between
overlapping EDLs. For particles to push past each other the double layer must be
distorted. This effect is known as the secondary electro-viscous effect (Hunter,
2001). Similar effects occur when the repulsion is by steric mechanism.
The influence of repulsive forces on suspension viscosity is usually handled by
considering the effective volume fraction of the particles. The effective volume
fraction is the volume fraction of the particles plus the fraction of volume
occupied by the repulsive region around the particle.
volume of solid þ excluded volume

feff ¼ ð5:18Þ
total volume
The effective volume fraction accounts for the volume fraction of fluid that
cannot be occupied by particles because they are excluded from that region by
the repulsive force as illustrated in Figure 5.17. The suspension rheology can be
modelled reasonably well using the Kreiger–Dougherty or Quemada model with
feff in place of f.
5.7.2 Attractive Forces
There is a fundamental difference between the rheological behaviour of hard

sphere or repulsive particle suspensions and attractive particle suspensions due
to the attractive bond between particles. The bonds between particles must be
broken in order to pull the particles apart to allow flow to occur. The result of the
attractive bonds between particles is that an attractive particle network is formed
when the suspension is at rest. The attractive bonding produces material
behaviour that is characterized by viscoelasticity, a yield stress (minimum stress
required for flow) and shear thinning behaviour.
The shear thinning of an attractive particle network is more pronounced than
for hard sphere suspensions of the same particles at the same volume fraction
100 000
(b)
10 000
Relative viscosity
1 000
φ actual φ eff
100
10
1
(a)
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7
Volume fraction
Figure 5.17 (a) Illustration of suspension of particles with volume fraction 0.4 (grey
circles) with repulsive interaction extending to the dotted line, resulting in an effective
volume fraction of 0.57. (b) Relative viscosity of suspensions of repulsive particles (black
dots and dotted line) as a function of actual volume fraction. When the rheological results
are plotted as a function of effective volume fraction (open dots) the data maps onto the
Quemada model (solid line)
and is caused by a different mechanism. The mechanism for shear thinning is

illustrated in Figure 5.18. At rest, the particle network spans the entire volume of
the container and resists flow. At low shear rates, the particle network is broken
up in to large clusters that flow as units. A large amount of liquid is trapped
within the particle clusters and the viscosity is high. As shear rate is increased
and hydrodynamic forces overcome interparticle attraction, the particle clusters
are broken down into smaller and smaller flow units releasing more and more
liquid and reducing the viscosity. At very high shear rates the particle network is
completely broken down and the particles flow as individuals again almost as if
they were non-interacting.
Greater magnitude interparticle attraction results in increased viscosities at all
shear rates. Thus stronger attraction between particles results in higher viscos-
ities. Attractive particle networks also exhibit a yield stress (minimum stress
required for flow) because there is an attractive force [as shown in Figure 5.2(a)
and (b)] which must be exceeded in order to pull two particles apart. The yield
stress of the suspension also depends upon the magnitude of the attraction, with
stronger attraction resulting in higher yield stresses. Figure 5.19 shows an
example of the yield stress of alumina suspensions as a function of pH. The
maximum in yield stress corresponds with the IEP of the powder. At low salt
concentration, as the pH is adjusted away from the IEP the EDL repulsion
increases as the zeta potential increases (see Figure 5.7) thus reducing the overall
attraction and decreasing the yield stress. As the salt concentration is increased at
pH away from the IEP, the magnitude of the zeta potential decreases (see
Figure 5.7) and the EDL repulsion decreases. As such, the resulting overall
interaction is attractive and the attraction increases as salt content is increased.
100 00
1000
shear thinning
100 of attractive
particle network
10
shear thinning
1 of hard sphere
suspension
0.1
0.01 0.1 1 10 100 1000
–1
Shear rate (s )
Figure 5.18 Comparison of typical shear thinning behaviour of attractive particle net-
work with less pronounced shear thinning of hard sphere suspensions. The attractive
particle network is broken down into smaller flow units as the shear rate is increased
250
alumina in KCl solution
200
0.01 M
Yield stress (Pa)
0.1 M
150
0.3 M
1.0 M
100
50
0
5 7 9 11 13
pH
Figure 5.19 Yield stress of 25 vol % alumina suspensions (0.3 mm diameter) as a function
of pH and salt concentration. (Data from Johnson et al., 1999)
The result presented in Figure 5.19 indicates that the yield stress increases as salt
is increased at pH away from the IEP consistent with the force predictions.
It has been pointed out in the previous section that the rheological behaviour of
hard sphere suspensions (non-interacting particles) was not influenced by the
size of the particles. This is not true of attractive particle networks. When the
particles in a suspension are attractive, smaller particle size results in increased
rheological properties such as yield stress, viscosity and elastic modulus
(described next). The influence of particle size can be determined by considering
that the rheological properties of attractive particle networks depend upon the
strength of the bond between particles and the number of bonds per unit volume
that need to be broken. For example, consider the shear yield stress:
Number of bonds
tY / Strength of bond ð5:19Þ
Unit volume
The strength of the bond of an attractive particle network increases linearly with
particle size as indicated by Equations (5.8) and (5.11).
Strength of bond / x ð5:20Þ
This would make one think that the larger size particles result in suspensions
with greater yield stress, viscosity and elastic modulus. It is the influence of the
number of bonds per unit volume that produces the opposite result. The number
of bonds that need to be broken per unit volume depends upon the structure of
the particle network and the size of the particles. In the first instance we assume
that the structure of the particle network does not vary with particle size. (Details
of the aggregate and particle network structure are beyond the scope of the
present text.) Then the number of bonds per unit volume simply varies with the
inverse cube of the particle size:
Number of bonds 1
/ 3 ð5:21Þ
Unit volume x
When the contributions of the strength of the bond and the number of bonds to
be broken are considered one finds that the rheological properties such as yield
stress, viscosity and elastic modulus vary inversely with the square of the particle
size:

1 1
tY / x / 2 ð5:22Þ
x3 x
Many experimental measurements confirm this result although there is consider-

able variation from the inverse square dependence in many other cases. One
example of well controlled experiments that confirm the inverse square depen-
dence of the yield stress on the particle size is shown in Figure 5.20.
When a stress less than the yield stress is applied to an attractive particle
network, the network responds with an elastic-like response. The attractive bonds
between the particles are stretched rather than broken and when the stress is
removed the particles are pulled back together again by the attractive bonds and
the suspension returns to near its original shape. Because the stretching and
10 000
alumina at pH 9 (its IEP)
Yield stress (Pa)

1000
100
10
100 1000
Particle size (nm)
Figure 5.20 Yield stress of alumina suspensions at their IEP as a function of particle size.
The best fit line has a slope of 2:01, correlating quite well with the predicted inverse
square particle size dependence as per Equation (5.22). (Data from Zhou et al., 2001).
breaking of bonds is a statistical phenomenon, pure elasticity is not usually

achieved, rather the attractive particle network is a visco-elastic material display-
ing behaviour characteristic of both solids and fluids. Some of the energy imparted
to deform the material is stored elastically and some of the energy is dissipated by
viscous mechanism.
5.8 NANOPARTICLES
Nanoparticles are finding application in many areas of technology due to their

unique properties. The very high ratio of surface atoms to bulk atoms is the
primary reason for the unique properties of nanoparticles. Due to the large
surface area and quantum effects related to very small nanoparticles, the optical,
electronic, and other properties are quite different than for larger particles of the
same materials. Because of the unusual properties of nanoparticles, there are
numerous emerging applications and processes where nanoparticles will be
used. Examples of applications of nanoparticles include such diverse topics as:
anti-reflective coatings;
fluorescent labels for biotechnology;
drug delivery systems;
clear inorganic (ZnO) sunscreens;
high performance solar cells;
catalysts;
WORKED EXAMPLES 145
high density magnetic storage media;

high energy density batteries;
self cleaning glass;
improved LEDs;
high performance fuel cells;
nanostructured materials.
The success of these potential applications for nanoparticles relies heavily on the
ability to efficiently produce, transport, separate and safely handle nanoparticles.
The concepts presented in this chapter on fine particles and colloids provide a
starting point for dealing with these issues.
5.9 WORKED EXAMPLES
WORKED EXAMPLE 5.1
Brownian Motion and Settling

Estimate the amount of time that each of the following suspensions will remain
stabilized against sedimentation due to Brownian motion at room temperature (300K).
(a) 200 nm diameter alumina ðr ¼ 3980 kg=m3 Þ in water (typical ceramic processing
suspension);
(b) 200 nm diameter latex particles ðr ¼ 1060 kg=m3 Þ in water (typical paint formulation);
(c) 150 nm diameter fat globules ðr ¼ 780 kg=m3 Þ in water (homogenized milk);
(d) 1000 nm diameter fat globules ðr ¼ 780 kg=m3 Þ in water (non-homogenized milk).
Solution
The time that the suspension remains stable against gravity can be approximated by
equating the average distance moved by a particle due to Brownian motion to the
distance settled due to gravity. This time is presented in Equation (5.13) as follows:
216kTm
t¼
pg2 ðrp rf Þ2 x5
where k ¼ 1:381 1023 J=K; mwater ¼ 0:001 Pa s; g ¼ 9:8 m=s2 ; rwater ¼ 1000 kg=m3 .
216ð1:381 1023 J=KÞ300 Kð0:001 Pa sÞ

then t¼
pð9:8 m=s2 Þ2 ðrp 1000 kg=m3 Þ2 x5
2:96 1024 kg2 s=m
t¼
ðrp kg=m3 1000 kg=m3 Þ2 x5 m5
(a) For the alumina suspension
2:96 1024 kg2 s=m

t¼ ¼ 1042 s ¼ 17:4 min
ð3980 kg=m3 1000 kg=m3 Þ2 ð200 109 Þ5 m5
(b) For the latex particles in paint
2:96 1024 kg2 s=m

t¼ ¼ 2:57 106 s ¼ 30 days
ð1060 kg=m3 1000 kg=m3 Þ2 ð200 109 Þ5 m5
(c) For the homogenized milk
2:96 1024 kg2 s=m

t¼ ¼ 8:06 105 s ¼ 9:3 days
ð780 kg=m3 1000 kg=m3 Þ2 ð150 109 Þ5 m5
(d) For the non-homogenized milk
2:96 1024 kg2 s=m

t¼ ¼ 61 s
ð780 kg=m3 1000 kg=m3 Þ2 ð1000 109 Þ5 m5
These characteristic times correspond best with the time for the first particle to settle out.
The time for all the particles to settle out depends upon the height of the container.
Nonetheless, one can understand the reasons why the alumina suspension needs to be
mixed to keep all of the particles suspended for extended periods of time, why latex
paints must be stirred if kept for a month and why milk is homogenized to prevent
cream from forming while the milk is in your fridge for a week or two.
WORKED EXAMPLE 5.2
van der Waals and EDL Forces

Use the DLVO equation, FT ¼ peeo x2o kekD ðAx=24 D2 Þ, to plot the total interparticle
force (FT) versus interparticle separation distance (D) for two alumina particles and for
two oil droplets under the following conditions. The particles are spherical, 1 mm in
diameter and suspended in water that contains 0.01 M NaCl. Plot three conditions for
each material: (a) at the IEP; (b) with ¼ 30 mV; and (c) with ¼ 60 mV. Comment on
the differences in the behaviour of the two different materials. Which particles are easier
to disperse and why?
Solution
Assume the surface potential equals the zeta potential ðo ¼ Þ.
Calculate the inverse Debye length (k) with Equation (5.10).

pffiffiffiffiffi pffiffiffiffiffiffiffiffiffi
k ¼ 3:29 ½c ðnm1 Þ ¼ k ¼ 3:29 0:01 ðnm1 Þ ¼ 0:329 ðnm1 Þ ¼ 3:29 108 m1
The relative permittivity of water ðeÞ is 80 and the permittivity of free space ðeo Þ is
8:854 1012 C2 =J=m.
WORKED EXAMPLES 147
The diameter of the particles is 1 106 m.
Then
m1 ÞD Að1 106 mÞ

FT ¼ p80ð8:854 1012 C2 =J=mÞð1 106 mÞ2o ð3:29 108 m1 Þeð3:2910
8

24D2
m1 ÞD ð1 106 mÞA
FT ¼ ð7:32 107 C2 =J=mÞ2o eð3:2x 10
8

24 D2
where o is in volts and D in meters.

From Table 5.1 the Hamaker constants (A) are:
For alumina A ¼ 5:0 1020 J
For oil A ¼ 0:4 1020 J
Then for alumina
ð1 106 mÞð5 1020 JÞ

m1 ÞD
FT ¼ ð7:32 107 C2 =J=mÞ2o eð3:2910
8

24 D2
26
8 1 ð5 10 J mÞ
FT ¼ ð7:32 107 C2 =J=mÞ2o eð3:2910 m ÞD
24 D2
and for oil
ð1 106 mÞð0:4 1020 JÞ

m1 ÞD
FT ¼ ð7:32 107 C2 =J=mÞ2o eð3:2910
8

24D2
26
8 1 ð0:4 10 J mÞ
FT ¼ ð7:32 107 C2 =J=mÞ2o eð3:2910 m ÞD
24D2
These equations can be plotted by a standard data plotting software such as

Excel, KG, or Sigmaplot, but first the units and typical values must be checked by
hand to insure no errors are made while writing the equation to the
spreadsheet.
Unit analysis
1
m Jm
FT ¼ C2 =J=m V2 em where V ¼ J=C
m2
1 Jm
m J J
FT ¼ C2 =J=m J2 =C2 em 2
so FT ¼ m1 J ¼ and J ¼ N m so
m m m
FT is in newtons so the units are OK:
Figures 5W2.1 and 5W2.2 are the plotted results.

The difference between the two materials is that the Hamaker constant for the
alumina is much greater than for the oil and thus the attraction between alumina
particles is much stronger between alumina than between oil droplets. Thus, it is
possible to just stabilize the oil droplets with 30 mV zeta potential, whereas when
the alumina has 30 mV zeta potential, there is still attraction between the
particles. Hence 60 mV is needed to stabilize the alumina to the same extent
that 30 mV was able to stabilize oil droplets.
Figure 5W2.1 Force versus separation distance curves for alumina particles
Figure 5W2.2 Force versus separation distance curves for oil droplets
TEST YOURSELF 149
TEST YOURSELF
5.1 What is the typical size range of colloidal particles?
5.2 What two influences are more important for colloidal particles than body forces?
5.3 What is the influence of Brownian motion on a suspension of colloidal particles?
5.4 What is the relationship between surface forces and the potential energy between a
pair of particles?
5.5 Under what conditions can you expect van der Waals interactions to be attractive
and under what conditions can you expect van der Waals interactions to be
repulsive? Which set of conditions is more commonly encountered?
5.6 What are surface hydroxyl groups? What are surface ionization reactions? What is
the isoelectric point?
5.7 What is the physical basis for the electrical double layer repulsion between similarly
charged particles?
5.8 What is bridging flocculation? What type of polymers are most suitable to induce
bridging attraction? What relative surface coverage of the polymer on the particles
surface is typically optimum for flocculation?
5.9 What is steric repulsion? What type of polymers are most suitable to induce steric
repulsion? What relative surface coverage of the polymer on the particles surface is
typically optimum for steric stabilization?
5.10 What is meant by the DLVO theory?
5.11 Why are fine particles in typical atmospheric conditions cohesive? What would
happen if all humidity were removed from the air?
5.12 What can be done to particles suspended in a liquid which typically cannot be done
to particles suspended in a gas?
5.13 Explain why suspension of repulsive colloidal particles cannot be economically

separated from liquid by sedimentation. What is the important parameter that is
changed when the particles are flocculated that allows the particles to be ecomo-
mically separated from the liquid by sedimentation?
5.14 How do interparticle interaction forces influence suspension consolidation?
5.15 Why does Einstein’s prediction of suspension rheology break down as solids
concentration increases above about 7 vol %?
5.16 What is the mechanism for shear thinning of hard sphere suspensions?
5.17 What happens to suspension viscosity as the volume fraction of solids is

increased?
5.18 How do repulsive forces influence suspension rheology?
5.19 How do attractive forces influence suspension rheology?
5.20 What three types of rheological behaviour are typical of attractive particle networks?
5.21 What is the mechanism for shear thinning in attractive particle networks?
5.22 Describe the influence of particle size on rheological properties of attractive particle
networks.
5.23 How do you think the concepts presented in this chapter will be important for
producing products from nano-particles?
EXERCISES
5.1 Colloidal particles may be either ‘dispersed’ or ‘aggregated’.
(a) What causes the difference between these two cases? Answer in terms of inter-
particle interactions.
(b) Name and describe at least two methods to create each type of colloidal dispersion.
(c) Describe the differences in the behaviour of the two types of dispersions (including
but not limited to rheological behaviour, settling rate, sediment bed properties.)
5.2
(a) What forces are important for colloidal particles? What forces are important for non-
colloidal particles?
(b) What is the relationship between interparticle potential energy and interparticle
force?
(c) Which three types of rheological behaviour are characteristic of suspensions of

attractive particles?
5.3
(a) Describe the mechanism responsible for shear thinning behaviour observed for
concentrated suspensions of micrometre sized hard sphere suspensions.
(b) Consider the same suspension as in (a) except instead of hard sphere interactions,
the particles are interacting with a strong attraction such as when they are at their
isoelectric point. In this case describe the mechanism for the shear thinning
behaviour observed.
(c) Draw a schematic plot (log–log) of the relative viscosity as a function of shear rate
comparing the behaviour of the two suspensions described in (a) and (b). Be sure to
indicate the relative magnitude of the low shear rate viscosites.
EXERCISES 151
(d) Consider two suspensions of particles. All factors are the same except for the
particle shape. One suspension has spherical particles and the other rod-shaped
particles like grains of rice.
(i) Which suspension will have a higher viscosity?
(ii) What two physical parameters does the shape of the particles influence that
affect the suspension viscosity.
5.4
(a) Explain why the permeability of the sediment from a flocculated mineral suspen-
sion (less than 5 mm) is greater than the permeability of the sediment of the same
mineral suspension that settles while dispersed.
(b) Fine clay particles (approximately 0.15 mm diameter) wash from a farmer’s soil into
a river due to rain.
(i) Explain why the particles will remain suspended and be carried down stream in
the fast flowing fresh water.
(ii) Explain what happens to the clay when the river empties into the ocean.
5.5 Calculate the effective volume fraction for a suspension of 150 nm silica particles at 40
vol % solids in a solution of 0.005 M NaCl.
(Answer: 0.473.)
5.6 You are a sales engineer working for a polymer supply company selling poly acrylic
acid (PAA). PAA is a water soluble anionic (negatively charged polymer) that comes in
different molecular weights: 10000, 100000, 1 million and 10 million. You have two
100
Percent of surface covered by polymer.
7
1 x10
6
1 x10
80 1 x10
5
4
1 x10
60
40
20
0
0 0.2 0.4 0.6 0.8 1
Concentration of PAA (wt %)
Figure 5E6.1 Adsorption isotherms for PAA of various molecular weights

customers. The first customer is using 0.8 mm alumina to produce ceramics. This customer
would like to reduce the viscosity of the suspension of 40 vol % solids suspensions. The
second customer is trying to remove 0.8 mm alumina from wastewater. There is about 2
vol % alumina in the water and he wants to remove it by settling. What would you
recommend to each customer? Consider if PAA is the right material to use, what
molecular weight should be used and how much should be used. Figure 5E6.1 shows
the adsorption isotherms for PAA with different molecular weights.
5.7
(a) Draw the typical log m versus log g_ plot for suspensions of hard spheres of
approximately micrometre sized particles at 40, 45, 50 and 55 vol % solids.
(b) Draw the relative viscosity ðms =ml Þ versus volume fraction curve for the low shear
viscosities of a typical hard sphere suspension.
6
Fluid Flow Through a Packed
Bed of Particles
6.1 PRESSURE DROP–FLOW RELATIONSHIP
6.1.1 Laminar Flow
In the nineteenth century Darcy (1856) observed that the flow of water through a
packed bed of sand was governed by the relationship:

pressure liquid ðpÞ
/ or /U ð6:1Þ
gradient velocity H
where U is the superficial fluid velocity through the bed and ðpÞ is the
frictional pressure drop across a bed depth H. (Superficial velocity ¼ fluid
volumetric flow rate/cross-sectional area of bed, Q=A.)
The flow of a fluid through a packed bed of solid particles may be analysed in
terms of the fluid flow through tubes. The starting point is the Hagen–Poiseuille
equation for laminar flow through a tube:
ðpÞ 32mU
¼ ð6:2Þ
H D2
where D is the tube diameter and m is the fluid viscosity.

Consider the packed bed to be equivalent to many tubes of equivalent diameter
De following tortuous paths of equivalent length He and carrying fluid with a
velocity Ui . Then, from Equation (6.2),
ðpÞ mUi
¼ K1 2 ð6:3Þ
He De

154 FLUID FLOW THROUGH A PACKED BED OF PARTICLES
Ui is the actual velocity of fluid through the interstices of the packed bed and is
related to superficial fluid velocity by:
Ui ¼ U=e ð6:4Þ
where e is the voidage or void fraction of the packed bed. (Refer to Section 8.1.4
for discussion on actual and superficial velocities.)
Although the paths of the tubes are tortuous, we can assume that their actual
length is proportional to the bed depth, that is,
He ¼ K2 H ð6:5Þ
The tube equivalent diameter is defined as
4 flow area
wetted perimeter
where flow area ¼ eA, where A is the cross-sectional area of the vessel holding
the bed; wetted perimeter ¼ SB A, where SB is the particle surface area per unit
volume of the bed.
That this is so may be demonstrated by comparison with pipe flow:
Total particle surface area in the bed ¼ SB AH. For a pipe,
wetted surface pDL

wetted perimeter ¼ ¼
length L
SB AH
and so for the packed bed, wetted perimeter ¼ ¼ SB A.
H
Now if Sv is the surface area per unit volume of particles, then
Sv ð1 eÞ ¼ SB ð6:6Þ
since

surface of particles volume of particles surface of particles
¼
volume of particles volume of bed volume of bed
and so
4eA 4e
equivalent diameter; De ¼ ¼ ð6:7Þ
SB Sv ð1 eÞ
Substituting Equations (6.4), (6.5) and (6.7) in (6.3):
ðpÞ ð1 eÞ2
¼ K3 mUS2v ð6:8Þ
H e3
where K3 ¼ K1 K2 . Equation (6.8) is known as the Carman–Kozeny equation [after
the work of Carman and Kozeny (Carman, 1937; Kozeny, 1927, 1933)] describing
PRESSURE DROP–FLOW RELATIONSHIP 155
laminar flow through randomly packed particles. The constant K3 depends on

particle shape and surface properties and has been found by experiment to have
a value of about 5. Taking K3 ¼ 5, for laminar flow through a randomly packed
bed of monosized spheres of diameter x (for which S ¼ 6=x) the Carman–Kozeny
equation becomes:
ðpÞ mU ð1 eÞ2
¼ 180 2 ð6:9Þ
H x e3
This is the most common form in which the Carman–Kozeny equation is quoted.
6.1.2 Turbulent Flow
For turbulent flow through a randomly packed bed of monosized spheres of

diameter x the equivalent equation is:
ðpÞ r U 2 ð1 eÞ
¼ 1:75 f ð6:10Þ
H x e3
6.1.3 General Equation for Turbulent and Laminar Flow
Based on extensive experimental data covering a wide range of size and shape of
particles, Ergun (1952) suggested the following general equation for any flow
conditions:
ðpÞ mU ð1 eÞ2 r U 2 ð1 eÞ
¼ 150 2 þ 1:75 f
H x e 3 x e3

laminar turbulent
ð6:11Þ
component component
This is known as the Ergun equation for flow through a randomly packed bed of
spherical particles of diameter x. Ergun’s equation additively combines the
laminar and turbulent components of the pressure gradient. Under laminar
conditions, the first term dominates and the equation reduces to the Carman–
Kozeny equation [Equation (6.9)], but with the constant 150 rather than 180. (The
difference in the values of the constants is probably due to differences in shape
and packing of the particles.) In laminar flow the pressure gradient increases
linearly with superficial fluid velocity and independent of fluid density. Under
turbulent flow conditions, the second term dominates; the pressure gradient
increases as the square of superficial fluid velocity and is independent of fluid
viscosity. In terms of the Reynolds number defined in Equation (6.12), fully
laminar condition exist for Re less than about 10 and fully turbulent flow exists
at Reynolds numbers greater than around 2000.
xUrf
Re ¼ ð6:12Þ
mð1 eÞ
In practice, the Ergun equation is often used to predict packed bed pressure
gradient over the entire range of flow conditions. For simplicity, this practice is
followed in the Worked Examples and Exercises in this chapter.
Ergun also expressed flow through a packed bed in terms of a friction factor
defined in Equation (6.13):
ðpÞ x e3
Friction factor; f ¼ ð6:13Þ
H rf U ð1 eÞ
2
(Compare the form of this friction factor with the familiar Fanning friction factor
for flow through pipes.)
Equation (6.11) then becomes
150
f ¼ þ 1:75 ð6:14Þ
Re
with
150
f ¼ for Re < 10 and f ¼ 1:75 for Re > 2000
Re
(see Figure 6.1).
6.1.4 Non-spherical Particles
The Ergun and Carman–Kozeny equations also accommodate non-spherical

particles if x is replaced by xsv the diameter of a sphere having the same surface
to volume ratio as the non-spherical particles in question. Use of xsv gives the
correct value of specific surface S (surface area of particles per unit volume of
particles). The relevance of this will be apparent if Equation (6.8) is recalled.
Figure 6.1 Friction factor versus Reynolds number plot for fluid flows through a packed
bed of spheres
FILTRATION 157
Thus, in general, the Ergun equation for flow through a randomly packed bed of
particles of surface-volume diameter xsv becomes
ðpÞ mU ð1 eÞ2 rf U 2 ð1 eÞ
¼ 150 2 þ 1:75 ð6:15Þ
H xsv e3 xsv e3
and the Carman–Kozeny equation for laminar flow through a randomly packed
bed of particles of surface-volume diameter xsv becomes:
ðpÞ mU ð1 eÞ2
¼ 180 2 ð6:16Þ
H xsv e3
It was shown in Chapter 1 that if the particles in the bed are not mono-sized,
then the correct mean size to use in these equations is the surface-volume
mean xsv .
6.2 FILTRATION
6.2.1 Introduction
As an example of the application of the above analysis for flow through packed
beds of particles, we will briefly consider cake filtration. Cake filtration is widely
used in industry to separate solid particles from suspension in liquid. It involves
the build up of a bed or ’cake‘ of particles on a porous surface known as the filter
medium, which commonly takes the form of a woven fabric. In cake filtration the
pore size of the medium is less than the size of the particles to be filtered. It will
be appreciated that this filtration process can be analysed in terms of the flow of
fluid through a packed bed of particles, the depth of which is increasing with
time. In practice the voidage of the cake may also change with time. However, we
will first consider the case where the cake voidage is constant, i.e. an incompres-
sible cake.
6.2.2 Incompressible Cake
First, if we ignore the filter medium and consider only the cake itself, the pressure
drop versus liquid flow relationship is described by the Ergun equation [Equa-
tion (6.15)]. The particle size and range of liquid flow and properties commonly
used in industry give rise to laminar flow and so the second (turbulent) term
vanishes. For a given slurry (particle properties fixed) the resulting cake resis-
tance is defined as:
150 ð1 eÞ2
cake resistance; rc ¼ ð6:17Þ
x2sv e3
and so Equation (6.15) becomes
ðpÞ
¼ rc mU ð6:18Þ
H
If V is the volume of filtrate (liquid) passed in a time t and dV=dt is the

instantaneous volumetric flow rate of filtrate at time t, then:
1 dV
superficial filtrate velocity at time t; U ¼ ð6:19Þ
A dt
Each unit volume of filtrate is assumed to deposit a certain mass of particles,

which form a certain volume of cake. This is expressed as f, the volume of cake
formed by the passage of unit volume of filtrate.
HA
f¼ ð6:20Þ
V
and so Equation (6.18) becomes
dV A2 ðpÞ
¼ ð6:21Þ
dt rc mfV
Constant rate filtration
If the filtration rate dV=dt is constant, then the pressure drop across the filter cake
will increase in direct proportion to the volume of filtrate passed V.
Constant pressure drop filtration
If ðpÞ is constant then,
dV 1
/
dt V
or, integrating Equation (6.21),
t
¼ C1 V ð6:22Þ
V
where
rc mf
C1 ¼ ð6:23Þ
2A ðpÞ
2
FILTRATION 159
6.2.3 Including the Resistance of the Filter Medium
The total resistance to flow is the sum of the resistance of the cake and the filter
medium. Hence,

total pressure pressure drop pressure drop
¼ þ
drop across medium across cake
ðpÞ ¼ ðpm Þ þ ðpc Þ
If the medium is assumed to behave as a packed bed of depth Hm and resistance

rm obeying the Carman–Kozeny equation, then
1 dV
ðpÞ ¼ ðrm mHm þ rc mHc Þ ð6:24Þ
A dt
The medium resistance is usually expressed as the equivalent thickness of cake
Heq :
rm Hm ¼ rc Heq
Hence, combining with Equation (6.20),
fVeq
Heq ¼ ð6:25Þ
A
where Veq is the volume of filtrate that must pass in order to create a cake of
thickness Heq . The volume Veq depends only on the properties of the suspension
and the filter medium.
Equation (6.24) becomes
1 dV ðpÞA
¼ ð6:26Þ
A dt rc mðV þ Veq Þf
Considering operation at constant pressure drop, which is the most common

case, integrating Equation (6.26) gives:
t rc fm rc fm
¼ Vþ 2 Veq ð6:27Þ
V 2A2 ðpÞ A ðpÞ
6.2.4 Washing the Cake
The solid particles separated by filtration often must be washed to remove filtrate
from the pores. There are two processes involved in washing. Much of the filtrate
occupying the voids between particles may be removed by displacement as clean
solvent is passed through the cake. Removal of filtrate held in less accessible
regions of the cake and from pores in the particles takes place by diffusion into
Figure 6.2 Removal of filtrate during washing of the filter cake
the wash water. Figure 6.2 shows how the filtrate concentration in the wash
solvent leaving the cake varies typically with volume of wash solvent passed.
6.2.5 Compressible Cake
In practice many materials give rise to compressible filter cakes. A compressible

cake is one whose cake resistance rc increases with applied pressure difference
ðpÞ. Change in rc is due mainly to the effect on the cake voidage [recall
Equation (6.17)]. Fluid drag on the particles in the cake causes a force which is
transmitted through the bed. Particles deeper in the bed experience the sum of
the forces acting on the particles above. The force on the particles causes the
particle packing to become more dense, i.e. cake voidage decreases. In the case of
soft particles, the shape or size of the particles may change, adding to the increase
in cake resistance.
Referring to Figure 6.3, liquid flows at a superficial velocity U through a
filter cake of thickness H. Consider an element of the filter cake of thickness dL
across which the pressure drop is dp. Applying the Carman–Kozeny equation
[Equation (6.18)] for flow through this element,
dp
¼ rc mU ð6:28Þ
dL
where rc is the resistance of this element of the cake. For a compressible cake, rc is
a function of the pressure difference between the upstream surface of the cake
and the element (i.e. referring to Figure 6.3, p1 p).
Letting ps ¼ p1 p ð6:29Þ
then dp ¼ dps ð6:30Þ
WORKED EXAMPLES 161
Figure 6.3 Analysis of the pressure drop – flow relationship for a compressible cake
and Equation (6.28) becomes

dps
¼ rc mU ð6:31Þ
dL
In practice the relationship between rc and ps must be found from laboratory

experiments before Equation (6.29) can be used in design.
6.3 FURTHER READING
For further information on fluid flow through packed beds and on filtration the
reader is referred to the following:
Coulson, J. M. and Richardson, J. R. (1991) Chemical Engineering, Vol. 2, Particle Technology

and Separation Processes, 5th Edition, Pergamon, Oxford.
Perry, R. H. and Green, D. (eds) (1984) Perry’s Chemical Engineering Handbook, 6th or later
editions, McGraw-Hill, New York.
6.4 WORKED EXAMPLES
WORKED EXAMPLE 6.1
Water flows through 3.6 kg of glass particles of density 2590 kg/m3 forming a packed
bed of depth 0.475 m and diameter 0.0757 m. The variation in frictional pressure drop
across the bed with water flow rate in the range 200 –1200 cm3/min is shown in columns
one and two in Table 6.W1.1.
(a) Demonstrate that the flow is laminar.
(b) Estimate the mean surface-volume diameter of the particles.
(c) Calculate the relevant Reynolds number.

Table 6W1.1
Water flow rate Pressure drop U Pressure
(cm3/min) (mmHg) (m/s 104) drop (Pa)
200 5.5 7.41 734
400 12.0 14.81 1600
500 14.5 18.52 1935
700 20.5 25.92 2735
1000 29.5 37.00 3936
1200 36.5 44.40 4870
Solution
(a) First, convert the volumetric water flow rate values into superficial velocities and the
pressure drop in millimetres of mercury into pascal. These values are shown in columns
3 and 4 of Table 6W1.1.
If the flow is laminar then the pressure gradient across the packed bed should increase
linearly with superficial fluid velocity, assuming constant bed voidage and fluid
viscosity. Under laminar conditions, the Ergun equation [Equation (6.15)] reduces to:
ðpÞ mU ð1 eÞ2
¼ 150 2
H xsv e3
Hence, since the bed depth H, the water viscosity m and the packed bed voidage e may
be assumed constant, then ðpÞ plotted against U should give a straight line of
gradient
mH ð1 eÞ2
150
x2sv e3
This plot is shown in Figure 6W1.1. The data points fall reasonably on a straight
line confirming laminar flow. The gradient of the straight line is 1:12 106 Pa s/m
and so:
mH ð1 eÞ2
150 ¼ 1:12 106 Pa s=m
x2sv e3
(b) Knowing the mass of particles in the bed, the density of the particles and the volume
of the bed, the voidage may be calculated:
mass of bed ¼ AHð1 eÞrp

giving e ¼ 0:3497
Substituting e ¼ 0:3497, H ¼ 0:475 m and m ¼ 0:001 Pa s in the expression for the gradient
of the straight line, we have
xsv ¼ 792 mm
WORKED EXAMPLES 163
5000
4500
Pressure drop (Pa)
4000
3500
3000
2500
2000
1500
1000
500
0
0 5 10 15 20 25 30 35 40 45
Superficial fluid velocity (m/s x 10000)
Figure 6W1.1 Plot of packed bed pressure drop versus superficial fluid velocity
xUrf
(c) The relevant Reynolds number is Re ¼ [Equation (6.12)] giving Re ¼ 5:4
mð1 eÞ
(for the maximum velocity used). This is less than the limiting value for laminar flow
(10); a further confirmation of laminar flow.
WORKED EXAMPLE 6.2
A leaf filter has an area of 0.5 m2 and operates at a constant pressure drop of 500 kPa.
The following test results were obtained for a slurry in water which gave rise to a filter
cake regarded as incompressible:
Volume of filtrate collected (m3) 0.1 0.2 0.3 0.4 0.5

Time (s) 140 360 660 1040 1500
Calculate:
(a) the time need to collect 0.8 m3 of filtrate at a constant pressure drop of 700 kPa;
(b) the time required to wash the resulting cake with 0.3 m3 of water at a pressure drop
of 400 kPa.
Solution
For filtration at constant pressure drop we use Equation (6.27), which indicates that if we
plot t=V versus V a straight line will have a gradient
rc fm
2A2 ðpÞ
rc fm
and an intercept Veq on the t=V axis.
A2 ðpÞ
Using the data given in the question:
Vðm3 Þ 0.1 0.2 0.3 0.4 0.5

t=V ðs=m3 Þ 1400 1800 2200 2600 3000
This is plotted in Figure 6W2.1.
From the plot : gradient ¼ 4000 s=m6

intercept ¼ 1000 s=m3
rc fm
hence ¼ 4000
2A2 ðpÞ
rc fm
and 2 Veq ¼ 1000
A ðpÞ
which, with A ¼ 0:5 m2 and ðpÞ ¼ 500 103 Pa, gives
rc fm ¼ 1 109 Pa s=m2
and Veq ¼ 0:125 m3
Substituting in Equation (6.27):

t 0:5 109
¼ ð4V þ 1Þ
V ðpÞ
which applies to the filtration of the same slurry in the same filter at any pressure drop.
(a) To calculate the time required to pass 0:8 m3 of filtrate at a pressure drop of 700 kPa,
we substitute V ¼ 0:8 m3 and ðpÞ ¼ 700 103 Pa in the above equation, giving
t ¼ 2400 s ðor 40 minÞ
3000
2500
2000
t/v
1500
1000
500
0
0 0.05 0.01 0.15 0.15 0.25 0.3 0.35 0.4 0.45 0.5
Volume of filtrate passed, V
Figure 6W2.1 Plot of t=V versus V

EXERCISES 165
(b) During the filtration the cake thickness is continuously increasing and, since the
pressure drop is constant, the volume flow rate of filtrate will continuously decrease.
The filtration rate is given by Equation (6.26). Substituting the volume of filtrate passed
at the end of the filtration period ðV ¼ 0:8 m3 Þ, rc fm ¼ 1 109 Pa s=m2 , Veq ¼ 0:125 m3
and ðpÞ ¼ 700 103 Pa, we find the filtration rate at the end of the filtration period is
dV=dt ¼ 1:89 104 m3 =s.
If we assume that the wash water has the same physical properties as the filtrate, then
during a wash period at a pressure drop of 700 kPa the wash rate is also 1:89
104 m3 =s. However, the applied pressure drop during the wash cycle is 400 kPa.
According to Equation (6.26) the liquid flow rate is directly proportional to the applied
pressure drop, and so

4 400 103
flow rate of wash water ðat 400 kPaÞ ¼ 1:89 10
700 103
¼ 1:08 104 m3 =s
Hence, the time needed to pass 0:3 m3 of wash water at this rate is 2778 s (or 46.3 min).
TEST YOURSELF
6.1 For low Reynolds number (<10) flow of a fluid through a packed bed of particles how
does the frictional pressure drop across the bed depend on (a) superficial fluid
velocity, (b) particle size, (c) fluid density, (d) fluid viscosity and (e) voidage?
6.2 For high Reynolds number (>500) flow of a fluid through a packed bed of particles
how does the frictional pressure drop across the bed depend on (a) superficial fluid
velocity, (b) particle size, (c) fluid density, (d) fluid viscosity and (e) voidage?
6.3 What is the correct mean particle diameter to be used in the Ergun equation? How
can this diameter be derived from a volume distribution?
6.4 During constant pressure drop filtration of an incompressible cake, how does filtrate
flow rate vary with time?
EXERCISES
6.1 A packed bed of solid particles of density 2500 kg/m3 occupies a depth of 1 m in a
vessel of cross-sectional area 0.04 m2. The mass of solids in the bed is 50 kg and the surface-
volume mean diameter of the particles is 1 mm. A liquid of density 800 kg=m3 and
viscosity 0:002 Pa s flows upwards through the bed, which is restrained at its upper
surface.
(a) Calculate the voidage (volume fraction occupied by voids) of the bed.
(b) Calculate the frictional pressure drop across the bed when the volume flow rate of
liquid is 1:44 m3 =h.
[Answer: (a) 0.50; (b) 6560 Pa (Ergun).]

6.2 A packed bed of solids of density 2000 kg/m3 occupies a depth of 0:6 m in a cylindrical
vessel of inside diameter 0:1 m. The mass of solids in the bed is 5 kg and the surface-
volume mean diameter of the particles is 300 mm. Water (density 1000 kg=m3 and viscosity
0:001 Pa s) flows upwards through the bed.
(a) What is the voidage of the packed bed?
(b) Calculate the frictional superficial liquid velocity at which the pressure drop across
the bed is 4130 Pa.
[Answer: (a) 0.4692; (b) 1:5 mm=s (Ergun).]
6.3 A gas absorption tower of diameter 2 m contains ceramic Raschig rings randomly
packed to a height of 5 m. Air containing a small proportion of sulfur dioxide passes
upwards through the absorption tower at a flow rate of 6 m3 =s. The viscosity and density
of the gas may be taken as 1:80 105 Pa s and 1:2 kg=m3 , respectively. Details of the
packing are given below:
Ceramic Raschig rings
surface area per unit volume of packed bed, SB ¼ 190 m2 =m3
voidage of randomly packed bed ¼ 0:71
(a) Calculate the diameter, dsv , of a sphere with the same surface-volume ratio as the
Raschig rings.
(b) Calculate the frictional pressure drop across the packing in the tower.
(c) Discuss how this pressure drop will vary with flow rate of the gas within 10% of the
quoted flow rate.
(d) Discuss how the pressure drop across the packing would vary with gas pressure and
temperature.
[Answer: (a) 9:16 mm; (b) 3460 Pa; for (c), (d) use the hint that turbulence dominates.]
6.4 A solution of density 1100 kg=m3 and viscosity 2 103 Pa s is flowing under gravity at
a rate of 0:24 kg=s through a bed of catalyst particles. The bed diameter is 0:2 m and the
depth is 0:5 m. The particles are cylindrical, with a diameter of 1 mm and length of 2 mm.
They are loosely packed to give a voidage of 0.3. Calculate the depth of liquid above the
top of the bed. (Hint: apply the mechanical energy equation between the bottom of the bed
and the surface of the liquid.)
[Answer: 0:716 m.]
6.5 In the regeneration of an ion exchange resin, hydrochloric acid of density 1200 kg=m3
and viscosity 2 103 Pa s flows upwards through a bed of resin particles of density
2500 kg=m3 resting on a porous support in a tube 4 cm in diameter. The particles are
EXERCISES 167
spherical, have a diameter 0:2 mm and form a bed of void fraction 0.5. The bed is 60 cm
deep and is unrestrained at its upper surface. Plot the frictional pressure drop across the
bed as function of acid flow rate up to a value of 0.1 litres/min.
[Answer: Pressure drop increases linearly up to a value of 3826 Pa beyond which point the
bed will fluidize and maintain this pressure drop (see Chapter 7).]
6.6 The reactor of a catalytic reformer contains spherical catalyst particles of diameter
1:46 mm. The packed volume of the reactor is to be 3:4 m3 and the void fraction is 0.45. The
reactor feed is a gas of density 30 kg=m3 and viscosity 2 105 Pa s flowing at a rate of
11 320 m3 =h. The gas properties may be assumed constant. The pressure loss through the
reactor is restricted to 68:95 kPa. Calculate the cross-sectional area for flow and the bed
depth required.
[Answer: area ¼ 4:78 m2 ; depth ¼ 0:711 m.]
6.7 A leaf filter has an area of 2 m2 and operates at a constant pressure drop of 250 kPa.
The following results were obtained during a test with an incompressible cake:
Volume of filtrate collected (litre) 280 430 540 680 800

Time (min) 10 20 30 45 60
Calculate:
(a) the time required to collect 1200 litre of filtrate at a constant pressure drop of 400 kPa
with the same feed slurry;
(b) the time required to wash the resulting filter cake with 500 litre of water (same
properties as the filtrate) at a pressure drop of 200 kPa.
[Answer: (a) 79:4 min; (b) 124 min.]
6.8 A laboratory leaf filter has an area of 0:1 m2 , operates at a constant pressure
drop of 400 kPa and produces the following results during a test on filtration of a
slurry:
Volume of filtrate collected (litre) 19 31 41 49 56 63

Time (s) 300 600 900 1200 1500 1800
(a) Calculate the time required to collect 1:5 m3 of filtrate during filtration of the same
slurry at a constant pressure drop of 300 kPa on a similar full-scale filter with an area
of 2 m2 .
(b) Calculate the rate of passage of filtrate at the end of the filtration in (a).
(c) Calculate the time required to wash the resulting filter cake with 0:5 m3 of water at a
constant pressure drop of 200 kPa.
(Assume the cake is incompressible and that the flow properties of the filtrate are the same
as those of the wash solution.)
[Answer: (a) 37:2 min; (b) 20:4 litre=min; (c) 36:7 min.]
6.9 A leaf filter has an area of 1:73 m2 , operates at a constant pressure drop of 300 kPa and
produces the following results during a test on filtration of a slurry:
Volume of filtrate collected ðm3 Þ 0.19 0.31 0.41 0.49 0.56 0.63
Time (s) 300 600 900 1200 1500 1800
(a) Calculate the time required to collect 1 m3 of filtrate during filtration of the same slurry
at a constant pressure drop of 400 kPa.
(b) Calculate the time required to wash the resulting filter cake with 0:8 m3 of water at a
constant pressure drop of 250 kPa.
(Assume the cake is incompressible and that the flow properties of the filtrate are the same
as those of the wash solution.)
[Answer: (a) 49:5 min; (b) 110:9 min.]

7
Fluidization
7.1 FUNDAMENTALS
When a fluid is passed upwards through a bed of particles the pressure loss in
the fluid due to frictional resistance increases with increasing fluid flow. A point
is reached when the upward drag force exerted by the fluid on the particles is
equal to the apparent weight of particles in the bed. At this point the particles are
lifted by the fluid, the separation of the particles increases, and the bed becomes
fluidized. The force balance across the fluidized bed dictates that the fluid
pressure loss across the bed of particles is equal to the apparent weight of the
particles per unit area of the bed. Thus:
weight of particles upthrust on particle

pressure drop ¼
bed cross-sectional area
For a bed of particles of density rp , fluidized by a fluid of density rf to form a bed

of depth H and voidage e in a vessel of cross-sectional area A:
HAð1 eÞðrp rf Þg
p ¼ ð7:1Þ
A
or
p ¼ Hð1 eÞðrp rf Þg ð7:2Þ
A plot of fluid pressure loss across the bed versus superficial fluid velocity through
the bed would have the appearance of Figure 7.1. Referring to Figure 7.1, the
straight line region OA is the packed bed region. Here the solid particles do not
move relative to one another and their separation is constant. The pressure loss

170 FLUIDIZATION
Figure 7.1 Pressure drop versus fluid velocity for packed and fluidized beds
versus fluid velocity relationship in this region is described by the Carman–

Kozeny equation [Equation (6.9)] in the laminar flow regime and the Ergun
equation in general [Equation (6.11)]. (See Chapter 6 for a detailed analysis of
packed bed flow.)
The region BC is the fluidized bed region where Equation (7.1) applies. At
point A it will be noticed that the pressure loss rises above the value predicted by
Equation (7.1). This rise is more marked in small vessels and in powders which
have been compacted to some extent before the test and is associated with the
extra force required to overcome wall friction and adhesive forces between bed
and the distributor.
The superficial fluid velocity at which the packed bed becomes a fluidized bed is
known as the minimum fluidization velocity, Umf . This is also sometimes referred
to as the velocity at incipient fluidization (incipient meaning beginning). Umf
increases with particle size and particle density and is affected by fluid properties.
It is possible to derive an expression for Umf by equating the expression for
pressure loss in a fluidized bed [Equation (7.2)] with the expression for pressure
loss across a packed bed. Thus recalling the Ergun equation [Equation (6.11)]:
ðpÞ ð1 eÞ2 mU ð1 eÞ rf U 2
¼ 150 þ 1:75 ð7:3Þ
H e3 x2sv e3 xsv
substituting the expression for ðpÞ from Equation (7.2):
ð1 eÞ2 mUmf ð1 eÞ rf Umf

2
ð1 eÞðrp rf Þg ¼ 150 þ 1:75 ð7:4Þ
e 3 xsv
2 e 3 xsv
Rearranging,
2
ð1 eÞ2 m Umf xsv rf
ð1 eÞðrp rf Þg ¼ 150
e3 rf x3sv m
2 2 2 2 ð7:5Þ
ð1 eÞ m Umf xsv rf
þ 1:75
e3 rf x3sv m2
FUNDAMENTALS 171
and so

rf x3sv ð1 eÞ2 ð1 eÞ 2
ð1 eÞðrp rf Þg ¼ 150 Remf þ 1:75 Remf ð7:6Þ
m2 e3 e3
or
ð1 eÞ 1
Ar ¼ 150 3
Remf þ 1:75 3 Re2mf ð7:7Þ
e e
where Ar is the dimensionless number known as the Archimedes number,
rf ðrp rf Þgx3sv
Ar ¼
m2
and Remf is the Reynolds number at incipient fluidization,

Umf xsv rf
Remf ¼
m
In order to obtain a value of Umf from Equation (7.7) we need to know the
voidage of the bed at incipient fluidization, e ¼ emf : Taking emf as the voidage
of the packed bed, we can obtain a crude Umf : However, in practice voidage at
the onset of fluidization may be considerably greater than the packed bed
voidage. A typical often used value of emf is 0.4. Using this value, Equation (7.7)
becomes
Ar ¼ 1406 Remf þ 27:3 Re2mf ð7:8Þ
Wen and Yu (1966) produced an empirical correlation for Umf with a form
similar to Equation (7.8):
Ar ¼ 1652Remf þ 24:51Re2mf ð7:9Þ
The Wen and Yu correlation is often expressed in the form:
Remf ¼ 33:7½ð1 þ 3:59 105 ArÞ0:5 1 ð7:10Þ
and is valid for spheres in the range 0:01 < Remf < 1000.
For gas fluidization the Wen and Yu correlation is often taken as being most
suitable for particles larger than 100 mm, whereas the correlation of Baeyens
and Geldart (1974), shown in Equation (7.11), is best for particles less than
100 mm.
ðrp rf Þ0:934 g0:934 x1:8

p
Umf ¼ ð7:11Þ
1110m0:87 r0:066
f
172 FLUIDIZATION
7.2 RELEVANT POWDER AND PARTICLE PROPERTIES
The correct density for use in fluidization equations is the particle density,
defined as the mass of a particle divided by its hydrodynamic volume. This is
the volume ’seen‘ by the fluid in its fluid dynamic interaction with the particle
and includes the volume of all the open and closed pores (see Figure 7.2):
mass of particle
particle density ¼
hydrodynamic volume of particle
For non-porous solids, this is easily measured by a gas pycnometer or specific

gravity bottle, but these devices should not be used for porous solids since they
give the true or absolute density rabs of the material of which the particle is made
and this is not appropriate where interaction with fluid flow is concerned:
mass of particle
absolute density ¼
volume of solids material making up the particle
For porous particles, the particle density rp (also called apparent or envelope
density) is not easy to measure directly although several methods are given in
Geldart (1990). Bed density is another term used in connection with fluidized
beds; bed density is defined as
mass of particles in a bed
bed density ¼
volume occupied by particles and voids between them
For example, 600 kg of powder is fluidized in a vessel of cross-sectional area 1 m2

and achieves a bed height of 0.5 m. What is the bed density?
Mass of particles in the bed ¼ 600 kg
Volume occupied by particles and voids ¼ 1 0:5 ¼ 0:5 m3
Hence, bed density ¼ 600=0:5 ¼ 1200 kg=m3 .
If the particle density of these solids is 2700 kg/m3, what is the bed voidage?
Bed density rB is related to particle density rp and bed voidage e by
Equation (7.12):
rB ¼ ð1 eÞrp ð7:12Þ
Figure 7.2 Hydrodynamic volume of a particle

BUBBLING AND NON-BUBBLING FLUIDIZATION 173
1200
Hence, voidage ¼ 1 ¼ 0:555.
2700
Another density often used when dealing with powders is the bulk density. It
is defined in a similar way to fluid bed density:
mass of particles
bulk density ¼
volume occupied by particles and voids between them
The most appropriate particle size to use in equations relating to fluid–particle

interactions is a hydrodynamic diameter, i.e. an equivalent sphere diameter
derived from a measurement technique involving hydrodynamic interaction
between the particle and fluid. In practice, however, in most industrial applica-
tions sizing is done using sieving and correlations use either sieve diameter, xp or
volume diameter, xv : For spherical or near spherical particles xv is equal to xp : For
angular particles, xv 1:13xp :
For use in fluidization applications, starting from a sieve analysis the mean size
of the powder is often calculated from
1
mean xp ¼ P ð7:13Þ
mi =xi
where xi is the arithmetic mean of adjacent sieves between which a mass fraction mi
is collected. This is the harmonic mean of the mass distribution, which was shown
in Chapter 1 to be equivalent to the arithmetic mean of a surface distribution.
7.3 BUBBLING AND NON-BUBBLING FLUIDIZATION
Beyond the minimum fluidization velocity bubbles or particle-free voids may

appear in the fluidized bed. Figure 7.3 shows bubbles in a gas fluidized bed. The
Figure 7.3 Sequence showing bubbles in a ‘two-dimensional’ fluidized bed of Group B

powder. Sketches taken from video
174 FLUIDIZATION
Figure 7.4 Expansion of a liquid fluidized bed: (a) just above Umf ; (b) liquid velocity
several times Umf : Note uniform increase in void fraciton. Sketches taken from video
equipment used Figure 7.3 is a so-called ‘two-dimensional fluidized bed’. A

favourite tool of researchers looking at bubble behaviour, this is actually a vessel
of a rectangular cross-section, whose shortest dimension (into the page) is usually
only 1 cm or so.
At superficial velocities above the minimum fluidization velocity, fluidization
may in general be either bubbling or non-bubbling. Some combinations of fluid
and particles give rise to only bubbling fluidization and some combinations give
only non-bubbling fluidization. Most liquid fluidized systems, except those invol-
ving very dense particles, do not give rise to bubbling. Figure 7.4 shows a bed of
glass spheres fluidized by water exhibiting non-bubbling fluidized bed beha-
viour. Gas fluidized systems, however, give either only bubbling fluidization or
non-bubbling fluidization beginning at Umf ; followed by bubbling fluidization as
fluidizing velocity increases. Non-bubbling fluidization is also known as parti-
culate or homogeneous fluidization and bubbling fluidization is often referred to
as aggregative or heterogeneous fluidization.
7.4 CLASSIFICATION OF POWDERS
Geldart (1973) classified powders into four groups according to their fluidization
properties at ambient conditions. The Geldart classification of powders is now used
widely in all fields of powder technology. Powders which when fluidized by air at
ambient conditions give a region of non-bubbling fluidization beginning at Umf ;
followed by bubbling fluidization as fluidizing velocity increases, are classified as
Group A. Powders which under these conditions give only bubbling fluidization are
classified as Group B. Geldart identified two further groups: Group C powders –
very fine, cohesive powders which are incapable of fluidization in the strict sense,
and Group D powders – large particles distinguished by their ability to produce deep
spouting beds (see Figure 7.5). Figure 7.6 shows how the group classifications are
related to the particle and gas properties.
CLASSIFICATION OF POWDERS 175
Figure 7.5 A spouted fluidized bed of rice
Figure 7.6 Simplified diagram showing Geldart’s classification of powders according to

their fluidization behaviour in air under ambient conditions (Geldart, 1973)
176 FLUIDIZATION
Table 7.1 Geldart’s classification of powders

Group C Group A Group B Group D
Most obvious Cohesive, Ideal for Starts bubbling Coarse solids
characteristic difficult to fluidization. at Umf
fluidize Exhibits range
of non-bubbling
fluidization
Typical solids Flour, cement Cracking Building sand Gravel, coffee
catalyst beans
Property
Bed expansion Low because High Moderate Low
of chanelling
De-aeration rate Initially fast, Slow, linear Fast Fast
then
exponential
Bubble No bubbles– Bubbles split No limit to size No limit to size
properties only channels and coalesce.
Maximum
bubble size
Solids mixing Very low High Moderate Low
Gas backmixing Very low High Moderate Low
Spouting No No Only in shallow Yes, even
beds in deep beds
The fluidization properties of a powder in air may be predicted by establishing

in which group it lies. It is important to note that at operating temperatures and
pressures above ambient a powder may appear in a different group from that
which it occupies at ambient conditions. This is due to the effect of gas properties
on the grouping and may have serious implications as far as the operation of the
fluidized bed is concerned. Table 7.1 presents a summary of the typical properties
of the different powder classes.
Since the range of gas velocities over which non-bubbling fluidization occurs in
Group A powders is small, bubbling fluidization is the type most commonly
encountered in gas fluidized systems in commercial use. The superficial gas
velocity at which bubbles first appear is known as the minimum bubbling velocity
Umb : Premature bubbling can be caused by poor distributor design or protuber-
ances inside the bed. Abrahamsen and Geldart (1980) correlated the maximum
values of Umb with gas and particle properties using the following correlation:
!
xp r0:06
g
Umb ¼ 2:07 expð0:716FÞ ð7:14Þ
m0:347
where F is the fraction of powder less than 45 mm.

In Group A powders Umb > Umf ; bubbles are constantly splitting and coales-
cing, and a maximum stable bubble size is achieved. This makes for good quality,
CLASSIFICATION OF POWDERS 177
Figure 7.7 Bubbles in a ‘two-dimensional’ fluidized bed of Group A powder. Sketch

taken from video
smooth fluidization. Figure 7.7 shows bubbles in a Group A powder in a two-

dimensional fluidized bed.
In Groups B and D powders Umb ¼ Umf ; bubbles continue to grow, never
achieving a maximum size (see Figure 7.3). This makes for rather poor quality
fluidization associated with large pressure fluctuations.
In Group C powders the interparticle forces are large compared with the
inertial forces on the particles. As a result, the particles are unable to achieve the
separation they require to be totally supported by drag and buoyancy forces and
true fluidization does not occur. Bubbles, as such, do not appear; instead the gas
flow forms channels through the powder (see Figure 7.8). Since the particles are
not fully supported by the gas, the pressure loss across the bed is always less than
apparent weight of the bed per unit cross-sectional area. Consequently, measure-
ment of bed pressure drop is one means of detecting this Group C behaviour if
visual observation is inconclusive. Fluidization, of sorts, can be achieved with the
assistance of a mechanical stirrer or vibration.
When the size of the bubbles is greater than about one-third of the diameter of
the equipment their rise velocity is controlled by the equipment and they become
slugs of gas. Slugging is attended by large pressure fluctuations and so it is
generally avoided in large units since it can cause vibration to the plant. Slugging
is unlikely to occur at any velocity if the bed is sufficiently shallow. According to
Yagi and Muchi (1952), slugging will not occur provided the following criterion is
satisfied:

Hmf 1:9
ð7:15Þ
D ðrp xp Þ0:3
This criterion works well for most powders. If the bed is deeper than this critical
height then slugging will occur when the gas velocity exceeds Ums as given by
(Baeyens and Geldart, 1974):
Ums ¼ Umf þ 0:16ð1:34D0:175 Hmf Þ2 þ 0:07ðgDÞ0:5 ð7:16Þ

178 FLUIDIZATION
Figure 7.8 Attempts to fluidize Group C powder producing cracks and channels or
discrete solid plugs
7.5 EXPANSION OF A FLUIDIZED BED
7.5.1 Non-bubbling Fluidization
In a non-bubbling fluidized bed beyond Umf the particle separation increases

with increasing fluid superficial velocity whilst the pressure loss across the bed
remains constant. This increase in bed voidage with fluidizing velocity is referred
to as bed expansion (see Figure 7.4). The relationship between fluid velocity and
bed voidage may be determined by recalling the analysis of multiple particle
systems (Chapter 3). For a particle suspension settling in a fluid under
force balance conditions the relative velocity Urel between particles and fluid
is given by:
Urel ¼ Up Uf ¼ UT efðeÞ ð7:17Þ
where Up and Uf are the actual downward vertical velocities of the particles and
the fluid, and UT is the single particle terminal velocity in the fluid. In the case of
a fluidized bed the time-averaged actual vertical particle velocity is zero ðUp ¼ 0Þ
and so
Uf ¼ UT efðeÞ ð7:18Þ
EXPANSION OF A FLUIDIZED BED 179
or
Ufs ¼ UT e2 fðeÞ ð7:19Þ
where Ufs is the downward volumetric fluid flux. In common with fluidization
practice, we will use the term superficial velocity ðUÞ rather than volumetric fluid
flux. Since the upward superficial fluid velocity (U) is equal to the upward
volumetric fluid flux ðUfs Þ; and Ufs ¼ Uf e, then:
U ¼ UT e2 fðeÞ ð7:20Þ
Richardson and Zaki (1954) found the function fðeÞ which applied to both
hindered settling and to non-bubbling fluidization. They found that in general,
fðeÞ ¼ en ; where the exponent n was independent of particle Reynolds number at
very low Reynolds numbers, when the drag force is independent of fluid density,
and at high Reynolds number, when the drag force is independent of fluid
viscosity, i.e.
In general : U ¼ UT en ð7:21Þ
For Rep 0:3; fðeÞ ¼ e 2:65
) U ¼ UT e 4:65
ð7:22Þ
For Rep 500; fðeÞ ¼ e 0:4
) U ¼ UT e 2:4
ð7:23Þ
where Rep is calculated at UT :

Khan and Richardson (1989) suggested the correlation given in Equation (3.25)
(Chapter 3) which permits the determination of the exponent n at intermediate
values of Reynolds number (although it is expressed in terms of the Archimedes
number Ar there is a direct relationship between Rep and Ar). This correlation
also incorporates the effect of the vessel diameter on the exponent. Thus
Equations (7.21), (7.22) and (7.23) in conjunction with Equation (3.25) permit
calculation of the variation in bed voidage with fluid velocity beyond Umf :
Knowledge of the bed voidage allows calculation of the fluidized bed height as
illustrated below:
mass of particles in the bed ¼ MB ¼ ð1 eÞrp AH ð7:24Þ
If packed bed depth ðH1 Þ and voidage ðe1 Þ are known, then if the mass remains
constant the bed depth at any voidage can be determined:
ð1 e2 Þrp AH2 ¼ ð1 e1 Þrp AH1 ð7:25Þ
hence
ð1 e1 Þ
H2 ¼ H1
ð1 e2 Þ
180 FLUIDIZATION
Figure 7.9 Bed expansion in a ‘two-dimensional’ fluidized bed of Group A powder: (a)
just above Umb ; (b) fluidized at several times Umb : Sketches taken from video
7.5.2 Bubbling Fluidization
The simplest description of the expansion of a bubbling fluidized bed is derived

from the two-phase theory of fluidization of Toomey and Johnstone (1952). This
theory considers the bubbling fluidized bed to be composed of two phases: the
bubbling phase (the gas bubbles); and the particulate phase (the fluidized solids
around the bubbles). The particulate phase is also referred to as the emulsion
phase. The theory states that any gas in excess of that required at incipient
fluidization will pass through the bed as bubbles. Figure 7.9 shows the effect of
fluidizing gas velocity on bed expansion of a Group A powder fluidized by air.
Thus, referring to Figure 7.10, Q is the actual gas flow rate to the fluid bed and
Qmf is the gas flow rate at incipient fluidization, then
Figure 7.10 Gas flows in a fluidized bed according to the two-phase theory
EXPANSION OF A FLUIDIZED BED 181
gas passing through the bed as bubbles ¼ Q Qmf ¼ ðU Umf ÞA ð7:26Þ

gas passing through the emulsion phase ¼ Qmf ¼ Umf A ð7:27Þ
Expressing the bed expansion in terms of the fraction of the bed occupied by
bubbles, eB :
H Hmf Q Qmf ðU Umf Þ

eB ¼ ¼ ¼ ð7:28Þ
H AUB UB
where H is the bed height at U and Hmf is the bed height at Umf and UB is the
mean rise velocity of a bubble in the bed (obtained from correlations; see below).
The voidage of the emulsion phase is taken to be that at minimum fluidization
emf . The mean bed voidage is then given by:
ð1 eÞ ¼ ð1 eB Þð1 emf Þ ð7:29Þ
In practice, the elegant two-phase theory overestimates the volume of gas passing
through the bed as bubbles (the visible bubble flow rate) and better estimates of
bed expansion may be obtained by replacing ðQ Qmf Þ in Equation (7.28) with
visible bubble flow rate;QB ¼ YAðU Umf Þ

where 0:8 < Y < 1:0 for Group A powders
ð7:30Þ
0:6 < Y < 0:8 for Group B powders
0:25 < Y < 0:6 for GroupDpowders
Strictly the equations should be written in terms of Umb rather than Umf and Qmb
rather than Qmf, so that they are valid for both Group A and Group B powders.
Here they have been written in their original form. In practice, however, it makes
little difference, since both Umb and Umf are usually much smaller than the
superficial fluidizing velocity, U [so ðU Umf Þ ffi ðU Umb Þ]. In rare cases where
the operating velocity is not much greater than Umb, then Umb should be used in
place of Umf in the equations.
The above analysis requires a knowledge of the bubble rise velocity UB ; which
depends on the bubble size dBv and bed diameter D. The bubble diameter at a
given height above the distributor depends on the orifice density in the dis-
tributor N, the distance above the distributor L and the excess gas velocity
ðU Umf Þ.
For Group B powders
0:54
dBv ¼ ðU Umf Þ0:4 ðL þ 4N 0:5 Þ0:8 ðDarton et al:; 1977Þ ð7:31Þ
g0:2
UB ¼ B ðgdBv Þ0:5 ðWerther;1983Þ ð7:32Þ
182 FLUIDIZATION
where
8 9
< B ¼ 0:64
> for D 0:1 m >
=
B ¼ 1:6D 0:4
for 0:1 < D 1 m ð7:33Þ
>
: >
;
B ¼ 1:6 for D > 1 m
For Group A powders
Bubbles reach a maximum stable size which may be estimated from
dBv max ¼ 2ðUT2:7 Þ2 =g ðGeldart; 1992Þ ð7:34Þ
where UT2:7 is the terminal free fall velocity for particles of diameter 2.7 times the
actual mean particle diameter.
Bubble velocity for Group A powders is given by:
UB ¼ A ðgdBv Þ0:5 ðWerther; 1983Þ ð7:35Þ
where
8 9
>
> ¼1 for D 0:1 m >
>
< A =
A ¼ 2:5D0:4
for 0:1 < D 1 m ð7:36Þ
>
> >
>
: ;
A ¼ 2:5 for D > 1 m
7.6 ENTRAINMENT
The term entrainment will be used here to describe the ejection of particles from
the surface of a bubbling bed and their removal from the vessel in the fluidizing
gas. In the literature on the subject other terms such as ‘carryover’ and ‘elutria-
tion’ are often used to describe the same process. In this section we will study the
factors affecting the rate of entrainment of solids from a fluidized bed and
develop a simple approach to the estimation of the entrainment rate and the size
distribution of entrained solids.
Consider a single particle falling under gravity in a static gas in the absence of
any solids boundaries. We know that this particle will reach a terminal velocity
when the forces of gravity, buoyancy and drag are balanced (see Chapter 2). If the
gas of infinite extent is now considered to be moving upwards at a velocity equal to
the terminal velocity of the particle, the particle will be stationary. If the gas is
moving upwards in a pipe at a superficial velocity equal to the particle’s terminal
velocity, then:
ENTRAINMENT 183
(a) in laminar flow: the particle may move up or down depending on its radial
position because of the parabolic velocity profile of the gas in the pipe.
(b) in turbulent flow: the particle may move up or down depending on its radial
position. In addition the random velocity fluctuations superimposed on the
time-averaged velocity profile make the actual particle motion less predictable.
If we now introduce into the moving gas stream a number of particles with a
range of particle size some particles may fall and some may rise depending on
their size and their radial position. Thus the entrainment of particles in an
upward-flowing gas stream is a complex process. We can see that the rate of
entrainment and the size distribution of entrained particles will in general
depend on particle size and density, gas properties, gas velocity, gas flow
regime–radial velocity profile and fluctuations and vessel diameter. In addition
(i) the mechanisms by which the particles are ejected into the gas stream from the
fluidized bed are dependent on the characteristics of the bed – in particular
bubble size and velocity at the surface, and (ii) the gas velocity profile immedi-
ately above the bed surface is distorted by the bursting bubbles. It is not
surprising then that prediction of entrainment from first principles is not possible
and in practice an empirical approach must be adopted.
This empirical approach defines coarse particles as particles whose terminal
velocities are greater than the superficial gas velocity ðUT > UÞ and fine particles
as those for which UT < U; and considers the region above the fluidized bed
surface to be composed of several zones shown in Figure 7.11:
Freeboard. Region between the bed surface and the gas outlet.
Splash zone. Region just above the bed surface in which coarse particles fall back
down.
Disengagement zone. Region above the splash zone in which the upward flux and
suspension concentration of fine particles decreases with increasing height.
Dilute-phase transport zone. Region above the disengagement zone in which all
particles are carried upwards; particle flux and suspension concentration are
constant with height.
Note that, although in general fine particles will be entrained and leave the
system and coarse particles will remain, in practice fine particles may stay in the
system at velocities several times their terminal velocity and coarse particles may
be entrained.
The height from the bed surface to the top of the disengagement zone is known
as the transport disengagement height (TDH). Above TDH the entrainment flux
and concentration of particles is constant. Thus, from the design point of view, in
order to gain maximum benefit from the effect of gravity in the freeboard, the gas
exit should be placed above the TDH. Many empirical correlations for TDH are
available in the literature; those of Horio et al. (1980) presented in Equation (7.37)
184 FLUIDIZATION
Figure 7.11 Zones in fluidized bed freeboard
and Zenz (1983) presented graphically in Figure 7.12 are two of the more reliable
ones.
TDH ¼ 4:47d0:5
bvs ð7:37Þ
Where dbvs is the equivalent volume diameter of a bubble at the surface.

The empirical estimation of entrainment rates from fluidized beds is based on
the following rather intuitive equation:

instantaneous rate of loss fraction of bed with
/ bed area
of solids of size xi size xi at timet
ð7:38Þ
d
i:e: Ri ¼ ðMB mBi Þ ¼ Kih AmBi
dt

where Kih is the elutriation rate constant (the entrainment flux at height h above
the bed surface for the solids of size xi , when mBi ¼ 1:0), MB is the total mass of
solids in the bed, A is the area of bed surface and mBi is the fraction of the bed
mass with size xi at time t.
ENTRAINMENT 185
Figure 7.12 Graph for determination of transport disengagement height after the method
of Zenz (1983). Reproduced by permission. [Note: TDH and the bubble diameter at the
bubble surface db are given in inches (1 in. ¼ 27.4 mm)]
For continuous operation, mBi and MB are constant and so

Ri ¼ Kih AmBi ð7:39Þ
and
X X

total rate of entrainment; RT ¼ Ri ¼ Kih AmBi ð7:40Þ
i ¼ Ri =UA and the total solids

The solids loading of size xi in the off-gases is rP
loading of the gas leaving the freeboard is rT ¼ ri .
For batch operation, the rates of entrainment of each size range, the total
entrainment rate and the particle size distribution of the bed change with time.
The problem can best be solved by writing Equation (7.38) in finite increment form:

ðmBi MB Þ ¼ Kih AmBi t ð7:41Þ
where ðmBi MB Þ is the mass of solids in size range i entrained in time incre-
ment t:
X
k
Total mass entrained in time t ¼ i¼1 ½ðmBi MB Þ ð7:42Þ
186 FLUIDIZATION
and mass of solids remaining in the bed at time

X
k
t þ t ¼ ðMB Þt i¼1 ½ðmBi MB Þt ð7:43Þ
where subscript t refers to the value at time t.
ðmBi MB Þt ½ðmBi MB Þt
Bed composition at time t þ t ¼ ðmBi Þtþt ¼ P ð7:44Þ
ðMB Þt ki¼1 fðmBi MB Þt g
Solution of a batch entrainment problem proceeds by sequential application of

Equations (7.41)–(7.44) for the required time period.

The elutriation rate constant Kih cannot be predicted from first principles and
so it is necessary to rely on the available correlations which differ significantly in
their predictions. Correlations are usually in terms of the carryover rate above

TDH, Ki1 . Two of the more reliable correlations are given below.
Geldart et al. (1979) (for particles > 100 mm and U > 1:2 m=s)

Ki1 UTi
¼ 23:7 exp 5:4 ð7:45Þ
rg U U
Zenz and Weil (1958) (for particles <100 mm and U < 1:2 m=s)
8 !1:88 ! 9
>
> U 2
U 2 >
>
>
> 1:26 107 < 3 104 >>
>
> gxi rp
when
gxi rp >
>

Ki1 < 2 2
=
¼ !1:18 ! ð7:46Þ
rg U > > >
>
>
> U2 U2 >
>
>
> 4:31 10 4
when > 3 10 4 >
>
: gxi rp2 gxi rp2 ;
7.7 HEAT TRANSFER IN FLUIDIZED BEDS
The transfer of heat between fluidized solids, gas and internal surfaces of
equipment is very good. This makes for uniform temperatures and ease of
control of bed temperature.
7.7.1 Gas–Particle Heat Transfer
Gas to particle heat transfer coefficients are typically small, of the order of
5–20 W
m2K. However, because of the very large heat transfer surface area
provided by a mass of small particles (1 m3 of 100 mm particles has a surface area
of 60 000 m2), the heat transfer between gas and particles is rarely limiting in fluid
bed heat transfer. One of the most commonly used correlations for gas–particle
heat transfer coefficient is that of Kunii and Levenspiel (1969):
Nu ¼ 0:03Re1:3
p ðRep < 50Þ ð7:47Þ
HEAT TRANSFER IN FLUIDIZED BEDS 187
Figure 7.13 Analysis of gas–particle heat transfer in an element of a fluidized bed
where Nu is the Nusselt number ½hgp x=kg and the single particle Reynolds
number is based on the relative velocity between fluid and particle as usual.
Gas–particle heat transfer is relevant where a hot fluidized bed is fluidized by
cold gas. The fact that particle–gas heat transfer presents little resistance in
bubbling fluidized beds can be demonstrated by the following example:
Consider a fluidized bed of solids held at a constant temperature Ts . Hot
fluidizing gas at temperature Tg0 enters the bed. At what distance above the
distributor is the difference between the inlet gas temperature and the bed solids
temperature reduced to half its original value?
Consider an element of the bed of height dL at a distance L above the
distributor (Figure 7.13). Let the temperature of the gas entering this element
be Tg and the change in gas temperature across the element be dTg : The particle
temperature in the element is Ts :
The energy balance across the element gives
rate of heat loss by the gas ¼ rate of heat transfer to the solids
that is
ðCg Urg ÞdTg ¼ hgp aðTg Ts ÞdL ð7:48Þ
where a is the surface area of solids per unit volume of bed, Cg is the specific heat
capacity of the gas, rp is particle density, hgp is the particle-to-gas heat transfer
coefficient and U is superficial gas velocity.
Integrating with the boundary condition Tg ¼ Tg0 at L ¼ 0,
!
Tg Ts hgp a
ln ¼ L ð7:49Þ
Tg0 Ts Urel rg Cg
The distance over which the temperature difference is reduced to half its initial
value, L0:5 , is then
Cg Urel rg Cg Urel rg
L0:5 ¼ lnð0:5Þ ¼ 0:693 ð7:50Þ
hgp a hgp a
188 FLUIDIZATION
For a bed of spherical particles of diameter x, the surface area per unit volume of
bed, a ¼ 6ð1 eÞ=x, where e is the bed voidage.
Using the correlation for hgp in Equation (7.47), then
m1:3 x0:7 Cg
L0:5 ¼ 3:85 ð7:51Þ
Urel rg ð1 eÞkg
0:3 0:3
As an example we will take a bed of particles of mean size 100 mm, particle density
2500 kg/m3, fluidized by air of density 1.2 kg/m3, viscosity 1:84 105 Pa s, con-
ductivity 0.0262 W/m/K and specific heat capacity 1005 J/kg/K.
Using the Baeyens equation for Umf [Equation (7.11)], Umf ¼ 9:3 103 m=s.
The relative velocity between particles and gas under fluidized conditions can be
approximated as Umf =e under these conditions.
Hence, assuming a fluidized bed voidage of 0.47, Urel ¼ 0:02 m=s.
Substituting these values in Equation (7.51), we find L0:5 ¼ 0:95 mm. So, within
1 mm of entering the bed the difference in temperature between the gas and the
bed will be reduced by half. Typically for particles less than 1 mm in diameter the
temperature difference between hot bed and cold fluidizing gas would be
reduced by half within the first 5 mm of the bed depth.
7.7.2 Bed–Surface Heat Transfer
In a bubbling fluidized bed the coefficient of heat transfer between bed and
immersed surfaces (vertical bed walls or tubes) can be considered to be made up
of three components which are approximately additive (Botterill, 1975).
bedsurface heat transfer coefficient; h ¼ hpc þ hgc þ hr
where hpc is the particle convective heat transfer coefficient and describes the heat
transfer due to the motion of packets of solids carrying heat to and from the
surface, hgc is the gas convective heat transfer coefficient describing the transfer
of heat by motion of the gas between the particles and hr is the radiant heat
transfer coefficient. Figure 7.14, after Botterill (1986), gives an indication of the
range of bed–surface heat transfer coefficients and the effect of particle size on the
dominant heat transfer mechanism.
Particle convective heat transfer: On a volumetric basis the solids in the fluidized
bed have about one thousand times the heat capacity of the gas and so, since the
solids are continuously circulating within the bed, they transport the heat around
the bed. For heat transfer between the bed and a surface the limiting factor is the gas
conductivity, since all the heat must be transferred through a gas film between the
particles and the surface (Figure 7.15). The particle–surface contact area is too small
to allow significant heat transfer. Factors affecting the gas film thickness or the gas
conductivity will therefore influence the heat transfer under particle convective
conditions. Decreasing particle size, for example, decreases the mean gas film
thickness and so improves hpc . However, reducing particle size into the Group C
range will reduce particle mobility and so reduce particle convective heat transfer.
Increasing gas temperature increases gas conductivity and so improves hpc .
HEAT TRANSFER IN FLUIDIZED BEDS 189
Figure 7.14 Range of bed–surface heat transfer coefficients
Particle convective heat transfer is dominant in Group A and B powders.

Increasing gas velocity beyond minimum fluidization improves particle circula-
tion and so increases particle convective heat transfer. The heat transfer coeffi-
cient increases with fluidizing velocity up to a broad maximum hmax and then
declines as the heat transfer surface becomes blanketed by bubbles. This is shown
in Figure 7.16 for powders in Groups A, B and D. The maximum in hpc occurs
relatively closer to Umf for Group B and D powders since these powders give rise
to bubbles at Umf and the size of these bubbles increases with increasing gas
velocity. Group A powders exhibit a non-bubbling fluidization between Umf and
Umb and achieve a maximum stable bubble size.
Botterill (1986) recommends the Zabrodsky (1966) correlation for hmax for
Group B powders:
k0:6
g rp
0:2
hmax ¼ 35:8 W=m2 =K ð7:52Þ
x0:36
Figure 7.15 Heat transfer from bed particles to an immersed surface

190 FLUIDIZATION
Bed to surface
heat transfer Group B
coefficient
Group D
Group A
Umb Group A
U/Umf
Umf
Figure 7.16 Effect of fluidizing gas velocity on bed–surface heat transfer coefficient in a
fluidized bed
and the correlation of Khan et al. (1978) for Group A powders:
Numax ¼ 0:157 Ar0:475 ð7:53Þ
Gas convective heat transfer is not important in Group A and B powders where
the flow of interstitial gas is laminar but becomes significant in Group D
powders, which fluidize at higher velocities and give rise to transitional or
turbulent flow of interstitial gas. Botterill suggests that the gas convective
mechanism takes over from particle convective heat transfer as the dominant
mechanism at Remf 12:5 ðRemf is the Reynolds number at minimum fluidization
and is equivalent to an Archimedes number Ar 26 000). In gas convective heat
transfer the gas specific heat capacity is important as the gas transports the heat
around. Gas specific heat capacity increases with increasing pressure and in
conditions where gas convective heat transfer is dominant, increasing operating
pressure gives rise to an improved heat transfer coefficient hgc . Botterill (1986)
recommends the correlations of Baskakov and Suprun (1972) for hgc .
Nugc ¼ 0:0175 Ar0:46 Pr0:33 ðfor U > Um Þ ð7:54Þ

0:3
U
Nugc ¼ 0:0175Ar0:46 Pr0:33 ðfor Umf < U < Um Þ ð7:55Þ
Um
where Um is the superficial velocity corresponding to the maximum overall bed

heat transfer coefficient.
For temperatures beyond 600 C radiative heat transfer plays an increasing role
and must be accounted for in calculations. The reader is referred to Botterill
(1986) or Kunii and Levenspiel (1990) for treatment of radiative heat transfer or
for a more detailed look at heat transfer in fluidized beds.
APPLICATIONS OF FLUIDIZED BEDS 191
7.8 APPLICATIONS OF FLUIDIZED BEDS
7.8.1 Physical Processes
Physical processes which use fluidized beds include drying, mixing, granula-
tion, coating, heating and cooling. All these processes take advantage of the
excellent mixing capabilities of the fluid bed. Good solids mixing gives rise to
good heat transfer, temperature uniformity and ease of process control. One
of the most important applications of the fluidized bed is to the drying of
solids. Fluidized beds are currently used commercially for drying such
materials as crushed minerals, sand, polymers, pharmaceuticals, fertilizers
and crystalline products. The reasons for the popularity of fluidized bed
drying are:
The dryers are compact, simple in construction and of relatively low capital
cost.
The absence of moving parts, other than the feeding and discharge devices,
leads to reliable operation and low maintenance.
The thermal efficiency of these dryers is relatively high.
Fluidized bed dryers are gentle in the handling of powders and this is useful
when dealing with friable materials.
Fluidized bed granulation is dealt with in Chapter 13 and mixing is

covered in Chapter 11. Fluidized beds are often used to cool particulate
solids following a reaction. Cooling may be by fluidizing air alone or by the
use of cooling water passing through tubes immersed in the bed (see
Figure 7.17 for example). Fluidized beds are used for coating particles in
the pharmaceutical and agricultural industries. Metal components may be
plastic coated by dipping them hot into an air-fluidized bed of powdered
thermosetting plastic.
7.8.2 Chemical Processes
The gas fluidized bed is a good medium in which to carry out a chemical reaction
involving a gas and a solid. Advantages of the fluidized bed for chemical reaction
include:
The gas–solid contacting is generally good.
The excellent solids circulation within the bed promotes good heat transfer
between bed particles and the fluidizing gas and between the bed and heat
transfer surfaces immersed in the bed.
192 FLUIDIZATION
Figure 7.17 Schematic diagram of a fluidized bed solid cooler
This gives rise to near isothermal conditions even when reactions are strongly
exothermic or endothermic.
The good heat transfer also gives rise to ease of control of the reaction.
The fluidity of the bed makes for ease of removal of solids from the reactor.
However, it is far from ideal; the main problems arise from the two phase
(bubbles and fluidized solids) nature of such systems. This problem is particu-
larly acute where the bed solids are the catalyst for a gas-phase reaction. In such a
case the ideal fluidized bed chemical reactor would have excellent gas–solid
contacting, no gas by-passing and no back-mixing of the gas against the main
direction of flow. In a bubbling fluidized bed the gas bypasses the solids by
passing through the bed as bubbles. This means that unreacted reactants appear
in the product. Also, gas circulation patterns within a bubbling fluidized bed are
such that products are back-mixed and may undergo undesirable secondary
reactions. These problems lead to serious practical difficulties particularly in the
scaling-up of a new fluidized bed process from pilot plant to full industrial scale.
This subject is dealt with in more detail in Kunii and Levenspiel (1990), Geldart
(1986) and Davidson and Harrison (1971).
Figure 7.18 is a schematic diagram of one type of fluid catalytic cracking (FCC)
unit, a celebrated example of fluidized bed technology for breaking down large
molecules in crude oil to small molecules suitable for gasoline, etc. Other
examples of the application of fluidized bed technology to different kinds of
chemical reaction are shown in Table 7.2.
APPLICATIONS OF FLUIDIZED BEDS 193
Figure 7.18 Kellogg’s Model A Orthoflow FCC unit
Table 7.2 Summary of the types of gas–solid chemical reactions employing fluidization
Type Example Reasons for using a fluidized bed

Homogeneous Ethylene Rapid heating of entering gas.
gas-phase hydrogenation Uniform controllable temperature
reactions
Heterogeneous Sulfide ore roasting, Ease of solids handling. Temperature
non-catalytic combustion uniformity. Good heat transfer
reactions
Heterogeneous Hydrocarbon cracking, Ease of solids handling. Temperature
catalytic reactions phthalic anhydride, uniformity. Good heat transfer
acrylonitrile
194 FLUIDIZATION
7.9 A SIMPLE MODEL FOR THE BUBBLING FLUIDIZED BED

REACTOR
In general, models for the fluidized bed reactor consider:
the division of gas between the bubble phase and particulate phase;
the degree of mixing in the particulate phase;
the transfer of gas between the phases.
It is outside the scope of this chapter to review in detail the models available for
the fluidized bed as a reactor. However, in order to demonstrate the key
components of such models, we will use the simple model of Orcutt et al.
(1962). Although simple, this model allows the key features of a fluidized bed
reactor for gas-phase catalytic reaction to be explored.
The approach assumes the following:
Original two-phase theory applies;
Perfect mixing takes place in the particulate phase;
There is no reaction in the bubble phase;
The model is one-dimensional and assumes steady state. The structure of the
model is shown diagramatically in Figure 7.19. The following notation is used: C0
CH
CBH
Cp
Particulate phase
C = Cp Gas Bubble phase

N crossflow
Reaction rate = kCp C = C B at height h
C0 C0
UmfA (U - Umf)A
Gas flow = UA
Figure 7.19 Schematic diagram of the Orcutt fluidized bed reactor model
A SIMPLE MODEL FOR THE BUBBLING FLUIDIZED BED REACTOR 195
is the concentration of reactant at distributor; Cp is the concentration of reactant

in the particulate phase; CB is the concentration of the reactant in the bubble
phase at height h above the distributor; CBH is the concentration of reactant
leaving the bubble phase; and CH is the concentration of reactant leaving the
reactor.
In steady state, the concentration of reactant in the particulate phase is constant
throughout the particulate phase because of the assumption of perfect mixing in
the particulate phase. Throughout the bed, gaseous reactant is assumed to pass
between particulate phase and bubble phase.
The overall mass balance on the reactant is:
0 1
molar flow of 0 1 0 1
B reactant into C molar flow out molar flow out in
B C B C B C
B C ¼ @ in the bubble phase A þ @ the particulate phase A
@ reactor A
ð2Þ ð3Þ
ð1Þ ð7:56Þ
0 1
rate of
B C
þ @ conversion A
ð4Þ
Term ð1Þ ¼ UAC0

Term (2): molar reactant flow in bubble phase changes with height L above
the distributor as gas is exchanged with the particulate phase. Consider an
element of bed of thickness dL at a height L above the distributor. In this
element:

rate of increase of rate of transfer of
¼
reactant in bubble phase reactant from particulate phase
i:e: ðU U ÞAdC ¼ K ðe AdLÞðC C Þ ð7:57Þ
mf B C B B p
in the limit as dL ! 0;
dCB KC eB ðCB Cp Þ
¼ ð7:58Þ
dL ðU Umf Þ
where KC is the mass transfer coefficient per unit bubble volume and eB is the
bubble fraction. Integrating with the boundary condition that CB ¼ C0 at L0 ¼ 0 :

KC L
CB ¼ Cp þ ðC0 Cp Þ exp ð7:59Þ
UB
since eB ¼ ðU Umf Þ=UB ½Equationð7:28Þ:

At the surface of the bed, L ¼ H and so the reactant concentration in the bubble
phase at the bed surface is given by:

KC H
CBH ¼ Cp þ ðC0 Cp Þ exp ð7:60Þ
UB
Term (2) ¼ CBH ðU Umf ÞA
196 FLUIDIZATION
Term (3) ¼ Umf ACp

Term (4): For a reaction which is jth order in the reactant under consideration,

molar rate of conversion
¼ kCjp
per unit volume of solids
where k is the reaction rate constant per unit volume of solids.

Therefore,
0 1 0 1
molar rate of volume of solids
molar rate of B C B C
¼ @ conversion per unit A @ per unit volume of A
conversion in bed
volume of solids particulate phase
0 1
volume of particulate
B C volume
@ phase per unit A
of bed
volume of bed
hence, term (4),

molar rate of
¼ kCjp ð1 ep Þð1 eB ÞAH ð7:61Þ
conversion in bed
where ep is the particulate phase voidage.

Substituting these expressions for terms (1)–(4), the mass balance becomes:

KC H
UAC0 ¼ Cp þ ðC0 Cp Þ exp ðU Umf ÞA þ Umf ACp
UB ð7:62Þ
þ kCjp ð1 ep Þð1 eB ÞAH
From this mass balance Cp may be found. The reactant concentration leaving
the reactor CH is then calculated from the reactant concentrations and gas flows
through the bubble and particulate phases:
Umf Cp þ ðU Umf ÞCBH

CH ¼ ð7:63Þ
U
In the case of a first-order reaction (j ¼ 1), solving the mass balance for Cp gives:
C0 ½U ðU Umf Þew
Cp ¼ ð7:64Þ
kHmf ð1 ep Þ þ ½U ðU Umf Þew
where w ¼ KC H=UB , equivalent to a number of mass transfer units for gas

exchange between the phases. w is related to bubble size and correlations are
available. Generally w decreases as bubble size increases and so small bubbles are
preferred.
A SIMPLE MODEL FOR THE BUBBLING FLUIDIZED BED REACTOR 197
Thus from Equations (7.63) and (7.64), we obtain an expression for the
conversion in the reactor:
CH ð1 bew Þ2
1 ¼ ð1 bew Þ ð7:65Þ
C0 kHmf ð1 ep Þ
þ ð1 bew Þ
U
where b ¼ ðU Umf Þ=U; the fraction of gas passing through the bed as bubbles.
It is interesting to note that although the two-phase theory does not always hold,
Equation (7.65) often holds with b still the fraction of gas passing through the bed
as bubbles, but not equal to ðU Umf Þ=U:
Readers interested in reactions of order different from unity, solids reactions
and more complex reactor models for the fluidized bed, are referred to Kunii and
Levenspiel (1990).
Although the Orcutt model is simple, it does allow us to explore the effects of
operating conditions, reaction rate and degree of interphase mass transfer on
performance of a fluidized bed as a gas-phase catalytic reactor. Figure 7.20 shows
the variation of conversion with reaction rate (expressed as kHmf ð1 ep =UÞ) with
excess gas velocity (expressed as b) calculated using Equation (7.65) for a first-
order reaction.
Noting that the value of w is dictated mainly by the bed hydrodynamics, we see
that:
For slow reactions, overall conversion is insensitive to bed hydrodynamics and

so reaction rate k is the rate controlling factor.
Reaction: slow intermediate fast

1.0
Conversion
CH Plug flow reactor χ = 2.0
1–
C o 0.8
χ = 1.0
Perfectly mixed reactor
0.6
χ = 0.5
0.4 χ = 0.2
χ = 0.1
χ=0
0.2
0
0.01 0.1 1 10 100
kHmf(1-εp)/U
Figure 7.20 Conversion as a function of reaction rate and interphase mass transfer for
b ¼ 0:75 for a first-order gas phase catalytic reaction [based on Equation (7.65)]
198 FLUIDIZATION
For intermediate reactions, both reaction rate and bed hydrodynamics affect the
conversion.
For fast reactions, the conversion is determined by the bed hydrodynamics.
These results are typical for a gas-phase catalytic reaction in a fluidized bed.
7.10 SOME PRACTICAL CONSIDERATIONS
7.10.1 Gas Distributor
The distributor is a device designed to ensure that the fluidizing gas is always
evenly distributed across the cross-section of the bed. It is a critical part of the
design of a fluidized bed system. Good design is based on achieving a pressure
drop which is a sufficient fraction of the bed pressure drop. Readers are referred
to Geldart (1986) for guidelines on distributor design. Many operating problems
can be traced back to poor distributor design. Some distributor designs in
common use are shown in Figure 7.21.
7.10.2 Loss of Fluidizing Gas
Loss of fluidizing gas will lead to collapse of the fluidized bed. If the process
involves the emission of heat then this heat will not be dissipated as well from the
packed bed as it was from the fluidized bed. The consequences of this should be
considered at the design stage.
(a) (b)
(c) (d)
(e)
Figure 7.21 Some distributor designs in common use: (a) drilled plate; (b) cap design; (c)
continuous horizontal slots; (d) standpipe design; (e) sparge tubes with holes pointing
downwards
WORKED EXAMPLES 199
7.10.3 Erosion
All parts of the fluidized bed unit are subject to erosion by the solid particles.
Heat transfer tubes within the bed or freeboard are particularly at risk and
erosion here may lead to tube failure. Erosion of the distributor may lead to poor
fluidization and areas of the bed becoming deaerated.
7.10.4 Loss of Fines
Loss of fine solids from the bed reduces the quality of fluidization and reduces
the area of contact between the solids and the gas in the process. In a catalytic
process this means lower conversion.
7.10.5 Cyclones
Cyclone separators are often used in fluidized beds for separating entrained
solids from the gas stream (see Chapter 9). Cyclones installed within the fluidized
bed vessel would be fitted with a dip-leg and seal in order to prevent gas entering
the solids exit. Fluidized systems may have two or more stages of cyclone in
series in order to improve separation efficiency. Cyclones are also the subject of
erosion and must be designed to cope with this.
7.10.6 Solids Feeders
Various devices are available for feeding solids into the fluidized bed. The choice
of device depends largely on the nature of the solids feed. Screw conveyors,
spray feeders and pneumatic conveying are in common use.
WORKED EXAMPLE 7.1
3.6 kg of solid particles of density 2590 kg/m3 and surface-volume mean size 748 mm form
a packed bed of height 0.475 m in a circular vessel of diameter 0.0757 m. Water of density
1000 kg/m3 and viscosity 0.001 Pa s is passed upwards through the bed. Calculate (a) the
bed pressure drop at incipient fluidization, (b) the superficial liquid velocity at incipient
fluidization, (c) the mean bed voidage at a superficial liquid velocity of 1.0 cm/s, (d) the
bed height at this velocity and (e) the pressure drop across the bed at this velocity.
Solution
(a) Applying Equation (7.24) to the packed bed, we find the packed bed voidage:
pð0:0757Þ2
mass of solids ¼ 3:6 ¼ ð1 eÞ 2590 0:475
4
200 FLUIDIZATION
hence, e ¼ 0:3498
Frictional pressure drop across the bed when fluidized:
weight of particles upthrust on particles

ðpÞ ¼
cross-sectional area
Mg Mgðrf =rp Þ
ðpÞ ¼ ðsince upthrust ¼ weight of fluid displaced by particlesÞ
A !
Mg rf 3:6 9:81 1000
Hence; ðpÞ ¼ 1 ¼ 1 ¼ 4817 Pa
A rp 4:50 103 2590
(b) Assuming that the voidage at the onset of fluidization is equal to the voidage of the
packed bed, we use the Ergun equation to express the relationship between packed
pressure drop and superficial liquid velocity:
ðpÞ
¼ 3:55 107 U 2 þ 2:648 106 U
H
Equating this expression for pressure drop across the packed bed to the fluidized bed
pressure drop, we determine superficial fluid velocity at incipient fluidization, Umf :
Umf ¼ 0:365 cm=s
(c) The Richardson–Zaki equation [Equation (7.21)] allows us to estimate the expansion
of a liquid fluidized bed.
U ¼ U T en ½Equationð7:21Þ
Using the method given in Chapter 2, we determine the single particle terminal
velocity, UT :
Ar ¼ 6527:9; CD Re2p ¼ 8704; Rep ¼ 90; UT ¼ 0:120 m=s
Note that Rep is calculated at UT : At this value of Reynolds number, the flow is
intermediate between viscous and inertial, and so we must use the correlation of
Khan and Richardson [Equation (3.25)] to determine the exponent n in Equation (7.21):
With Ar ¼ 6527:9; n ¼ 3:202
Hence from Equation (7.21), e ¼ 0:460 when U ¼ 0:01 m=s.
Mean bed voidage is 0.460 when the superficial liquid velocity is 1 cm/s.
(d) From Equation (7.25), we now determine the mean bed height at this velocity:
ð1 0:3498Þ
Bed heightðat U ¼ 0:01 m=sÞ ¼ 0:475 ¼ 0:572 m
ð1 0:460Þ
(e) The frictional pressure drop across the bed remains essentially constant once the bed
is fluidized. Hence at a superficial liquid velocity of 1 cm/s the frictional pressure
drop across the bed is 4817 Pa.
WORKED EXAMPLES 201
However, the measured pressure drop across the bed will include the hydrostatic head
of the liquid in the bed. Applying the mechanical energy equation between the bottom (1)
and the top (2) of the fluidized bed:
p1 p2 U12 U22 4817

þ þ ðz1 z2 Þ ¼ friction head loss ¼
pf g 2g rf g
U1 ¼ U2 ; z1 z2 ¼ H ¼ 0:572 m
Hence, p1 p2 ¼ 10 428 Pa.
WORKED EXAMPLE 7.2
A powder having the size distribution given below and a particle density of 2500 kg/m3 is
fed into a fluidized bed of cross-sectional area 4 m2 at a rate of 1.0 kg/s.
Size range number (i) Size range (mm) Mass fraction in feed
1 10–30 0.20
2 30–50 0.65
3 50–70 0.15
The bed is fluidized using air of density 1.2 kg/m3 at a superficial velocity of 0.25 m/s.
Processed solids are continuously withdrawn from the base of the fluidized bed in order to
maintain a constant bed mass. Solids carried over with the gas leaving the vessel are
collected by a bag filter operating at 100% total efficiency. None of the solids caught by the
filter are returned to the bed. Assuming that the fluidized bed is well-mixed and that the
freeboard height is greater than the transport disengagement height under these condi-
tions, calculate at equilibrium:
(a) the flow rate of solids entering the filter bag;
(b) the size distribution of the solids in the bed;
(c) the size distribution of the solids entering the filter bag;
(d) the rate of withdrawal of processed solids from the base of the bed;
(e) the solids loading in the gas entering the filter.
Solution
First calculate the elutriation rate constants for the three size ranges under these
conditions from the Zenz and Weil correlation [Equation (7.46)]. The value of particle
size x used in the correlation is the arithmetic mean of each size range:
x1 ¼ 20 106 m; x2 ¼ 40 106 m; x3 ¼ 60 106 m

202 FLUIDIZATION
With U ¼ 0:25 m=s; rp ¼ 2500 kg=m3 and rf ¼ 1:2 kg=m3

K11 ¼ 3:21 102 kg=m2 s

K21 ¼ 8:74 103 kg=m2 s

K31 ¼ 4:08 103 kg=m2 s
Referring to Figure 7.W2.1 the overall and component material balances over the
fluidized bed system are:
Overall balance : F ¼ Q þ R ð7W2:1Þ

Component balance : FmFi ¼ QmQi þ RmRi ð7W2:2Þ
where F, Q and R are the mass flow rates of solids in the feed, withdrawal and filter
discharge, respectively, and mFi ; mQi and mRi are the mass fractions of solids in size
range i in the feed, withdrawal and filter discharge, respectively.
From Equation (7.39) the entrainment rate of size range i at the gas exit from the
freeboard is given by:

Ri ¼ RmRi ¼ Ki1 AmBi ð7W2:3Þ
and X X
R¼ Ri ¼ RmRi ð7W2:4Þ
Combining these equations with the assumption that the bed is well mixed ðmQi ¼ mBi Þ,
FmFi
mBi ¼ A ð7W2:5Þ
F R þ Ki1
Gas only
Solids feed Fine solids

F, mFi discharge
R, mRi
mBi
Solids discharge
Q, mQi
Figure 7W2.1 Schematic diagram showing solids flows and size distributions for the
fluidized bed
WORKED EXAMPLES 203
P
Now both mBi and R are unknown. However, noting that mBi ¼ 1; we have
1:0 0:2 1:0 0:65 1:0 0:15

þ þ ¼ 1:0
1:0 R þ ð3:21 102 4Þ 1:0 R þ ð8:74 103 4Þ 1:0 R þ ð4:08 103 4Þ
Solving for R by trial and error, R ¼ 0:05 kg=s
(b) Substituting R ¼ 0:05 kg=s in Equation (7W2.5), mB1 ¼ 0:1855; mB2 ¼ 0:6599 and
mB3 ¼ 0:1552
Therefore size distribution of bed:
Size range number (i) Size range (mm) Mass fraction in bed
1 10–30 0.1855
2 30–50 0.6599
3 50–70 0.1552
(c) From Equation (7W2.3), knowing R and mBi ; we can calculate mRi :

K11 AmB1 3:21 102 4 0:1855
m Ri ¼ ¼ ¼ 0:476
R 0:05
similarly, mR2 ¼ 0:4614; mR3 ¼ 0:0506
Therefore size distribution of solids entering filter:
Size range number (i) Size range (mm) Mass fraction entering filter
1 10–30 0.476
2 30–50 0.4614
3 50–70 0.0506
(d) From Equation (7W2.1), the rate of withdrawal of solids from the bed, Q ¼ 0:95 kg=s
(e) Solids loading for gas entering the filter,
mass flow of solids R

¼ ¼ 0:05 kg=m3
volume flow of gas UA
WORKED EXAMPLE 7.3
A gas phase catalytic reaction is performed in a fluidized bed operating at a superficial gas
velocity of 0.3 m/s. For this reaction under these conditions it is known that the reaction is
first order in reactant A. The following information is given:
204 FLUIDIZATION
bed height at incipient fluidization ¼ 1.5 m;
operating mean bed height ¼ 1.65 m;
voidage at incipient fluidization ¼ 0.47;
reaction rate constant ¼ 75.47 (per unit volume of solids);
Umf ¼ 0:033 m=s;
mean bubble rise velocity ¼ 0.111 m/s;
mass transfer coefficient between bubbles and emulsion ¼ 0.1009 (based on

unit bubble volume) minimum fluidization velocity ¼ 0:033 m=s.
Use the reactor model of Orcutt et al. to determine:

(a) the conversion of reactant A;
(b) the effect on the conversion found in (a) of reducing the inventory of catalyst by one
half;
(c) the effect on the conversion found in (a) of halving the bubble size (assuming the
interphase mass transfer coefficient is inversely proportional to the square root of the
bubble diameter).
Discuss your answers to (b) and (c) and state which mechanism is controlling conversion
in the reactor.
Solution
(a) From Section 7.9 the model of Orcutt et al. gives for a first order reaction:
CH ð1 bew Þ2
conversion; 1 ¼ ð1 bew Þ ½Equationð7:65Þ
C0 kHmf ð1 ep Þ
U þ ð1 bew Þ
where
KC H
w¼ and b ¼ ðU Umf Þ=U
UB
From the information given,
KC ¼ 0:1009; UB ¼ 0:111 m=s; U ¼ 0:3 m=s; Umf ¼ 0:033 m=s;

H ¼ 1:65 m; Hmf ¼ 1:5 m; k ¼ 75:47:
Hence, w ¼ 1:5; b ¼ 0:89 and kHmf ð1 ep Þ=U ¼ 200 (assuming ep ¼ emf )
So, from Equation (7.65), conversion ¼ 0:798.

TEST YOURSELF 205
(b) If the inventory of solids in the bed is halved, both the operating bed height H and the
height at incipient fluidization Hmf are halved. Thus, assuming all else remains
constant, under the new conditions
w ¼ 0:75; b ¼ 0:89 and kHmf ð1 ep Þ=U ¼ 100
and so the new conversion ¼ 0:576.

pffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
(c) If the bubble size is halved and KC is proportional to 1= ðdouble diameterÞ,
new KC ¼ 1:414 0:1009 ¼ 0:1427
Hence, w ¼ 2:121; giving conversion ¼ 0:889.
(d) Comparing the conversion achieved in (c) with that achieved in (a), we see that
improving interphase mass transfer has a significant effect on the conversion. We may
also note that doubling the reaction rate (say by increasing the reactor temperature)
and keeping everything else constant has a negligible effect on the conversion
achieved in (a). We conclude, therefore, that under these conditions the transfer of
gas between bubble phase and emulsion phase controls the conversion.
TEST YOURSELF
7.1 Write down the equation for the force balance across a fluidized bed and use it to
come up with an expression for the pressure drop across a fluidized bed.
7.2 15 kg of particles of particle density 2000 kg/m3 are fluidized in a vessel of cross-
sectional area 0.03 m2 by a fluid of density 900 kg/m3. (a) What is the frictional
pressure drop across the bed? (b) If the bed height is 0.6 m, what is the bed
voidage?
7.3 Sketch a plot of pressure drop across a bed of powder versus velocity of the fluid
flowing upwards through it. Include packed bed and fluidized bed regions. Mark on
the incipient fluidization velocity.
7.4 What are the chief behaviour characteristics of the four Geldart powder groups?
7.5 What differentiates a Geldart Group A powder from a Geldart Group B powder?
7.6 According to Richardson and Zaki, how does bed voidage in a liquid-fluidized bed
vary with fluidizing velocity at Reynolds numbers less than 0.3?
7.7 What is the basic assumption of the two-phase theory? Write down an equation that
describes bed expansion as a function of superficial fluidizing velocity according to
the two-phase theory.
7.8 Explain what is meant by particle convective heat transfer in a fluidized bed. In
which Geldart group is particle convective heat transfer dominant?
7.9 Under what conditions does gas convective heat transfer play a significant role?
206 FLUIDIZATION
7.10 A fast gas phase catalytic reaction is performed in a fluidized bed using a particulate
catalyst. Would conversion be increased by improving conditions for mass transfer
between particulate phase and bubble phase?
EXERCISES
7.1 A packed bed of solid particles of density 2500 kg/m3, occupies a depth of 1 m in a
volume mean diameter of the particles is 1 mm. A liquid of density 800 kg/m2 and
viscosity 0.002 Pa s flows upwards through the bed.
(b) Calculate the pressure drop across the bed when the volume flow rate of liquid is
1.44 m3/h.
(c) Calculate the pressure drop across, the bed when it becomes fluidized.
[Answer: (a) 0.5; (b) 6560 Pa; (c) 8338 Pa.]
7.2 130 kg of uniform spherical particles with a diameter of 50 mm and particle density
1500 kg/m3 are fluidized by water (density 1000 kg/m3, viscosity 0.001 Pa s) in a circular
bed of cross-sectional area 0.2 m2. The single particle terminal velocity of the particles is
0.68 mm/s and the voidage at incipient fluidization is known to be 0.47.
(a) Calculate the bed height at incipient fluidization.
(b) Calculate the mean bed voidage when the liquid flow rate is 2 105 m3 =s.
[Answer: (a) 0.818 m; (b) 0.6622.]
7.3 130 kg of uniform spherical particles with a diameter of 60 mm and particle density
1500 kg/m3 are fluidized by water (density 1000 kg/m3, viscosity 0.001 Pa s) in a circular
bed of cross-sectional area 0.2 m2. The single particle terminal velocity of the particles is
0.98 mm/s and the voidage at incipient fluidization is known to be 0.47.
(a) Calculate the bed height at incipient fluidization.
(b) Calculate the mean fluidized bed voidage when the liquid flow rate is 2 105 m3 =s.
[Answer: (a) 0.818 m; (b) 0.6121.]
7.4 A packed bed of solid particles of density 2500 kg/m3, occupies a depth of 1 m in a
volume mean diameter of the particles is 1 mm. A liquid of density 800 kg/m3 and
viscosity 0.002 Pa s flows upwards through the bed.
EXERCISES 207
(b) Calculate the pressure drop across the bed when the volume flow rate of liquid is
0.72 m3/h.
(c) Calculate the pressure drop across the bed when it becomes fluidized.
[Answer: (a) 0.41; (b) 7876 Pa; (c) 9839 Pa.]
7.5 12 kg of spherical resin particles of density 1200 kg/m3 and uniform diameter 70 mm
are fluidized by water (density 1000 kg/m3 and viscosity 0.001 Pa s) in a vessel of diameter
0.3 m and form an expanded bed of height 0.25 m.
(a) Calculate the difference in pressure between the base and the top of the bed.
(b) If the flow rate of water is increased to 7 cm3/s, what will be the resultant bed height
and bed voidage (liquid volume fraction)?
State and justify the major assumptions.
[Answer: (a) Frictional pressure drop ¼ 277.5 Pa, pressure difference ¼ 2730 Pa; (b) height
¼ 0.465 m; voidage ¼ 0.696.]
7.6 A packed bed of solids of density 2000 kg/m3 occupies a depth of 0.6 m in a cylindrical
vessel of inside diameter 0.1 m. The mass of solids in the bed is 5 kg and the surface-
volume mean diameter of the particles is 300 mm. Water (density 1000 kg/m3 and viscosity
0.001 Pa s) flows upwards through the bed.
(b) Use a force balance over the bed to determine the bed pressure drop when fluidized.
(c) Hence, assuming laminar flow and that the voidage at incipient fluidization is the
same as the packed bed voidage, determine the minimum fluidization velocity. Verify
the assumption of laminar flow.
[Answer: (a) 0.4692; (b) 3124 Pa; (c) 1.145 mm/s.]
7.7 A packed bed of solids of density 2000 kg/m3 occupies a depth of 0.5 m in a cylindrical
vessel of inside diameter 0.1 m. The mass of solids in the bed is 4 kg and the surface-
volume mean diameter of the particles is 400 mm. Water (density 1000 kg and viscosity
0.001 Pa s) flows upwards through the bed.
(b) Use a force balance over the bed to determine the bed pressure drop when fluidized.
(c) Hence, assuming laminar flow and that the voidage at incipient fluidization is the
same as the packed bed voidage, determine the minimum fluidization velocity. Verify
the assumption of laminar flow.
[Answer: (a) 0.4907; (b) 2498 Pa; (c) 2.43 mm/s.]

208 FLUIDIZATION
7.8 By applying a force balance, calculate the incipient fluidizing velocity for a system
with particles of particle density 5000 kg/m3 and mean volume diameter 100 mm and a
fluid of density 1.2 kg/m3 and viscosity 1:8 105 Pa s. Assume that the voidage at
incipient fluidization is 0.5.
If in the above example the particle size is changed to 2 mm, what is Umf ?
[Answer: 0.045 m/s; 2.26 m/s.]
7.9 A powder of mean sieve size 60 mm and particle density 1800 kg/m3 is fluidized by air
of density 1.2 kg/m3 and viscosity 1:84 105 Pa s in a circular vessel of diameter 0.5 m.
The mass of powder charged to the bed is 240 kg and the volume flow rate of air to the bed
is 140 m3/h. It is known that the average bed voidage at incipient fluidization is 0.45 and
correlation reveals that the average bubble rise velocity under the conditions in question is
0.8 m/s. Estimate:
(a) the minimum fluidization velocity, Umf ;
(b) the bed height at incipient fluidization;
(c) the visible bubble flow rate;
(d) the bubble fraction;
(e) the particulate phase voidage;
(f) the mean bed height;
(g) the mean bed voidage.
[Answer: (a) Baeyens and Geldart correlation [Equation (7.11)], 0.0027 m/s; (b) 1.24 m; (c)
0.038 m3/s (assumes Umf ffi Umb ); (d) 0.245; (e) 0.45; (f) 1.64 m; (g) 0.585.]
7.10 A batch fluidized bed process has an initial charge of 2000 kg of solids of particle
density 1800 kg/s3 and with the size distribution shown below:
1 15–30 0.10
2 30–50 0.20
3 50–70 0.30
4 70–100 0.40
The bed is fluidized by a gas of density 1.2 kg/m3 Pa s at a superficial gas velocity of
0.4 m/s.
The fluid bed vessel has a cross-sectional area of 1 m2.
Using a discrete time interval calculation with a time increment of 5 min, calculate:
EXERCISES 209
(a) the size distribution of the bed after 50 min;
(b) the total mass of solids lost from the bed in that time;
(c) the maximum solids loading at the process exit;
(d) the entrainment flux above the transport disengagement height of solids in size range
1 (15–30 mm) after 50 min.
Assume that the process exit is positioned above TDH and that none of the entrained
solids are returned to the bed.
[Answer: (a) (range 1) 0.029, (2) 0.165, (3) 0.324, (4) 0.482; (b) 527 kg; (c) 0.514 kg/m3 s; (d)
0.024 kg/m2 s.]
7.11 A powder having a particle density of 1800 kg/m3 and the following size distribution:
1 20–40 0.10
2 40–60 0.35
3 60–80 0.40
4 80–100 0.15
is fed into a fluidized bed 2 m in diameter at a rate of 0.2 kg/s. The cyclone inlet is 4 m
above the distributor and the mass of solids in the bed is held constant at 4000 kg by
withdrawing solids continuously from the bed. The bed is fluidized using dry air at 700 K
(density 0.504 kg/m3 and viscosity 3:33 105 Pa s) giving a superficial gas velocity of
0.3 m/s. Under these conditions the mean bed voidage is 0.55 and the mean bubble size at
the bed surface is 5 cm. For this powder, under these conditions, Umb ¼ 0:155 cm=s.
Assuming that none of the entrained solids are returned to the bed, estimate:
(a) the flow rate and size distribution of the entrained solids entering the cyclone;
(b) the equilibrium size distribution of solids in the bed;
(c) the solids loading of the gas entering the cyclone;
(d) the rate at which solids are withdrawn from the bed.
[Answer: (a) 0.0485 kg/s, (range 1) 0.213, (2) 0.420, (3) 0.295, (4) 0.074; (b) (range 1) 0.0638,
(2) 0.328, (3) 0.433, (4) 0.174; (c) 51.5 g/m3; (d) 0.152 kg/s.]
7.12 A gas phase catalytic reaction is performed in a fluidized bed operating at a

superficial gas velocity equivalent to 10 Umf . For this reaction under these conditions
it is known that the reaction is first order in reactant A. Given the following information:
KC H
kHmf ð1 ep Þ=U ¼ 100; w ¼ ¼ 1:0
UB
210 FLUIDIZATION
use the reactor model of Orcutt et al. to determine:
(a) the conversion of reactant A;
(b) the effect on the conversion found in (a) of doubling the inventory of catalyst;
(c) the effect on the conversion found in (a) of halving the bubble size by using suitable
baffles (assuming the interphase mass transfer coefficient is inversely proportional to
the bubble diameter).
If the reaction rate were two orders of magnitude smaller, comment on the wisdom of
installing baffles in the bed with a view to improving conversion.
[Answer: (a) 0.6645; (b) 0.8744; (c) 0.8706.]

8
Pneumatic Transport and
Standpipes
In this chapter we deal with two examples of the transport of particulate solids in
the presence of a gas. The first example is pneumatic transport (sometimes
referred to as pneumatic conveying), which is the use of a gas to transport a
particulate solid through a pipeline. The second example is the standpipe, which
has been used for many years, particularly in the oil industry, for transferring
solids downwards from a vessel at low pressure to a vessel at a higher pressure.
8.1 PNEUMATIC TRANSPORT
For many years gases have been used successfully in industry to transport a wide
range of particulate solids – from wheat flour to wheat grain and plastic chips to
coal. Until quite recently most pneumatic transport was done in dilute suspen-
sion using large volumes of air at high velocity. Since the mid-1960s, however,
there has been increasing interest in the so-called ‘dense phase’ mode of transport
in which the solid particles are not fully suspended. The attractions of dense
phase transport lie in its low air requirements. Thus, in dense phase transport, a
minimum amount of air is delivered to the process with the solids (a particular
attraction in feeding solids into fluidized bed reactors, for example). A low air
requirement also generally means a lower energy requirement (in spite of the
higher pressures needed). The resulting low solids velocities mean that in dense
phase transport product degradation by attrition, and pipeline erosion are not
the major problems they are in dilute phase pneumatic transport.
In this section we will look at the distinguishing characteristics of dense and
dilute phase transport and the types of equipment and systems used with each.
The design of dilute phase systems is dealt with in detail and the approach to
design of dense phase systems is summarized.

212 PNEUMATIC TRANSPORT AND STANDPIPES
8.1.1 Dilute Phase and Dense Phase Transport
The pneumatic transport of particulate solids is broadly classified into two flow
regimes: dilute (or lean) phase flow; and dense phase flow. Dilute phase flow in
its most recognizable form is characterized by high gas velocities (greater than
20 m/s), low solids concentrations (less than 1% by volume) and low pressure
drops per unit length of transport line (typically less than 5 mbar/m). Dilute
phase pneumatic transport is limited to short route, continuous transport of
solids at rates of less than 10 t/h and is the only system capable of operation
under negative pressure. Under these dilute flow conditions the solid particles
behave as individuals, fully suspended in the gas, and fluid-particle forces
dominate. At the opposite end of the scale is dense phase flow, characterized
by low gas velocities (1–5 m/s, high solids concentrations (greater than 30% by
volume) and high pressure drops per unit length of pipe (typically greater than
20 mbar/m). In dense phase transport particles are not fully suspended and there
is much interaction between the particles.
The boundary between dilute phase flow and dense phase flow, however, is
not clear cut and there are as yet no universally accepted definitions of dense
phase and dilute phase transport.
Konrad (1986) lists four alternative means of distinguishing dense phase flow
from dilute phase flow:
(a) on the basis of solids/air mass flow rates;
(b) on the basis of solids concentration;
(c) dense phase flow exists where the solids completely fill the cross–section of
the pipe at some point;
(d) dense phase flow exists when, for horizontal flow, the gas velocity is
insufficient to support all particles in suspension, and, for vertical flow,
where reverse flow of solids occurs.
In all these cases different authors claim different values and apply different
interpretations.
In this chapter the ‘choking’ and ‘saltation’ velocities will be used to mark the
boundaries between dilute phase transport and dense phase transport in vertical
and horizontal pipelines, respectively. These terms are defined below in consider-
ing the relationships between gas velocity, solids mass flow rate and pressure drop
per unit length of transport line in both horizontal and vertical transport.
8.1.2 The Choking Velocity in Vertical Transport
We will see in Section 8.1.4 that the pressure drop across a length of transport line
has in general six components:
pressure drop due to gas acceleration;

PNEUMATIC TRANSPORT 213
pressure drop due to particle acceleration;
pressure drop due to gas-to-pipe friction;
pressure drop related to solid-to-pipe friction;
pressure drop due to the static head of the solids;
pressure drop due to the static head of the gas.
The general relationship between gas velocity and pressure gradient p=L
for a vertical transport line is shown in Figure 8.1. Line AB represents the
frictional pressure loss due to gas only in a vertical transport line. Curve CDE
is for a solids flux of G1 and curve FG is for a higher feed rate G2 . At point C the
gas velocity is high, the concentration is low, and frictional resistance between
gas and pipe wall predominates. As the gas velocity is decreased the frictional
resistance decreases but, since the concentration of the suspension increases, the
static head required to support these solids increases. If the gas velocity is
decreased below point D then the increase in static head outweighs the decrease
in frictional resistance and p=L rises again. In the region DE the decreasing
velocity causes a rapid increase in solids concentration and a point is reached
when the gas can no longer entrain all the solids. At this point a flowing,
slugging fluidized bed (see Chapter 7) is formed in the transport line. The
phenomenon is known as ‘choking’ and is usually attended by large pressure
fluctuations. The choking velocity, UCH , is the lowest velocity at which this
dilute phase transport line can be operated at the solids feed rate G1 . At the
higher solids feed rate, G2 , the choking velocity is higher. The choking velocity
marks the boundary between dilute phase and dense phase vertical pneumatic
Figure 8.1 Phase diagram for dilute-phase vertical pneumatic transport

transport. Note that choking can be reached by decreasing the gas velocity at a
constant solids flow rate, or by increasing the solids flow rate at a constant gas
velocity.
It is not possible to theoretically predict the conditions for choking to occur.
However, many correlations for predicting choking velocities are available in the
literature. Knowlton (1986) recommends the correlation of Punwani et al. (1976),
which takes account of the considerable effect of gas density. This correlation is
presented below:
UCH G
UT ¼ ð8:1Þ
eCH rp ð1 eCH Þ
2250Dðe4:7
CH 1Þ
r0:77
f ¼ 2 ð8:2Þ
UCH
eCH U T
where eCH is the voidage in the pipe at the choking velocity UCH , rp is the particle
density, rf is the gas density, G is the mass flux of solids ð¼ Mp =AÞ and UT is
the free fall, or terminal velocity, of a single particle in the gas. (Note that the
constant is dimensional and that SI units must be used.)
Equation (8.1) represents the solids velocity at choking and includes the
assumption that the slip velocity Uslip is equal to UT (see Section 8.1.4 below
for definition of slip velocity). Equations (8.1) and (8.2) must be solved simulta-
neously by trial and error to give eCH and UCH .
8.1.3 The Saltation Velocity in Horizontal Transport
The general relationship between gas velocity and pressure gradient p=L for a
horizontal transport line is shown in Figure 8.2 and is in many ways similar to
that for a vertical transport line. Line AB represents the curve obtained for gas
only in the line, CDEF for a solids flux, G1 , and curve GH for a higher solids feed
Figure 8.2 Phase diagram for dilute-phase horizontal pneumatic transport

rate, G2 . At point C, the gas velocity is sufficiently high to carry all the solids in
very dilute suspension. The solid particles are prevented from settling to the
walls of the pipe by the turbulent eddies generated in the flowing gas. If the gas
velocity is reduced whilst solids feed rate is kept constant, the frictional
resistance and p=L decrease. The solids move more slowly and the solids
concentration increases. At point D the gas velocity is insufficient to maintain the
solids in suspension and the solids begin to settle out in the bottom of the pipe.
The gas velocity at which this occurs is termed the ‘saltation velocity’. Further
decrease in gas velocity results in rapid ‘salting out’ of solids and rapid increase
in p=L as the area available for flow of gas is restricted by settled solids.
In the region E and F some solids may move in dense phase flow along the
bottom of the pipe whilst others travel in dilute phase flow in the gas in the upper
part of the pipe. The saltation velocity marks the boundary between dilute phase
flow and dense phase flow in horizontal pneumatic transport.
Once again, it is not possible to theoretically predict the conditions under which
saltation will occur. However, many correlations for predicting saltation velocity
are available in the literature. The correlation by Zenz (1964) is frequently used
but is entirely empirical and requires the use of a graph. It is reported by Leung
and Jones (1978) to have an average error of 54 %. The correlation of Rizk (1973),
based on a semi-theoretical approach, is considerably simpler to use, and has a
similar error range. It is most unambiguously expressed as:
ð1100xþ2:5Þ
Mp 1 Usalt
¼ pffiffiffiffiffiffi ð8:3Þ
rf Usalt A 10ð1440xþ1:96Þ gD

MP mass flow rate of solids
where is the solids loading
rf Usalt A mass flow rate of gas
U
psalt
ffiffiffiffiffiffiffi is the Froude number at saltation
gD
Usalt is the superficial gas velocity (see Section 8.1.4 for the definition of super-
ficial velocity) at saltation when the mass flow rate of solids is Mp , the pipe
diameter is D and the particle size is x. (The units are SI.)
8.1.4 Fundamentals
In this section we generate some basic relationships governing the flow of gas
and particles in a pipe.
Gas and particle velocities
We have to be careful in the definition of gas and particle velocities and in the
relative velocity between them, the slip velocity. The terms are often used loosely
in the literature and are defined below.
The term ‘superficial velocity’ is also commonly used. Superficial gas and
solids (particles) velocities are defined as:
volume flow of gas Qf
superficial gas velocity; Ufs ¼ ¼ ð8:4Þ
cross-sectional area of pipe A
volume flow of solids Qp
superficial solids velocity; Ups ¼ ¼ ð8:5Þ
cross-sectional area of pipe A
where subscript ‘s’ denotes superficial and subscripts ‘f’ and ‘p’ refer to the fluid
and particles, respectively.
The fraction of pipe cross-sectional area available for the flow of gas is usually
assumed to be equal to the volume fraction occupied by gas, i.e. the voidage or
void fraction e. The fraction of pipe area available for the flow of solids is
therefore ð1 eÞ.
And so, actual gas velocity,
Qf
Uf ¼ ð8:6Þ
Ae
and actual particle velocity,
Qp
Up ¼ ð8:7Þ
Að1 eÞ
Thus superficial velocities are related to actual velocities by the equations:

Ufs
Uf ¼ ð8:8Þ
e
Ups
Up ¼ ð8:9Þ
1e
It is common practice in dealing with fluidization and pneumatic transport to
simply use the symbol U to denote superficial fluid velocity. This practice will be
followed in this chapter. Also, in line with common practice, the symbol G will be
used to denote the mass flux of solids, i.e. G ¼ Mp =A, where Mp is the mass flow
rate of solids.
The relative velocity between particle and fluid Urel is defined as:
Urel ¼ Uf Up ð8:10Þ
This velocity is often also referred to as the ‘slip velocity’ Uslip .

It is often assumed that in vertical dilute phase flow the slip velocity is equal to
the single particle terminal velocity UT .
Continuity
Consider a length of transport pipe into which are fed particles and gas at mass
flow rates of Mp and Mf , respectively. The continuity equations for particles and
gas are:
for the particles

Mp ¼ AUp ð1 eÞrp ð8:11Þ
for the gas

Mf ¼ AUf erf ð8:12Þ
Combining these continuity equations gives an expression for the ratio of mass
flow rates. This ratio is known as the solids loading:
Mp Up ð1 eÞrp
Solids loading; ¼ ð8:13Þ
Mf Uf erf
This shows us that the average voidage e, at a particular position along the length
of the pipe, is a function of the solids loading and the magnitudes of the gas and
solids velocities for given gas and particle density.
Pressure drop
In order to obtain an expression for the total pressure drop along a section of
transport line we will write down the momentum equation for a section of pipe.
Consider a section of pipe of cross-sectional area A and length dL inclined to the
horizontal at an angle y and carrying a suspension of voidage e (see Figure 8.3).
Figure 8.3 Section of conveying pipe: basis for momentum equation
The momentum balance equation is:

net force acting rate of increase in
¼
on pipe contents momentum of contents
Therefore,

pressure gaswall solidswall gravitational

force friction force friction force force
0 1 0 1
rate of increase rate of increase
B C B C
¼ @ in momentum A þ @ in momentum A
of the gas of the solids
or
Adp Ffw A dL Fpw A dL ½Að1 eÞrp dLg sin y ðAerf dLÞg sin y
ð8:14Þ
¼ rf AeUf dUf þ rp Að1 eÞUp dUp
where Ffw and Fpw are the gas-to-wall friction force and solids-to-wall friction
force per unit volume of pipe, respectively.
Rearranging Equation (8.14) and integrating assuming constant gas density
and voidage:
1 1
p1 p2 ¼ e rf Uf2 þ ð1 eÞ rp Up2 þ Ffw L þ Fpw L
2 ð1Þ 2 ð2Þ ð3Þ ð4Þ
ð8:15Þ
þ rp Lð1 eÞ g sin y þ rf Le g sin y
ð5Þ ð6Þ
Readers should note that Equations (8.4) and (8.15) apply in general to the flow
of any gas–particle mixture in a pipe. No assumption has been made as to
whether the particles are transported in dilute phase or dense phase.
Equation (8.15) indicates that the total pressure drop along a straight length of
pipe carrying solids in dilute phase transport is made up of a number of terms:
(1) pressure drop due to gas acceleration;
(2) pressure drop due to particle acceleration;
(3) pressure drop due to gas-to-wall friction;
(4) pressure drop related to solids-to-wall friction;
(5) pressure drop due to the static head of the solids;
(6) pressure drop due to the static head of the gas.
Some of these terms may be ignored depending on circumstance. If the gas and
the solids are already accelerated in the line, then the first two terms should be
omitted from the calculation of the pressure drop; if the pipe is horizontal,
terms (5) and (6) can be omitted. The main difficulties are in knowing what the
solids-to-wall friction is, and whether the gas-to-wall friction can be assumed
independent of the presence of the solids; these will be covered in Section 8.1.5.
8.1.5 Design for Dilute Phase Transport
Design of a dilute phase transport system involves selection of a combination of

pipe size and gas velocity to ensure dilute flow, calculation of the resulting
pipeline pressure drop and selection of appropriate equipment for moving the
gas and separating the solids from the gas at the end of the line.
Gas velocity
In both horizontal and vertical dilute phase transport it is desirable to operate at

the lowest possible velocity in order to minimize frictional pressure loss, reduce
attrition and reduce running costs. For a particular pipe size and solids flow rate,
the saltation velocity is always higher than the choking velocity. Therefore, in a
transport system comprising both vertical and horizontal lines, the gas velocity
must be selected to avoid saltation. In this way choking will also be avoided.
These systems would ideally operate at a gas velocity slightly to the right of
point D in Figure 8.2. In practice, however, Usalt is not known with great
confidence and so conservative design leads to operation well to the right of
point D with the consequent increase in frictional losses. Another factor
encouraging caution in selecting the design velocity is the fact that the region
near to point D is unstable; slight perturbations in the system may bring about
saltation.
If the system consists only of a lift line, then the choking velocity becomes the
important criterion. Here again, since UCH cannot be predicted with confidence,
conservative design is necessary. In systems using a centrifugal blower, char-
acterized by reduced capacity at increased pressure, choking can almost be self-
induced. For example, if a small perturbation in the system gives rise to an
increase in solids feed rate, the pressure gradient in the vertical line will increase
(Figure 8.1). This results in a higher back pressure at the blower giving rise to
reduced volume flow of gas. Less gas means higher pressure gradient and the
system soon reaches the condition of choking. The system fills with solids and
can only be restarted by draining off the solids.
Bearing in mind the uncertainty in the correlations for predicting choking and
saltation velocities, safety margins of 50 % and greater are recommended when
selecting the operating gas velocity.
Pipeline pressure drop
Equation (8.15) applies in general to the flow of any gas–particle mixture in a

pipe. In order to make the equation specific to dilute phase transport, we must
find expressions for terms 3 (gas-to-wall friction) and 4 (solids-to-wall friction).
In dilute transport the gas-to-wall friction is often assumed independent of the

presence of the solids and so the friction factor for the gas may be used (e.g.
Fanning friction factor – see worked example on dilute pneumatic transport).
Several approaches to estimating solids-to-wall friction are presented in the
literature. Here we will use the modified Konno and Saito (1969) correlation for
estimating the pressure loss due to solid-to-pipe friction in vertical transport and
the Hinkle (1953) correlation for estimating this pressure loss in horizontal
transport. Thus for vertical transport (Konno and Saito, 1969):
rffiffiffiffi
g
Fpw L ¼ 0:057GL ð8:16Þ
D
and for horizontal transport:
2fp ð1 eÞrp Up2 L

Fpw L ¼ ð8:17aÞ
D
or
2fp GUp L
Fpw L ¼ ð8:17bÞ
D
where
Up ¼ Uð1 0:0638x0:3 r0:5

p Þ ð8:18Þ
and (Hinkle, 1953)

3 rf D Uf Up 2
fp ¼ CD ð8:19Þ
8 rp x Up
where CD is the drag coefficient between the particle and gas (see Chapter 2).
Note:
Hinkle’s analysis assumes that particles lose momentum by collision with the
pipe walls. The pressure loss due to solids–wall friction is the gas pressure
loss as a result of re-accelerating the solids. Thus, from Chapter 2, the drag
force on a single particle is given by:
2
px2 ðUf Up Þ
FD ¼ rf CD ð8:20Þ
4 2
If the void fraction is e, then the number of particles per unit volume of pipe
Nv is
ð1 eÞ
Nv ¼ ð8:21Þ
px3 =6
Therefore the force exerted by the gas on the particles in unit volume of pipe
Fv is
ð1 eÞ
Fv ¼ F D ð8:22Þ
px3 =6
Based on Hinkle’s assumption, this is equal to the solids–wall friction force

per unit volume of pipe, Fpw . Hence,
3 L
Fpw L ¼ rf CD ð1 eÞðUf Up Þ2 ð8:23Þ
4 x
Expressing this in terms of a friction factor, fp we obtain Equations (8.17) and

(8.19).
Equation (8.15) relates to pressure losses along lengths of straight pipe.

Pressure losses are also associated with bends in pipelines and estimations of
the value of these losses will be covered in the next section.
Bends
Bends complicate the design of pneumatic dilute phase transport systems and
when designing a transport system it is best to use as few bends as possible.
Bends increase the pressure drop in a line, and also are the points of most serious
erosion and particle attrition.
Solids normally in suspension in straight, horizontal or vertical pipes tend to
salt out at bends due to the centrifugal force encountered while travelling aro-
und the bend. Because of this operation, the particles slow down and are then
re entrained and re-accelerated after they pass through the bend, resulting in the
higher pressure drops associated with bends.
There is a greater tendency for particles to salt out in a horizontal pipe which is
preceded by a downflowing vertical to horizontal bend than in any other
configuration. If this type of bend is present in a system, it is possible for solids
to remain on the bottom of the pipe for very long distances following the bend
before they redisperse. Therefore, it is recommended that downflowing vertical
to horizontal bends be avoided if at all possible in dilute phase pneumatic
transport systems.
In the past, designers of dilute phase pneumatic transport systems intuitively
thought that gradually sloped, long radius elbows would reduce the erosion and
increase bend service life relative to 90 elbows. Zenz (1964), however, recom-
mended that blinded tees (Figure 8.4) be used in place of elbows in pneumatic
transport systems. The theory behind the use of the blinded tee is that a cushion
of stagnant particles collects in the blinded or unused branch of the tee, and the
conveyed particles then impinge upon the stagnant particles in the tee rather
Figure 8.4 Blinded tee bend
than on the metal surface, as in a long radius or short radius elbow. Bodner
(1982) determined the service life and pressure drop of various bend configura-
tions. He found that the service life of the blinded tee configuration was far
better than any other configuration tested and that it gave a service life 15 times
greater than that of radius bends or elbows. This was due to the cushioning
accumulation of particles in the blinded branch of the tee which he observed in
glass bend models. Bodner also reported that pressure drops and solid attrition
rates for the blinded tee were approximately the same as those observed for
radius bends.
In spite of a considerable amount of research into bend pressure drop, there is
no reliable method of predicting accurate bend pressure drops other than by
experiment for the actual conditions expected. In industrial practice, bend
pressure drop is often approximated by assuming that it is equivalent to
approximately 7:5 m of vertical section pressure drop. In the absence of any
reliable correlation to predict bend pressure drop, this crude method is probably
as reliable and as conservative as any.
Equipment
Dilute phase transport is carried in systems in which the solids are fed into the air
stream. Solids are fed from a hopper at a controlled rate through a rotary air lock
into the air stream. The system may be positive pressure, negative pressure or
employ a combination of both. Positive pressure systems are usually limited to a
maximum pressure of 1 bar gauge and negative pressure systems to a vacuum of
about 0.4 bar by the types of blowers and exhausters used.
Typical dilute phase systems are shown in Figures 8.5 and 8.6. Blowers are
normally of the positive displacement type which may or may not have speed
control in order to vary volume flow rate. Rotary airlocks enable solids to be fed
at a controlled rate into the air stream against the air pressure. Screw feeders are
frequently used to transfer solids. Cyclone separators (see Chapter 9) are used to
recover the solids from the gas stream at the receiving end of the transport line.
Filters of various types and with various methods of solids recovery are used to
clean up the transport gas before discharge or recycle.
Storage
hopper
Blower
Conveying line Filter
Check valve
Rotary airlock Receiving
Filter/silencer hopper
Rotary airlock
To process
Figure 8.5 Dilute-phase transport: positive pressure system
In some circumstances it may not be desirable to use once-through air as the

transport gas (e.g. for the risk of contamination of the factory with toxic or
radioactive substances; for risk of explosion an inert gas may be used; in order to
control humidity when the solids are moisture sensitive). In these cases a closed
loop system is used. If a rotary positive displacement blower is used then the
solids must be separated from the gas by cyclone separator and by inline fabric
filter. If lower system pressures are acceptable (0.2 bar gauge) then a centrifugal
blower may be used in conjunction with only a cyclone separator. The centrifugal
fan is able to pass small quantities of solids without damage, whereas the positive
displacement blower will not pass dust.
Continuous
dust collector
Vent
Storage Silencer
Conveying line
hopper
Vacuum relief
Rotary airlock
Rotary airlock Exhauster
feeder
To process
End open to
atmosphere
Figure 8.6 Dilute-phase transport: negative pressure system

8.1.6 Dense Phase Transport
Flow patterns
As pointed out in the introduction to this chapter, there are many different
definitions of dense phase transport and of the transition point between dilute
phase and dense phase transport. For the purpose of this section dense phase
transport is described as the condition in which solids are conveyed such that
they are not entirely suspended in the gas. Thus, the transition point between
dilute and dense phase transport is saltation for horizontal transport and choking
for vertical transport.
However, even within the dense phase regime a number of different flow
patterns occur in both horizontal and vertical transport. Each of these flow
patterns has particular characteristics giving rise to particular relationships
between gas velocity, solids flow rate and pipeline pressure drop. In Figure 8.7
for example, five different flow patterns are identified within the dense phase
regime for horizontal transport.
The continuous dense phase flow pattern, in which the solids occupy the entire
pipe, is virtually extrusion. Transport in this form requires very high gas
pressures and is limited to short straight pipe lengths and granular materials
(which have a high permeability).
Discontinuous dense phase flow can be divided into three fairly distinct flow
patterns: ‘discrete plug flow’ in which discrete plugs of solids occupy the full
pipe cross-section; ‘dune flow’ in which a layer of solids settled at the bottom of
Figure 8.7 Flow patterns in horizontal pneumatic conveying

the pipe move along in the form of rolling dunes; a hybrid of discrete plug flow
and dune flow in which the rolling dunes completely fill the pipe cross-section
but in which there are no discrete plugs (also known as ‘plug flow’).
Saltating flow is encountered at gas velocities just below the saltation velocity.
Particles are conveyed in suspension above a layer of settled solids. Particles may
be deposited and re-entrained from this layer. As the gas velocity is decreased the
thickness of the layer of settled solids increases and eventually we have dune
flow.
It should be noted, first, that not all powders exhibit all these flow patterns and,
secondly, that within any transport line it is possible to encounter more than one
regime.
The main advantages of dense phase transport arise from the low gas require-
ments and low solids velocities. Low gas volume requirements generally mean
low energy requirements per kilogram of product conveyed, and also mean that
smaller pipelines and recovery and solids–gas separation are required. Indeed in
some cases, since the solids are not suspended in the transport gas, it may be
possible to operate without a filter at the receiving end of the pipeline. Low solids
velocities means that abrasive and friable materials may be conveyed without
major pipeline erosion or product degradation.
It is interesting to look at the characteristics of the different dense phase flow
patterns with a view to selecting the optimum for a dense phase transport
system. The continuous dense phase flow pattern is the most attractive from the
point of view of low gas requirements and solid velocities, but has the serious
drawback that it is limited to use in the transport of granular materials along
short straight pipes and requires very high pressures. Saltating flow occurs at a
velocity too close to the saltation velocity and is therefore unstable. In addition
this flow pattern offers little advantage in the area of gas and solids velocity. We
are then left with the so-called discontinuous dense phase flow pattern with its
plugs and dunes. However, performance in this area is unpredictable, can give
rise to complete pipeline blockages and requires high pressures. Most commer-
cial dense phase transport systems operate in this flow pattern and incorporate
some means of controlling plug length in order to increase predictability and
reduce the chance of blockages.
It is therefore necessary to consider how the pressure drop across a plug of
solids depends on its length. Unfortunately contradictory experimental evi-
dence is reported in the literature. Konrad (1986) points out that the pressure
drop across a moving plug has been reported to increase (a) linearly with plug
length, (b) as the square of the plug length and (c) exponentially with plug
length. A possible explanation of these apparent contradictions is reported by
Klintworth and Marcus (1985) who cite the work of Wilson (1981) on the effect
of stress on the deformation within the plug. Large cohesionless particles
[typically Geldart Group D particles (Geldart’s classification of powders –
see Chapter 7 on Fluidization)] give rise to a permeable plug permitting the
passage of a significant gas flow at low pressure drops. In this case the stress
developed in the plug would be low and a linear dependence of pressure drop
on plug length would result. Plugs of fine cohesive particles (typically Geldart
Group C) would be virtually impermeable to gas flow at the pressures usually
encountered. In this case, the plug moves as a piston in a cylinder by purely

mechanical means. The stress developed within the plug is high. The high
stress translates to a high wall shear stress which gives rise to an exponential
increase in pressure drop with plug length. Thus it is the degree of perme-
ability of the plug which determines the relationship between plug length and
pressure drop: the pressure drop across a plug can vary between a linear and
an exponential function of the plug length depending on the permeability of
the plug.
Large cohesionless particles form permeable plugs and are therefore suitable
for discontinuous dense phase transport. In other materials, where interaction
under the action of stress and interparticle forces give rise to low permeability
plugs, discontinuous dense phase transport is only possible if some mechanism is
used to limit plug length, avoiding blockages.
Equipment
In commercial systems, the problem of plug formation is tackled in three ways:
1. Detect the plug at its formation and take appropriate action to either:
(a) use a bypass system in which the pressure build-up behind a plug causes
more air to flow around the bypass line and break up the plug from its front
end (Figure 8.8);
(b) detect the pressure build-up using pressure actuated valves which divert
auxiliary air to break up the plugs into smaller lengths (Figure 8.9).
2. Form stable plugs – stable plugs of granular material do form naturally under
certain conditions. However, to form stable plugs of manageable length of
other materials, it is generally necessary to induce them artificially by one of
the following means:
(a) use an air knife to chop up solids fed in continuous dense phase flow from a
blow tank (Figure 8.10);
Figure 8.8 Dense phase conveying system using a bypass line to break up plugs of
solids
Figure 8.9 Dense phase conveying system using pressure-actuated valves to direct gas
(b) use an alternating valves system (Figure 8.11) in order to cut up the
continuous dense phase flow from the blow tank;
(c) for free-flowing materials it is possible to use an air-operated diaphragm in

the blow tank to create plugs (Figure 8.12);
Figure 8.10 Solid plug formation using timer-operated air knife

Figure 8.11 Solid plug formation using alternating air valves (valves 1 and 2 open and
close alternately to create plugs of solids in the discharge pipe)
(d) a novel idea reported by Tsuji (1983) uses table tennis balls to separate solids
into plugs.
3. Fluidization–add extra air along the transport line in order to maintain the
aeration of the solids and hence avoid the formation of blockages.
Whatever the mechanism used to tackle the plug problem, all commercial
dense phase transport systems employ a blow tank which may be with fluidizing
element (Figure 8.13) or without (Figure 8.14).
Figure 8.12 Solid plug creation using air-operated diaphragm

Solids inlet
valve
Conveying
Vent
line
valve
Solids
Air balance line
Fluidizing Fluidizing
air line element
Plenum
chamber
Air Primary conveying

air inlet
Figure 8.13 Dense phase transport blow tank with fluidizing element
The blow tank is automatically taken through repeated cycles of filling, pressur-
izing and discharging. Since one third of the cycle time is used for filling the blow
tank, a system required to give a mean delivery rate of 20 t/h must be able to
deliver a peak rate of over 30 t/h. Dense phase transport is thus a batch operation
because of the high pressures involved, whereas dilute phase transport can be
continuous because of the relatively low pressures and the use of rotary valves.
The dense phase system can be made to operate in semi-continuous mode by the
use of two blow tanks in parallel.
Figure 8.14 Blow tank without fluidizing element

Design for dense phase transport
Whereas dilute phase transport systems can be designed, albeit with a large
safety margin, from first principles together with the help of some empirical
correlations, the design of commercial dense phase systems is largely empirically
based. Although in theory the equation for pressure drop in two phase flow
developed earlier in this chapter [Equation (8.15)] may be applied to dense phase
flow, in practice it is of little use. Generally a test facility which can be made to
simulate most transport situations is used to monitor the important transport
parameters during tests on a particular material. From these results, details of the
dense phase transport characteristics of the material can be built up and the
optimum conditions of pipe size, air flow rate, and type of dense phase system
can be determined. Commercial dense phase systems are designed on the basis of
past experience together with the results of tests such as these. Details of how this
is done may be found in Mills (1990).
8.1.7 Matching the System to the Powder
Generally speaking it is possible to convey any powder in the dilute phase mode,
but because of the attractions of dense phase transport, there is great interest in
assessing the suitability of a powder for transport in this mode. The most
commonly used procedure is to undertake a series of tests on a sample of the
powder in a pilot plant. This is obviously expensive. An alternative approach
offered by Dixon (1979) is available. Dixon recognized the similarities between
gas fluidization and dense phase transport and proposed a method of assessing
the suitability of a powder for transport in the dense phase based on Geldart’s
(1973) classification of powders (see Chapter 7 on Fluidization). Dixon proposed
a ‘slugging diagram’ which allows prediction of the possible dense phase flow
patterns from a knowledge of particle size and density. Dixon concluded that
Geldart’s Groups A and D were suitable for dense phase transport whereas
Groups B and C were generally not suitable.
Mainwaring and Reed (1987) claim that although Dixon’s approach gives a
good general indication of the most likely mode of dense phase transport, it is not
the most appropriate means of determining whether a powder will convey in this
mode in the first instance. These authors propose an assessment based on the
results of bench-scale measurements of the permeability and de-aeration char-
acteristics of the powder. On this basis powders achieving a sufficiently high
permeability in the test would be suitable for plug type dense phase transport
and powders scoring high on air retention would be suitable for transport in the
rolling dune mode of dense phase flow. According to the authors, powders
satisfying neither of these criteria are unsuitable for transport by conventional
blow tank systems. Flain (1972) offered a qualitative approach to matching the
powder to the system. He lists twelve devices for bringing about the initial
contact between gas and solids in a transport system and matches powder char-
acteristics to device. This is a useful starting point since certain equipment can be
excluded for use with a particular powder.
STANDPIPES 231
Figure 8.15 (a) Overflow and (b) underflow type standpipes transporting solids from low
pressure fluidized bed to bed at higher pressure
8.2 STANDPIPES
Standpipes have been used for many years, particularly in the oil industry, for
transferring solids downwards from a region of low pressure to a region of
higher pressure. The overview of standpipe operation given here is based largely
on the work of Knowlton (1997).
Typical overflow and underflow standpipes are shown in Figure 8.15, where
they are used to continuously transfer solids from an upper fluidized bed to a
lower fluidized bed. For solids to be transferred downwards against the pressure
gradient gas must flow upward relative to the solids. The friction losses devel-
oped by the flow of the gas through the packed or fluidized bed of solids in the
standpipe generates the required pressure gradient. If the gas must flow upwards
relative to the downflowing solids there are two possible cases: (i) the gas flows
upward relative to the standpipe wall; and (ii) the gas flows downwards relative
to the standpipe wall; but at a lower velocity than the solids.
A standpipe may operate in two basic flow regimes depending on the relative
velocity of the gas to the solids; packed bed flow and fluidized bed flow.
8.2.1 Standpipes in Packed Bed Flow
If the relative upward velocity of the gas ðUf Up Þ is less than the relative
velocity at incipient fluidization ðUf Up Þmf , then packed bed flow results and
the relationship between gas velocity and pressure gradient is in general
determined by the Ergun equation [see Chapter 6, Equation (6.11)].
The Ergun equation is usually expressed in terms of the superficial gas velocity
through the packed bed. However, for the purposes of standpipe calculations it is
useful to write the Ergun equation in terms of the magnitude of the velocity of the
gas relative to the velocity of the solids jUrel jð¼ jUf Up jÞ. (Refer to Section 8.1.4
for clarification of relationships between superficial and actual velocities.)
Superficial gas velocity; U ¼ ejUrel j ð8:24Þ
And so in terms of jUrel j the Ergun equation becomes:

" #
ðpÞ m ð1 eÞ2 rf ð1 eÞ
¼ 150 2 jUrel j þ 1:75 jUrel j2 ð8:25Þ
H xsv e2 xsv e
The equation allows us to calculate the value of jUrel j required to give a particular
pressure gradient. We now adopt a sign convention for velocities. For standpipes
it is convenient to take downward velocities as positive. In order to create the
pressure gradient in the required direction (higher pressure at the lower end of
the standpipe), the gas must flow upwards relative to the solids. Hence, Urel
should always be negative in normal operation. Solids flow is downwards, so Up ,
the actual velocity of the solids (relative to the pipe wall), is always positive.
Knowing the magnitude and direction of Up and Urel , the magnitude and
direction of the actual gas velocity (relative to the pipe wall) may be found from
Urel ¼ Uf Up . In this way the quantity of gas passing up or down the standpipe
may be estimated.
8.2.2 Standpipes in Fluidized Bed Flow
If the relative upward velocity of the gas ðUf Up Þ is greater than the relative
velocity at incipient fluidization ðUf Up Þmf , then fluidized bed flow will result.
In fluidized bed flow the pressure gradient is independent of relative gas
velocity. Assuming that in fluidized bed flow the entire apparent weight of the
particles is supported by the gas flow, then the pressure gradient is given by (see
Chapter 7):
ðpÞ
¼ ð1 eÞðrp rf Þg ð8:26Þ
H
where ðpÞ is the pressure drop across a height H of solids in the standpipe, e is
the voidage and rp is the particle density.
Fluidized bed flow may be non-bubbling flow or bubbling flow. Non-bubbling
flow occurs only with Geldart Group A solids (described in Chapter 7) when the
relative gas velocity lies between the relative velocity for incipient fluidization
and the relative velocity for minimum bubbling ðUf Up Þmb . For Geldart Group
B materials (Chapter 7) with ðUf Up Þ > ðUf Up Þmf and for Group A solids
with ðUf Up Þ > ðUf Up Þmb bubbling fluidized flow results.
Four types of bubbling fluidized bed flow in standpipes are possible depend-
ing on the direction of motion of the gas in the bubble phase and emulsion phases
relative to the standpipe walls. These are depicted in Figure 8.16. In practice,
bubbles are undesirable in a standpipe. The presence of rising bubbles hinders
the flow of solids and reduces the pressure gradient developed in the standpipe.
If the bubble rise velocity is greater than the solids velocity, then the bubbles will
STANDPIPES 233
Figure 8.16 Types of fluidized flow in a standpipe
rise and grow by coalescence. Larger standpipes are easier to operate since they
can tolerate larger bubbles than smaller standpipes. For optimum standpipe
operation, when using Group B solids, the relative gas velocity should be slightly
greater than relative velocity for incipient fluidization. For Group A solids,
relative gas velocity should lie between ðUf Up Þmf and ðUf Up Þmb .
In practice, aeration is often added along the length of a standpipe in order to
maintain the solids in a fluidized state just above minimum fluidization velocity.
If this were not done then, with a constant mass flow of gas, relative velocities
would decrease towards the high-pressure end of the standpipe. The lower
velocities would result in lower mean voidages and the possibility of an
unfluidized region at the bottom of the standpipe. Aeration gas is added in
stages along the length of the standpipe and only the minimum requirement is
added at any level. If too much is added, bubbles are created which may hinder
solids flow. The analysis below, based on that of Kunii and Levenspiel (1990),
enables calculation of the position and quantity of aeration gas to be added.
The starting point is Equation (8.13), the equation derived from the continuity
equations for gas and solids flow in a pipe. For fine Group A solids in question
the relative velocity between gas and particles will be very small in comparison
with the actual velocities, and so we can assume with little error that Up ¼ Uf :
Hence, from Equation (8.13):
Mp ð1 eÞ rp
¼ ð8:27Þ
Mf e rf
Using subscripts 1 and 2 to refer to the upper (low pressure) and lower (high
pressure) level in the standpipe, since Mp , Mf and rp are constant:
ð1 e1 Þ 1 ð1 e2 Þ 1
¼ ð8:28Þ
e 1 r f1 e 2 rf 2
And so, since the pressure ratio p2 =p1 ¼ rf2 =rf1 , then
p2 ð1 e2 Þ e1
¼ ð8:29Þ
p1 e2 ð1 e1 Þ
Let us assume that the voidage e2 is the lowest voidage acceptable for maintaining
fluidized standpipe flow. Equation (8.29) allows calculation of the equivalent
maximum pressure ratio, and hence the pressure drop between levels 1 and 2.
Assuming the solids are fully supported, this pressure difference will be equal to
the apparent weight per unit cross-sectional area of the standpipe [Equation (8.26)].
ðp2 p1 Þ ¼ ðrp rf Þð1 ea ÞHg ð8:30Þ
where ea is the average voidage over the section between levels 1 and 2, H is the
distance between the levels and g is the acceleration due to gravity.
If e1 and e2 are known and gas density is regarded as negligible compared to
particle density, H may be calculated from Equation (8.30).
The objective of adding aeration gas is to raise the voidage at the lower level to
equal that at the upper level. Applying Equation (8.27),
ð1 e2 Þ Mp rf2 Mp rf1
¼ ¼ ð8:31Þ
e2 ðMf þ Mf2 Þ rp Mf rp
where Mf2 is the mass flow of aeration air added at level 2.
Then rearranging,

rf2
M f2 ¼ M f 1 ð8:32Þ
rf1
e1 rf1
and, since from Equation (8.27), Mf ¼ Mp
ð1 e1 Þ rp

e1 rf1 rf2
M f2 ¼ M p 1 ð8:33Þ
ð1 e1 Þ rp rf1
STANDPIPES 235
and so mass flow of aeration air to be added,
e1 M p
M f2 ¼ ðr rf1 Þ ð8:34Þ
ð1 e1 Þ rp f2
from which, it can also be shown that

e1 r
Qf2 ¼ Qp 1 f1 ð8:35Þ
ð1 e1 Þ rf2
where Qf2 is the volume flow rate of gas to be added at pressure p2 and Qp is the
volume flow rate of solids down the standpipe.
For long standpipes aeration gas will need to be added at several levels in
order to keep the voidage within the required range (see the worked example on
standpipe aeration).
8.2.3 Pressure Balance During Standpipe Operation
As an example of the operation of a standpipe, we will consider how an overflow

standpipe operating in fluidized bed flow reacts to a change in gas flow rate.
Figure 8.17(a) shows the pressure profile over such a system. The pressure
balance equation over this system is:
pSP ¼ pLB þ pUB þ pd ð8:36Þ
where pSP , pLB , pUB and pd are the pressure drops across the standpipe, the
lower fluidized bed, the upper fluidized bed and the distributor of the upper
fluidized bed, respectively.
Let us consider a disturbance in the system such that the gas flow through the
fluidized beds increases [Figure 8.17(b)]. If the gas flow through the lower bed
increases, although the pressure drops across the lower and upper beds will
remain constant, the pressure drop across the upper distributor will increase
pdðnewÞ . To match this increase, the pressure across the standpipe must rise to
pSPðnewÞ [Figure 8.17(b)]. In the case of an overflow standpipe operating in
fluidized flow the increase in standpipe pressure drop results from a rise in the
height of solids in the standpipe to HSPðnewÞ .
Consider now the case of an underflow standpipe operating in packed bed
flow (Figure 8.18), the pressure balance across the system is given by:
pSP ¼ pd þ pV ð8:37Þ
where pSP , pd and pv are the pressure drops across the standpipe, the
distributor of the upper fluidized bed and the standpipe valve, respectively.
If the gas flow from the lower bed increases, the pressure drop across the upper
bed distributor increases to pdðnewÞ . The pressure balance then calls for an
increase in standpipe pressure drop. Since in this case the standpipe length is
height
p
1
upper bed ∆pUB
distributor ∆pd
∆pLB
Hsp
p2
lower bed ∆psp
distributor p2
p1
pressure
profile in fluid beds

profile in standpipe
(a)
Height
p1
Upper bed
∆pUB
∆pd(new)
Hsp(new)
∆pLB
p2(new)
Lower bed ∆psp(new)
p1 p2(new)
pressure
Profile in fluid beds
Profile in standpipe
(b)
Figure 8.17 Operation of an overflow standpipe: (a) before increasing gas flow;
(b) change in pressure profile due to increased gas flow through the fluid beds
fixed, in packed bed flow this increase in pressure drop is achieved by an increase
in the magnitude of the relative velocity jUrel j. The standpipe pressure drop will
increase to pSPðnewÞ and the valve pressure drop, which depends on the solids
flow, will remain essentially constant. Once the standpipe pressure gradient
reaches that required for fluidized bed flow, its pressure drop will remain
constant so it will not be able to adjust to system changes.
WORKED EXAMPLES 237
Height Original profile

Profile at increased gas flow
∆psp(new)
∆psp
P1 ∆pd
Hsp p2
∆pv
Pressure
p1 p2 p2(new)
Figure 8.18 Pressure balance during operation of an underflow standpipe: effect of

increasing gas flow through fluid beds
A standpipe commonly used in the petroleum industry is the underflow

vertical standpipe with slide valve at the lower end. In this case the standpipe
generates more head than is required and the excess is used across the slide
valve in controlling the solids flow. Such a standpipe is used in the fluid catalytic
cracking (FCC) unit to transfer solids from the reactor to the regenerator.
8.3 FURTHER READING
Readers wishing to learn more about solids circulation systems, standpipe flow
and non-mechanical valves are referred to Kunii and Levenspiel (1990) or the
chapters by Knowlton in either Geldart (1986) or Grace et al. (1997).
8.4 WORKED EXAMPLES
WORKED EXAMPLE 8.1
Design a positive pressure dilute-phase pneumatic transport system to transport

900 kg/h of sand of particle density 2500 kg/m3 and mean particle size 100 mm between
two points in a plant separated by 10 m vertical distance and 30 m horizontal distance
using ambient air. Assume that six 90 bends are required and that the allowable
pressure loss is 0.55 bar.
Solution
In this case, to design the system means to determine the pipe size and air flow rate
which would give a total system pressure loss near to the allowable pressure loss.
The design procedure requires trial and error calculations. Pipes are available in fixed
sizes and so the procedure adopted here is to select a pipe size and determine the
saltation velocity from Equation (8.1). The system pressure loss is then calculated at
a superficial gas velocity equal to 1.5 times the saltation velocity [this gives a reasonable
safety margin bearing in mind the accuracy of the correlation in Equation (8.1)]. The
calculated system pressure loss is then compared with the allowable pressure loss.
The pipe size selected may then be altered and the above procedure repeated until the
calculated pressure loss matches that allowed.
Step 1. Selection of pipe size
Select 78 mm inside diameter pipe.
Step 2. Determine gas velocity
Use the Rizk correlation of Equation (8.3) to estimate the saltation velocity, Usalt .
Equation (8.3) rearranged becomes
!1=ðbþ1Þ
4Mp 10a gb=2 Dðb=2Þ2
Usalt ¼
prf
where a ¼ 1440x þ 1:96 and b ¼ 1100x þ 2:5.
In the present case a ¼ 2:104, b ¼ 2:61 and Usalt ¼ 9:88.
Therefore, superficial gas velocity, U ¼ 1:5 9:88 m=s ¼ 14:82 m=s.
Step 3. Pressure loss calculations
(a) Horizontal sections. Starting with Equation (8.15) an expression for the total pressure
loss in the horizontal sections of the transport line may be generated. We will
assume that all the initial acceleration of the solids and the gas take place in the
horizontal sections and so terms (1) and (2) are required. For term (3) the Fanning
friction equation is used assuming that the pressure loss due to gas-to-wall friction
is independent of the presence of solids. For term (4) we employ the Hinkle
correlation [Equation (8.17)]. Terms (5) and (6) become zero as y ¼ 0 for horizontal
pipes. Thus, the pressure loss, pH , in the horizontal sections of the transport line
is given by:
rf eH UfH
2 rp ð1 eH ÞUpH 2fg rf U 2 LH 2fp rp ð1 eH ÞUpH LH
2 2
pH ¼ þ þ þ
2 2 D D
where the subscript H refers to the values specific to the horizontal sections.
To use this equation we need to know eH , UfH and UpH . Hinkle’s correlation gives us
U pH :
UpH ¼ Uð1 0:0638x0:3 r0:5

p Þ ¼ 11:84 m=s
WORKED EXAMPLES 239
From continuity, G ¼ rp ð1 eH ÞUpH
G
thus eH ¼ 1 ¼ 0:9982
rp UpH
U 14:82
and UfH ¼ ¼ ¼ 14:85 m=s
eH 0:9982
Friction factor fp is found from Equation (8.19) with CD estimated at the relative
velocity ðUf Up Þ, using the approximate correlations given below [or by using an
appropriate CD versus Re chart (see Chapter 2)]:
Rep < 1 CD ¼ 24=Rep

1 < Rep < 500 CD ¼ 18:5Re0:6
p
500 < Rep < 2 10 5
CD ¼ 0:44
Thus, for flow in the horizontal sections,

rf ðUfH UpH Þx
Rep ¼
m
for ambient air rf ¼ 1:2 kg=m3 and m ¼ 18:4 106 Pa s, giving
Rep ¼ 19:63
and so, using the approximate correlations above,
CD ¼ 18:5Re0:6
p ¼ 3:1
Substituting CD ¼ 3:1 in Equation (8.19) we have:

3 1:2 0:078 14:85 11:84 2
fp ¼ 3:1
8 2500 100 106 11:84
The gas friction factor is taken as fg ¼ 0:005. This gives pH ¼ 14:864 Pa:
(b) Vertical sections. Starting again with Equation (8.15), the general pressure loss equa-
tion, an expression for the total pressure loss in the vertical section may be derived.
Since the initial acceleration of solids and gas was assumed to take place in the
horizontal sections, terms (1) and (2) become zero. The Fanning friction equation is
used to estimate the pressure loss due to gas-to-wall friction [term (3)] assuming solids
have negligible effect on this pressure loss. For term (4) the modified Konno and Saito
correlation [Equation (8.16)] is used. For vertical transport y becomes equal to 90 in
terms (5) and (6).
Thus, the pressure loss, pv , in the vertical sections of the transport line is given by:
rffiffiffiffi
2fg rf U 2 Lv g
pv ¼ þ 0:057GLv þ rp ð1 ev ÞgLv þ rf ev gLv
D D
where subscript v refers to values specific to the vertical sections.
To use this equation we need to calculate the voidage of the suspension in the vertical
pipe line ev .
Assuming particles behave as individuals, then slip velocity is equal to single particle
terminal velocity, UT (also noting that the superficial gas velocity in both horizontal and
vertical sections is the same and equal to U), i.e.
U
Upv ¼ UT
ev
continuity gives particle mass flux, G ¼ rp ð1 ev ÞUpv .
Combining these equations gives a quadratic in ev which has only one possible
root.
!
G
e2v UT UT þ U þ ev þ U ¼ 0
rp
The single particle terminal velocity, UT may be estimated as shown in Chapter 2, giving
UT ¼ 0:52 m=s assuming the particles are spherical.
And so, solving the quadratic equation, ev ¼ 0:9985 and thus pv ¼ 1148 Pa.
(c) Bends. The pressure loss across each 90 bend is taken to be equivalent to that
across 7.5 m of vertical pipe.
pv
Pressure loss per metre of vertical pipe ¼ ¼ 114:8 Pa=m
Lv
Therefore, pressure loss across six 90 bends
¼ 6 7:5 114:8 Pa
¼ 5166 Pa
And so,
0 1
! ! loss across !
total pressure loss across B C loss across
¼ þ @ horizontal A þ
loss vertical sections bends
sections
¼ 11:48 þ 14 864 þ 5166 Pa
¼ 0:212 bar
Step 4. Compare calculated and allowable pressure losses
The allowable system pressure loss is 0.55 bar and so we may select a smaller pipe size
and repeat the above calculation procedure. The table below gives the results for a range
of pipe sizes.
WORKED EXAMPLES 241
Pipe inside Total system

diameter (mm) pressure loss (bar)
78 0.212
63 0.322
50 0.512
40 0.809
In this case we would select 50 mm pipe which gives a total system pressure loss of
0.512 bar. (An economic option could be found if capital and running cost were
incorporated.) The design details for this selection are given below:
pipe size ¼ 50 mm inside diameter

air flow rate ¼ 0:0317 m3 =s
air superficial velocity ¼ 16:15 m=s
saltation velocity ¼ 10:77 m=s
solids loading ¼ 6:57 kg solid=kg air
total system pressure loss ¼ 0:512 bar
WORKED EXAMPLE 8.2
A 20 m long standpipe carrying a Group A solids at a rate of 80 kg/s is to be aerated in

order to maintain fluidized flow with a voidage in the range 0.5–0.53. Solids enter the
top of the standpipe at a voidage of 0.53. The pressure and gas density at the top of the
standpipe are 1.3 bar (abs) and 1.0 kg/m3, respectively.
The particle density of the solids is 1200 kg/m3.

Determine the aeration positions and rates.
Solution
From Equation (8.29), pressure ratio,

p2 ð1 0:50Þ 0:53
¼ ¼ 1:128
p1 0:50 ð1 0:53Þ
Therefore, p2 ¼ 1:466 barðabsÞ

Pressure difference, p2 p1 ¼ 0:166 105 Pa.
Hence, from Equation (8.30) [with ea ¼ ð0:5 þ 0:53Þ=2 ¼ 0:515],
0:166 105
length to first aeration point; H ¼ ¼ 2:91 m
1200 ð1 0:515Þ 9:81

Assuming ideal gas behaviour, density at level 2, rf2 ¼ rf1 pp21 ¼ 1:128 kg=m3
Applying Equation (8.34), aeration gas mass flow at first aeration point,
0:53 80
M f2 ¼ ð1:128 1:0Þ ¼ 0:0096 kg=s
ð1 0:53Þ 1200
The above calculation is repeated in order to determine the position and rates of
subsequent aeration points. The results are summarized below:
First Second Third Fourth Fifth

point point point point point
Distance from top of 2.91 6.18 9.88 14.04 18.75
standpipe (m)
Aeration rate (kg/s) 0.0096 0.0108 0.0122 0.0138 0.0155
Pressure at aeration
point (bar) 1.47 1.65 1.86 2.10 2.37
WORKED EXAMPLE 8.3
A 10 m long vertical standpipe of inside diameter 0.1 m transports solids at a flux of

100 kg/m2s from an upper vessel which is held at a pressure 1.0 bar to a lower vessel
held at 1.5 bar. The particle density of the solids is 2500 kg/m3 and the surface-volume
mean particle size is 250 mm. Assuming that the voidage is constant along the stand-
pipe and equal to 0.50, and that the effect of pressure change may be ignored, determine
the direction and flow rate of gas passing between the vessels. (Properties of gas in the
system: density, 1 kg/m3; viscosity, 2 105 Pa s.)
Solution
First check that the solids are moving in packed bed flow. We do this by comparing the
actual pressure gradient with the pressure gradient for fluidization.
Assuming that in fluidized flow the apparent weight of the solids will be supported by
the gas flow, Equation (8.26) gives the pressure gradient for fluidized bed flow:
ðpÞ
¼ ð1 0:5Þ ð2500 1Þ 9:81 ¼ 12258 Pa=m
H
ð1:5 1:0Þ 105
Actual pressure gradient ¼ ¼ 5000 Pa=m
10
Since the actual pressure gradient is well below that for fluidized flow, the standpipe is
operating in packed bed flow.
The pressure gradient in packed bed flow is generated by the upward flow of gas
relative to the solids in the standpipe. The Ergun equation [Equation (8.25)] provides the
relationship between gas flow and pressure gradient in a packed bed.
Knowing the required pressure gradient, the packed bed voidage and the particle and
gas properties, Equation (8.25) can be solved for jUrel j, the magnitude of the relative gas
velocity:
Ignoring the negative root of the quadratic, jUrel j ¼ 0:1026 m=s

TEST YOURSELF 243
We now adopt a sign convention for velocities. For standpipes it is convenient to take
downward velocities as positive. In order to create the pressure gradient in the required
direction, the gas must flow upwards relative to the solids. Hence, Urel is negative:
Urel ¼ 0:1026 m=s
From the continuity for the solids [Equation (8.11)],
Mp
solids flux; ¼ Up ð1 eÞrp
A
The solids flux is given as 100 kg/m2s and so
100
Up ¼ ¼ 0:08 m=s
ð1 0:5Þ 2500
Solids flow is downwards, so Up ¼ þ0:08 m=s
The relative velocity, Urel ¼ Uf Up
hence, actual gas velocity, Uf ¼ 0:1026 þ 0:08 ¼ 0:0226 m=s ðupwardsÞ
Therefore the gas flows upwards at a velocity of 0.0226 m/s relative to the standpipe
walls. The superficial gas velocity is therefore:
U ¼ eUf ¼ 0:0113 m=s
From the continuity for the gas [Equation (8.12)] mass flow rate of gas,
Mf ¼ eUf rf A
¼ 8:9 105 kg=s
So for the standpipe to operate as required, 8:9 105 kg=s of gas must flow from the
lower vessel to the upper vessel.
TEST YOURSELF
8.1 In horizontal pneumatic transport of particulate solids, what is meant by the term
saltation velocity?
8.2 In vertical pneumatic transport of particulate solids, what is meant by the term
choking velocity?
8.3 In horizontal pneumatic transport of particulate solids, why is there a minimum in

the pressure drop versus gas velocity plot?
8.4 In vertical pneumatic transport of particulate solids, why is there a minimum in the
pressure drop versus gas velocity plot?
8.5 There are six components in the equation describing the pressure drop across a pipe
carrying solids by pneumatic transport. Write down these six components, in words.
8.6 In a dilute phase pneumatic transport system, what are the two main reasons for
using a rotary airlock?
8.7 In a dense phase pneumatic transport system, why is it necessary to limit plug
length in some cases? Describe three ways in which the plug length might be limited
in practice?
8.8 How do we determine whether a standpipe is operating in packed bed flow or

fluidized bed flow?
8.9 For a standpipe operating in packed bed flow, how do we determine the quantity of
gas flow and whether the gas is flowing upwards or downwards?
8.10 For a standpipe operating in fluidized bed flow, why is it often necessary to add
aeration gas at several points along the standpipe? What approach is taken to
calculation of the quantities of gas to be added and the positions of the aeration points?
EXERCISES
8.1 Design a positive pressure dilute-phase pneumatic transport system to carry 500 kg/h of
a powder of particle density 1800 kg/m3 and mean particle size 150 mm across a horizontal
distance of 100 m and a vertical distance of 20 m using ambient air. Assume that the pipe is
smooth, that four 90 bends are required and that the allowable pressure loss is 0.7 bar. See
below for Blasius correlation for the gas-wall friction factor for smooth pipes.
(Answer: 50 mm diameter pipe gives total pressure drop of 0.55 bar; superficial gas
velocity 13.8 m/s.)
8.2 It is required to use an existing 50 mm inside diameter vertical smooth pipe as lift line to
transfer 2000 kg/h of sand of mean particle size 270 mm and particle density 2500 kg/m3 to a
process 50 m above the solids feed point. A blower is available which is capable of delivering
60 m3/h of ambient air at a pressure of 0.3 bar. Will the system operate as required?
(Answer: Using a superficial gas velocity of 8:49 m=sð¼ 1:55 UCH Þ the total pressure drop
is 0.344 bar. System will not operate as required since allowable p ¼ 0:3 bar)
8.3 Design a negative pressure dilute-phase pneumatic transport system to carry 700 kg/h
of plastic spheres of particle density 1000 kg/m3 and mean particle size 1 mm between two
points in a factory separated by a vertical distance of 15 m and a horizontal distance of
80 m using ambient air. Assume that the pipe is smooth, that five 90 bends are required
and that the allowable pressure loss is 0.4 bar.
(Answer: Using a superficial gas velocity of 16.4 m/s in a pipe of inside diameter 40 mm,
the total pressure drop is 0.38 bar.)
8.4 A 25 m long standpipe carrying Group A solids at a rate of 75 kg/s is to be aerated in

order to maintain fluidized flow with a voidage in the range 0.50–0.55. Solids enter the top
of the standpipe at a voidage of 0.55. The pressure and gas density at the top of the
standpipe are 1.4 bar (abs) and 1.1 kg/m3, respectively. The particle density of the solids is
1050 kg/m3.
EXERCISES 245
Determine the aeration positions and rates.
(Answer: Positions: 6.36 m, 14.13 m, 23.6 m. Rates: 0.0213 kg/s, 0.0261 kg/s, 0.0319 kg/s.)
8.5 A 15 m long standpipe carrying Group A solids at a rate of 120 kg/s is to be aerated in
order to maintain fluidized flow with a voidage in the range 0.50–0.54. Solids enter the top
of the standpipe at a voidage of 0.54. The pressure and gas density at the top of the
standpipe are 1.2 bar (abs) and 0.9 kg/m3, respectively. The particle density of the solids is
1100 kg/m3.
Determine the aeration positions and rates. What is the pressure at the lowest aeration
point?
(Answer: Positions: 4.03 m, 6.76 m, 14.3 m. Rates: 0.0200 kg/s, 0.0235 kg/s, 0.0276 kg/s.
Pressure: 1.94 bar.)
8.6 A 5 m long vertical standpipe of inside diameter 0.3 m transports solids at flux
of 500 kg/m2s from an upper vessel which is held at a pressure of 1.25 bar to a lower
vessel held at 1.6 bar. The particle density of the solids is 1800 kg/m3 and the surface-
volume mean particle size is 200 mm. Assuming that the voidage is 0.48 and is constant
along the standpipe, determine the direction and flow rate of gas passing
between the vessels. (Properties of gas in the system: density, 1.5 kg/m3; viscosity,
1:9 105 Pa s.)
(Answer: 0.023 kg/s downwards.)
8.7 A vertical standpipe of inside diameter 0.3 m transports solids at a flux of 300 kg/m2s
from an upper vessel which is held at a pressure 2.0 bar to a lower vessel held at 2.72 bar.
The particle density of the solids is 2000 kg/m3 and the surface-volume mean particle size
is 220 mm. The density and viscosity of the gas in the system are 2.0 kg/m3 and
2 105 Pa s, respectively.
Assuming that the voidage is 0.47 and is constant along the standpipe.
(a) Determine the minimum standpipe length required to avoid fluidized flow.
(b) Given that the actual standpipe is 8 m long, determine the direction and flow rate of
gas passing between the vessels.
(Answer: (a) 6.92 m; (b) 0.0114 kg/s downwards.)
Blasius correlation for the gas-wall friction factor for smooth pipes: fg ¼ 0.079 Re0.25
9
Separation of Particles
from a Gas: Gas Cyclones
There are many cases during the processing and handling of particulate solids
when particles are required to be separated from suspension in a gas. We saw in
Chapter 7 that in fluidized bed processes the passage of gas through the bed
entrains fine particles. These particles must be removed from the gas and
returned to the bed before the gas can be discharged or sent to the next stage
in the process. Keeping the very small particles in the fluid bed may be crucial to
the successful operation of the process, as is the case in fluid catalytic cracking
of oil.
In Chapter 8, we saw how a gas may be used to transport powders within a
process. The efficient separation of the product from the gas at the end of the
transport line plays an important part in the successful application of this method
of powder transportation. In the combustion of solid fuels, fine particles of fuel
ash become suspended in the combustion gases and must be removed before the
gases can be discharged to the environment.
In any application, the size of the particles to be removed from the gas
determine, to a large extent, the method to be used for their separation. Generally
speaking, particles larger than about 100 mm can be separated easily by gravity
settling. For particles less than 10 mm more energy intensive methods such as
filtration, wet scrubbing and electrostatic precipitation must be used. Figure 9.1
shows typical grade efficiency curves for gas–particle separation devices. The
grade efficiency curve describes how the separation efficiency of the device varies
with particle size. In this chapter we will focus on the device known as the
cyclone separator or cyclone. Gas cyclones are generally not suitable for separa-
tion involving suspensions with a large proportion of particles less than 10 mm.
They are best suited as primary separation devices and for relatively coarse
particles, with an electrostatic precipitator or fabric filter being used downstream
to remove very fine particles.

248 SEPARATION OF PARTICLES FROM A GAS: GAS CYCLONES
Figure 9.1 Typical grade efficiency curves for gas–particle separators
Readers wishing to know more about other methods of gas–particle separation

and about the choice between methods are referred to Svarovsky (1981, 1990) and
Perry and Green (1984).
9.1 GAS CYCLONES–DESCRIPTION
The most common type of cyclone is known as the reverse flow type (Figure 9.2).
Inlet gas is brought tangentially into the cylindrical section and a strong vortex is
thus created inside the cyclone body. Particles in the gas are subjected to
centrifugal forces which move them radially outwards, against the inward flow
of gas and towards the inside surface of the cyclone on which the solids separate.
The direction of flow of the vortex reverses near the bottom of the cylindrical
Figure 9.2 Schematic diagram of a reverse flow cyclone separator

EFFICIENCY OF SEPARATION 249
section and the gas leaves the cyclone via the outlet in the top (the solids outlet is
sealed to gas). The solids at the wall of the cyclone are pushed downwards by the
outer vortex and out of the solids exit. Gravity has been shown to have little effect
on the operation of the cyclone.
9.2 FLOW CHARACTERISTICS
Rotational flow in the forced vortex within the cyclone body gives rise to a radial
pressure gradient. This pressure gradient, combined with the frictional pressure
losses at the gas inlet and outlet and losses due to changes in flow direction,
make up the total pressure drop. This pressure drop, measured between the inlet
and the gas outlet, is usually proportional to the square of gas flow rate through
the cyclone. A resistance coefficient, the Euler number Eu, relates the cyclone
pressure drop p to a characteristic velocity v:
Eu ¼ p=ðrf v2 =2Þ ð9:1Þ
where rf is the gas density.

The characteristic velocity v can be defined for gas cyclones in various ways
but the simplest and most appropriate definition is based on the cross-section of
the cylindrical body of the cyclone, so that:
v ¼ 4q=ðpD2 Þ ð9:2Þ
where q is the gas flow rate and D is the cyclone inside diameter.
The Euler number represents the ratio of pressure forces to the inertial forces
acting on a fluid element. Its value is practically constant for a given cyclone
geometry, independent of the cyclone body diameter (see Section 9.4).
9.3 EFFICIENCY OF SEPARATION
9.3.1 Total Efficiency and Grade Efficiency
Consider a cyclone to which the solids mass flow rate is M, the mass flow
discharged from the solids exit orifice is Mc (known as the coarse product) and
the solids mass flow rate leaving with the gas is Mf (known as the fine product).
The total material balance on the solids over this cyclone may be written:
Total : M ¼ Mf þ Mc ð9:3Þ
and the ‘component’ material balance for each particle size x (assuming no
breakage or growth of particles within the cyclone) is
Component : MðdF=dxÞ ¼ Mf ðdFf =dxÞ þ Mc ðdFc =dxÞ ð9:4Þ

where, dF=dx; dFf =dx and dFc =dx are the differential frequency size distributions
by mass (i.e. mass fraction of size x) for the feed, fine product and coarse product
respectively. F, Ff and Fc are the cumulative frequency size distributions by mass
(mass fraction less than size x) for the feed, fine product and coarse product,
respectively. Refer to Chapter 1 for further details on representations of particle
size distributions.
The total efficiency of separation of particles from gas, ET , is defined as the
fraction of the total feed which appears in the coarse product collected, i.e.
ET ¼ Mc =M ð9:5Þ
The efficiency with which the cyclone collects particles of a certain size is
described by the grade efficiency, G(x), which is defined as:
mass of solids of size x in coarse product

GðxÞ ¼ ð9:6Þ
mass of solids of size x in feed
Using the notation for size distribution described above:
Mc ðdFc =dxÞ
GðxÞ ¼ ð9:7Þ
MðdF=dxÞ
Combining with Equation (9.5), we find an expression linking grade efficiency

with total efficiency of separation:
ðdFc =dxÞ
GðxÞ ¼ ET ð9:8Þ
ðdF=dxÞ
From Equations (9.3)–(9.5), we have
ðdF=dxÞ ¼ ET ðdFc =dxÞ þ ð1 ET ÞðdFf =dxÞ ð9:9Þ
Equation (9.9) relates the size distributions of the feed (no subscript), the coarse
product (subscript c) and the fine product (subscript f). In cumulative form this
becomes
F ¼ ET Fc þ ð1 ET ÞFf ð9:10Þ
9.3.2 Simple Theoretical Analysis for the Gas Cyclone Separator
Referring to Figure 9.3, consider a reverse flow cyclone with a cylindrical section
of radius R. Particles entering the cyclone with the gas stream are forced into
circular motion. The net flow of gas is radially inwards towards the central gas
outlet. The forces acting on a particle following a circular path are drag, buoyancy
and centrifugal force. The balance between these forces determines the equili-
brium orbit adopted by the particle. The drag force is caused by the inward flow
of gas past the particle and acts radially inwards. Consider a particle of diameter
EFFICIENCY OF SEPARATION 251
Figure 9.3 Reverse flow cyclone – a simple theory for separation efficiency
x and density rp following an orbit of radius r in a gas of density rf and viscosity

m. Let the tangential velocity of the particle be Uy and the radial inward velocity
of the gas be Ur . If we assume that Stokes’ law applies under these conditions
then the drag force is given by:
FD ¼ 3pxmUr ð9:11Þ
The centrifugal and buoyancy forces acting on the particle moving with a
tangential velocity component Uy at radius r are, respectively:
px3 Uy2
FC ¼ r ð9:12Þ
6 p r
px3 Uy2
FB ¼ r ð9:13Þ
6 f r
Under the action of these forces the particle moves inwards or outwards until the
forces are balanced and the particle assumes its equilibrium orbit. At this point,
FC ¼ FD þ FB ð9:14Þ
and so

18m r
x2 ¼ Ur ð9:15Þ
ðrp rf Þ Uy2
To go any further we need a relationship between Uy and the radius r for the
vortex in a cyclone. Now for a rotating solid body, Uy ¼ ro, where o is the
angular velocity and for a free vortex Uy r ¼ constant. For the confined vortex
inside the cyclone body it is has been found experimentally that the following
holds approximately:
Uy r1=2 ¼ constant
hence
Uy r1=2 ¼ UyR R1=2 ð9:16Þ
If we also assume uniform flow of gas towards the central outlet, then we are able
to derive the radial variation in the radial component of gas velocity, Ur :
gas flow rate; q ¼ 2prLUr ¼ 2pRLUR ð9:17Þ
hence
UR ¼ Ur ðr=RÞ ð9:18Þ
Combining Equations (9.16) and (9.18) with Equation (9.15), we find
18m UR
x2 ¼ r ð9:19Þ
ðrp rf Þ UyR
2
where r is the radius of the equilibrium orbit for a particle of diameter x.

If we assume that all particles with an equilibrium orbit radius greater than or
equal to the cyclone body radius will be collected, then substituting r ¼ R in
Equation (9.19) we derive the expression below for the critical particle diameter
for separation, xcrit :
18m UR
x2crit ¼ R ð9:20Þ
ðrp rf Þ UyR
2
The values of the radial and tangential velocity components at the cyclone wall,
UR and UyR , in Equation (9.20) may be found from a knowledge of the cyclone
geometry and the gas flow rate.
This analysis predicts an ideal grade efficiency curve shown in Figure 9.4. All
particles of diameter xcrit and greater are collected and all particles of size less
than xcrit are not collected.
9.3.3 Cyclone Grade Efficiency in Practice
In practice, gas velocity fluctuations and particle–particle interactions result in

some particles larger than xcrit being lost and some particles smaller than xcrit
SCALE-UP OF CYCLONES 253
Figure 9.4 Theoretical and actual grade efficiency curves
being collected. Consequently, in practice the cyclone does not achieve such a
sharp cut-off as predicted by the theoretical analysis above. In common with
other separation devices in which body forces are opposed by drag forces, the
grade efficiency curve for gas cyclones is usually S-shaped.
For such a curve, the particle size for which the grade efficiency is 50%, x50 , is
often used as a single number measurement of the efficiency of the cyclone. x50 is
also know as the equiprobable size since it is that size of particle which has a 50%
probability of appearing in the coarse product. This also means that, in a large
population of particles, 50% of the particles of this size will appear in the coarse
product. x50 is sometimes simply referred to as the cut size of the cyclone (or
other separation device).
The concept of x50 cut size is useful where the efficiency of a cyclone is to be
expressed as a single number independent of the feed solid size distribution,
such as in scale-up calculation.
9.4 SCALE-UP OF CYCLONES
The scale-up of cyclones is based on a dimensionless group, the Stokes number,

which characterizes the separation performance of a family of geometrically
similar cyclones. The Stokes number Stk50 is defined as:
x250 rp v
Stk50 ¼ ð9:21Þ
18mD
where m is gas viscosity, rp is solids density, v is the characteristic velocity

defined by Equation (9.2) and D is the diameter of the cyclone body. The physical
significance of the Stokes number is that it is a ratio of the centrifugal force (less
buoyancy) to the drag force, both acting on a particle of size x50 . Readers will note
the similarity between our theoretical expression of Equation (9.20) and the
Stokes number of Equation (9.21). There is therefore some theoretical justification
for the use of the Stokes number in scale-up. (We will also meet the Stokes
number in Chapter 14, when we consider the capture of particles in the
respiratory airways. Analysis shows that for a gas carrying particles in a duct,
the Stokes number is the dimensionless ratio of the force required to cause a
particle to change direction and the drag force available to bring about that
change in direction. The greater the value of Stokes number is above unity, the
greater is the tendency for particles to impact with the airway walls and so be
captured. There are obvious similarities between the conditions required for
collection of particles in the gas cyclone and those required for deposition of
particles by inertial impaction on the walls of the lungs. In each case, for
the particle not to be captured when the gas changes direction, the available
drag force must be sufficient to bring about the change of direction of the particle.
For large industrial cyclones the Stokes number, like the Euler number defined
previously, is independent of Reynolds number. For suspensions of concentra-
tion less than about 5 g/m3, the Stokes and Euler numbers are usually constant
for a given cyclone geometry (i.e. a set of geometric proportions relative to
cyclone diameter D). The geometries and values of Eu and Stk50 for two common
industrial cyclones, the Stairmand high efficiency (HE) and the Stairmand high
rate (HR) are given in Figure 9.5.
The use of the two dimensionless groups Eu and Stk50 in cyclone scale-up and
design is demonstrated in the worked examples at the end of this chapter.
As can be seen from Equation (9.21), the separation efficiency is described only
by the cut size x50 and no regard is given to the shape of the grade efficiency
curve. If the whole grade efficiency curve is required in performance calculations,
it may be generated around the given cut size using plots or analytical functions
of a generalized grade efficiency function available from the literature or from
previously measured data. For example, Perry and Green (1984) give the grade
efficiency expression:
ðx=x50 Þ2
grade efficiency ¼ ð9:22Þ
½1 þ ðx=x50 Þ2
for a reverse flow cyclone with the geometry:
A B C E J K N
4.0 2.0 2.0 0.25 0.625 0.5 0.5
(Letters refer to the cyclone geometry diagram shown in Figure 9.5.)

This expression gives rise to the grade efficiency curve shown in Figure 9.6 for
an x50 cut size of 5mm. Very little is known how the shape of the grade efficiency
curve is affected by operating pressure drop, cyclone size or design, and feed
solids concentration.
RANGE OF OPERATION 255
Figure 9.5 Geometries and Euler and Stokes numbers for two common cyclones.
9.5 RANGE OF OPERATION
One of the most important characteristics of gas cyclones is the way in which
their efficiency is affected by pressure drop (or flow rate). For a particular cyclone
and inlet particle concentration, total efficiency of separation and pressure drop
vary with gas flow rate as shown in Figure 9.7. Theory predicts that efficiency
increases with increasing gas flow rate. However, in practice, the total efficiency
Figure 9.6 Grade efficiency curve described by Equation (9.22) for a cut size x50 ¼ 5 mm
curve falls away at high flow rates because re-entrainment of separated solids
increases with increased turbulence at high velocities. Optimum operation is
achieved somewhere between points A and B, where maximum total separation
efficiency is achieved with reasonable pressure loss (and hence reasonable power
consumption). The position of point B changes only slightly for different dusts.
Correctly designed and operated cyclones should operate at pressure drops
within a recommended range; and this, for most cyclone designs operated at
ambient conditions, is between 50 and 150 mm of water gauge (WG) (approxi-
mately from 500 to 1500 Pa). Within this range, the total separation efficiency ET
increases with applied pressure drop, in accordance with the inertial separation
theory shown above.
Above the top limit the total efficiency no longer increases with increasing
pressure drop and it may actually decline due to re-entrainment of dust from
the dust outlet orifice. It is, therefore, wasteful of energy to operate cyclones
above the limit. At pressure drops below the bottom limit, the cyclone represents
Figure 9.7 Total separation efficiency and pressure drop versus gas flow rate through a
reverse flow cyclone
SOME PRACTICAL DESIGN AND OPERATION DETAILS 257
little more than a settling chamber, giving low efficiency due to low velocities
within it which may not be capable of generating a stable vortex.
9.6 SOME PRACTICAL DESIGN AND OPERATION DETAILS
The following practical considerations for design and operation of reverse flow
gas cyclones are among those listed by Svarovsky (1986).
9.6.1 Effect of Dust Loading on Efficiency
One of the important operating variables affecting total efficiency is the concen-
tration of particles in the suspension (known as the dust loading). Generally, high
dust loadings (above about 5 g=m3 Þ lead to higher total separation efficiencies
due to particle enlargement through agglomeration of particles (caused, for
example, by the effect of humidity).
9.6.2 Cyclone Types
The many reverse flow cyclone designs available today may be divided into two
main groups: high efficiency designs (e.g. Stairmand HE) and the high rate designs
(e.g. Stairmand HR). High efficiency cyclones give high recoveries and are
characterized by relatively small inlet and gas outlet orifices. The high rate
designs have lower total efficiencies, but offer low resistance to flow so that a unit
of a given size will give much higher gas capacity than a high efficiency design of
the same body diameter. The high rate cyclones have large inlets and gas outlets,
and are usually shorter. The geometries and values of Eu and Stk50 for two
common cyclones, the Stairmand HE and the Stairmand HR are given in
Figure 9.5.
For well-designed cyclones there is a direct correlation between Eu and Stk50.
High values of the resistance coefficient usually lead to low values of Stk50
(therefore low cut sizes and high efficiencies), and vice versa. The general trend
can be described by the following approximate empirical correlation:
sffiffiffiffiffiffiffiffiffiffi
12
Eu ¼ ð9:23Þ
Stk50
9.6.3 Abrasion
Abrasion in gas cyclones is an important aspect of cyclone performance and it is

affected by the way cyclones are installed and operated as much as by the
material construction and design. Materials of construction are usually steels of
different grades, sometimes lined with rubber, refractory lining or other material.
Within the cyclone body there are two critical zones for abrasion: in the
cylindrical part just beyond the inlet opening and in the conical part near the
dust discharge.
9.6.4 Attrition of Solids
Attrition or break-up of solids is known to take place on collection in gas cyclones

but little is known about how it is related to particle properties, although large
particles are more likely to be affected by attrition than finer fractions. Attrition is
most detectable in recirculating systems such as fluidized beds where cyclones
are used to return the carry-over material back to the bed (see Chapter 7). The
complete inventory of the bed may pass through the cyclones many times per
hour and the effect of attrition is thus exaggerated.
9.6.5 Blockages
Blockages, usually caused by overloading of the solids outlet orifice, is one of the
most common causes of failure in cyclone operation. The cyclone cone rapidly
fills up with dust, the pressure drop increases and efficiency falls dramatically.
Blockages arise due to mechanical defects in the cyclone body (bumps on the
cyclone cone, protruding welds or gasket) or changes in chemical or physical
properties of the solids (e.g. condensation of water vapour from the gas onto the
surface of particles).
9.6.6 Discharge Hoppers and Diplegs
The design of the solids discharge is important for correct functioning of a gas
cyclone. If the cyclone operates under vacuum, any inward leakages of air at the
discharge end cause particles to be re-entrained and this leads to a sharp decrease
in separation efficiency. If the cyclone is under pressure, outward leakages may
cause a slight increase in separation efficiency, but also results in loss of product
and pollution of the local environment. It is therefore best to keep the solids
discharge as gas-tight as possible.
The strong vortex inside a cyclone reaches into the space underneath the solids
outlet and it is important that no powder surface is allowed to build up to within
at least one cyclone diameter below the underflow orifice. A conical
vortex breaker positioned just under the dust discharge orifice may be used to
prevent the vortex from intruding into the discharge hopper below. Some
cyclone manufacturers use a ‘stepped’ cone to counter the effects of re-entrain-
ment and abrasion, and Svarovsky (1981) demonstrated the value of this design
feature.
In fluidized beds with internal cyclones, ‘diplegs’ are used to return the
collected entrained particles into the fluidized bed. Diplegs are vertical pipes
connected directly to the solids discharge orifice of the cyclone extending down
to below the fluidized bed surface. Particles discharged from the cyclone collect
as a moving settled suspension in the lower part of the dipleg before it enters the
bed. The level of the settled suspension in the dipleg is always higher than
the fluidized bed surface and it provides a necessary resistance to minimize both
the flow of gas up the dipleg and the consequent reduction of cyclone efficiency.
WORKED EXAMPLES 259
9.6.7 Cyclones in Series
Connecting cyclones in series is often done in practice to increase recovery.

Usually the primary cyclone would be of medium or low efficiency design and
the secondary and subsequent cyclones of progressively more efficient design or
smaller diameter.
9.6.8 Cyclones in Parallel
The x50 cut size achievable for a given cyclone geometry and operating pressure
drop decreases with decreasing cyclone size [see Equation (9.21)]. The size a
single cyclone for treating a given volume flow rate of gas is determined by that
gas flow rate [Equations (9.1) and (9.2)]. For large gas flow rates the resulting
cyclone may be so large that the x50 cut size is unacceptably high. The solution is
to split the gas flow into several smaller cyclones operating in parallel. In this
way, both the operating pressure drop and x50 cut size requirements can be
achieved. The worked examples at the end of the chapter demonstrate how the
number and diameter of cyclones in parallel are estimated.
9.7 WORKED EXAMPLES
WORKED EXAMPLE 9.1 – DESIGN OF A CYCLONE
Determine the diameter and number of gas cyclones required to treat 2 m3/s of ambient
air (viscosity, 18:25 106 Pa s; density, 1.2 kg/m3) laden with solids of density 1000 kg/
m3 at a suitable pressure drop and with a cut size of 4 mm. Use a Stairmand HE (high
efficiency) cyclone for which Eu ¼ 320 and Stk50 ¼ 1:4 104 .
Optimum pressure drop ¼ 100 m gas

¼ 100 1:2 9:81 Pa
¼ 1177 Pa
Solution
From Equation (9.1),
characteristic velocity; v ¼ 2:476 m=s
Hence, from Equation (9.2), diameter of cyclone, D ¼ 1:014 m
With this cyclone, using Equation (9.21), cut size, x50 ¼ 4:34 mm
This is too high and we must therefore opt for passing the gas through several smaller
cyclones in parallel.
Assuming that n cyclones in parallel are required and that the total flow is
evenly split, then for each cyclone the flow rate will be q ¼ 2=n.
Therefore from Equations (9.1) and (9.2), new cyclone diameter, D ¼ 1:014=n0:5 . Substitut-
ing in Equation (9.21) for D, the required cut size and v (2.476 m/s, as originally calculated,
since this is determined solely by the pressure drop requirement), we find that
n ¼ 1:386
We will therefore need two cyclones. Now with n ¼ 2, we recalculate the cyclone
diameter from D ¼ 1:014=n0:5 and the actual achieved cut size from Equation (9.21).
Thus, D ¼ 0:717 m, and using this value for D in Equation (9.21) together with required
cut size and v ¼ 2:476 m=s, we find that the actual cut size is 3:65 mm.
Therefore, two 0.717 m diameter Stairmand HE cyclones in parallel will give a cut size of
3:65 mm using a pressure drop of 1177 Pa.
WORKED EXAMPLE 9.2
Tests on a reverse flow gas cyclone give the results shown in the table below:
Size range (mm) 0–5 5–10 10–15 15–20 20–25 25–30

Feed size analysis, m (g) 10 15 25 30 15 5
Course product size analysis, mc (g) 0.1 3.53 18.0 27.3 14.63 5.0
(a) From these results determine the total efficiency of the cyclone.
(b) Plot the grade efficiency curve and hence show that the x50 cut size is 10 mm.
(c) The dimensionless constants describing this cyclone are: Eu ¼ 384 and
Stk50 ¼ 1 103 . Determine the diameter and number of cyclones to be operated
in parallel to achieve this cut size when handling 10 m3 =s of a gas of density 1.2 kg/
m3 and viscosity 18:4 106 Pa s, laden with dust of particle density 2500 kg/m3.
The available pressure drop is 1200 Pa.
(d) What is the actual cut size of your design?
Solution
(a) From the test results:
Mass of feed, M ¼ 10 þ 15 þ 25 þ 30 þ 15 þ 5 ¼ 100 g
Mass of coarse product, Mc ¼ 0:1 þ 3:53 þ 18:0 þ 27:3 þ 14:63 þ 5:0 ¼ 68:56 g
Therefore, from Equation (9.5), total efficiency,
Mc
ET ¼ ¼ 0:6856 ðor 68:56%Þ
M
WORKED EXAMPLES 261
(b) From Equation (9.7), grade efficiency,
Mc dFc dx dFc =dx

GðxÞ ¼ ¼ ET
M dF=dx dF=dx
In this case, G(x) may be obtained directly from the results table as
mc
GðxÞ ¼
m
And so, the grade efficiency curve data becomes:
Size range ðmmÞ 0–5 5–10 10–15 15–20 20–25 25–30

G(x) 0.01 0.235 0.721 0.909 0.975 1.00
Plotting these data gives x50 ¼ 10 mm, as may be seen from Figure 9W.2.1.
For interest, we can calculate the size distributions of the feed, dF=dx and the coarse
product, dFc =dx:
Size range (mm) 0–5 5–10 10–15 15–20 20–25 25–30

dFc =dx 0.00146 0.0515 0.263 0.398 0.2134 0.0729
dF=dx 0.1 0.15 0.25 0.30 0.15 0.05
We can then verify the calculated G(x) values. For example, in the size range 10–15:
dFc =dx 0:263

GðxÞ ¼ ET ¼ 0:6856 ¼ 0:721
dF=dx 0:25
1
0.9
0.8
0.7
0.6
G(x)
0.5
0.4
0.3
0.2
0.1
0
0 5 10 15 20 25 30
Particle size x (mm)
Figure 9.W2.1 Grade efficiency curve

(c) Using Equation (9.1), noting that the allowable pressure is 1200 Pa, we calculate the
characteristic velocity, v: sffiffiffiffiffiffiffiffiffiffi
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
2p 2 1200
v¼ ¼ ¼ 2:282 m=s
Eurf 384 1:2
If we have n cyclones in parallel then assuming even distribution of the gas between the
cyclones, flow rate to each cyclone, q ¼ Q=n and from Equation (9.2),
rffiffiffiffiffiffiffiffi rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
4Q 4 10 2:362
D¼ ¼ ¼ pffiffiffi
npv np 2:282 n
Now substitute this expression for D and the required cut size x50 in Equation (9.21) for
Stk50 :
x250 rp v
Stk50 ¼
18 mD
ð10 106 Þ2 2500 2:282
1 103 ¼ pffiffiffi
18 18:4 106 ð2:362= nÞ
giving n ¼ 1:88.
We therefore require two cyclones. With two cyclones, using all of the allowable
pressure drop the characteristic velocity will be the same (2.282 m/s) and the required
cyclone diameter may be calculated from the expression derived above:
2:362
D ¼ pffiffiffi
n
giving D ¼ 1:67 m.
(d) The actual cut size achieved with two cyclones is calculated from Equation (9.21)
with D ¼ 1:67 m and v ¼ 2:282 m=s:
rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
1 103 18 18:4 106 1:67
actual cut size; x50 ¼ ¼ 9:85 106 m
2500 2:282
Summary. Two cyclones (described by Eu ¼ 384 and Stk50 ¼ 1 103 ) of diameter 1.67 m
and operating at a pressure drop of 1200 Pa, will achieve a equiprobable cut size of
9:85 mm.
TEST YOURSELF
9.1 Typically in what particle size range are industrial cyclone separators useful?
9.2 With the aid of a sketch, describe the operation of a reverse flow cyclone separator.
9.3 What forces act on a particle inside a cyclone separator? What factors govern the
magnitudes of each of these forces?
9.4 For a gas–particle separation device, define total efficiency and grade efficiency. Using
these definitions and the mass balance, derive an expression relating the size
EXERCISES 263
distributions of the feed, coarse product and fine product for a gas–particle separa-
tion device.
9.5 What is meant by the x50 cut size?
9.6 Define the two dimensionless numbers which are used in the scale up of cyclone
separators.
9.7 Theory suggests that the total efficiency of a cyclone separator will increase with
increasing gas flow rate. Explain why, in practice, cyclone separators are operated
within a certain range of pressure drops.
9.8 Under what conditions might we choose to operate cyclone separators in

parallel?
EXERCISES
9.1 A gas–particle separation device is tested and gives the results shown in the table
below:
Size range (mm) 0–10 10–20 20–30 30–40 40–50

Range mean (mm) 5 15 25 35 45
Feed mass (kg) 45 69 120 45 21
Coarse product mass (kg) 1.35 19.32 99.0 44.33 21.0
(a) Find the total efficiency of the device.
(b) Produce a plot of the grade efficiency for this device and determine the equiprobable
cut size.
[Answer: (a) 61.7%; (b) 19:4 mm.]
9.2 A gas–particle separation device is tested and gives the results shown in the table
below:
Size range (mm) 6.6–9.4 9.4–13.3 13.3–18.7 18.7–27.0 27.0–37.0 37.0–53.0

Feed size distribution 0.05 0.2 0.35 0.25 0.1 0.05
Coarse product size distribution 0.016 0.139 0.366 0.30 0.12 0.06
Given that the total mass of feed is 200 kg and the total mass of coarse product collected is
166.5 kg:
(a) Find the total efficiency of the device.
(b) Determine the size distribution of the fine product.
(c) Plot the grade efficiency curve for this device and determine the equiprobable
size.
(d) If this same device were fed with a material with the size distribution below, what
would be the resulting coarse product size distribution?
Size range (mm) 6.6–9.4 9.4–13.3 13.3–18.7 18.7–27.0 27.0–37.0 37.0–53.0

Feed size distribution 0.08 0.13 0.27 0.36 0.14 0.02
[Answer: (a) 83.25%; (b) 0.219, 0.503, 0.271, 0.0015, 0.0006, 0.0003; (c) 10.5 mm; (d) 0.025,
0.089, 0.276, 0.422, 0.165, 0.024].
9.3
(a) Explain what a ‘grade efficiency curve’ is with reference to a gas–solids separation
device and sketch an example of such a curve for a gas cyclone separator.
(b) Determine the diameter and number of Stairmand HR gas cyclones to be operated in
parallel to treat 3 m3 =s of gas of density 0.5 kg/m3 and viscosity 2 105 Pa s carrying
a dust of density 2000 kg/m3. A x50 cut size of at most 7 mm is to be achieved at a
pressure drop of 1200 Pa.
(For a Stairmand HR cyclone: Eu ¼ 46 and Stk50 ¼ 6 103 .)
(c) Give the actual cut size achieved by your design.
(d) A change in process conditions requirements necessitates a 50% drop in gas flow rate.
What effect will this have on the cut size achieved by your design?
[Answer: (a) Two cyclones 0.43 m in diameter; (b) x50 ¼ 6:8 mm; (c) new x50 ¼ 9:6 mm.]
9.4
(a) Determine the diameter and number of Stairmand HE gas cyclones to be operated in
parallel to treat 1 m3/s of gas of density 1.2 kg/m3 and viscosity 18:5 106 Pa s
carrying a dust of density 1000 kg/m3. An x50 cut size of at most 5 mm is to be achieved
at a pressure drop of 1200 Pa.
(For a Stairmand HE cyclone: Eu ¼ 320 and Stk50 ¼ 1:4 104 .)
(b) Give the actual cut size achieved by your design.
[Answer: (a) One cyclone, 0.714 m in diameter; (b) x50 ¼ 3:6 mm.]
9.5 Stairmand HR cyclones are to be used to clean up 2.5 m3/s of ambient air (density,
1.2 kg/m3; viscosity, 18:5 106 Pa s) laden with dust of particle density 2600 kg/m3. The
available pressure drop is 1200 Pa and the required cut size is to be not more than 6 mm.
(a) What size of cyclones are required?
(b) How many cyclones are needed and in what arrangement?
(c) What is the actual cut size achieved?

[Answer: (a) Diameter ¼ 0:311 m; (b) five cyclones in parallel; (c) actual cut size ¼ 6 mm.]
10
Storage and Flow of
Powders – Hopper Design
10.1 INTRODUCTION
The short-term storage of raw materials, intermediates and products in the form
of particulate solids in process plants presents problems which are often under-
estimated and which, as was pointed out in the introduction of this text, may
frequently be responsible for production stoppages.
One common problem in such plants is the interruption of flow from the
discharge orifice in the hopper, or converging section beneath a storage vessel for
powders. However, a technology is available which will allow us to design such
storage vessels to ensure flow of the powders when desired. Within the bounds
of a single chapter it is not possible to cover all aspects of the gravity flow of
unaerated powders, and so here we will confine ourselves to a study of the
design philosophy to ensure flow from conical hoppers when required. The
approach used is that first proposed by Jenike (1964).
10.2 MASS FLOW AND CORE FLOW
Mass flow. In perfect mass flow, all the powder in a silo is in motion whenever any
of it is drawn from the outlet as shown in Figure 10.1(b). The flowing channel
coincides with the walls of the silo. Mass flow hoppers are smooth and steep.
Figure 10.2(a–d) shows sketches taken from a sequence of photographs of a
hopper operating in mass flow. The use of alternate layers of coloured powder in
this sequence clearly shows the key features of the flow pattern. Note how the
powder surface remains level until it reaches the sloping section.

266 STORAGE AND FLOW OF POWDERS – HOPPER DESIGN
Figure 10.1 Mass flow and core flow in hoppers: (a) core flow; (b) mass flow
Core flow. This occurs when the powder flows towards the outlet of a silo in a
channel formed within the powder itself [Figure 10.1(a)]. We will not concern
ourselves with core flow silo design. Figure 10.3 (a–d) shows sketches taken from
a sequence of photographs of a hopper operating in core flow. Note the regions of
Figure 10.2 Sequence of sketches taken from photographs showing a mass flow pattern
as a hopper empties. (The black bands are layers of coloured tracer particles)
MASS FLOW AND CORE FLOW 267
Figure 10.3 Sequence of sketches taken from photographs showing a core flow pattern as
a hopper empties. (The black bands are layers of coloured tracer particles)
powder lower down in the hopper are stagnant until the hopper is almost
empty. The inclined surface of the powder gives rise to size segregation (see
Chapter 11).
Mass flow has many advantages over core flow. In mass flow, the motion of
the powder is uniform and steady state can be closely approximated. The bulk
density of the discharged powder is constant and practically independent of the
height in the silo. In mass flow stresses are generally low throughout the mass of
solids, giving low compaction of the powder. There are no stagnant regions in
the mass flow hopper. Thus the risk of product degradation is small compared
with the case of the core flow hopper. The first-in–first-out flow pattern of the
mass flow hopper ensures a narrow range of residence times for solids in the
silo. Also, segregation of particles according to size is far less of a problem in
mass flow than in core flow. Mass flow has one disadvantage which may be
overriding in certain cases. Friction between the moving solids and the silo and
hopper walls result in erosion of the wall, which gives rise to contamination of
the solids by the material of the hopper wall. If either contamination of the solids
or serious erosion of the wall material are unacceptable, then a core flow hopper
should be considered.
For conical hoppers the slope angle required to ensure mass flow depends on
the powder/powder friction and the powder/wall friction. Later we will see
how these are quantified and how it is possible to determine the conditions
which give rise to mass flow. Note that there is no such thing as a mass flow
hopper; a hopper which gives mass flow with one powder may give core flow
with another.
Figure 10.4 Arching in the flow of powder from a hopper
10.3 THE DESIGN PHILOSOPHY
We will consider the blockage or obstruction to flow called arching and assume
that if this does not occur then flow will take place (Figure 10.4). Now, in general,
powders develop strength under the action of compacting stresses. The greater
the compacting stress, the greater the strength developed (Figure 10.5). (Free-
flowing solids such as dry coarse sand do not develop strength as the result of
compacting stresses and will always flow.)
10.3.1 Flow–No Flow Criterion
Gravity flow of a solid in a channel will take place provided the strength
developed by the solids under the action of consolidating pressures is insuffi-
cient to support an obstruction to flow. An arch occurs when the strength
developed by the solids is greater than the stresses acting within the surface of
the arch.
Figure 10.5 Variation of strength of powder with compacting stress for cohesive and
free-flowing powders
THE DESIGN PHILOSOPHY 269
10.3.2 The Hopper Flow Factor, ff
The hopper flow factor, ff, relates the stress developed in a particulate solid with
the compacting stress acting in a particular hopper. The hopper flow factor is
defined as:
sC compacting stress in the hopper

ff ¼ ¼ ð10:1Þ
sD stress developed in the powder
A high value of ff means low flowability since high sC means greater compaction,
and a low value of sD means more chance of an arch forming.
The hopper flow factor depends on:
the nature of the solid;
the nature of the wall material;
the slope of the hopper wall.
These relationships will be quantified later.
10.3.3 Unconfined Yield Stress, sy
We are interested in the strength developed by the powder in the arch surface.
Suppose that the yield stress (i.e. the stress which causes flow) of the powder in
the exposed surface of the arch is sy . The stress sy is known as the unconfined
yield stress of the powder. Then if the stresses developed in the powder forming
the arch are greater than the unconfined yield stress of the powder in the arch,
flow will occur. That is, for flow:
sD > sy ð10:2Þ
Incorporating Equation (10.1), this criterion may be rewritten as:

sC
> sy ð10:3Þ
ff
10.3.4 Powder Flow Function
Obviously, the unconfined yield stress, sy , of the solids varies with compacting
stress, sC :
sy ¼ fnðsC Þ
Figure 10.6 Powder flow function (a property of the solids only)
This relationship is determined experimentally and is usually presented graphi-

cally (Figure 10.6). This relationship has several different names, some of which
are misleading. Here we will call it the powder flow function. Note that it is a
function only of the powder properties.
10.3.5 Critical Conditions for Flow
From Equation (10.3), the limiting condition for flow is:

sC
¼ sy
ff
This may be plotted on the same axes as the powder flow function (unconfined
yield stress, sy and compacting stress, sC ) in order to reveal the conditions under
which flow will occur for this powder in the hopper. The limiting condition gives
a straight line of slope 1=ff. Figure 10.7 shows such a plot.
Where the powder has a yield stress greater than sC =ff, no flow occurs [powder
flow function (a)]. Where the powder has a yield stress less than sC =ff flow occurs
[powder flow function (c)]. For powder flow function (b) there is a critical
condition, where unconfined yield stress, sy , is equal to stress developed in the
powder, sC =ff. This gives rise to a critical value of stress, scrit , which is the critical
stress developed in the surface of the arch:
If actual stress developed < scrit ) no flow

If actual stress developed > scrit ) flow
10.3.6 Critical Outlet Dimension
Intuitively, for a given hopper geometry, one would expect the stress developed
in the arch to increase with the span of the arch and the weight of solids in the
arch. In practice this is the case and the stress developed in the arch is related to
THE DESIGN PHILOSOPHY 271
Figure 10.7 Determination of critical conditions for flow
the size of the hopper outlet, B, and the bulk density, rB , of the material by the
relationship:
HðyÞscrit
minimum outlet dimension; B ¼ ð10:4Þ
rB g
where HðyÞ is a factor determined by the slope of the hopper wall and g is the
acceleration due to gravity. An approximate expression for HðyÞ for conical
hoppers is
y
HðyÞ ¼ 2:0 þ ð10:5Þ
60
10.3.7 Summary
From the above discussion of the design philosophy for ensuring mass flow from
a conical hopper, we see that the following are required:
(1) the relationship between the strength of the powder in the arch, sy (uncon-
fined yield stress) with the compacting stress acting on the powder, sC ;
(2) the variation of hopper flow factor, ff, with:
(a) the nature of the powder (characterized by the effective angle of internal
friction, d);
(b) the nature of the hopper wall (characterized by the angle of wall friction,
W );
(c) the slope of the hopper wall (characterized by y, the semi-included angle of
the conical section, i.e. the angle between the sloping hopper wall and the
vertical).
Knowing d, w , and y, the hopper flow factor, ff, can be fixed. The hopper flow
factor is therefore a function both of powder properties and of the hopper
properties (geometry and the material of construction of the hopper walls).
Knowing the hopper flow factor and the powder flow function (sy versus sC )
the critical stress in the arch can be determined and the minimum size of outlet
found corresponding to this stress.
10.4 SHEAR CELL TEST
The data listed above can be found by performing shear cell tests on the powder.
The Jenike shear cell (Figure 10.8) allows powders to be compacted to any
degree and sheared under controlled load conditions. At the same time the shear
force (and hence stress) can be measured.
Generally powders change bulk density under shear. Under the action of shear,
for a specific normal load:
a loosely packed powder would contract (increase bulk density);
a very tightly packed powder would expand (decrease bulk density);
a critically packed powder would not change in volume.
For a particular bulk density there is a critical normal load which gives failure
(yield) without volume change. A powder flowing in a hopper is in this critical
condition. Yield without volume change is therefore of particular interest to us in
design.
Using a standardized test procedure five or six samples of powder are
prepared all having the same bulk density. Referring to the diagram of the
Jenike shear cell shown in Figure 10.8 a normal load is applied to the lid of the
cell and the horizontal force applied to the sample via the bracket and loading pin
Figure 10.8 Jenike shear cell

SHEAR CELL TEST 273
Figure 10.9 A single yield locus
is recorded. That horizontal force necessary to initiate shear of flow of the powder
sample is noted. This procedure is repeated for each identical powder sample but
with a greater normal load applied to the lid each time. This test thus generates a
set of five or six pairs of values for normal load and shear force and hence pairs of
values of compacting stress and shear stress for a powder of a particular bulk
density. The pairs of values are plotted to give a yield locus (Figure 10.9). The end
point of the yield locus corresponds to critical flow conditions where initiation of
flow is not accompanied by a change in bulk density. Experience with the
procedure permits the operator to select combinations of normal and shear force
which achieve the critical conditions. This entire test procedure is repeated two or
three times with samples prepared to different bulk densities. In this way a
family of yield loci is generated (Figure 10.10).
These yield loci characterize the flow properties of the unaerated powder. The
following section deals with the generation of the powder flow function from this
family of yield loci.
Figure 10.10 A family of yield loci

Figure 10.11 Mohr’s circle construction
10.5 ANALYSIS OF SHEAR CELL TEST RESULTS
The mathematical stress analysis of the flow of unaerated powders in a hopper

requires the use of principal stresses. We therefore need to use the Mohr’s stress
circle in order to determine principal stresses from the results of the shear tests.
10.5.1 Mohr’s Circle – in Brief
Principal stresses – in any stress system there are two planes at right angles to
each other in which the shear stresses are zero. The normal stresses acting on
these planes are called the principal stresses.
The Mohr’s circle represents the possible combinations of normal and shear
stresses acting on any plane in a body (or powder) under stress. Figure 10.11
shows how the Mohr’s circle relates to the stress system. Further information
on the background to the use of Mohr’s circles may be found in most texts
dealing with the strength of materials and the analysis of stress and strain in
solids.
10.5.2 Application of Mohr’s Circle to Analysis of the Yield Locus
Each point on a yield locus represents that point on a particular Mohr’s circle for
which failure or yield of the powder occurs. A yield locus is then tangent to all the
Mohr’s circles representing stress systems under which the powder will fail (flow).
ANALYSIS OF SHEAR CELL TEST RESULTS 275
Figure 10.12 Identification of the applicable Mohr’s circle
For example, in Figure 10.12 Mohr’s circles (a) and (b) represent stress systems
under which the powder would fail. In circle (c) the stresses are insufficient to
cause flow. Circle (d) is not relevant since the system under consideration cannot
support stress combinations above the yield locus. It is therefore Mohr’s circles
which are tangential to yield loci that are important to our analysis.
10.5.3 Determination of sy and sc
Two tangential Mohr’s circles are of particular interest. Referring to Figure 10.13,
the smaller Mohr’s circle represents conditions at the free surface of the arch: this
free surface is a plane in which there is zero shear and zero normal stress and so
the Mohr’s circle which represents flow (failure) under these conditions must
pass through the origin of the shear stress versus normal stress plot. This Mohr’s
circle gives the (major principal) unconfined yield stress, and this is the value we
use for sy . The larger Mohr’s circle is tangent to the yield locus at its end point
and therefore represents conditions for critical failure. The major principal stress
from this Mohr’s circle is taken as our value of compacting stress, sC .
Pairs of values of sy and sC are found from each yield locus and plotted against
each other to give the powder flow function (Figure 10.6).
Figure 10.13 Determination of unconfined yield stress, sy and compacting stress, sC

Figure 10.14 Definition of effective yield locus and effective angle of internal friction, d
10.5.4 Determination of d from Shear Cell Tests
Experiments carried out on hundreds of bulk solids (Jenike, 1964) have demon-
strated that for an element of powder flowing in a hopper:
s1 major principal stress on the element

¼ ¼ a constant
s2 minor principal stress on the element
This property of bulk solids is expressed by the relationship:
s1 1 þ sin d
¼ ð10:6Þ
s2 1 sin d
where d is the effective angle of internal friction of the solid. In terms of the
Mohr’s stress circle this means that Mohr’s circles for the critical failure are all
tangent to a straight line through the origin, the slope of the line being tan d
(Figure 10.14).
This straight line is called the effective yield locus of the powder. By drawing
in this line, d can be determined. Note that d is not a real physical angle within the
powder; it is the tangent of the ratio of shear stress to normal stress. Note also
that for a free-flowing solid, which does not gain strength under compaction,
there is only one yield locus and this locus coincides with the effective yield locus
(Figure 10.15). (This type of relationship between normal stress and shear stress is
known as Coulomb friction.)
10.5.5 The Kinematic Angle of Friction between Powder

and Hopper Wall, w
The kinematic angle of friction between powder and hopper wall is otherwise
known as the angle of wall friction, w This gives us the relationship between
normal stress acting between powder and wall and the shear stress under flow
conditions. To determine w it is necessary to first construct the wall yield locus
ANALYSIS OF SHEAR CELL TEST RESULTS 277
Figure 10.15 Yield locus for a free-flowing powder
from shear cell tests. The wall yield locus is determined by shearing the powder
against a sample of the wall material under various normal loads. The apparatus
used is shown in Figure 10.16, and a typical wall yield locus is shown in
Figure 10.17.
The kinematic angle of wall friction is given by the gradient of the wall yield
locus (Figure 10.17), i.e.
shear stress at the wall
tan w ¼
normal stress at the wall
10.5.6 Determination of the Hopper Flow Factor, ff
The hopper flow factor, ff, is a function of d, w , and y and can be calculated from
first principles. However, Jenike (1964) obtained values for a conical hopper and
for a wedge-shaped hopper with a slot outlet for values of d of 30 , 40 , 50 , 60
and 70 . Examples of the ‘flow factor charts’ for conical hoppers are shown in
Figure 10.16 Apparatus for the measurement of kinematic angle of wall friction, w
Figure 10.17 Kinematic angle of wall friction, w
Figure 10.18. It will be noticed that values of flow factor exist only in a triangular
region; this defines the conditions under which mass flow is possible.
The following is an example of the use of these flow factor charts. Suppose that
shear cell tests have given us d and w equal to 30 and 19 , respectively, then
entering the chart for conical hoppers with effective angle of friction d ¼ 30 , we
find that the limiting value of wall slope, y, to ensure mass flow is 30:5 (point X
in Figure 10.19). In practice it is usual to allow a safety margin of 3 , and so, in
this case the semi-included angle of the conical hopper y would be chosen as
27:5 , giving a hopper flow factor, ff ¼ 1:8 (point Y, Figure 10.19).
10.6 SUMMARY OF DESIGN PROCEDURE
The following is a summary of the procedure for the design of conical hoppers
for mass flows:
(i) Shear cell tests on powder give a family of yield loci.
(ii) Mohr’s circle stress analysis gives pairs of values of unconfined yield stress, sy ,
and compacting stress, sC , and the value of the effective angle of internal friction, d.
(iii) Pairs of values of sy and sC give the powder flow function.
(iv) Shear cell tests on the powder and the material of the hopper wall give the
kinematic angle of wall friction, w .
(v) w and d are used to obtain hopper flow factor, ff, and semi-included angle
of conical hopper wall slope, y.
(vi) Powder flow function and hopper flow factor are combined to give the
stress corresponding to the critical flow – no flow condition, scrit .
(vii) scrit , HðyÞ and bulk density, rB , are used to calculate the minimum diameter
of the conical hopper outlet B.
SUMMARY OF DESIGN PROCEDURE 279
Figure 10.18 (a) Hopper flow factor values for conical channels, d ¼ 30 . (b) Hopper flow
factor values for conical channels, d ¼ 40 . (c) Hopper flow factor values for conical
channels, d ¼ 50 . (d) Hopper flow factor values for conical channels, d ¼ 60
Figure 10.18 (Continued)

PRESSURE ON THE BASE OF A TALL CYLINDRICAL BIN 281
Figure 10.19 Worked example of the use of hopper flow factor charts. Hopper flow factor
values for conical channels, d ¼ 30
10.7 DISCHARGE AIDS
A range of devices designed to facilitate flow of powders from silos and hoppers
are commercially available. These are known as discharge aids or silo activators.
These should not, however, be employed as an alternative to good hopper design.
Discharge aids may be used where proper design recommends an unaccep-
tably large hopper outlet incompatible with the device immediately downstream.
In this case the hopper should be designed to deliver uninterrupted mass flow to
the inlet of the discharge aid, i.e. the slope of the hopper wall and inlet
dimensions of the discharge aid are those calculated according to the procedure
outlined in this chapter.
10.8 PRESSURE ON THE BASE OF A TALL CYLINDRICAL BIN
It is interesting to examine the variation of stress exerted on the base of a bin

with increasing depth of powder. For simplicity we will assume that the pow-
der is non-cohesive (i.e. does not gain strength on compaction). Referring to
Figure 10.20, consider a slice of thickness H at a depth H below the surface of
the powder. The downward force is
pD2
sv ð10:7Þ
4
where D is the bin diameter and sv is the stress acting on the top surface of the
slice. Assuming stress increases with depth, the reaction of the powder below the
slice acts upwards and is
pD2
ðsv þ sv Þ ð10:8Þ
4
Figure 10.20 Forces acting on a horizontal slice of powder in a tall cylinder
The net upward force on the slice is then
pD2
sv ð10:9Þ
4
If the stress exerted on the wall by the powder in the slice is sh and the wall
friction is tan w , then the friction force (upwards) on the slice is
pDH tan w sh ð10:10Þ
The gravitational force on the slice is
pD2
r gH acting downwards ð10:11Þ
4 B
where rB is the bulk density of the powder, assumed to be constant throughout

the powder (independent of depth).
If the slice is in equilibrium the upward and downward forces are equated,
giving
Dsv þ 4 tan w sh H ¼ DrB gH ð10:12Þ
If we assume that the horizontal stress is proportional to the vertical stress and
that the relationship does not vary with depth,
sh ¼ ksv ð10:13Þ
PRESSURE ON THE BASE OF A TALL CYLINDRICAL BIN 283
and so as H tends to zero,

dsv 4 tan w k
þ sv ¼ rB g ð10:14Þ
dH D
Noting that this is the same as
dsv ð4 tan w k=DÞH

ðe sv Þ ¼ rB geð4 tan w k=DÞH ð10:15Þ
dH
and integrating, we have
DrB g
sv eð4 tan w k=DÞH ¼ eð4 tan w k=DÞH þ constant ð10:16Þ
4 tan w k
If, in general the stress acting on the surface of the powder is sv0 ðat H ¼ 0Þ the
result is
DrB g
sv ¼ ½1 eð4 tan w k=DÞH þ sv0 eð4 tan w k=DÞH ð10:17Þ
4 tan w k
This result was first demonstrated by Janssen (1895).

If there is no force acting on the free surface of the powder, sv0 ¼ 0 and so
DrB g
sv ¼ ð1 eð4 tan w k=DÞH Þ ð10:18Þ
4 tan w k
When H is very small
sv ffi rB Hg
z ð10:19Þ
ðsince for very small z; e ffi 1 zÞ
equivalent to the static pressure at a depth H in fluid of density rB .

When H is large, inspection of Equation (10.18) gives
DrB g
sv ffi ð10:20Þ
4 tan w k
and so the vertical stress developed becomes independent of depth of powder

above. The variation in stress with depth of powder for the case of no force acting
on the free surface of the powder ðsv0 ¼ 0Þ is shown in Figure 10.21. Thus, contrary
to intuition (which is usually based on our experience with fluids), the force
exerted by a bed of powder becomes independent of depth if the bed is deep
Figure 10.21 Variation in vertical pressure with depth of powder (for sv0 ¼ 0)
enough. Hence most of the weight of the powder is supported by the walls of the
bin. In practice, the stress becomes independent of depth (and also independent of
any load applied to the powder surface) beyond a depth of about 4D.
10.9 MASS FLOW RATES
The rate of discharge of powder from an orifice at the base of a bin is found to be
independent of the depth of powder unless the bin is nearly empty. This means
that the observation for a static powder that the pressure exerted by the powder
is independent of depth for large depths is also true for a dynamic system. It
confirms that fluid flow theory cannot be applied to the flow of a powder. For
flow through an orifice in the flat-based cylinder, experiment shows that:
mass flow rate; Mp / ðB aÞ2:5 for a circular orifice of diameter B
where a is a correction factor dependent on particle size. [For example, for solids
discharge from conical apertures in flat-based cylinders, Beverloo et al. (1961)
give Mp ¼ 0:58rB g0:5 ðB kxÞ2:5 .]
For cohesionless coarse particles free falling ffi a distance h their velocity,
over
neglecting drag and interaction, will be u ¼ 2gh.
If these particles are flowing at a bulk density rB through a circular orifice of
diameter B, then the theortical mass flow rate will be:
p pffiffiffi
Mp ¼ 2rB g0:5 h0:5 B2
4
WORKED EXAMPLES 285
The practical observation that flow rate is proportional to B2:5 suggests that, in
practice, particles only approach the free fall model when h is the same order as
the orifice diameter.
10.10 CONCLUSIONS
Within the confines of a single chapter it has been possible only to outline the
principles involved in the analysis of the flow of unaerated powders. This has
been done by reference to the specific example of the design of conical hoppers
for mass flow. Other important considerations in the design of hoppers such as
time consolidation effects and determination of the stress acting in the hopper
and bin wall have been omitted. These aspects together with the details of shear
cell testing procedure are covered in texts specific to the subject. Readers wishing
to pursue the analysis of failure (flow) in particulate solids in greater detail may
refer to texts on soil mechanics.
WORKED EXAMPLE 10.1
The results of shear cell tests on a powder are shown in Figure 10W1.1. In addition, it is
known that the angle of friction on stainless steel is 19 for this powder, and under flow
conditions the bulk density of the powder is 1300 kg=m3 . A conical stainless steel hopper
is to be designed to hold this powder.
Figure 10W1.1 Shear cell test data

Figure 10W1.2 Determination of critical stress
Determine:
(a) the effective angle of internal friction;
(b) the maximum semi-included angle of the conical hopper which will confidently give
mass flow;
(c) the minimum diameter of the circular hopper outlet necessary to ensure flow when
the outlet slide valve is opened.
Solution
(a) From Figure 10W1.1, determine the slope of the effective yield locus (line AB).
Slope ¼ 0:578.
Hence, the effective angle of internal friction, d ¼ tan1 ð0:578Þ ¼ 30
(b) From Figure 10W1.1, determine the pairs of values of sC and sy necessary to plot the
powder flow function (Figure 10W1.2).
sC 2.4 2.0 1.6 1.3

sy 0.97 0.91 0.85 0.78
Using the flow factor chart for d ¼ 30 [Figure 10.18(a)] with v ¼ 19 and a 3 margin of
safety gives a hopper flow factor, ff ¼ 1:8, and the semi-included angle of hopper wall,
y ¼ 27:5 (see Figure 10W1.3).
(c) The relationship sy ¼ sC =ff is plotted on the same axes as the powder flow function
(Figure 10W1.2) and where this line intersepts the powder flow function we find a value
of critical unconfined yield stress, scrit ¼ 0:83 kN=m2 . From Equation (10.5),
WORKED EXAMPLES 287
Figure 10W1.3 Determination of y and ff
HðyÞ ¼ 2:46 when y ¼ 27:5
and from Equation (10.4), the minimum outlet diameter for mass flow, B, is
2:46 0:83 103

B¼ ¼ 0:160 m
1300 9:81
Summarizing, then, to achieve mass flow without risk of blockage using the powder in
question we require a stainless steel conical hopper with a maximum semi-included
angle of cone, 27:5 and a circular outlet with a diameter of at least 16.0 cm.
WORKED EXAMPLE 10.2
Shear cell tests on a powder give the following information:

Effective angle of internal friction, d ¼ 40
Kinematic angle of wall friction on mild steel, w ¼ 16
Bulk density under flow condition, rB ¼ 2000 kg=m3
The powder flow function which can be represented by the relationship, sy ¼ s0:6 C ,
where sy is unconfined yield stress ðkN=m2 Þ and sC is consolidating stress ðkN=m2 Þ
Determine (a) the maximum semi-included angle of a conical mild steel hopper that will
confidently ensure mass flow, and (b) the minimum diameter of circular outlet to ensure
flow when the outlet is opened.
Solution
(a) With an effective angle of internal friction d ¼ 40 we refer to the flow factor chart in
Figure 10.18(b), from which at w ¼ 16 and with a safety margin of 3 we obtain the
hopper flow factor, ff ¼ 1:5 and hopper semi-included angle for mass flow, y ¼ 30
(Figure 10W2.1).
Figure 10W2.1 Determination of y and ff
sC
(b) For flow: > sy [Equation (10.3)]
ff
but for the powder in question sy and sC are related by the material flow function:
sy ¼ s0:6
C .
Thus, the criterion for flow becomes
1=0:6
!
sy
> sy
ff
1=0:6
!
sy
and so the critical value of unconfined yield stress scrit is found when ¼ sy
ff
hence, scrit ¼ 1:837 kN=m2 .
From Equation (10.5), HðyÞ ¼ 2:5 when y ¼ 30 and hence, from Equation (10.4),
minimum diameter of circular outlet,
2:5 1:837 103

B¼ ¼ 0:234 m
2000 9:81
Summarizing, mass flow without blockages is ensured by using a mild steel hopper with
maximum semi-included cone angle 30 and a circular outlet diameter of at least
23.4 cm.
EXERCISES 289
TEST YOURSELF
10.1 Explain with the aid of sketches what is meant by the terms mass flow and core flow
with respect to solids flow in storage hoppers.
10.2 The starting point for the design philosophy presented in this chapter is the flow-no
flow criterion. What is the flow-no flow criterion?
10.3 Which quantity describes the strength developed by a powder in an arch preventing
flow from the base of a hopper? How is this quantity related to the hopper flow
factor?
10.4 What is the powder flow function? Is the powder flow function dependent on (a) the
powder properties, (b) the hopper geometry, (c) both the powder properties and the
hopper geometry?
10.5 Show how the critical value of stress is determined from a knowledge of the hopper
flow factor and the powder flow function.
10.6 What is meant by critical failure (yield) of a powder? What is its significance?
10.7 With the aid of a sketch plot of shear stress versus normal stress, show how the
effective angle of internal of a powder is determined from a family of yield loci.
10.8 What is the kinematic angle of wall friction and how is it determined?
10.9 A powder is poured gradually into a measuring cylinder of diameter 3 cm. At the base
of the cylinder is a load cell which measures the normal force exerted by the powder
on the base. Produce a sketch plot showing how the normal force on the cylinder base
would be expected to vary with powder depth, up to a depth of 18 cm.
10.10 How would you expect the mass flow rate of particulate solids from a hole in the
base of a flat-bottomed container to vary with (a) the hole diameter and (b) the
depth of solids?
EXERCISES
10.1 Shear cell tests on a powder show that its effective angle of internal friction is 40 and
its powder flow function can be represented by the equation: sy ¼ s0:45 C , where sy is the
unconfined yield stress and sC is the compacting stress, both in kN=m2 . The bulk density
of the powder is 1000 kg=m3 and angle of friction on a mild steel plate is 16 . It is proposed
to store the powder in a mild steel conical hopper of semi-included angle 30 and having a
circular discharge opening of 0:30 m diameter. What is the critical outlet diameter to give
mass flow? Will mass flow occur?
(Answer: 0.355 m; no flow.)
10.2 Describe how you would use shear cell tests to determine the effective angle of
internal friction of a powder.
A powder has an effective angle of internal friction of 60 and has a powder flow function
represented in the graph shown in Figure 10E2.1. If the bulk density of the powder is
1500 kg=m3 and its angle of friction on mild steel plate is 24:5 , determine, for a mild steel
hopper, the maximum semi-included angle of cone required to safely ensure mass flow, and
the minimum size of circular outlet to ensure flow when the outlet is opened.
(Answer: 17:5 ; 18.92 cm.)
Figure 10E2.1 Powder flow function

10.3
(a) Summarize the philosophy used in the design of conical hoppers to ensure flow from
the outlet when the outlet valve is opened.
(b) Explain how the powder flow function and the effective angle of internal friction are
extracted from the results of shear cell tests on a powder.
(c) A firm having serious hopper problems takes on a chemical engineering graduate.
The hopper in question feeds a conveyor belt and periodically blocks at the outlet and
needs to be ‘encouraged’ to restart. The graduate makes an investigation on the hopper,
commissions shear cell tests on the powder and recommends a minor modification to the
hopper. After the modification the hopper gives no further trouble and the graduate’s
reputation is established. Given the information below, what was the graduate’s recom-
mendation?
EXERCISES 291
Existing design: Material of wall – mild steel
Semi-included angle of conical hopper 33
Outlet – circular, fitted with 25 cm diameter slide valve
Shear cell test data: Effective angle of internal friction, d ¼ 60
Angle of wall friction on mild steel, w ¼ 8
Bulk density, rB ¼ 1250 kg=m3
Powder flow function: sy ¼ s0:55

C (sy and sC in kN=m2 )
10.4 Shear cell tests are carried out on a powder for which a stainless steel conical hopper is
to be designed. The results of the tests are shown graphically in Figure 10E4.1. In addition it
is found that the friction between the powder on stainless steel can be described by an angle
of wall friction of 11 , and that the relevant bulk density of the powder is 900 kg=m3 :
(a) From the shear cell results of Figure 10E4.1, deduce the effective angle of internal
friction d of the powder.
(b) Determine:
(i) the semi-included hopper angle safely ensuring mass flow;
(ii) the hopper flow factor, ff.
Figure 10E4.1 Shear cell test data

Figure 10E5.1 Shear cell test data
(c) Combine this information with further information gathered from Figure 10E4.1 in
order to determine the minimum diameter of outlet to ensure flow when required.
(Note: Extrapolation is necessary here.)
(d) What do you understand by ‘angle of wall friction’ and ‘effective angle of internal
friction’?
[Answer: (a) 60 ; (b) (i) 32:5 , (ii) 1.29; (c) 0.110 m.]
10.5 The results of shear cell tests on a powder are given in Figure 10E5.1. An aluminium
conical hopper is to be designed to suit this powder. It is known that the angle of wall
friction between the powder and aluminium is 16 and that the relevant bulk density is
900 kg=m3 .
(a) From Figure 10E5.1 determine the effective angle of internal friction of the powder.
(b) Determine:
(i) the semi-included hopper angle safely ensuring mass flow;
(ii) the hopper flow factor, ff.
(c) Combine the information with further information gathered from Figure 10E5.1 in
order to determine the minimum diameter of circular outlet to ensure flow when
required. (Note: Extrapolation of these experimental results may be necessary.)
[Answer: (a) 40 ; (b)(i) 29:5 ; (ii) 1.5; (c) 0:5 m approximately 7% depending on the
extrapolation.]
11
Mixing and Segregation
11.1 INTRODUCTION
Achieving good mixing of particulate solids of different size and density is

important in many of the process industries, and yet it is not a trivial exercise. For
free-flowing powders, the preferred state for particles of different size and
density is to remain segregated. This is why in a packet of muesli the large
particles come to the top as a result of the vibration caused by handling of the
packet. An extreme example of this segregation is that a large steel ball can be
made to rise to the top of a beaker of sand by simply shaking the beaker up and
down – this has to be seen to be believed! Since the preferred state for free
flowing powders is to segregate by size and density, it is not surprising that many
processing steps give rise to segregation. Processing steps which promote
segregation should not follow steps in which mixing is promoted. In this chapter
we will examine mechanisms of segregation and mixing in particulate solids,
briefly look at how mixing is carried out in practice and how the quality of a
mixture is assessed.
11.2 TYPES OF MIXTURE
A perfect mixture of two types of particles is one in which a group of particles

taken from any position in the mixture will contain the same proportions of each
particle as the proportions present in the whole mixture. In practice, a perfect
mixture cannot be obtained. Generally, the aim is to produce a random mixture,
i.e. a mixture in which the probability of finding a particle of any component is
the same at all locations and equal to the proportion of that component in the
mixture as a whole. When attempting to mix particles which are not subject to
segregation, this is generally the best quality of mixture that can be achieved. If
the particles to be mixed differ in physical properties then segregation may occur.
In this case particles of one component have a greater probability of being found

294 MIXING AND SEGREGATION
Figure 11.1 Types of mixture
in one part of the mixture and so a random mixture cannot be achieved. In

Figure 11.1 examples are given of what is meant by perfect, random and
segregating mixtures of two components. The random mixture was obtained
by tossing a coin – heads gives a black particle at a given location and tails gives a
white particle. For the segregating mixture the coin is replaced by a die. In this
case the black particles differ in some property which causes them to have a
greater probability of appearing in the lower half of the box. In this case, in the
lower half of the mixture there is a chance of two in three that a particle will be
black (i.e. a throw of 1, 2, 3 or 4) whereas in the upper half the probability is one
in three (a throw of 5 or 6). It is possible to produce mixtures with better than
random quality by taking advantage of the natural attractive forces between
particles; such mixtures are achieved through ‘ordered’ or ‘interactive’ mixing
(see below).
11.3 SEGREGATION
11.3.1 Causes and Consequences of Segregation
When particles to be mixed have the same important physical properties (size
distribution, shape, density) then, provided the mixing process goes on for long
enough, a random mixture will be obtained. However, in many common
systems, the particles to be mixed have different properties and tend to exhibit
segregation. Particles with the same physical property then collect together in one
part of the mixture and the random mixture is not a natural state for such a
system of particles. Even if particles are originally mixed by some means, they
will tend to unmix on handling (moving, pouring, conveying, processing).
Although differences in size, density and shape of the constituent particles of a
mixture may give rise to segregation, difference in particle size is by far the most
important of these. Density difference is comparatively unimportant (see steel
ball in sand example below) except in gas fluidization where density difference is
more important than size difference. Many industrial problems arise from
segregation. Even if satisfactory mixing of constituents is achieved in a powder
mixing device, unless great care is taken, subsequent processing and handling of
the mixture will result in demixing or segregation.
SEGREGATION 295
This can give rise to variations in bulk density of the powder going to
packaging (e.g. not possible to fit 25 kg into a 25 kg bag) or, more seriously, the
chemical composition of the product may be off specification (e.g. in blending of
constituents for detergents or drugs).
11.3.2 Mechanisms of Segregation
Four mechanisms (Williams, 1990) of segregation according to size may be

identified:
(1) Trajectory segregation. If a small particle of diameter x and density rp , whose

drag is governed by Stokes’ law, is projected horizontally with a velocity U
into a fluid of viscosity m and density rf , the limiting distance that it can travel
horizontally is Urp x2 =18m.
2
px
From Chapter 2, the retarding force on the particle ¼ CD 12 rf U 2
4
retarding force
Deceleration of the particle ¼
mass of particle
In Stokes’ law region, CD ¼ 24=Rep
18Um
Hence, deceleration ¼
rp x 2
From the equation of motion a particle with an initial velocity U and constant
deceleration 18Um=rp x2 will travel a distance Urp x2 =18m before coming to rest.
A particle of diameter 2x would therefore travel four times as far before

coming to rest. This mechanism can cause segregation where particles are
caused to move through the air (Figure 11.2). This also happens when
powders fall from the end of a conveyor belt.
(2) Percolation of fine particles. If a mass of particles is disturbed in such a way that
individual particles move, a rearrangement in the packing of the particles
occurs. The gaps created allow particles from above to fall, and particles in
some other place to move upwards. If the powder is composed of particles of
different size, it will be easier for small particles to fall down and so there will
be a tendency for small particles to move downwards leading to segregation.
Even a very small difference in particle size can give rise to significant
segregation.
Segregation by percolation of fine particles can occur whenever the mixture
is disturbed, causing rearrangement of particles. This can happen during
stirring, shaking, vibration or when pouring particles into a heap. Note that
stirring, shaking and vibration would all be expected to promote mixing in
Figure 11.2 Mechanisms of segregation
liquids or gases, but cause segregation in free-flowing particle mixtures. Figure

11.3 shows segregation in the heap formed by pouring a mixture of two sizes
of particles. The shearing caused when a particle mixture is rotated in a drum
can also give rise to segregation by percolation.
Segregation by percolation occurs in charging and discharging storage
hoppers. As particles are fed into a hopper they generally pour into a heap
resulting in segregation if there is a size distribution and the powder is
free-flowing. There are some devices and procedures available to minimize
this effect if segregation is a particular concern. However, during discharge of
a core flow hopper (see Chapter 10) sloping surfaces form, along which
particles roll, and this gives rise to segregation in free-flowing powders. If
segregation is a cause for concern, therefore, core flow hoppers should be
avoided.
(3) Rise of coarse particles on vibration. If a mixture of particles of different size is

vibrated the larger particles move upwards. This can be demonstrated by
placing a single large ball at the bottom of a bed of sand (for example, a
20 mm steel ball or similarly sized pebble in a beaker of sand from the
beach). On shaking the beaker up and down, the steel ball rises to the
surface. Figure 11.4 show a series of photographs taken from a ‘two-
dimensional’ version of the steel ball experiment. This so-called ‘Brazil-
nut effect’ has received much attention in the literature over recent years,
SEGREGATION 297
Figure 11.3 Segregation pattern formed by pouring a free-flowing mixture of two sizes of
particles into a heap
but research and comment date back much further. The rise of the larger or
denser ‘intruder’ within the bed of smaller particles has been explained in
terms of creation and filling of voids beneath the intruder (Duran et al.,
1993; Jullien and Meakin, 1992; Rosato et al., 1987, 2002; Williams, 1976;)
and establishment of convection cells within the bed of small particles
(Cooke et al., 1996; Knight et al., 1993, 1996; Rosato et al., 2002). Observa-
tions that intruder rise times decrease with increasing intruder density
(Liffman et al., 2001; Mobius et al., 2001; Shinbrot and Muzzie, 1998;)
suggest that intruder inertia must play a part. However, Mobius et al.
(2001) showed that this trend reverses for very low intruder densities
suggesting that some other effect is present. Rhodes et al. (2003) suggested
that this may be explained by a buoyancy effect created by the carrying
pressure generated across the vibrated bed. Mobius et al. (2001) also
demonstrated that interstitial gas plays a significant role in determination
of the intruder rise time.
(4) Elutriation segregation. When a powder containing an appreciable proportion

of particles under 50 mm is charged into a storage vessel or hopper, air is
displaced upwards. The upward velocity of this air may exceed the terminal
freefall velocity (see Chapter 2) of some of the finer particles, which may then
remain in suspension after the larger particles have settled to the surface of
the hopper contents (Figure 11.2). For particles in this size range in air the
terminal freefall velocity will be typically of the order of a few centimetres per
second and will increase as the square of particle diameter (e.g. for 30 mm
sand particles the terminal velocity is 7 cm/s). Thus a pocket of fine particles
is generated in the hopper each time solids are charged.
Figure 11.4 Series of photographs showing the rise of a steel disc through a bed of 2 mm
glass spheres due to vibration (a ‘two-dimensional’ version of the rising steel ball experiment)
11.4 REDUCTION OF SEGREGATION
Segregation occurs primarily as a result of size difference. The difficulty of mixing

two components can therefore be reduced by making the size of the components as
similar as possible and by reducing the absolute size of both components.
Segregation is generally not a serious problem when all particles are less than
30 mm (for particle densities in the range 2000–3000 kg/m3). In such fine powders
EQUIPMENT FOR PARTICULATE MIXING 299
Figure 11.5 An ordered mixture of small particles on carrier particles
the interparticle forces (see Chapter 13) generated by electrostatic charging, van der
Waals forces and forces due to moisture are large compared with the gravitational
and inertial forces on the particles. This causes the particles to stick together
preventing segregation as the particles are not free to move relative to one another.
These powders are referred to as cohesive powders (Geldart’s classification of
powders for fluidization is relevant here – see Chapter 7). The lack of mobility of
individual particles in cohesive powders is one reason why they give better quality
of mixing. The other reason is that if a random mixture is approached, the standard
deviation of the composition of samples taken from the mixture will decrease in
inverse proportion to the number of particles in the sample. Therefore, for a given
mass of sample the standard deviation decreases and mixture quality increases
with decreasing particle size. The mobility of particles in free-flowing powders can
be reduced by the addition of small quantities of liquid. The reduction in mobility
reduces segregation and permits better mixing.
It is possible to take advantage of this natural tendency for particles to adhere
to produce mixtures of quality better that random mixtures. Such mixtures are
known as ordered or interactive mixtures; they are made up of small particles
(e.g. < 5 mm) adhered to the surface of a carrier particle in a controlled manner
(Figure 11.5). By careful selection of particle size and engineering of interparticle
forces, high quality mixtures with very small variance can be achieved. This
technique is use in the pharmaceutical industry where quality control standards
are exacting. For further details on ordered mixing and on the mixing of cohesive
powders the reader is referred to Harnby et al. (1992).
If it is not possible to alter the size of the components of the mixture or to add
liquid, then in order to avoid serious segregation, care should be taken to avoid
situations which are likely to promote segregation. In particular pouring opera-
tions and the formation of a moving sloping powder surface should be avoided.
11.5 EQUIPMENT FOR PARTICULATE MIXING
11.5.1 Mechanisms of Mixing
Lacey (1954) identified three mechanisms of powder mixing:
(1) shear mixing;

(2) diffusive mixing;
(3) convective mixing.
In shear mixing, shear stresses give rise to slip zones and mixing takes place by
interchange of particles between layers within the zone. Diffusive mixing occurs
when particles roll down a sloping surface. Convective mixing is by deliberate
bulk movement of packets of powder around the powder mass.
In free-flowing powders both diffusive mixing and shear mixing give rise to
size segregation and so for such powders convective mixing is the major
mechanism promoting mixing.
11.5.2 Types of Mixer
(1) Tumbling mixers. A tumbling mixer comprises a closed vessel rotating about
its axis. Common shapes for the vessel are cube, double cone and V (Figure
11.6). The dominant mechanism is diffusive mixing. Since this can give rise to
segregation in free-flowing powders the quality of mixture achievable with
such powder in tumbling mixers is limited. Baffles may be installed in an
attempt to reduce segregation, but have little effect.
(2) Convective mixers. In convective mixers circulation patterns are set up within a
static shell by rotating blades or paddles. The main mechanism is convective
mixing as the name suggests, although this is accompanied by some diffusive
and shear mixing. One of the most common convective mixers is the ribbon
blender in which helical blades or ribbons rotate on a horizontal axis in a static
cylinder or trough (Figure 11.7). Rotational speeds are typically less than one
revolution per second. A somewhat different type of convective mixer is the
Nautamix (Figure 11.8) in which an Archimedean screw lifts material from the
base of a conical hopper and progresses around the hopper wall.
(3) Fluidized bed mixers. These rely on the natural mobility afforded particles in
the fluidized bed. The mixing is largely convective with the circulation
Figure 11.6 Tumbling mixers: V-mixer; double cone mixer; and rotating cube mixer
ASSESSING THE MIXTURE 301
Figure 11.7 Ribbon blender
patterns set up by the bubble motion within the bed. An important feature of
the fluidized bed mixer is that several processing steps (e.g. mixing, reaction,
coating drying, etc.) may be carried out in the same vessel.
(4) High shear mixers. Local high shear stresses are created by devices similar to
those used in comminution; for example, high velocity rotating blades, low
velocity–high compression rollers (see Chapter 12). In the high shear mixers
the emphasis is on breaking down agglomerates of cohesive powders rather
than breaking individual particles. The dominant mechanism is shear mixing.
11.6 ASSESSING THE MIXTURE
11.6.1 Quality of a Mixture
The end use of a particle mixture will determine the quality of mixture required.
The end use imposes a scale of scrutiny on the mixture. ‘Scale of scrutiny’ was a
term used by Danckwerts (1953) meaning ‘the maximum size of the regions of
segregation in the mixture which would cause it to be regarded as imperfectly
Figure 11.8 Schematic diagram of the Nautamixer

mixed’. For example, the appropriate scale of scrutiny for a detergent powder
composed of active ingredients in particulate form is the quantity of detergent in
the scoop used to dipense it into the washing machine. The composition should
not vary significantly between the first and last scoops taken from the box. At
another extreme the scale of scrutiny for a pharmaceutical drug is the quantity of
material making up the tablet or capsule. The quality of a mixture decreases with
decreasing scale of scrutiny until in the extreme we are scrutinizing only
individual particles. An example of this is the image on a television screen,
which at normal viewing distance appears as a lifelike image, but which under
close ‘scrutiny’ is made up of tiny dots of red, green and blue colour.
11.6.2 Sampling
To determine the quality of a mixture it is generally necessary to take samples. In

order to avoid bias in taking samples from a particulate mixture, the guidelines of
sampling powders set out in Chapter 2 must be followed. The size of the sample
required in order to determine the quality of the mixture is governed by the scale
of scrutiny imposed by the intended use of the mixture.
11.6.3 Statistics Relevant to Mixing
It is evident that the sampling of mixtures and the analysis of mixture quality
require the application of statistical methods. The statistics relevant to random
binary mixtures are summarized below:
Mean composition. The true composition of a mixture m is often not known but
an estimate y may be found by sampling. If we have N samples of composition
y1 to yN in one component, the estimate of the mixture composition y is given
by:
1X N
y ¼ yi ð11:1Þ
N i¼1
Standard deviation and variance. The true standard deviation, s, and the true
variance, s2 , of the composition of the mixture are quantitative measures of
the quality of the mixture. The true variance is usually not known but an
estimate S2 is defined as:
P
N
ðyi mÞ2
S2 ¼ i¼1 if the true composition m is known ð11:2Þ
N
P
N
ðyi yÞ2
S2 ¼ i¼1 if the true composition m is unknown ð11:3Þ
N1
ASSESSING THE MIXTURE 303
The standard deviation is equal to the square root of variance.
Theoretical limits of variance. For a two-component system the theoretical upper

and lower limits of mixture variance are:
ðaÞ upper limit ðcompletely segregatedÞ s20 ¼ pð1 pÞ ð11:4Þ
pð1 pÞ
ðbÞ lower limit ðrandomly mixedÞ s2R ¼ ð11:5Þ
n
where p and ð1 pÞ are the proportions of the two components determined

from samples and n is the number of particles in each sample.
Actual values of mixture variance lie between these two extreme
values.
Mixing indices. A measure of the degree of mixing is the Lacey mixing index
(Lacey, 1954):
s20 s2
Lacey mixing index ¼ ð11:6Þ
s20 s2R
In practical terms the Lacey mixing index is the ratio of ‘mixing achieved’ to
‘mixing possible’. A Lacey mixing index of zero would represent complete
segregation and a value of unity would represent a completely random
mixture. Practical values of this mixing index, however, are found to lie in
the range 0.75 to 1.0 and so the Lacey mixing index does not provide sufficient
discrimination between mixtures.
A further mixing index suggested by Poole et al. (1964) is defined as:
s
Poole et al: mixing index ¼ ð11:7Þ
sR
This index gives better discrimination for practical mixtures and approaches
unity for completely random mixtures.
Standard error. When the sample compositions have a normal distribution the
sampled variance values will also have a normal distribution. The standard
deviation of the variance of the sample compositions is known as the
‘standard error’ of the variance EðS2 Þ.
Tests for precision of mixture composition and variance. The mean mixture
composition and variance which we measure from sampling are only samples
from the normal distribution of mixture compositions and variance values for
that mixture. We need to be able to assign a certain confidence to this estimate
and to determine its precision.
(Note: Standard statistical tables, which are widely and readily available, are a
source of Student’s t-values and w2 (chi squared) distribution values.)
Assuming that the sample compositions are normally distributed:
(1) Sample composition
Based on N samples of mixture composition with mean y and estimated standard

deviation S, the true mixture composition m may be stated with precision:
tS
m ¼ y pffiffiffiffi ð11:8Þ
N
where t is from Student’s t-test for statistical significance. The value of t

depends on the confidence level required. For example, at 95% confidence
level, t ¼ 2:0 for N ¼ 60, and so there is a 95% probability that the true mean
mixture composition lies in the range: y 0:258 S. In other words, 1 in 20
estimates of mixture variance estimates would lie outside this range.
(2) Variance
(a) When more than 50 samples are taken (i.e. n > 50), the distribution
of variance values can also be assumed to be normal and the Student’s
t-test may be used. The best estimate of the true variance s2 is then given
by:
s2 ¼ S2 ½t EðS2 Þ ð11:9Þ
The standard error of the mixture variance required in this test is usually
not known but is estimated from:
rffiffiffiffi
2
EðS Þ ¼ S
2 2
ð11:10Þ
N
pffiffiffiffi pffiffiffiffi
The standard error decreases as 1= N and so the precision increases as N .
(b) When less than 50 samples are taken (i.e. n < 50), the variance distribution
curve may not be normal and is likely to be a w2 (chi squared) distribution. In
this case the limits of precision are not symmetrical. The range of values of
mixture variance is defined by lower and upper limits:
S2 ðN 1Þ
lower limit : s2L ¼ ð11:11Þ
w2a
S2 ðN 1Þ
upper limit : s2U ¼ ð11:12Þ
w21a
where a is the significance level [for a 90% confidence range, a ¼ 0:5ð1 90=100Þ
¼ 0:05; for a 95% confidence range, a ¼ 0:5ð1 95=100Þ ¼ 0:025]. The lower and
upper w2 values, w2a and w21a , for a given confidence level are found in w2
distribution tables.
WORKED EXAMPLES 305
WORKED EXAMPLE 11.1 (AFTER WILLIAMS, 1990)
A random mixture consists of two components A and B in proportions 60 and 40% by

mass, respectively. The particles are spherical and A and B have particle densities 500
and 700 kg=m3 , respectively. The cumulative undersize mass distributions of the two
components are shown in Table 11W.1.
If samples of 1 g are withdrawn from the mixture, what is the expected value for the
standard deviation of the composition of the samples?
Table 11W1.1 Size distributions of particles A and B

Size x 2057 1676 1405 1204 1003 853 699 599 500 422
(mm)
FA ðxÞ 1.00 0.80 0.50 0.32 0.19 0.12 0.07 0.04 0.02 0
FB ðxÞ 1.00 0.88 0.68 0.44 0.21 0.08 0
Solution
The first step is to estimate the number of particles per unit mass of A and B. This is
done by converting the size distributions into differential frequency number distribu-
tions and using:

mass of particles number of particles mass of one
¼
in each size range in size range particle
rp px3
dm ¼ dn
6
where rp is the particle density and x is the arithmetic mean of adjacent sieve
sizes.
These calculations are summarized in Tables 11W1.2 and 11W1.3.
Table 11W.1.2 A particles

Mean size of range x ðmmÞ dm dn
1866.5 0.20 117 468
1540.5 0.30 334 081
1304.5 0.18 309 681
1103.5 0.13 369 489
928 0.07 334 525
776 0.05 408 658
649 0.03 419 143
54.5 0.02 460 365
461 0.02 779 655
Totals 1.00 3:51 106
Table 11W.1.3 B particles

Mean size of range x ðmmÞ dm dn
1866.5 0 0
1540.5 0 0
1304.5 0.12 0:147 106
1103.5 0.20 0:406 106
928 0.24 0:819 106
776 0.23 1:343 106
649 0.13 1:297 106
54.5 0.08 1:315 106
461 0 0
Totals 1.00 5:33 106
Thus nA ¼ 3:51 106 particles per kg
and
nB ¼ 5:33 106 particles per kg
And in samples of 1 g (0.001 kg) we would expect a total number of particles:
n ¼ 0:001 ð3:51 106 0:6 þ 5:33 106 0:4Þ

¼ 4238 particles
And so, from Equation (11.5) for a random mixture,

rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
0:6 0:4
standard deviation; s ¼ ¼ 0:0075
4238
WORKED EXAMPLE 11.2 (AFTER WILLIAMS, 1990)
Sixteen samples are removed from a binary mixture and the percentage proportions of
one component by mass are:
41; 37; 41; 39; 45; 37; 39; 40
41; 43; 40; 38; 39; 37; 43; 40
Determine the upper and lower 95% and 90% confidence limits for the standard
deviation of the mixture.
Solution
From Equation (11.1), the mean value of the sample composition is:
1 X 16
y ¼ yi ¼ 40%
16 i¼1
WORKED EXAMPLES 307
Since the true mixture composition is not known an estimate of the standard deviation is
found from Equation (11.3):
v" ffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
#
u
u 1 X 16
S¼t ðyi 40Þ2 ¼ 2:31
16 1 i¼1
Since there are less than 50 samples, the variance distribution curve is more likely to be a
w2 distribution. Therefore, from Equations (11.11) and (11.12):
2:312 ð16 1Þ
lower limit : s2L ¼
w2a
2:312 ð16 1Þ
upper limit : s2U ¼
w21a
At the 90% confidence level a ¼ 0:05 and so referring to the w2 distribution tables with 15
degrees of freedom w2a ¼ 24:996 and w21a ¼ 7:261.
Hence, s2L ¼ 3:2 and s2U ¼ 11:02.
At the 95% confidence level a ¼ 0:025 and so referring to the w2 distribution tables
with 15 degrees of freedom w2a ¼ 27:49 and w21a ¼ 6:26.
Hence, s2L ¼ 2:91 and s2U ¼ 12:78.
WORKED EXAMPLE 11.3
During the mixing of a drug with an excipient the standard deviation of the composi-
tions of 100 mg samples tends to a constant value of 0:005. The size distributions of
drug (D) and excipient (E) are given in Table 11W3.1.
Table 11W3.1 Size distributions of drug and excipient
Size x (mm) 420 355 250 190 150 75 53 0

FD ðxÞ 1.00 0.991 0.982 0.973 0.964 0.746 0.047 0
FE ðxÞ 1.00 1.00 0.977 0.967 0.946 0.654 0.284 0
The mean proportion by mass of drug is know to be 0.2. The densities of drug and
excipient are 1100 and 900 kg/m3, respectively.
Determine whether the mixing is satisfactory (a) if the criterion is a random mixture
and (b) if the criterion is an in-house specification that the composition of 95% of the
samples should lie within 15% of the mean.
Solution
The number of particles of drug (Table 11W3.2) and excipient (Table 11W3.3) in each
sample is first calculated as shown in Worked Example 11.1.
Thus nD ¼ 8:96 109 particles per kg

Table 11W3.2 Number of drug particles in each kg of

sample
Mean size of range x (mm) dm dn
388 0.009 2:67 105
303 0.009 5:62 105
220 0.009 1:47 106
170 0.009 3:18 106
113 0.218 2:62 108
64 0.700 4:64 109
27 0.046 4:06 109
20 0.00 0
0 0.00 0
Totals 1.00 8:96 109
Table 11W3.3 Number of excipient particles in each kg of

sample
Mean size of range x (mm) dm dn

388 0 0
303 0.023 1:75 106
220 0.010 1:99 106
170 0.021 9:07 106
113 0.292 4:29 108
64 0.374 3:03 109
27 0.28 3:02 1010
20 0.00 0
0 0 0
Totals 1.00 3:37 1010
and
nE ¼ 3:37 1010 particles per kg
And in samples of 1 g (0.001 kg) we would expect a total number of particles:
n ¼ 100 106 ð8:96 109 0:2 þ 3:37 1010 0:8Þ

¼ 2:88 106 particles
And so, from Equation (11.5) for a random mixture,

rffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi
0:2 0:8
standard deviation; sR ¼ ¼ 0:000235
2:88 106
Conclusion. The actual standard deviation of the mixture is greater than that for a
random mixture and so the criterion of random mixing is not achieved.
For a normal distribution the in-house criterion that 95% of samples should lie within
15% of the mean suggests that:
1:96s ¼ 0:15 0:2
EXERCISES 309
(since for a normal distribution 95% of the values lie within 1:96 standard deviations of
the mean).
Hence, s ¼ 0:0153. So the in-house criterion is achieved.
TEST YOURSELF
1.1 Explain the difference between a random mixture and perfect mixture. Which of these
two types of mixture is more likely to occur in an industrial process?
1.2 Explain how trajectory segregation occurs. Give examples of two practical situations
that might give rise to trajectory segregation of powders in the process industries.
1.3 What type of segregation is produced when a free-flowing mixture of particles is

poured into a heap? Describe the typical segregation pattern produced.
1.4 Explain how core flow of free-flowing particulate mixture from a hopper gives rise to
a size-segregated discharge.
1.5 What is the Brazil Nut Effect? Under what conditions, relevant to the process
industries, might it occur?
1.6 Explain why size segregation is generally not a problem if all components of the
particulate mixture are smaller than around 30 mm.
1.7 Describe two types of industrially relevant mixer. Which mixing mechanism dom-
inates in each type of mixer?
1.8 Explain what is meant by scale of scrutiny of a particulate mixture. What scale of
scrutiny would be appropriate for (a) the active drug in powder mixture fed to the
tabletting machine, (b) muesli breakfast cereal, (c) a health supplement fed to
chickens?
1.9 For a two-component mixture, write down expressions for (a) mean composition, (b)
estimated variance when the true mean is unknown, (c) upper and lower theoretical
limits of mixture variance. Define all symbols used.
1.10 Explain how one would go about determining whether the mixture produced by an
industrial process is satisfactory.
EXERCISES
11.1 Thirty-one samples are removed from a binary mixture and the percentage propor-
tions of one component by mass are:
19, 22, 20, 24, 23, 25, 22, 18, 24, 21, 27, 22, 18, 20, 23, 19,
20, 22, 25, 21, 17, 26, 21, 24, 25, 22, 19, 20, 24, 21, 23
Determine the upper and lower 95% confidence limits for the standard deviation of the
mixture.
(Answer: 0.355 to 0.595.)
11.2 A random mixture consists of two components A and B in proportions 30% and 70%
by mass, respectively. The particles are spherical and components A and B have particle
densities 500 and 700 kg/m3, respectively. The cumulative undersize mass distributions of
the two components are shown in Table 11E2.1.
Table 11E.2.1 Size distributions of particles A and B

Size x (mm) 2057 1676 1405 1204 1003 853 699 599 500 422 357
FA ðxÞ 1.00 1.00 0.85 0.55 0.38 0.25 0.15 0.10 0.07 0.02 0.00
FB ðxÞ 1.00 0.80 0.68 0.45 0.25 0.12 0.06 0.00 0.00
If samples of 5 g are withdrawn from the mixture, what is the expected value for the
standard deviation of the composition of the samples?
(Answer: 0.0025.)
11.3 During the mixing of a drug with an excipient the standard deviation of the
compositions of 10 mg samples tends to a constant value of 0:005. The size distributions
by mass of drug (D) and excipient (E) are given in Table 11E3.1.
Table 11E3.1 Size distributions of drug and excipient

Size x (mm) 499 420 355 250 190 150 75 53 0
FD ðxÞ 1.00 0.98 0.96 0.94 0.90 0.75 0.05 0.00 0.00
FE ðxÞ 1.00 1.00 0.97 0.96 0.93 0.65 0.25 0.05 0.00
The mean proportion by mass of drug is known to be 0.1. The densities of the drug and
the excipient are 800 and 1000 kg/m3, respectively.
Determine whether the mixing is satisfactory if:
(a) the criterion is a random mixture;
(b) the criterion is an in-house specification that the composition of 99% of the samples
should lie within 20% of the mean.
[Answer: (a) 0.00118, criterion not achieved; (b) 0.00775, criterion achieved.]
12
Particle Size Reduction
12.1 INTRODUCTION
Size reduction, or comminution, is an important step in the processing of many

solid materials. It may be used to create particles of a certain size and shape, to
increase the surface area available for chemical reaction or to liberate valuable
minerals held within particles.
The size reduction of solids is an energy intensive and highly inefficient
process: 5% of all electricity generated is used in size reduction; based on the
energy required for the creation of new surfaces, the industrial scale process is
generally less than 1% efficient. The two statements would indicate that there is
great incentive to improve the efficiency of size reduction processes. However, in
spite of a considerable research effort over the years, size reduction processes
have remained stubbornly inefficient. Also, in spite of the existence of a well-
developed theory for a strength and breakage mechanism of solids, the design
and scale-up of comminution processes is usually based on past experience and
testing, and is very much in the hands of the manufacturer of comminution
equipment.
This chapter is intended as a introduction to the topic of size reduction
covering the concepts and models involved and including a broad survey of
practical equipment and systems. The chapter is divided into the following
sections:
particle fracture mechanisms;
models for prediction of energy requirements and product size distribution;
equipment: matching machine to material and duty.

312 PARTICLE SIZE REDUCTION
12.2 PARTICLE FRACTURE MECHANISMS
Consider a crystal of sodium chloride (common salt) as a simple and convenient

model of a brittle material. Such a crystal is composed of a lattice of positively
charged sodium ions and negatively charged chloride ions arranged such that
each ion is surrounded by six ions of the opposite sign. Between the oppositely
charged ions there is an attractive force whose magnitude is inversely propor-
tional to the square of the separation of the ions. There is also a repulsive force
between the negatively charged electron clouds of these ions which becomes
important at very small interatomic distances. Therefore two oppositely charged
ions have an equilibrium separation such that the attractive and repulsive forces
between them are equal and opposite. Figure 12.1 shows how the sum of the
attractive and repulsive forces varies with changing separation of the ions. It can
be appreciated that if the separation of the ions is increased or decreased by a
small amount from the equilibrium separation there will be a resultant net force
restoring the ions to the equilibrium position. The ions in the sodium chloride
crystal lattice are held in equilibrium positions governed by the balance between
attractive and repulsive forces. Over a small range of interatomic distances the
relationship between applied tensile or compressive force and resulting change
in ion separation is linear. That is, in this region (AB in Figure 12.1) Hooke’s law
applies: strain is directly proportional to applied stress. The Young’s modulus of
the material (stress/strain) describes this proportionality. In this Hooke’s law
range the deformation of the crystal is elastic, i.e. the original shape of the crystal
is recovered upon removal of the stress.
In order to break the crystal it is necessary to separate adjacent layers of ions in
the crystal and this involves increasing the separation of the adjacent ions beyond
the region where Hooke’s law applies, i.e. beyond point B in Figure 12.1 into the
plastic deformation range. The applied stress required to induce this plastic
Force between
ions
Tension
Interatomic distance Interatomic distance (tension)

(Compression)
A Mean interatomic
distance
Compression
Figure 12.1 Force versus distance on an atomic scale

PARTICLE FRACTURE MECHANISMS 313
behaviour is known as the elastic limit or yield stress, and is sometimes defined as
the material’s strength. With a knowledge of the magnitude of attractive and
repulsive forces between ions in such a crystal, it is therefore possible to estimate
the strength of a salt crystal. One could assume first that under tensile stress all
bonds in the crystal planes perpendicular to the applied stress are stretched until
they simultaneously break and the material splits into many planes one atom
thick–this gives a theoretical strength much greater than in reality. Alternatively,
one could assume that only those bonds which are to be broken are stretched – this
gives a theoretical strength much less than reality. In practice the true fracture
mechanism for these materials turns out to be more involved and more interesting.
A body under tension stores energy–strain energy. The amount of strain
energy stored by a brittle material under tension is given by the area under the
appropriate stress–strain graph. This strain energy is not uniformly distributed
throughout the body but is concentrated around holes, corners and cracks. Inglis
(1913) proposed that the stress concentration factor, K, around a hole, crack or
corner could be calculated according to the formula:
rffiffiffiffi!
L
K ¼ 1þ2 ð12:1Þ
R
where L is the half the length of the crack, R is the radius of crack tip or hole and
K is the stress concentration factor ðlocal stress=mean stress in bodyÞ.
Thus, for a round hole, K ¼ 3:
For a 2mm long crack with tip radius equal to half the inter atomic distance
ðR ¼ 1010 mÞ; K ¼ 201.
Griffith (1921) proposed that for a crack in the surface of a body to propagate
the following criteria must be satisfied:
(1) The strain energy that would be released must be greater than the surface
energy created.
(2) There must be a crack propagation mechanism available.
Griffith also pointed out that for a given mean stress applied to a body there
should be a critical minimum crack length for which the stress concentration at
the tip will just be sufficient to cause the crack to propagate. Under the action of
this mean stress a crack initially longer than the critical crack length for that stress
will grow longer and, since K increases as L increases, crack growth increases
until the body is broken. As the crack grows, provided the mean stress remains
constant, there is strain energy excess to that required to propagate that crack
(since K is increasing). This excess strain energy is dissipated at the velocity of
sound in the material to concentrate at the tips of other cracks, causing them to
propagate. The rate of crack propagation is lower than the velocity of sound in
the material and so other cracks begin to propagate before the first crack brings
about failure. Thus, in brittle materials multiple fracture is common. If cracks in
the surface of brittle materials can be avoided then the material strength would
be near to the theoretical value. This can be demonstrated by heating a glass rod
until it softens and then drawing it out to create a new surface. As soon as the rod
is cooled it can withstand surprisingly high tensile stress, as demonstrated by
bending the rod. Once the new surface is handled or even exposed to the normal
environment for a short period, its tensile strength diminishes due to the
formation of microscopic cracks in the surface. It has been shown that the
surfaces of all materials have cracks in them.
Gilvary (1961) proposed the concept of volume, facial and edge flaws (cracks)
in order to calculate the size distribution of breakage products. Assuming that all
flaws were randomly distributed and independent of each other and that the
initial stress system is removed once the first flaws begin to propagate, Gilvary
showed that the product size distributions common to comminuted materials
could be predicted. For example, if edge flaws dominate, then the common
Rosin–Rammler distribution results.
Evans et al. (1961) showed that for a disc acted upon by opposing diametrical
loads, there is a uniform tensile stress acting at 90 to the diameter. Under
sufficiently high compressive loads, therefore, the resulting tensile stress could
exceed the cohesive strength of the material and the disc would split across the
diameter. Evans extended the analysis to three-dimensional particles to show that
even when particles are stressed compressively, the stress pattern set up by virtue
of the shape of the particle may cause it to fail in tension, whether cracks exist or not.
Cracks are less important for ‘tough’ materials (e.g. rubber, plastics and metals)
since excess strain energy is used in deformation of the material rather than crack
propagation. Thus in ductile metals, for example the stress concentration at the
top of a crack will cause deformation of the material around the crack tip,
resulting in a larger tip radius and lower stress concentration.
The observation that small particles are more difficult to break than large
particles can be explained using the concept of failure by crack propagation. First,
the length of a crack is limited by the size of the particle and so one would expect
lower maximum stress concentration factors to be achieved in small particles.
Lower stress concentrations mean that higher mean stresses have to be applied to
the particles to cause failure. Secondly, the Inglis equation [Equation (12.1)]
overpredicts K in the case of small particles since in these particles there is less
room for the stress distribution patterns to develop. This effectively limits the
maximum stress concentration possible and means that a higher mean stress is
necessary to cause crack propagation. Kendal (1978) showed that as particle size
decreases, the fracture strength increases until a critical size is reached when
crack propagation becomes impossible. Kendal offered a way of predicting this
critical particle size.
12.3 MODEL PREDICTING ENERGY REQUIREMENT

AND PRODUCT SIZE DISTRIBUTION
12.3.1 Energy Requirement
There are three well-known postulates predicting energy requirements for

particle size reduction. We will cover them in the chronological order in which
MODEL PREDICTING ENERGY REQUIREMENT AND PRODUCT SIZE DISTRIBUTION 315
they were proposed. Rittinger (1867) proposed that the energy required for
particle size reduction was directly proportional to the area of new surface
created. Thus, if the initial and final particle sizes are x1 and x2 , respectively, then
assuming a volume shape factor kv independent of size,
volume of initial particle ¼ kv x31

volume of final particle ¼ kv x32
and each particle of size x1 will give rise to x31 =x32 particles of size x2 .
If the surface shape factor ks is also independent of size, then for each original
particle, the new surface created upon reduction is given by the expression:
3
x1
ks x22 ks x21 ð12:2Þ
x32
which simplifies to:

1 1
ks x31 ð12:3Þ
x2 x1
Therefore,
new surface created per unit mass of original particles

1 1
¼ ks x31 ðnumber of original particles per unit massÞ
x2 x1
!
3 1 1 1
¼ k s x1
x2 x1 kv x31 rp

ks 1 1 1
¼
k v rp x 2 x 1
where rp is the particle density. Hence assuming shape factors and density are
constant, Rittinger’s postulate may be expressed as:

1 1
breakage energy per unit mass of feed; E ¼ CR ð12:4Þ
x2 x1
where CR is a constant. If this is the integral form, then in differential form,

Rittinger’s postulate becomes:
dE 1
¼ CR 2 ð12:5Þ
dx x
However, since in practice the energy requirement is usually 200–300 times that
required for creation of new surface, it is unlikely that energy requirement and
surface created are related.
On the basis of stress analysis theory for plastic deformation, Kick (1885)
proposed that the energy required in any comminution process was directly
proportional to the ratio of the volume of the feed particle to the product particle.
Taking this assumption as our starting point, we see that:
volume ratio, x31 =x32 , determines the energy requirement

(assuming shape factor is constant)
Therefore, size ratio, x1 =x2 fixes the volume ratio, x31 =x32 , which determines the
energy requirement. And so, if x1 is the change in particle size,
x2 x1 x1 x1
¼ ¼1
x1 x1 x1
which fixes volume ratio, x31 =x32 , and determines the energy requirement.
And so, x1 =x1 determines the energy requirement for particle size reduction
from x1 to x1 x1 . Or

x
E ¼ CK
x
As x1 ! 0, we have
dE 1
¼ CK ð12:6Þ
dx x
This is Kick’s law in differential form (CK is the Kick’s law constant). Integrating,
we have

x1
E ¼ CK ln ð12:7Þ
x2
This proposal is unrealistic in most cases since it predicts that the same energy is
required to reduce 10 mm particles to 1 mm particles as is required to reduce 1 m
boulders to 10 cm blocks. This is clearly not true and Kick’s law gives ridiculously
low values if data gathered for large product sizes are extrapolated to predict
energy requirements for small product sizes.
Bond (1952) suggested a more useful formula, presented in its basic form in
Equation (12.8a):

1 1
E ¼ CB pffiffiffiffiffi pffiffiffiffiffi ð12:8aÞ
x2 x1
However, Bond’s law is usually presented in the form shown in Equation (12.8b).
The law is based on data which Bond obtained from industrial and laboratory
scale processes involving many materials.

10 10
EB ¼ W1 pffiffiffiffiffiffi pffiffiffiffiffiffi ð12:8bÞ
X2 X1
where EB is the energy required to reduce the top particle size of the material
from x1 to x2 and WI is the Bond work index.
Since top size is difficult to define, in practice X1 to X2 are taken to be the sieve size
in micrometres through which 80% of the material, in the feed and product,
respectively, will pass. Bond attached particular significance to the 80% passing size.
Inspection of Equation (12.8b) reveals that WI is defined as the energy required
to reduce the size of unit mass of material from infinity to 100 mm in size.
Although the work index is defined in this way, it is actually determined through
laboratory scale experiment and assumed to be independent of final product size.
Both EB and WI have the dimensions of energy per unit mass and commonly
expressed in the units kilowatt-hour per short ton (2000 lb) (1 kWh/short ton
4000 J/kg). The Bond work index, WI , must be determined empirically. Some
common examples are: bauxite, 9.45 kWh/short ton; coke from coal, 20.7 kWh/
short ton; gypsum rock, 8.16 kWh/short ton.
Bond’s formula gives a fairly reliable first approximation to the energy
requirement provided the product top size is not less than 100 mm. In differential
form Bond’s formula becomes:
dE 1
¼ CB 3=2 ð12:9Þ
dx x
Attempts have been made (e.g. Holmes, 1957; Hukki, 1961) to find the general
formula for which the proposals of Rittinger, Kick and Bond are special cases. It
can be seen from the results of the above analysis that these three proposals can
be considered as being the integrals of the same differential equation:
dE 1
¼ C N ð12:10Þ
dx x
with
N¼2 C ¼ CR for Rittinger

N¼1 C ¼ CK for Kick
N ¼ 1:5 C ¼ CB for Bond
It has been suggested that the three approaches to prediction of energy requirem-
ents mentioned above are each more applicable in certain areas of product size. It
is common practice to assume that Kick’s proposal is applicable for large particle
size (coarse crushing and crushing), Rittinger’s for very small particle size (ultra-
fine grinding) and the Bond formula being suitable for intermediate particle size–
the most common range for many industrial grinding processes. This is shown in
Figure 12.2, in which specific energy requirement is plotted against particle size
on logarithmic scales. For Rittinger’s postulate, E / 1=x and so ln E / 1 lnðxÞ
and hence the slope is 1. For Bond’s formula, E / 1=x0:5 and so ln E / 0:5 lnðxÞ
and hence the slope is 0.5. For Kick’s law, the specific energy requirement is
Specific energy
requirement
(kWh/tonne)
104
Rittinger
103
2
10
Bond
10
1.0 Kick
–1
10
–9 –6 –3
10 10 10 1.0
Particle size (m)
Figure 12.2 Specific energy requirement for breakage: relationship to laws of Rittinger,
Bond and Kick
dependent on the reduction ratio x1 =x2 irrespective of the actual particle size;
hence the slope is zero.
In practice, however, it is generally advisable to rely on the past experience of
equipment manufacturers and on tests in order to predict energy requirements
for the milling of a particular material.
12.3.2 Prediction of the Product Size Distribution
It is common practice to model the breakage process in comminution equipment

on the basis of two functions, the specific rate of breakage and the breakage
distribution function. The specific rate of breakage Sj is the probability of a
particle of size j being broken in unit time (in practice, ‘unit time’ may mean a
certain number of mill revolutions, for example). The breakage distribution
function b(i, j) describes the size distribution of the product from the breakage
of a given size of particle. For example, b(i, j) is the fraction of breakage product
from size interval j which falls into size interval i. Figure 12.3 helps demonstrate
the meaning of Sj and b(i, j) when dealing with 10 kg of monosized particles in
size interval 1. If S1 ¼ 0:6 we would expect 4 kg of material to remain in size
interval 1 after unit time. The size distribution of the breakage product would
be described by the set of b(i, j) values. Thus, for example, if bð4; 1Þ ¼ 0:25 we
would expect to find 25% by mass from size interval 1 to fall into size interval 4.
The breakage distribution function may also be expressed in cumulative form as
Bði; jÞ, the fraction of the breakage product from size interval j which falls into
size intervals j to n, where n is the total number of size intervals. [Bði; jÞ is thus a
cumulative undersize distribution.]
Size interval Mass (kg) b (i, j) B (i, j)
2 0.9 0.15 1
10 kg of monosized 4kg of unbroken
particles in interval 1 feed particles
3 1.8 0.3 0.85
4 1.5 0.25 0.55
5 1.2 0.2 0.3
6 0.6 0.1 0.1
Unbroken Broken
product product
Feed Product
Figure 12.3 Meanings of specific rate of breakage and breakage distribution function
Thus, remembering that S is a rate of breakage, we have Equation (12.11),

which expresses the rate of change of the mass of particles in size interval i with
time:
j¼i1
X
dmi
¼ ½bði; jÞSj mj Si mi ð12:11Þ
dt j¼1
where
j¼i1
X
½bði; jÞSj mj ¼ mass broken into interval i from all intervals of j > i
j¼1
Si mi ¼ mass broken out of interval i
Since mi ¼ yi M and mj ¼ yj M; where M is the total mass of feed material and yi is

the mass fraction in size interval i, then we can write a similar expression for the
rate of change of mass fraction of material in size interval, i with time:
j¼i1
X
dyi
¼ ½bði; jÞSj yj Si yi ð12:12Þ
dt j¼1
Thus, with a set of S and b values for a given feed material, the product size
distribution after a given time in a mill may be determined. In practice, both S
and b are dependent on particle size, material and machine. From the earlier
discussion on particle fracture mechanisms it would be expected that the specific
rate of breakage should decrease with decreasing particle size, and this is found
to be the case. The aim of this approach is to be able to use values of S and b
determined from small-scale tests to predict product size distributions on a large
scale. This method is found to give fairly reliable predictions.
12.4 TYPES OF COMMINUTION EQUIPMENT
12.4.1 Factors Affecting Choice of Machine
The choice of machine selected for a particular grinding operation will depend on
the following variables:
stressing mechanism;
size of feed and product;
material properties;
carrier medium;
mode of operation;
capacity;
combination with other unit operations.
12.4.2 Stressing Mechanisms
It is possible to identify three stresses mechanisms responsible for particle size

reduction in mills:
(1) Stress applied between two surfaces (either surface–particle or particle–

particle) at low velocity, 0.01–10 m/s. Crushing plus attrition, Figure 12.4.
Figure 12.4 Stresses applied between two surfaces

TYPES OF COMMINUTION EQUIPMENT 321
Figure 12.5 Stresses applied at a single solid surface
(2) Stress applied at a single solid surface (surface–particle or particle–particle)

at high velocity, 10–200 m/s. Impact fracture plus attrition (Figure 12.5).
(3) Stress applied by carrier medium–usually in wet grinding to bring about

disagglomeration.
An initial classification of comminution equipment can be made according to the

stressing mechanisms employed, as follows.
Machines using mainly mechanism 1, crushing
The jaw crusher behaves like a pair of giant nutcrackers (Figure 12.6). One jaw is
fixed and the other, which is hinged at its upper end, is moved towards and away
from the fixed jaw by means of toggles driven by an eccentric. The lumps of
material are crushed between the jaws and leave the crusher when they are able
to pass through a grid at the bottom.
The gyratory crusher, shown in Figure 12.7, has a fixed jaw in the form of a
truncated cone. The other jaw is a cone which rotates inside the fixed jaw on an
eccentric mounting. Material is discharged when it is small enough to pass
through the gap between the jaws.
In the crushing roll machine two cylindrical rolls rotate in opposite directions,
horizontally and side by side with an adjustable gap between them (Figure 12.8).
As the rolls rotate, they drag in material which is choke-fed by gravity so that
Feed
Static jaw
Hing
Moving jaw
Crushing
Jaw motion
chamber
Discharge
Figure 12.6 Schematic diagram of a jaw crusher

Motion of
gyratory
head
Gyratory
Crusher jaws head
Drive for
gyratory
head
Discharge
Figure 12.7 Schematic diagram of gyratory crusher
particle fracture occurs as the material passes through the gap between the rolls.
The rolls may be ribbed to give improved purchase between material and rolls.
In the horizontal table mill, shown in Figure 12.9, the feed material falls on to the
centre of a circular rotating table and is thrown out by centrifugal force. In
moving outwards the material passes under a roller and is crushed.
Machines using mainly mechanism 2, high velocity impact
The hammer mill, shown in Figure 12.10, consists of a rotating shaft to which are
attached fixed or pivoted hammers. This device rotates inside a cylinder. The
Feed
Direction of
rotation of
rolls
Rolls Discharge
Figure 12.8 Schematic diagram of crushing rolls

Spring forcing
roller on to table
Roller
Hinge Feed
Discharge
Horizontal
table
Figure 12.9 Schematic diagram of horizontal table mill
particles are fed into the cylinder either by gravity or by gas stream. In the
gravity-fed version the particles leave the chamber when they are small enough
to pass through a grid at the bottom.
A pin mill consists of two parallel circular discs each carrying a set of projecting
pins (Figure 12.11). One disc is fixed and the other rotates at high speed so that its
Feed
Rotating disc
carrying the
hammers
Hammers
Screen
Discharge
Figure 12.10 Schematic diagram of a hammer mill

Stator
Pins
Feed
Rotor
Rotor
Discharge
Figure 12.11 Schematic diagram of a pin mill
pins pass close to those on the fixed disc. Particles are carried in air into the centre
and as they move radially outwards are fractured by impact or by attrition.
The fluid energy mill relies on the turbulence created in high velocity jets of air
or steam in order to produce conditions for interparticle collisions which bring
about particle fracture. A common form of fluid energy mill is the loop or oval jet
mill shown in Figure 12.12. Material is conveyed from the grinding area near the
jets at the base of the loop to the classifier and exit situated at the top of the loop.
These mills have a very high specific energy consumption and are subject to
extreme wear when handling abrasive materials. These problems have been
overcome to a certain extent in the fluidized bed jet mill in which the bed is used
to absorb the energy from the high-speed particles ejected from the grinding
zone.
Feed
Zones of
turbulence
Fluid
Fluid
Fluid
Fluid
Figure 12.12 Schematic diagram of a fluid energy mill

Figure 12.13 Schematic diagram of a sand mill
Machines using a combination of mechanisms 1 and 2, crushing

and impact with attrition
The sand mill, shown in Figure 12.13, is a vertical cylinder containing a stirred bed
of sand, glass beads or shot. The feed, in the form of a slurry, is pumped into the
bottom of the bed and the product passes out at the top through a screen which
retains the bed material.
In the colloid mill, the feed in the form of a slurry passes through the gap
between a male, ribbed cone rotating at high speed and a female static cone
(Figure 12.14).
The ball mill, shown in Figure 12.15, is a rotating cylindrical or cylindrical–
conical shell about half filled with balls of steel or ceramic. The speed of rotation
of the cylinder is such that the balls are caused to tumble over one another
Discharge
Feed
Male ribbed
cone rotating
at high speed
Figure 12.14 Schematic diagram of a colloid mill

Figure 12.15 Schematiac diagram of a ball mill
without causing cascading. This speed is usually less than 80% of the critical
speed which would just cause the charge of balls and feed material to be
centrifuged. In continuous milling the carrier medium is air, which may be
heated to avoid moisture which tends to cause clogging. Ball mills may also
be used for wet grinding with water being used as the carrier medium. The size
of balls is chosen to suit the desired product size. The conical section of the mill
shown in Figure 12.15 causes the smaller balls to move towards the discharge end
and accomplish the fine grinding. Tube mills are very long ball mills which are
often compartmented by diaphragms, with balls graded along the length from
large at the feed end to small at the discharge end.
12.4.3 Particle Size
Although it is technically interesting to classify mills according to the stressing

mechanisms it is the size of the feed and the product size distribution required
which in most cases determine the choice of a suitable mill. Generally the
terminology shown in Table 12.1 is used.
Table 12.2 indicates how the product size determines the type of mill to be
used.
Table 12.1 Terminology used in comminution

Size range of product Term used
1–0.1 m Coarse crushing
0.1 m Crushing
1 cm Fine crushing, coarse grinding
1 mm Intermediate grinding, milling
100 mm Fine grinding
10 mm Ultrafine grinding
Table 12.2 Categorizing comminution equipment according to product size

Down to 3 mm 3 mm–50 mm <50 mm
Crushers Ball mills Ball mills
Table mills Rod mills Vibration mills
Edge runner mills Pin mills Sand mills
Tube mills Perl mills
Vibration mills Colloid mills
Fluid energy mills
12.4.4 Material Properties
Material properties affect the selection of mill type, but to a lesser extent than
feed and product particle size. The following material properties may need to be
considered when selecting a mill:
Hardness. Hardness is usually measured on the Mohs’ scale of hardness where

graphite is ranked 1 and diamond is ranked 10. The property hardness is a
measure of the resistance to abrasion.
Abrasiveness. This is linked closely to hardness and is considered by some to be

the most important factor in selection of commercial mills. Very abrasive
materials must generally be ground in mills operating at low speeds to reduce
wear of machine parts in contact with the material (e.g. ball mills).
Toughness. This is the property whereby the material resists the propagation of
cracks. In tough materials excess strain energy brings about plastic deforma-
tion rather than propagation of new cracks. Brittleness is the opposite of
toughness. Tough materials present problems in grinding, although in some
cases it is possible to reduce the temperature of the material, thereby reducing
the propensity to plastic flow and rendering the material more brittle.
Cohesivity/adhesivity. The properties whereby particles of material stick together

and to other surfaces. Cohesivity and adhesivity are related to moisture content
and particle size. Decrease of particle size or increasing moisture content
increases the cohesivity and adhesivity of the material. Problems caused by
cohesivity/adhesivity due to particle size may be overcome by wet grinding.
Fibrous nature. Materials of a fibrous nature are a special case and must be
comminuted in shredders or cutters which are based on the hammer mill
design.
Low melting point. The heat generated in a mill may be sufficient to cause
melting of such materials causing problems of increased toughness and
increased cohesivity and adhesivity. In some cases, the problem may be
overcome by using cold air as the carrier medium.
Other special properties. Materials which are thermally sensitive and have a
tendency to spontaneous combustion or high inflammability must be ground
using an inert carrier medium (e.g. nitrogen). Toxic or radioactive materials
must be ground using a carrier medium operating on a closed circuit.
12.4.5 Carrier Medium
The carrier medium may be a gas or a liquid. Although the most common gas
used is air, inert gases may be used in some cases as indicated above. The most
common liquid used in wet grinding is water although oils are sometimes used.
The carrier medium not only serves to transport the material through the mill
but, in general, transmits forces to the particles, influences friction and hence
abrasion, affects crack formation and cohesivity/adhesivity. The carrier medium
can also influence the electrostatic charging and the flammability of the material.
12.4.6 Mode of Operation
Mills operate in either batch or continuous mode. Choice between modes will be
based on throughput, the process and economics. The capacity of batch mills
varies from a few grammes on the laboratory scale to a few tonnes on a
commercial scale. The throughput of continuous milling systems may vary
from several hundred grammes per hour at laboratory scale to several thousand
tonnes per hour at industrial scale.
12.4.7 Combination with other Operations
Some mills have a dual purpose and thus may bring about drying, mixing or
classification of the material in addition to its size reduction.
12.4.8 Types of Milling Circuit
Milling circuits are either ‘open circuit’ or ‘closed circuit’. In open circuit milling
(Figure 12.16) the material passes only once through the mill, and so the only
controllable variable is the residence time of the material in the mill. Thus the
Feed
Mill
Product
Control: residence time
Figure 12.16 Open circuit milling

WORKED EXAMPLES 329
Mill Feed
Classifier
Control: residence time

feed to mill
classifier cut size Product
Figure 12.17 Closed circuit milling
product size and distribution may be controlled over a certain range by varying
the material residence time (thoughput), i.e. feed rate governs product size and
so the system is inflexible.
In closed circuit milling (Figure 12.17) the material leaving the mill is subjected
to some form of classification (separation according to particle size) with the
oversize being returned to the mill with the feed material. Such a system is far
more flexible since both product mean size and size distribution may be
controlled.
Figures 12.18 and 12.19 show the equipment necessary for feeding material into
the mill, removing material from the mill, classifying, recycling oversize material
and removing product in the case of dry and wet closed milling circuits,
respectively.
Classifier
Cyclone
Air
Mill
Product
Feed
Figure 12.18 Dry milling: closed circuit operation
WORKED EXAMPLE 12.1
A material consisting originally of 25 mm particles is crushed to an average size of 7 mm

and requires 20 kJ/kg for this size reduction. Determine the energy required to crush the
Product
hydrocyclone
Water Feed
Water
Mill
Water
Figure 12.19 Wet milling: closed circuit operation
material from 25 mm to 3.5 mm assuming (a) Rittinger’s law, (b) Kick’s law and
(c) Bond’s law.
Solution
(a) Applying Rittinger’s law as expressed by Equation (12.4):

1 1
20 ¼ CR
7 25
hence CR ¼ 194:4 and so with x2 ¼ 3:5 mm,

1 1
E ¼ 194:4
3:5 25
hence E ¼ 47:8 kJ=kg
(b) Applying Kick’s law as expressed by Equation (12.7):

7
20 ¼ CK ln
25
hence CK ¼ 15:7 and so with x2 ¼ 3:5 mm,

3:5
E ¼ 15:7 ln
25
(c) Applying Bond’s law as expressed by Equation (12.8a):

1 1
20 ¼ CB pffiffiffi pffiffiffiffiffi
7 25
WORKED EXAMPLES 331
Table 12W2.1 Specific rates of breakage and breakage distribution function for the ball
mill
Size interval (mm) 212–150 150–106 106–75 75–53 53–37 37–0
Interval no. 1 2 3 4 5 6
Sj 0.7 0.6 0.5 0.35 0.3 0
bð1; jÞ 0 0 0 0 0 0
bð2; jÞ 0.32 0 0 0 0 0
bð3; jÞ 0.3 0.4 0 0 0 0
bð4; jÞ 0.14 0.2 0.5 0 0 0
bð5; jÞ 0.12 0.2 0.25 0.6 0 0
bð6; jÞ 0.12 0.2 0.25 0.4 1.0 0
hence CB ¼ 112:4 and so with x2 ¼ 3:5 mm,

1 1
E ¼ 112:4 pffiffiffiffiffiffiffi
3:5 25
WORKED EXAMPLE 12.2
Values of breakage distribution function b(i, j) and specific rates of breakage Sj for a
particular material in a ball mill are shown in Table 12W2.1. To test the validity of these
values, a sample of the material with the size distribution indicated in Table 12W2.2
is to be ground in a ball mill. Use the information in these tables to predict the size
distribution of the product after one minute in the mill. (Note: Sj values in Table 12W2.1
are based on 1 minute grinding time.)
Solution
Applying Equation (12.12):
Change of fraction in interval 1
dy1
¼ 0 S1 y1 ¼ 0 0:7 0:2
dt
¼ 0:14
Hence, new y1 ¼ 0:2 0:14 ¼ 0:06
Table 12W2.2 Feed size distribution
Interval no. (j) 1 2 3 4 5 6

Fraction 0.2 0.4 0.3 0.06 0.04 0
dy2
¼ bð2; 1ÞS1 y1 S2 y2
dt
¼ ð0:32 0:7 0:2Þ ð0:6 0:4Þ
¼ 0:1952
Hence new y2 ¼ 0:4 0:1952 ¼ 0:2048
dy3
¼ ½bð3; 1ÞS1 y1 þ bð3; 2ÞS2 y2 S3 y3
dt
¼ ½ð0:3 0:7 0:2Þ þ ð0:4 0:6 0:4Þ ð0:5 0:3Þ
¼ 0:012
Hence, new y3 ¼ 0:3 0:012 ¼ 0:288
Similarly for intervals 4, 5 and 6:
new y4 ¼ 0:1816
new y5 ¼ 0:1429
new y6 ¼ 0:1227
Checking:
Sum of predicted product interval mass fractions ¼ y1 þ y2 þ y3 þ y4 þ y5 þ y6 ¼ 1:000
Hence product size distribution:
Interval no. (j) 1 2 3 4 5 6

Fraction 0.06 0.2048 0.288 0.1816 0.1429 0.1227
TEST YOURSELF
12.1 Explain why in brittle materials multiple fracture is common.
12.2 Using the concept of failure by crack propagation, explain why small particles are
more difficult to break than large particles.
12.3 Summarize three different models for predicting the energy requirement associated
with particle size reduction. Over what size ranges might each model be most
appropriately applied?
12.4 Define selection function and breakage function, functions used in the prediction of
product size distribution in a size reduction process.
EXERCISES 333
12.5 Explain in words the meaning for the following equation.
j¼i1
X
dyi
¼ ½bði; jÞSj yj Si yi
dt j¼1
12.6 Describe the operation of the hammer mill, the fluid energy mill and the ball mill. In
each case identify the dominant stressing mechanism responsible for particle
breakage.
12.7 Under what conditions might wet grinding be used?
12.8 List five material properties that would influence selection of a mill type.
EXERCISES
12.1 (a) Rittinger’s energy law postulated that the energy expended in crushing is
proportional to the area of new surface created. Derive an expression relating the
specific energy consumption in reducing the size of particles from x1 to x2 according to
this law.
(b) Table 12E1.1 gives values of specific rates of breakage and breakage distribution
functions for the grinding of limestone in a hammer mill. Given that values of specific
rates of breakage are based on 30 s in the mill at a particular speed, determine the size
distribution of the product resulting from the feed described in Table 12E1.2 after 30 s
in the mill at this speed.
(Answer: 0.12, 0.322, 0.314, 0.244.)
Table 12E1.1 Specific rates of breakage and breakage distribution function for the
hammer mill
Interval (mm) 106–75 75–53 53–37 37–0
Interval no. j 1 2 3 4
Sj 0.6 0.5 0.45 0
bð1; jÞ 0 0 0 0
bð2; jÞ 0.4 0 0 0
bð3; jÞ 0.3 0.6 0 0
bð4; jÞ 0.3 0.4 1.0 0
Table 12E1.2 Feed size distribution
Interval 1 2 3 4
Fraction 0.3 0.5 0.2 0
12.2 Table 12E2.1 gives information gathered from tests on the size reduction of coal in a
ball mill. Assuming that the values of specific rates of breakage, Sj , are based on 25
revolutions of the mill at a particular speed, predict the product size distribution resulting
from the feed material, details of which are given in Table 12E2.2 after 25 revolutions in the
mill at that speed.
(Answer: 0.125, 0.2787, 0.2047, 0.1661, 0.0987, 0.0779, 0.04878.)
Table 12E2.1 Results of ball mill tests on coal

Interval (mm) 300–212 212–150 150–106 106–75 75–53 53–37 37–0
Interval no. j 1 2 3 4 5 6 7
Sj 0.5 0.45 0.42 0.4 0.38 0.25 0
bð1; jÞ 0 0 0 0 0 0 0
bð2; jÞ 0.25 0 0 0 0 0 0
bð3; jÞ 0.24 0.29 0 0 0 0 0
bð4; jÞ 0.19 0.27 0.33 0 0 0 0
bð5; jÞ 0.12 0.2 0.3 0.45 0 0 0
bð6; jÞ 0.1 0.16 0.25 0.3 0.6 0 0
bð7; jÞ 0.1 0.08 0.12 0.25 0.4 1.0 0
Interval 1 2 3 4 5 6 7
Fraction 0.25 0.45 0.2 0.1 0 0 0
12.3 Table 12E3.1 gives information on the size reduction of a sand-like material in a ball
mill. Given that the values of specific rates of breakage Sj are based on five revolutions of
the mill, determine the size distribution of the feed materials shown in Table 12E3.2 after
five revolutions of the mill.
(Answer: 0.0875, 0.2369, 0.2596, 0.2115, 0.2045.)
Table 12E3.1 Results of ball mill tests

Interval (mm) 150–106 106–75 75–53 53–37 37–0
Interval no. (j) 1 2 3 4 5
Sj 0.65 0.55 0.4 0.35 0
bð1; jÞ 0 0 0 0 0
bð2; jÞ 0.35 0 0 0 0
bð3; jÞ 0.25 0.45 0 0 0
bð4; jÞ 0.2 0.3 0.6 0 0
bð5; jÞ 0.2 0.25 0.4 1.0 0
EXERCISES 335

Interval 1 2 3 4 5
Fraction 0.25 0.4 0.2 0.1 0.05
12.4 Comminution processes are generally less than 1% efficient. Where does all the
wasted energy go?
13
Size Enlargement
Karen Hapgood and Martin Rhodes
13.1 INTRODUCTION
Size enlargement is the process by which smaller particles are put together to
form larger masses in which the original particles can still be identified. Size
enlargement is one of the single most important process steps involving parti-
culate solids in the process industries. Size enlargement is mainly associated with
the pharmaceutical, agricultural and food industries, but also plays an important
role in other industries including minerals, metallurgical and ceramics.
There are many reasons why we may wish to increase the mean size of a
product or intermediate. These include reduction of dust hazard (explosion
hazard or health hazard), to reduce caking and lump formation, to improve
flow properties, increase bulk density for storage, creation of non-segregating
mixtures of ingredients of differing original size, to provide a defined metered
quantity of active ingredient (e.g. pharmaceutical drug formulations), and control
of surface to volume ratio (e.g. in catalyst supports).
Methods by which size enlargement is brought about include granulation,
compaction (e.g. tabletting), extrusion, sintering, spray drying and prilling.
Agglomeration is the formation of agglomerates or aggregates by sticking together
of smaller particles and granulation is agglomeration by agitation methods. Since it
is not possible in the confines of a single chapter to cover all size enlargement
methods adequately, the focus of this chapter will be on granulation, which will
serve as an example.
In this chapter the different types of interparticle forces and their relative
importance as a function of particle size are summarized. Liquid bridge forces,
which are specifically important to granulation processes, are covered in more
detail. The rate processes important to granulation (wetting, growth, consolidation

338 SIZE ENLARGEMENT
and attrition) are reviewed and population balance included in order to develop a
simple model for simulation for the granulation process. To conclude, a brief
overview of industrial granulation equipment is also given.
13.2 INTERPARTICLE FORCES
13.2.1 van der Waals Forces
There exist between all solids molecularly based attractive forces collectively
known as van der Waals forces. The energy of these forces is of the order of 0.1 eV
and decreases with the sixth power of the distance between molecules. The range
of van der Waals forces is large compared with that of chemical bonds. The
attractive force, Fvw , between a sphere and a plane surface as a result of van der
Waals forces was derived by Hamaker (1937) and is usually presented in the
form:
KH R
Fvw ¼ ð13:1Þ
6y2
where KH is the Hamaker constant, R is the radius of the sphere and y is the gap
between the sphere and the plane.
13.2.2 Forces due to Adsorbed Liquid Layers
Particles in the presence of a condensable vapour will have a layer of adsorbed

vapour on their surface. If these particles are in contact a bonding forces results
from the overlapping of the adsorbed layers. The strength of the bond is
dependent on the area of contact and the tensile strength of the adsorbed layers.
The thickness and strength of the layers increase with increasing partial pressure
of the vapour in the surrounding atmosphere. According to Coelho and Harnby
(1978) there is a critical partial pressure at which the adsorbed layer bonding
gives way to liquid bridge bonding.
13.2.3 Forces due to Liquid Bridges
In addition to the interparticle forces resulting from adsorbed liquid layers, as

described above, even in very small proportions the presence of liquid on the
surface of particles affects the interparticle forces by the smoothing effect it has on
surface imperfections (increasing particle–particle contact) and its effect of redu-
cing the interparticle distance. However, these forces are usually negligible in
magnitude compared with forces resulting when the proportion of liquid present is
sufficient to form interparticle liquid bridges. Newitt and Conway-Jones (1958)
identified four types of liquid states depending on the proportion of liquid present
between groups of particles. These states are known as pendular, funicular,
INTERPARTICLE FORCES 339
Figure 13.1 Liquid bonding between particles: (a) pendular; (b) funicular; (c) capillary;
(d) droplet
capillary and droplet. These are shown in Figure 13.1. In the pendular state liquid is
held as a point contact in a bridge neck between particles. The liquid bridges are all
separate and independent of each other. The interstitial space between the particles
is the porosity or voidage. The strong boundary forces resulting from the surface
tension of the liquid draw the particles together. In addition there is capillary
pressure resulting from the curved liquid surfaces of the bridge. The capillary
pressure is given by:

1 1
pc ¼ g ð13:2Þ
r1 r2
where g is the liquid surface tension and r1 and r2 are the radii of curvature of the
liquid surfaces. If the pressure in the liquid bridge is less than the ambient
pressure, the capillary pressure and surface tension boundary attractive force are
additive.
As the proportion of liquid to particles is increased the liquid is free to move
and the attractive force between particles decreases (funicular). When there is
sufficient liquid to completely fill the interstitial pores between the particles
(capillary) the granule strength falls further as there are fewer curved liquid
surfaces and fewer boundaries for surface tension forces to act on. Clearly when
the particles are completely dispersed in the liquid (droplet) the strength of the
structure is very low.
In the pendular state increasing the amount of liquid present has little effect on
the strength of the bond between the particles until the funicular state is
achieved. However, increasing the proportion of liquid increases the resistance
of the bond to rupture since the particles can be pulled further apart without
rupture of bridges. This has practical implication for granulation processes;
pendular bridges give rise to strong granules in which the quantity of liquid is
not critical but should be less than that required to move into the funicular and
capillary regimes.
The saturation can also be increased by reducing the voidage or porosity and
moving the particles closer together (i.e. densifying the granule). This reduces the
open pore space available for liquid, and the granule saturation gradually
increases from the funicular state through to the droplet state as shown in
Figure 13.1.
13.2.4 Electrostatic Forces
Electrostatic charging of particles and surfaces occurs as a result of friction

caused by interparticle collisions and frequent rubbing of particles against
equipment surfaces during processing. The charge is caused by the transfer of
electrons between the bodies. The force between two charged spheres is propor-
tional to the product of their charges. Electrostatic forces may be attractive or
repulsive, do not require contact between particles and can act over relatively
long distances compared with adhesional forces which require contact.
13.2.5 Solid Bridges
Granules formed by liquid bridges are usually not the end product in a
granulation process. More permanent bonding within the granule is created by
solid bridges formed as liquid is removed from the original granule. Solid
bridges between particles may take three forms: crystalline bridges, liquid binder
bridges and solid binder bridges. If the material of the particles is soluble in the
liquid added to create granules, crystalline bridges may be formed when the
liquid evaporates. The process of evaporation reduces the proportion of liquid in
the granules producing high strength pendular bridges before crystals form.
Alternatively the liquid used initially to form the granules may contain a binder
or glue which takes effect upon evaporation of solvent.
In some cases a solid binder may be used. This is a finely ground solid which
reacts with the liquid present to produce a solid cement to hold the particles
together.
13.2.6 Comparison and Interaction between Forces
In practice all interparticle forces act simultaneously. The relative importance of

the forces varies with changes in particle properties and with changes in the
humidity of the surrounding atmosphere. There is considerable interaction
between the bonding forces. For example, in aqueous systems adsorbed moisture
can considerably increase van der Waals forces. Adsorbed moisture can also
reduce interparticle friction and potential for interlocking, making the powder
more free-flowing. Electrostatic forces decay rapidly if the humidity of the
surrounding air is increased.
A powder which in a dry atmosphere exhibits cohesivity due to electrostatic
charging may become more free-flowing as humidity of the atmosphere is
GRANULATION 341
Figure 13.2 Theoretical tensile strength of agglomerates with different bonding mechan-
isms (after Rumpf, 1962)
increased. If humidity is further increased liquid bridge formation can result in a

return to cohesive behaviour. This effect has been reported in powder mixing
studies by Coelho and Harnby (1978) and Karra and Fuerstenau (1977).
Figure 13.2, after Rumpf (1962), illustrates the relative magnitude of the
different bonds discussed above as a function of particle size. We see that van
der Waals forces become important only for particles below 1 mm in size,
adsorbed vapour forces are relevant below 80 mm and liquid bridge forces are
active below about 500 mm.
13.3 GRANULATION
13.3.1 Introduction
Granulation is particle size enlargement by sticking together smaller particles

using agitation to impart energy to particles and granules. The most common type
of granulation method is wet granulation where a liquid binder is distributed over
the bed to initiate granule formation. The resulting assembly of particles is called a
’granule‘ and consists of the primary particles arranged as a three-dimensional
porous structure. Important properties of granules include their size, porosity,
strength, flow properties, dissolution, and composition uniformity.
The motion of the particles and granules in the granulator results in collisions
which produce growth by coalescence and coating. In general the individual
component particles are held together by a liquid (glue-like) or solid (cement-
like) binder which is sprayed into the agitated particles in the granulator. A
hybrid process is melt granulation, where a polymer binder is heated and

sprayed in liquid form onto the powder, and cooled during granulation to
form solid bonds between the particles. Alternatively, a solvent may be used to
induce dissolution and recrystallization of the material of which the particles are
made.
13.3.2 Granulation Rate Processes
In granulation the formation of granules or agglomerates is controlled by three

rate processes, illustrated in Figure 13.3. These are (1) wetting and nucleation of the
original particles by the binding liquid, (2) coalescence or growth to form granules
plus consolidation of the granule and (3) attrition or breakage of the granule.
Nucleation is the term used to describe the initial process of combining primary
solid particles with a liquid drop to form new granules or nuclei. Coalescence is
the joining together of two granules (or a granule plus a primary particle) to form
a larger granule. These processes combine to determine the properties of the
product granule (size distribution, porosity, strength, dispersibility, etc.). The
(i) Wetting & Nucleation
(ii) Consolidation & Coalescence
(iii) Attrition & Breakage
Figure 13.3 Summary of the three granulation mechanisms. Reprinted from Powder
Technology, 117 (1–2), Iveson et al., ’Nucleation, growth and breakage phenomena in
agitated wet granulation processes: a review‘, pp. 3–39, Copyright (2001), with permission
from Elsevier
GRANULATION 343
final granule size in a granulation process is controlled by the competing

mechanisms of growth, breakage and consolidation.
Wetting and Nucleation
Wetting is the process by which air within the voids between particles is replaced
by liquid. Ennis and Litster (1997) stress the important influence which the extent
and rate of wetting have on product quality in a granulation process. For example,
poor wetting can result in much material being left ungranulated and requiring
recycling. When granulation is used to combine ingredients, account must be
taken of the different wetting properties which components of the final granule
may have.
Wetting is governed by the surface tension of the liquid and the contact angle it
forms with the material of the particles. The rate at which wetting occurs is
important in granulation. An impression of this rate is given by the Washburn
equation [Equation (13.3)] for the rate of penetration of liquid of viscosity m and
surface tension g into a bed of powder when gravity is not significant:
dz Rp g cos y
¼ ð13:3Þ
dt 4mz
where t is the time, z is the penetration distance of the liquid into the powder and
y is the dynamic contact angle of the liquid with the solid of the powder. Rp is
the average pore radius which is related to the packing density and the size
distribution of the powder. Thus in granulation, the factors controlling the rate of
wetting are adhesive tension ðg cos yÞ, liquid viscosity, packing density and the
size distribution.
The Washburn test requires some specialized testing equipment to perform,
and an alternate test is the drop penetration time test which is more directly
related to the wetting of spray drops into a granulating powder (Hapgood et al.,
2003). A drop of known volume Vd is gently placed onto a small powder bed with
porosity eb and the time taken for the drop to completely sink into the powder
bed is measured. The drop penetration time, tp, is given by:
2=3
Vd m
tp ¼ 1:35 ð13:4Þ
eb Rg cos y
2
The Washburn test and drop penetration time test are closely related, but the
latter is simpler to perform as a screening and investigation test when developing
or troubleshooting a granulation process.
In general, improved wetting is desirable. It gives a narrower granule size
distribution and improved product quality through better control over the gran-
ulation process. In practice, the rate of wetting will significantly influence the
extent of wetting of the powder mass, especially where evaporation of binder
solvent takes place simultaneously with wetting. The brief analysis above shows us
that the rate of wetting is increased by reducing viscosity, increasing surface
tension, minimizing contact angle and increasing the size of pores within the
powder. Viscosity is determined by the binder concentration and the operating
temperature. As concentration changes with solvent evaporation, the binder
viscosity will increase. Small particles give small pores and large particles give
large pores. Also, a wider particle size distribution will give rise to smaller pores.
Large pores ensure a high rate of liquid penetration but give rise to a lower extent
of wetting.
In addition to the wetting characteristics, the drop size and overall distribution
of liquid are crucial parameters in granulation. If one drop is added to a
granulator, only one nucleus granule will be formed, and the size of the nucleus
granule will be proportional to the size of the drop (Waldie, 1991). During
atomization of the fluid onto the powder, it is important the conditions in the
spray zone balance the rate of incoming fluid drops with the rate of penetration
into the powder and/or removal of wet powder from the spray zone. Ideally,
each spray droplet should land on the powder without touching other droplets
and sink quickly into the powder to form a new nucleus granule. These ideal
conditions are called the ’drop controlled nucleation regime‘ and occur at low
penetration time (described above) and low dimensionless spray flux a, which is
given by (Litster et al., 2001):
3Q
ca ¼ ð13:5Þ
2vs ws dd
where Q is the solution flow rate, vs is the powder velocity in the spray zone, dd is
the average drop diameter and ws is the width of the spray. The dimensionless
spray flux is a measure of the density of drops falling on the powder surface. At
low spray flux ðca 1Þ drop footprints will not overlap and each drop will form
a separate nucleus granule. At high spray flux ðca 1Þ there will significant
overlap of drops hitting the powder bed. Nuclei granules formed will be much
larger and their size will no longer be a simple function of the original drop size.
At a given spray flux value, the fraction of the powder surface that is wetted by
spray drops as it passes beneath the spray zone (fwet) is given by (Hapgood et al.,
2004):
fwet ¼ 1 expða Þ ð13:6Þ
and the fraction of nuclei fn formed by n drops can be calculated using (Hapgood
et al., 2004):
" #
ð4a Þn1
fn ¼ expð4a Þ ð13:7Þ
ðn 1Þ!
The dimensionless spray flux parameter can be used both as a scale-up para-
meter and as a parameter to estimate nuclei starting sizes for population
balance modelling (see Section 13.3.3). When combined with the drop penetr-
ation time, a forms part of a nucleation regime map (see Figure 13.4) (Hapgood
GRANULATION 345
10
Mechanical
no change Dispersion
in distribution regime
1.0
tp
Intermediate
0.1 narrower nuclei

size distribution
Drop
controlled
Caking
0.01 0.1 1.0 10
Ψa
Figure 13.4 Nucleation regime map. For ideal nucleation in the drop controlled regime,
low a and low tp are required. Reprinted from AIChE Journal, 49 (2), Hapgood et al.,
’Nucleation regime map for liquid bound granules’, pp. 350–361. Reproduced with
permission. Copyright 2003 American Institute of chemical Engineers (AIChE)
et al., 2003). Three nucleation regimes have been defined: drop controlled, shear
controlled, and an intermediate zone. Drop controlled nucleation occurs when one
drop forms one nucleus and should occur when there is both:
(1) Low spray flux ca – the spray density is low and relatively few drops
overlap;
(2) Fast penetration time tp – the drop must penetrate completely into the
powder bed before it touches either other drops on the powder surface or
new drops arriving from the spray.
If either criterion is not met, powder mixing and shear characteristics will
dominate: this is the mechanical dispersion regime. Viscous or poorly wetting
binders are slow to flow through the powder pores and form nuclei. Drop
coalescence on the powder surface (also known as ‘pooling’) may occur and
create a very broad nuclei size distribution. In the mechanical dispersion
regime, the liquid binder can only be dispersed by powder shear and agitation.
Granule Consolidation
Consolidation is the term used to describe the increase in granule density caused
by closer packing of primary particles as liquid is squeezed out as a result of
collisions. Consolidation can only occur whilst the binder is still liquid. Con-
solidation determines the porosity and density of the final granules. Factors
influencing the rate and degree of consolidation include particle size, size
distribution and binder viscosity. The granule porosity e, and the liquid level w,
control the granule saturation s, which is the fraction of pore space filled with
liquid:
wrs ð1 eÞ
s¼ ð13:8Þ
rl e
where rs is the solid density and rl is the liquid density. The saturation increases
as the porosity decreases, and once the saturation exceeds 100%, further con-
solidation pushes liquid to the granule surface, making the surface wet. Surface
wetness causes dramatic changes in granule growth rates (see below).
Growth
For two colliding primary granules to coalesce their kinetic energy must be
dissipated and the strength of the resulting bond must be able to resist the external
forces exerted by the agitation of the powder mass in the granulator. Granules
which are able to deform readily will absorb the collisional energy and create
increased surface area for bonding. As granules grow so do the internal forces
trying to pull the granule apart. It is possible to predict a critical maximum size of
granule beyond which coalescence is not possible during collision (see below).
Ennis and Litster (1997) suggest a rationale for interpreting observed granule
growth regimes in terms of collision physics. Consider collision between two
rigid granules (assume low deformability) of density rg, each coated with a layer
of thickness h of liquid of viscosity m, having a diameter x and approach velocity
Vapp . The parameter which determines whether coalescence will occur is a Stokes
number Stk:
rg Vapp x
Stk ¼ ð13:9Þ
16m
This Stokes number is different from that used in cyclone scale-up in Chapter 9.
The cyclone scale-up Stokes number Stk50 incorporates the dimensionless ratio
of particle size to cyclone diameter, i.e.:
rvx250 x50 rvx50

Stk50 ¼ ¼
18mD D 18m
where v is the characteristic gas velocity.
The Stokes number is a measure of the ratio of collisional kinetic energy to

energy dissipated through viscous dissipation. For coalescence to occur the
Stokes number must be less than a
criticalvalue
Stk*, given by:
1 h
Stk ¼ 1 þ ln ð13:10Þ
e ha
GRANULATION 347
where e is the coefficient of restitution for the collision and ha is a measure of

surface roughness of the granule.
Based on this criterion, three regimes of granule growth are identified for
batch systems with relatively low agitation intensity. These are the non-inertial,
inertial and coating regimes. Within the granulator at any time there will be a
distribution of granule sizes and velocities which gives rise to a distribution of
Stokes numbers for collisions. In the non-inertial regime Stokes number is less
than Stk* for all granules and primary particles and practically all collisions
result in coalescence. In this regime therefore the growth rate is largely
independent of liquid viscosity, granule or primary particle size and kinetic
energy of collision. The rate of wetting of the particles controls the rate of growth
in this regime.
As granules grow some collisions will occur for which the Stokes number
exceeds the critical value. We now enter the inertial regime in which the rate of
growth is dependent on liquid viscosity, granule size and collision energy. The
proportion of collisions for which the Stokes number exceeds the critical value
increases throughout this regime and the proportion of successful collisions
decreases. Once the average Stokes number for the powder mass in the
granulator is comparable with the critical value, granule growth is balanced
by breakage and growth continues by coating of primary particles onto
existing granules, since these are the only possible successful collisions
according to our criterion. This simple analysis breaks down when granule
deformation cannot be ignored, as in high agitation intensity systems (Ennis
and Litster, 1997).
The two types of growth behaviour that occur depending on granule deforma-
tion are shown in Figure 13.5 (Iveson et al., 2001). Steady growth occurs when the
granule size increase is roughly proportional to granulation time i.e. a plot of
granule size versus time is linear. Induction growth occurs when there is a long
period during which no increase in size occurs. The granules form and consolidate,
but do not grow further until the granule porosity is reduced enough to squeeze
liquid to the surface. This excess free liquid on the granules causes sudden
coalescence of many granules and a rapid increase in granule size (Figure 13.5).
Deformation during granule collisions can be characterized by a Stokes
deformation number, Stdef relating the kinetic energy of collision to the energy
dissipated during granule deformation (Tardos et al., 1997):
rg Uc2
Stdef ¼ ð13:11Þ
2Yd
where Uc is the representative collision velocity in the granulator and rg is the

average granule density and Yd is the dynamic yield stress of the granule, respec-
tively. Both Yd and rg are strong functions of granule porosity and the granulation
formulation properties, and are often evaluated at the maximum granule density,
when the granules are strongest. This occurs when the granule porosity reaches a
minimum value emin after which the granule density remains constant.
All types of granule growth can be described using the saturation and
deformation Stdef and the granule growth regime map (Hapgood et al., 2007)
Steady Growth Behaviour Induction Behaviour
Increasing
Liquid Content
Granule Granule
Size Size
Increasing
Liquid Content
Granulation Time Granulation Time
High Deformation System Low Deformation System

surface wet
rapid
slow coalescence
coalescence
consolidation growth
growth
Figure 13.5 Schematic of the two main different types of granule growth and the way
that they depend on the deformability of the granules. Reprinted from Handbook of Powder
Technology, Vol. 11, eds Salman et al., ’Granule rate processes’, Hapgood et al., p. 933,
Copyright (2007) Elsevier
shown in Figure 13.6. At very low liquid contents, the product is similar to a dry
powder. At slightly higher granule saturation, granule nuclei will form, but there
is insufficient moisture for these nuclei to grow any further.
For systems with high liquid content, the behaviour depends on the granule
strength and Stdef. A weak system will form a slurry, an intermediate strength
Figure 13.6 Granule growth regime map. Reprinted from Handbook of Powder Technology,
Vol. 11, eds Salman et al., ’Granule rate processes’, Hapgood et al., p. 933, Copyright (2007)
Elsevier
GRANULATION 349
system will display steady growth, and a strong system (low Stdef) will exhibit
induction time behaviour. At extremely high liquid saturations, rapid growth
occurs where the granules grow in size extremely quickly and any induction time
is reduced to zero. The granule growth regime map has been successfully
validated for several formulations in mixers, fluid beds and tumbling granulators
(Iveson et al., 2001).
Granule breakage
Granule breakage also takes place during the granulation process. Breakage (also
called fragmentation) is the fracture of a granule to form two or more pieces.
Attrition (also called erosion) is the reduction in size of a granule by loss of
primary particles from its surface. Empirical and theoretical approaches exist for
modelling the different breakage mechanisms (Ennis and Litster, 1997). In
practice, breakage may be controlled by altering the granule properties (e.g.
increase fracture toughness and increase resistance to attrition) and by making
changes to the process (e.g. reduce agitation intensity).
13.3.3 Simulation of the Granulation Process
As in the processes of comminution and crystallization, the simulation of

granulation hinges on the population balance. The population balance tracks
the size distribution (by number, volume or mass) with time as the process
progresses. It is a statement of the material balance for the process at a given
instant. In the case of granulation the instantaneous population balance equation
is often written in terms of the number distribution of the volume of granules, n
(v, t) (rather than granule diameter since volume is assumed to be conserved in
any coalescence). n(v, t) is the number frequency distribution of granule volume
at time t. Its units are number of granules per unit volume size increment, v, per
unit volume of granulator, V. In words it is written as:
0 1 0 1
0 1 0 1 0 1
B rate of C B rate at C
B increase C B rate of C B rate of C B rate at which C B which C
B C B in flow C B C B granules C B C
B C B C B outflow C B C B C
B of number C B of granules C B of granules C B enter size C B granules C
B C B C B C B C B C
B of granules C ¼ B CB CþB CB leave size C
B C B in size C B in size C B range C B C
B in size C B C B C B C B range C
B C B interval C B interval C B v to v þ dv C B C
B interval C @ A @ A @ A B v to v þ dv C
@ A v to v þ dv v to v þ dv by growth @ A
v to v þ dv ð2Þ ð3Þ ð4Þ
by breakage
ð1Þ ð5Þ
ð13:12Þ
Term (4) may be expanded to account for the different growth mechanisms and
term (5) may be expanded to include the different mechanisms by which
breakage occurs.
For a constant volume granulator the terms in the population balance equation
become:
Term (1)
qnðv; tÞ
ð13:13Þ
qt
Term (2)term (3)

Qin Qout
nin ðvÞ nout ðvÞ ð13:14Þ
V V
Term (4)
0 1
net rate of
@ growth A þ rate growth þ
rate of growth
by nucleation by coalescence
by coating
Growth by coating causes granules to grow into and out of the size range v to
v þ dv.
qGðvÞnðv; tÞ
Hence; the net rate of growth by coating ¼ ð13:15Þ
qv
The rate of growth by nucleation ¼ Bnuc ðvÞ ð13:16Þ
G(v) is the volumetric growth rate constant for coating, Bnuc ðvÞ is the rate constant
for nucleation. It is often acceptable to assume that G(v) is proportional to the
available granule surface area; this is equivalent to assuming a constant linear
growth rate, G(x). In reference to granulation processes, the use of the term
’nucleation‘ is sometimes confusing. Sastry and Loftus (1989) suggest that in a
granulation process there is in general a continuous phase and a particulate phase.
The continuous phase may, for example, be a solution, slurry or very small particles;
the particulate phase is made up of original particles and granules. Nuclei are
formed from the continuous phase and then become part of the particulate phase.
What constitutes the continuous phase depends on the nature of the granulation,
and the cut-off between continuous and particulate phases may be arbitrary. It will
be appreciated therefore that the form of the granulation rate constant may vary
considerably depending on the definitions of continuous and particulate phases.
The rate of growth of granules by coalescence may be written as (Randolph
and Larson, 1971):
" Z # "Z #
v 1
1
2 b ðu; v u; tÞnðu; tÞnðv u; tÞ du þ b ðu; v; tÞ n ðu; tÞ n ðv; tÞ du
0 ðiÞ 0 ðiiÞ
ð13:17aÞ
Term (i) is the rate of formation of granules of size v by coalescence of smaller

granules. Term (ii) is the rate at which granules of size v are lost by coalescence to
GRANULATION 351
form larger granules. b is called the coalescence kernel. The rate of coalescence of
two granules of volume u and (v u) to form a new granule of volume v is
assumed to be directly proportional to the product of the number densities of the
starting granules:
2 3
number density of
collision rate of granules number density of
/ 4 granules of volume 5
of volume u andðv u granules of volumeu
vu
The number densities are time dependent in general and so n(u, t), the number
density of granules of volume u at time t and n(v u, t) is the number density of
granules of volume (v u) at time t. The constant in this proportionality is b, the
coalescence kernel or coalescence rate constant, which is in general assumed to
be dependent on the volumes of the colliding granules. Hence, b(u, v u, t) is the
coalescence rate constant for collision between granules of volume u and (u v)
at time t.
The above assumes a pseudo-second order process of coalescence in which all
granules have an equal opportunity to collide with all other particles. In real
granulation systems this assumption does not hold and collision opportunities
are limited to local granules. Sastry and Fuerstenau (1970) suggested that for a
batch granulation system, which was effectively restricted in space, the appro-
priate form for terms (i) and (ii) was:
" Z # " Z #
v 1
1 1
bðu; v u; tÞnðu; tÞnðv u; tÞdu þ bðu; v; tÞ n ðu; tÞ n ðv; tÞdu
2NðtÞ 0 ðiÞ NðtÞ 0 ðiiÞ
ð13:17bÞ
where N(t) is the total number of granules in the system at time t.

The integrals in Equation (13.17b) account for all the possible collisions and the
1
2 in term (i) of this equation ensures that collisions are only counted once.
In practice, many coalescence kernels are determined empirically and based on
laboratory or plant data specific to the granulation process and the product. More
recent, physically derived kernels (Litster and Ennis, 2004) have been tested in
laboratories and over time are expected to slowly replace empirically derived
kernels in industrial models.
According to Sastry (1975) the coalescence kernel is best expressed in two parts:
bðu; vÞ ¼ b0 b1 ðu; vÞ ð13:18Þ
b0 is the coalescence rate constant which determines the rate at which successful
collisions occur and hence governs average granule size. It depends on solid and
liquid properties and agitation intensity. b1 ðu; vÞ governs the functional depen-
dency of the kernel on the sizes of the coalescing granules, u and v. b1 ðu; vÞ
determines the shape of the size distribution of granules. Various forms of b
have been published; Ennis and Litster (1997) suggest the form shown in
Equation (13.19), which is consistent with the granulation regime analysis

described above:

b0 ; w < w ðuvÞa
bðu; vÞ ¼ where w ¼ ð13:19Þ
0; w > w ðu þ vÞb
w* is the critical average granule volume in a collision and corresponds to the

critical Stokes number value Stk*. From the definition the Stokes number given in
Equation (13.10), the critical diameter x* would be:
16m Stk
x ¼ ð13:20Þ
rgr Vapp
and so, assuming spherical granules,

p 16m Stk 3
w ¼ ð13:21Þ
6 r Vapp
The exponents a and b in Equation (13.19) are dependent on granule deform-

ability and on the granule volumes u and v. In the case of small feed particles in
the non-inertial regime, b reduces to the size-independent rate constant b0 and
the coalescence rate is independent of granule size. Under these conditions the
mean granule size increases exponentially with time. Coalescence stops (b ¼ 0)
when the critical Stokes number is reached.
Using this approach, Adetayo and Ennis (1997) were able to demonstrate the
three regimes of granulation (nucleation, transition and coating) traditionally
observed in drum granulation and to model a variety of apparently contradictory
observations.
Term (5)

rate of breakage rate of breakage
þ
by attrition by fragmentation
ð13:22Þ
qAðvÞnðv; tÞ
rate of breakage by attrition ¼
qv
A(v) is the rate constant for attrition. The rate of attrition depends on the material
to be granulated, the binder, the type of equipment used for granulation and the
intensity of agitation. The rate of breakage may also be accounted for by the use
of selection and breakage function as used in the simulation of population
balances in comminution (see Chapter 12).
13.3.4 Granulation Equipment
Three categories of granulator are in common use: tumbling, mixer and fluidized
granulators. Typical product properties, scale and applications of each of these
granulators are summarized in Table 13.1 (after Ennis and Litster, 1997).
GRANULATION 353
Table 13.1 Types of granulator, their features and applications (after Ennis and Litster,
1997)
Product
granule Granule Scale/ Typical
Method size(mm) density throughput Comments applications
Tumbling 0.5–20 Moderate 0.5–800 t/h Very Fertilizers, iron
(disc, drum) spherical ore, agricultural
granules chemicals
Mixer 0.1–2 Low <50 t/h or Handles Chemicals, deter
(continuous <200 kg/ cohesive gents, pharmaceuticals,
and batch high batch materials ceramics
shear) well
Fluidized 0.1–2 High <500 kg/batch Good for Continuous
(bubbling coating, easy (fertilizers,
beds, spouted to scale up detergents) batch
beds) (pharmaceuticals,
agricultural
chemicals)
Tumbling granulators
In tumbling granulators a tumbling motion is imparted to the particles in an

inclined cylinder (drum granulator) or pan (disc granulator, Figure 13.7). Tumbling
granulators operate in continuous mode and are able to deal with large through-
puts (see Table 13.1). Solids and liquid feeds are delivered continuously to the
granulator. In the case of the disc granulator the tumbling action gives rise to a
Solids liquid
feed
Axis of
rotation
Disc
Product
granules
Figure 13.7 Schematic of disc granulator

Figure 13.8 Schematic of a horizontal axis (a) and vertical axis (b) mixer granulator.
Reprinted from Perry Chemical Engineers‘ Handbook, 7th Edition, ’Section 20: size enlarge-
ment‘, Ennis and Litster, pp. 20–77. Copyright (1977) with permission of The McGraw-Hill
Companies
natural classification of the contents according to size. Advantage is taken of this

effect and the result is a product with a narrow size distribution.
Mixer Granulators
In mixer granulators the motion of the particles is brought about by some form of
agitator rotating at low or high speed on a vertical or horizontal axis. Rotation
speeds vary from 50 revolutions per minute (rpm) in the case of the horizontal
pug mixers used for fertilizer granulation to over 3000 pm in the case of the
vertical Schugi high shear continuous granulator used for detergents and
agricultural chemicals. For vertical axis mixers used by the pharmaceutical
industry (Figure 13.8), impeller speeds range from 500 to 1500 rpm for mixers
less than 30 cm in diameter, and decreasing to 50–200 rpm for mixers larger than
1 m in diameter. In general, the agitator speed decreases as mixer scale increases,
in order to maintain either (a) constant maximum velocity at the blade tip or (b)
constant mixing patterns and Froude number.
Fluidized bed granulators
In fluidized bed granulators the particles are set in motion by fluidizing air. The
fluidized bed may be either a bubbling or spouted bed (see Chapter 7) and may
operate in batch or continuous mode. Liquid binder and wetting agents are
sprayed in atomized form above or within the bed. The advantages which this
granulator has over others include good heat and mass transfer, mechanical
simplicity, ability to combine the drying stage with the granulation stage and
ability to produce small granules from powder feeds. However, running costs
and attrition rates can be high compared with other devices. A typical spouted
bed granulator circuit is shown in Figure 13.9.
WORKED EXAMPLES 355
Cyclone
seperator
Spouted
bed Temperature
control Fines for
recycle
Binder
solution
Atomising
air
Pump
Heater Air supply
Figure 13.9 Schematic of a spouted fluidized bed granulator circuit (Liu and Litster,
1993)
For further details of industrial equipment for granulation and other means of
size enlargement the reader is referred to Capes (1980), Ennis and Litster (1997)
or Litster and Ennis (2004).
WORKED EXAMPLE 13.1
A pharmaceutical product is being scaled up from a pilot scale mixer granulator with a
batch size of 15 kg to a full scale mixer granulator with a 75 kg batch size. In the pilot
scale mixer, 3 kg of water is added to the mixer over 6 min. through a nozzle producing
200 mm diameter spray drops across a 0.2 m wide spray. During scale-up, the ratio of
liquid to dry powder is kept constant but the solution flowrate can be scaled to maintain
constant spray time or constant spray rate through the nozzle. If the flow rate is
increased to maintain constant spray time, the new nozzle produces 400 mm drops over a
0.3 m wide spray zone. Powder velocity in the spray zone is currently 0.7 m/s at pilot
scale. At full scale, the powder velocities are 0.55 m/s and 1 m/s at the ’low‘ and ’high‘
impeller speeds, respectively. Calculate the change in dimensionless spray flux for the
following cases:
(a) base case at pilot scale;
(b) scale-up to full scale using spray time of 6 min and low impeller speed;
(c) full scale using constant spray rate and low impeller speed;
(d) full scale using constant spray rate and high impeller speed.
Solution
Using Equation (13.5) and ensuring consistent units, the calculations are summarized in
Table 13W1.1.
Table 13W1.1
(a) Pilot (b) Constants (c) Constant (d) Constant spray
Scale-up scale spray time, low spray rate, rate, high
approach base case impeller low impeller impeller
Batch size (kg) 15 75 75 75
Spray amount (kg) 3 15 15 15
Spray time (min) 6 6 30 30
Flow rate (kg/min) 0.5 2.5 0.5 0.5
Drop size (mm) 200 400 200 200
Spray width (m) 0.2 0.3 0.2 0.2
Impeller speed (rpm) 216 108 108 220
Powder velocity (m/s) 0.7 0.55 0.55 1
Spray flux a 0.45 0.95 0.57 0.31
Worked Example 13.2
When the spray flux is 0.1, 0.2, 0.5 and 1.0:
(a) Calculate the fraction of the spray zone wetted.
(b) Calculate the number of nucleus formed from only one drop (f1).
(c) If the drop controlled regime was defined as the spray flux at which 50% or
more of the nuclei are formed from a single drop, what would be the
critical value of spray flux and what fraction of the spray zone would be
wetted?
Solution
Using Equation (13.6) for (a) and (c), solutions are shown in Table 13W2.1. To calculate
the fraction of nuclei formed from a single drop for (b), use Equation (13.7) with n¼1,
which simplifies to f1 ¼ expð4a Þ.
EXERCISES 357
TEST YOURSELF
13.1 Redraw Figure 13.1 showing how saturation increases as the porosity of the granule
decreases.
13.2 How do the rate of wetting and drop penetration time change with (a) increase in
viscosity, (b) decrease in surface tension, (c) increase in contact angle?
13.3 If the flow rate of solution to be added to the granulator doubles, how much wider
does the spray zone need to be to maintain constant spray flux? If the spray cannot
be adjusted, what does the bed velocity need to be to maintain constant spray flux?
13.4 At a spray flux of 0.1, calculate the number of nuclei formed from on drop, two
drops and three drops, etc. What fraction of the powder surface will be wetted by
the spray?
13.5 Explain the non-inertial, inertial, and coating regimes of granule granule growth.
What happens to the maximum granule size as (a) the approach velocity increases,
(b) the viscosity increases?
13.6 Explain the difference between the steady growth and the induction growth regimes
on the granule growth regime map.
13.7 Explain how induction growth is linked to granule porosity and staturation.
13.8 Explain the five terms in the granulation population balance.
EXERCISES
13.1 In the pharmaceutical industry, any batch that deviates from the set parameters is
designated as an ’atypical‘ batch and must be investigated before the product can be
released. You are a pharmaceutical process engineer, responsible for granulating a
pharmaceutical product in a 600 litre mixer containing 150 kg of dry powders. It was
noticed while manufacturing a new batch that the liquid delivery stage ended earlier than
usual and the batch contained larger granules than normal. During normal production, the
impeller speed is set to 90 rpm and water is added at a flowrate of 2 litre/m n through a
nozzle producing an average drop size of 400 mm. Due to an incorrect setting, the actual
flow rate used in the atypical batch was 3.5 litre/min and the actual drop size was
Table 13W2.1
a fwet(%) f1(%)
0.1 10 67
0.17 16 51
0.2 18 45
0.5 39 14
1 63 2
estimated at 250 mm. The spray width and powder surface velocity were unaffected and
remained constant at 40 cm and 60 cm/s, respectively. Calculate the dimensionless spray
flux for the normal case and the atypical batch, and explain why this would have created
larger granules.
(Answer: normal 0.52; atypical, 1.46.)
13.2 Calculate the fraction or percentage of nuclei formed from one drop, two drops and
three drops, etc. at spray flux values of (a) 0.05, (b) 0.3, (c) 0.8. What fraction of the powder
surface will be wetted by the spray?
[Answer: (a) 0.82, 0.16, 0.02, 0.0, 0.0; (b) 0.30, 0.36, 0.22, 0.09, 0.03; (c) 0.04, 0.13, 0.21, 0.22,
0.18.]
14
Health Effects of Fine
Powders
14.1 INTRODUCTION
When we think of the health effects of fine powders we might think first of the
negative effects related to inhalation of particles which have acute or chronic
(asbestos fibres, coal dust) effects on the lungs and the body. However, with the
invention of the metred dose inhaler in 1955, the widespread use of fine particle
drugs delivered directly to the lungs for the treatment of asthma began.
Pulmonary delivery, as this method is called, is now a widespread method of
drug delivery. In this chapter, therefore, we will look at both the negative and
positive health effects of fine powders, beginning with a description of the
respiratory system and an analysis of the interaction of the system with fine
particles.
14.2 THE HUMAN RESPIRATORY SYSTEM
14.2.1 Operation
The requirement for the human body to exchange oxygen and carbon dioxide
with the environment is fulfilled by the respiratory system. Air is delivered to the
lungs via the nose and mouth, the pharynx and larynx and the trachea. Beyond
the trachea, the single airway branches to produce the two main bronchi which
deliver air to each of two lungs. Within each lung the bronchi branch repeatedly
to produce many smaller airways called bronchioles, giving an inverted tree-like
structure (Figure 14.1). The upper bronchioles and bronchi are lined with
specialized cells some of which secrete mucus whilst others have hairs or cilia
which beat causing an upward flow of mucus along the walls. The bronchioles

360 HEALTH EFFECTS OF FINE POWDERS
Figure 14.1 Human tracheobronchial tree. Reprinted from Particulate Interactions in Dry
Powder Formulations of Inhalation, Xian Ming Zeng, Gary Martin and Christopher Marriott,
Copyright 2001, Taylor & Francis with permission
lead to alveolar ducts (or alveoli) which terminate in alveolar sacs. In the adult
male there are about 300 million alveoli, each approximately 0.2 mm in diameter.
The walls of the alveoli have a rich supply of blood vessels. Oxygen from the air
diffuses across a thin membrane around the alveolar sacs into the blood and
carbon dioxide from the blood diffuses in the reverse direction.
Air is forced in and out of the lungs by the movement of the diaphragm muscle
beneath the thoracic cage or chest cavity. The lungs are sealed within the chest
cavity, so that as the diaphragm muscle moves down, the pressure within the
cavity falls below atmospheric, causing air to be drawn into the lungs. The lungs
expand, filling the chest cavity. As the diaphragm muscle moves up, the lungs
are squeezed and the air within them is expelled to the environment.
THE HUMAN RESPIRATORY SYSTEM 361
Table 14.1 Characteristics of the respiratory tract, based on steady flow of 60 litre/min.
Reprinted from Particulate Interactions in Dry Powder Formulations of Inhalation, Xian Ming
Zeng, Gary Martin and Christopher Marriott, Copyright 2001, Taylor & Frances with
permission
Diameter Length Typical air Typical
Part Number (mm) (mm) velocity (m/s) residence time (s)
Nasal airways 5–9 9
Mouth 1 20 70 3.2 0.022
Pharynx 1 30 30 1.4 0.021
Trachea 1 18 120 4.4 0.027
Two main bronchi 2 13 37 3.7 0.01
Lobar bronchi 5 8 28 4.0 0.007
Segmental bronchi 18 5 60 2.9 0.021
Bronchioles 504 2 20 0.6 0.032
Secondary bronchioles 3024 1 15 0.4 0.036
Terminal bronchioles 12 100 0.7 5 0.2 0.023
Alveolar ducts 8:5 105 0.8 1 0.0023 0.44
Alveolar sacs 2:1 107 0.3 0.5 0.0007 0.75
Alveoli 5:3 108 0.15 0.15 0.00004 4
14.2.2 Dimensions and Flows
A systematic description commonly used is that of Weibel (1963). In this

treatment the respiratory system is considered as a sequence of regular branches
or dichotomies. The tree starts with the trachea, as ‘generation’ 0, leading to the
two main bronchi, as ‘generation’ 1. Within the lungs the branching continues
until generation 23 representing the alveolar sacs. According to Weibel’s model,
at generation n there are 2n tubes. So, for example, at generation 16 (the terminal
bronchioles) there are 65 536 tubes of diameter 0.6 mm.
Table 14.1 is based more on direct measurement and gives the typical dimen-
sions of the component of the airways together with typical air velocities and
residence times.
The nasal airways are quite tortuous and change diameters several times in
their path. The lower section is lined with hairs. The narrowest section is
the nasal valve, which has a cross-sectional area of 20–60 mm2 (equivalent to
5 – 9 mm diameter) and typically accounts for 50% of the resistance to flow in the
nasal airways. Typical air flow rates in the adult nasal airways range from 180
ml/s during normal breathing to 1000 ml/s during a strong sniff. This gives
velocities in the nasal airways as high as 9 m/s during normal breathing and
50 m/s during a strong sniff.
The mouth leading to the pharynx and larynx presents a far smoother path for
the flow of air and offers lower resistance. However, whilst moving through the
pharynx and larynx the airstream is subject to some sharp changes in direction. A
typical air velocity in the mouth during normal breathing is 3 m/s.
We see from Table 14.1 that due mainly to the continuous branching, the air
velocity in the airways decreases at the start of the bronchioles. The result is that
the residence time in the different sections of the airways is of the same order
until the alveolar region is reached, where the residence time increases signifi-
cantly.
14.3 INTERACTION OF FINE POWDERS WITH THE

RESPIRATORY SYSTEM
Airborne particles entering the respiratory tract will be deposited on the surface
of any part of the airways with which they come into contact. Because the
surfaces of the airways are always moist, there is a negligible chance of a
particle becoming re-entrained in the air after once having made contact with a
surface. Particles which do not make contact with the airway surfaces will be
exhaled. The deposition of particles in the airways is a complicated process. Zeng
et al. (2001) identify five possible mechanisms contributing to the deposition of
particles carried into the respiratory tract. These are sedimentation, inertial
impaction, diffusion, interception and electrostatic precipitation. After introdu-
cing each mechanism, their relative importance in each part of the respiratory
tract will be discussed.
14.3.1 Sedimentation
Particles sediment in air under the influence of gravity. As discussed in Chapter 2,

a particle in a static fluid of infinite extent will accelerate from rest under the
influence of the gravity and buoyancy forces (which are constant) and the fluid
drag force, which increases with relative velocity between the particle and the
fluid. When the upward-acting drag and buoyancy forces balance the gravity force,
a constant, terminal velocity is reached. For particles of the size of relevance here
(less than 40 mm), falling in air, the drag force will be given by Stokes’ law
[Equation (2.3)] and the terminal velocity will be given by [Equation (2.13)]:
" #
x2 ðrp rf Þg
UT ¼
18m
(For particles of diameter less that the mean free path of air, 0.0665 mm, a
correction factor must be applied. Particles as small as this will not be considered
here.) Particles in the size range under consideration accelerate rapidly to their
terminal velocity in air. For example, a 40 mm particle of density 1000 kg/m3
accelerates to 99% of its terminal velocity (47 mm/s) in 20 ms and travels a
distance less than 1 mm in doing so. So, for these particle in air, we can take the
sedimentation velocity as equivalent to the terminal velocity. The above analysis
is relevant to particles falling in stagnant air or air in laminar flow. If the air flow
becomes turbulent, as it may do in certain airways at higher breathing rates, the
characteristic velocity fluctuations increase the propensity of particles to
deposit.
INTERACTION OF FINE POWDERS WITH THE RESPIRATORY SYSTEM 363
14.3.2 Inertial Impaction
Inhaled air follows a tortuous path as it makes its way through the airways.
Whether the airborne particles follow the path taken by the air at each turn
depends on the balance between the force required to cause the particle to change
direction and the fluid drag available to provide that force. If the drag force is
sufficient to cause the required change in direction, the particle will follow the
gas and will not be deposited.
Consider a particle of diameter x travelling at a velocity Up in air of viscosity m
within an airway of diameter D. Let us consider the extreme case where this
particle is required to make a 90 change in direction. The necessary force FR is
that required to cause the particle to stop and then be re-accelerated to velocity
Up. The distance within which the particle must stop is of the order of the airway
of diameter D and so:
work done ¼ force distance ¼ particle kinetic energy

1
FR D ¼ 2 mUp 2
ð14:1Þ
2
(The 2 on the right-hand side is there because we need to re-accelerate the

particle.)
p 1
Therefore; required force; FR ¼ x3 rp Up2 ð14:2Þ
6 D
The force available is the fluid drag. Stokes’ law [Equation (2.3)] will apply to the
particles under consideration and so:
Available drag force; FD ¼ 3pmxUp
The rationale for using Up as the relevant relative velocity is that this represents
the maximum relative velocity that would be experienced by the particle as it
attempts to continue in a straight line.
The ratio of the force required FR to the force available FD is then:
x2 rp Up
ð14:3Þ
18mD
The greater the value of this ratio is above unity, the greater will be the tendency
for particles to impact with the airway walls and so deposit. The further the value
is below unity, the greater will be the tendency for the particles to follow the gas.
This dimensionless ratio is known as the Stokes number:
x2 rp Up
Stk ¼ ð14:4Þ
18mD
(We also met the Stokes number in Chapter 9, where it was one of the
dimensionless numbers used in the scale up of gas cyclones for the separation
of particles from gases. There are obvious similarities between the collection of
particles in a gas cyclone and ‘collection’ of particles in the airways of the
respiratory system. The Stokes number we met in Chapter 13, describing collision
between granules, is not readily comparable with the one used here.)
14.3.3 Diffusion
The motion of smaller airborne particles is influenced by the bombardment of air

molecules. This is known as Brownian motion and results in a random motion of
the particles. Since the motion is random, the particle displacement is expressed
as a root mean square:
Root mean square displacement in time t; L ¼ 6at ð14:5Þ
where a is the diffusion coefficient given by:
kT
a¼ ð14:6Þ
3pmx
for a particle of diameter x in a fluid of viscosity m at a temperature T: k is the

Boltzmann constant, which has the value 1:3805 1023 J=K.
14.3.4 Interception
Interception is deposition of the particle by reason of its size and shape compared
with the size of the airway.
14.3.5 Electrostatic Precipitation
Particles and droplets may become electrostatically charged, particularly during

the dispersion stage, by interaction with each other or with nearby surfaces. It has
been speculated that charged particle could induce opposite charges on the walls
of some airways, resulting in the particles being attracted to the walls and
deposited.
14.3.6 Relative Importance of These Mechanisms Within the

Respiratory Tract
Under the humid conditions found with the respiratory tract, it is most likely that
any charges on particles will be quickly dissipated and so electrostatic precipita-
tion is unlikely to play a significant role in particle deposition anywhere in the
airways.
INTERACTION OF FINE POWDERS WITH THE RESPIRATORY SYSTEM 365
Table 14.2 A comparison of displacements due to sedimentation and diffusion for

particles of density 1000 kg/m3 in air at 30 C, with a density 1.21 kg/m3 and viscosity
1:81 105 Pa s
Particle Displacement Displacement

Particle terminal in 1 s due to in 1 s due to
diameter (mm) velocity (m/s) sedimentation (mm) Brownian motion (mm)
50 7:5 102 75000 1.7
30 2:7 102 27000 2.2
20 1:2 102 12000 2.7
10 3:0 103 3000 3.8
5 7:5 104 750 5.4
2 1:2 104 120 8.5
1 3:0 105 30 12.0
0.5 7:5 106 7.5 17.0
0.3 2:7 106 2.7 21.9
0.2 1:2 106 1.2 26.8
0.1 3:0 107 0.3 37.9
Deposition by interception is also not significant, since the particles of interest

are far smaller than the airways.
We will now consider the relative importance of the other three mechanisms,
sedimentation, inertial impaction and diffusion, in the various parts of the respira-
tory tract. First, it is interesting to compare, for different particle sizes, the
displacements due to sedimentation and diffusion under the conditions typically
found within the respiratory tract. Table 14.2 makes this comparison for particles
of density 1000 kg/m3 in air at a temperature of 30 C.
From Table 14.2 we can see that diffusion does not become significant
compared with sedimentation until particle size falls below 1 mm. In the case
where Brownian motion was to act downwards with the sedimentation, the
minimum displacement would occur for particles of around 0.5 mm in diameter.
This would suggest that particles around this diameter would have the least
chance of being deposited by these mechanisms. We see that particles smaller
than about 10 mm would require significant residence times to travel far enough
to be deposited. For example, in Table 14.3, we look at the time required for
particles to be displaced a distance equivalent to the airway diameter, due to the
combined effect of sedimentation and diffusion. In practice, sedimentation
becomes a significant mechanism for deposition only in the smaller airways
and in the alveolar region, where air velocities are low, airway dimensions are
small and air residence times are relatively high.
Now we will consider the importance of inertial impaction as a mechanism for
causing deposition. In Table 14.4 we have calculated [using Equation (14.4)] the
Stokes numbers for particles of different sizes in the various areas of the
respiratory duct, based on the information provided in Table 14.1. This calcula-
tion assumes that the particle velocity is the same as the air velocity in the
relevant part of the respiratory tract.
Table 14.3 Time required for particles of different diameters to be displaced a distance
equivalent to the airway diameter, due to the combined effect of sedimentation and
diffusion
Required particle component

residence time (s)
Airway Diameter Typical air
component (mm) residence time (s) 5 mm 1 mm 0.5 mm
Two main bronchi 13 0.01 17.2 309 580
Bronchioles 2 0.032 2.6 48 90
Secondary bronchioles 1 0.036 1.3 24 45
Terminal bronchioles 0.7 0.023 1 17 30
Alveolar ducts 0.8 0.44 1 19 35
Alveolar sacs 0.3 0.75 0.4 7 13
Alveoli 0.15 4 0.2 3.5 6.6
Recalling that the further the value of the Stokes number is above unity, the
greater will be the tendency for particles to impact with the airway walls and so
deposit, we see that particles as small as 50 mm are likely to be deposited in the
mouth or nose, pharynx, larynx and trachea. These figures are for steady
breathing; higher rates will give higher Stokes numbers and so would cause
smaller particles to be deposited at a given part of the tract.
Whilst moving through the mouth or nose, pharynx and larynx, the airstream
is subject to some sharp changes in direction. This induces turbulence and
instabilities which increase the chances of particle deposition by inertial
impaction.
Table 14.4 Stokes number for a range of different size particles in each section of the
respiratory tract. Also typical Reynolds number for flow in each section of the respiratory
tract
Stokes number for particles of different sizes
Region 1 mm 5 mm 10 mm 20 mm 50 mm 100 mm Re flow

Nose 3:1 103 7:7 104 0.31 1.2 7.7 31 5415
Mouth 4:9 104 1:2 104 0.05 0.2 1.2 5 4254
Pharynx 1:5 104 3:7 105 0.01 0.1 0.4 1 2865
Trachea 7:6 104 1:9 104 0.08 0.3 1.9 8 5348
2 main bronchi 8:7 104 2:2 104 0.09 0.3 2.2 9 3216
Lobar bronchi 1:5 103 3:8 104 0.15 0.6 3.8 15 2139
Segmental bronchi 1:8 103 4:4 104 0.18 0.7 4.4 18 955
Bronchioles 9:6 104 2:4 104 0.10 0.4 2.4 10 84
Secondary bronchioles 1:3 103 3:2 104 0.13 0.5 3.2 13 28
Terminal bronchioles 9:5 104 2:4 104 0.10 0.4 2.4 10 10
Alveolar ducts 8:7 106 2:2 106 0.0009 0.003 0.022 0 0
Alveolar sacs 6:8 106 1:7 106 0.0007 0.003 0.017 0 0
Alveoli 7:7 107 1:9 107 0.0001 0.003 0.002 0 0
PULMONARY DELIVERY OF DRUGS 367
In summary, inertial impaction is responsible for the deposition of the

larger airborne particles and this occurs mainly in the upper airways. In
practice, therefore, we find that only those particles smaller than about 10 mm
will travel beyond the main bronchi. Such particles have a decreasing propen-
sity to be deposited by inertial impaction the further they travel into the lungs,
but are more likely to be deposited by the action of sedimentation and diffusion
as they reach the smaller airways and the alveolar region, where air velocities
are low, airway dimensions are small and air residence times are relatively
high.
14.4 PULMONARY DELIVERY OF DRUGS
Target areas: The delivery of drugs for treatment of lung diseases (asthma,
bronchitis, etc.) via aerosols direct to the lungs is attractive for number of reasons.
Compared with other methods of drug delivery (oral, injection) pulmonary
delivery gives a rapid, predictable onset of drug action with minimum dose
and minimum side effects. The adult human lung has a very large surface area
for drug absorption (typically 120 m2). The alveoli wall membrane is permeable
to many drug molecules and has rich blood supply. This makes so-called aerosol
delivery attractive for the delivery of drugs for treatment of other illnesses.
(Aerosols are suspensions of liquid drops or solid particles in air or other gas.) In
pulmonary delivery using aerosols, the prime targets for the aerosol particles are
the alveoli, where the conditions for absorption are best. In practice, particles
larger than about 2 mm rarely reach the alveoli and particles smaller than about
0.5 mm may reach the alveoli but are exhaled without deposition (Smith and
Bernstein, 1996; see also analysis above).
Surprisingly, the use of aerosols for medicinal use on humans dates back
thousands of years. These include volatile aromatic substances such as thymol,
menthol and eucalyptus and smoke generated from the burning of leaves.
Nebulizers – devices which generate a fine mist of aqueous drug solution –
have been used in western hospitals for over 100 years, although the modern
nebulizer bears little resemblance to the earlier devices. The modern nebulizer
(Figure 14.2) is used where patients cannot use other devices or when large doses
of drugs are required. Portable nebulizers have been developed, although these
devices still require a source of power for air compression.
In the 1950s the metered-dose inhaler (MDI) was invented. This was the
precursor to the modern MDI which has been used widely by asthma sufferers
for many years – despite its disadvantages (Zeng et al., 2001). In the MDI the
drug, which is dispersed or dissolved in a liquid propellant, is held in a small
pressurized container (Figure 14.3). Each activation of the device releases a
metered quantity of propellant carrying a predetermined dose of drug. The
liquid in the droplets rapidly vaporizes leaving solid particles. The high velocity
of discharge from the container means that many particles impact on the back of
the throat and are therefore ineffective. Another disadvantage is that the patient
must, usually in a stressed condition, coordinate the activation of the MDI with
inspiration.
Figure 14.2 Schematic of a nebulizer The compressed air expands as it leaves the nozzle.
This causes reduced pressure which induces the drug solution to flow up and out of the
nozzle where it atomized by contact with the air stream. Copyright (1996) from Lung
Biology in Health and Disease, Vol. 94, Dalby et al., Inhalation Aerosols, p. 452. Reproduced by
permission of Routledge/Taylor & Francis Group, LLC
The third common type of device for pulmonary drug delivery is the dry
powder inhaler (DPI). This device now has many forms, some of which appear
remarkably simple in their design (Figure 14.4). Particular effort has gone into the
formulation of the powder. In most cases the drug is of the order a few
micrometre in size and is adhered – usually by natural forces – to inert ‘carrier
Figure 14.3 Metered-dose inhaler. Copyright (1996) from Lung Biology in Health and
Disease, Vol. 94, Dalby et al., Inhalation Aerosols, p. 452. Reproduced by permission of
Routledge/Taylor & Francis Group, LLC
HARMFUL EFFECTS OF FINE POWDERS 369
Figure 14.4 Carrier particles in a dry powder inhaler. The powder may be initially
loosely compacted, but by the shearing action of the air stream and impingement on a
screen the agglomerates are dispersed and the drug particles dislodged from the carrier
particles. Copyright (1996) from Lung Biology in Health and Disease, Vol. 94, Dalby et al.,
Inhalation Aerosols, p. 452. Reproduced by permission of Routledge/Taylor & Francis
Group, LLC
particles’, which are much larger in size (100 mm or more). The carrier particles
are required for two reasons: because the required quantity of drug is so small
that it would be difficult to package; and because such a fine powder would be
very cohesive – therefore difficult to handle and unlikely to easily disperse in air.
The intention is that the carrier particles should be left in the device, in the back
of the mouth or the upper airways and that the drug particles should detach
during inspiration and travel to the lower airways before deposition.
14.5 HARMFUL EFFECTS OF FINE POWDERS
Particles which find their way into the lungs can also have a negative effect on
health. In the workplace and in our everyday lives, exposure to fine particle
aerosols should be avoided. History has shown that exposure to coal dust, silica
dust and asbestos dust, for example, can have disastrous effects on the health of
workers many years after exposure. Many other workplace dusts, less well
known, have been found to have negative health effects.
As discussed above, particles smaller than 10 mm present the greatest risk, since
they can penetrate deep into the lungs – offering the greatest chance of chemical
absorption into the blood as well as physical interaction with the lungs.
If a dust hazard is suspected in the workplace, the first step is to monitor the
working environment to determine the exposure of the worker. One of the better
methods of achieving this is for the worker to wear a portable sampling device,
which gives a measure of the type of particles and their size distribution in the air
immediately around the worker. Such devices usually sample at a typical
respiration rate and velocity and some devices are designed to capture directly
only the respirable particles (particles capable of reaching the alveoli) or the
inhalable particles (particles capable of being inhaled).
The second step in dealing with the potential dust hazard is for the results of
the monitoring process to be compared with the accepted workplace standards
for the particulate materials in question. If the concentration of respirable
particles is found to exceed the accepted limit for that material, then we proceed
to the third stage, namely control.
When dealing with any hazard, there is a hierarchy of control measures that
may be put in place. In the modern workplace, the aim is to produce a safe
environment rather that a safe person. To understand what is meant by this,
consider the hierarchy of control measures:
specification;
substitution;
containment;
ventilation;
reduced time of exposure;
protective equipment.
In designing a process, an engineer or scientist should aim for control measures

at the top of the hierarchy. Only as a last resort should the measures lower down
in the hierarchy be used.
Specification: Devising an alternative process which does not include this
hazard. In the case of dust hazard, this may mean using a completely different
wet process. For example, using wet milling rather than dry milling. Granula-
tion may be an option – with loose granules, the large surface area provided by
fine particles can still be made available, but without the associated dust
hazard.
Substitution: Replacing the hazardous material with a non-hazardous material,
for example; by using wood fibres instead of asbestos in the manufacture of
building products.
Containment: Designing the process using equipment which ensures that hazar-
dous materials are contained and do not, under normal operation, escape into the
environment.
An example is using pneumatic transport rather than conveyors belts or other
mechanical conveyors in transporting powders within the workplace. Also, use
fully enclosed conveyor belts.
Ventilation: Accepting that the hazardous material is present in the workplace
environment and creating airflows to draw the material away from workers or
reduce its concentration in the environment.
Reduced time of exposure: Accepting that the hazardous material is present in the
workplace environment and reducing the time spent by each worker in that
environment.
Protective equipment: Accepting that the worker must work in an environment
where the hazardous material is present and providing suitable protective
equipment for the worker to wear. Examples for controlling dust hazard (in
order of decreasing efficacy) are: air-line helmets – clean air is provided under
pressure via flexible tubing to a full headset worn my the worker; positive
EXERCISES 371
pressure sets – a pump and filter worn by the worker provides air to a headset
which may partially or fully enclose the worker’s head; airstream helmets – a
pump and filter fitted to a hard hat with a visor such that the filtered air stream is
blown across the worker’s face; ori-nasal respirators – a well-fitting rubber or
plastic mask covering the nose and mouth and fitted with efficient filters suitable
for the material in question; disposable facemasks – mask made of filter material
covering the nose and mouth and usually not well-fitting.
TEST YOURSELF
14.1 Make a diagrammatic sketch of the human lung, labelling the following regions:
alveoli sacs, bronchi, trachea, respiratory brochioles.
14.2 In the human respiratory systems what are the typical diameters and air velocities in
the trachea, terminal brochioles, main bronchi?
14.3 List the mechanisms by which inhaled particles may become deposited on the walls
of the airways in the respiratory systems. Which mechanism dominates for particles
smaller than around 10 mm in the upper airways, and why?
14.4 What is the Stokes number and what does it tell us about the likelihood of particles
being deposited on the walls on the respiratory system?
14.5 In which part of the respiratory system is sedimentation important as a mechanism

for depositing particles?
14.6 For pulmonary delivery of drugs, what size range of particles is desirable and
why?
14.7 Describe the construction and operation of three types of device for the delivery of
respirable drugs.
14.8 What is a carrier particle and why is it needed?
14.9 What steps should be taken to determine whether a dust in the workplace has the
potential to cause a health hazard through inhalation?
14.10 Explain what is meant by the hierarchy of control measures when applied to the
control of a dust hazard.
EXERCISES
14.1 Determine, by calculation, the likely fate of a 20 mm particle of density 2000 kg/m3
suspended in the air inhaled by a human at a rate giving rise to the following velocities in
parts of the respiratory system:

Part Number (mm) (mm) velocity (m/s) residence time (s)
Mouth 1 20 70 3.2 0.022
Pharynx 1 30 30 1.4 0.021
Trachea 1 18 120 4.4 0.027
Two main bronchi 2 13 37 3.7 0.01
14.2 Given the following information, in which region of the respiratory tract is a 3 mm
particle of density 1500 kg/m3 most likely to be deposited and by which mechanism?
Support your conclusion by calculation.

Part (mm) (mm) velocity (m/s) residence time (s)
Trachea 18 120 4.4 0.027
Bronchioles 2 20 0.6 0.032
Terminal bronchioles 0.7 5 0.2 0.023
Alveolar ducts 0.8 1 0.0023 0.44
Alveoli 0.15 0.15 0.00004 4
14.3 Compare the Stokes numbers for 2, 5, 10 and 40 mm particles of density 1200 kg/m3 in
air passing through the nose. What conclusions do you draw regarding the likelihood of
deposition of these particles in the nose?
Data:
Characteristic velocity in the nose: 9 m/s
Characteristic diameter of the airway in the nose: 6 mm
Viscosity of air: 1:81 105 Pa s.
Density of air: 1.21 kg/m3
14.4 Carrier particles are used in dry powder inhalers. What is a carrier particle? What is
the role of a carrier particle? Why are carrier particles needed in these inhalers?
14.5 With reference to the control of dusts as a health hazard, explain what is meant by the
hierarchy of controls.
14.6 The required dose of a particulate drug of particle size 3 mm and particle density
1000 kg/m3 is 10 mg. Estimate the number of particles in this dose and the volume
occupied by the dose, assuming a voidage of 0.6.
(Answer: 7 105 ; 0.25 mm3.)

15
Fire and Explosion Hazards
of Fine Powders
15.1 INTRODUCTION
Finely divided combustible solids, or dusts, dispersed in air can give rise to
explosions in much the same way as flammable gases. In the case of flammable
gases, fuel concentration, local heat transfer conditions, oxygen concentration
and initial temperature all affect ignition and resulting explosion characteristics.
In the case of dusts, however, more variables are involved (e.g. particle size
distribution, moisture content) and so the analysis and prediction of dust
explosion characteristics is more complex than for the flammable gases. Dust
explosions have been known to give rise to serious property damage and loss of
life. Most people are probably aware that dust explosions have occurred in grain
silos, flour mills and in the processing of coal. However, explosions of disper-
sions of fine particles of metals (e.g. aluminium), plastics, sugar and pharma-
ceutical products can be particularly potent. Process industries where fine
combustible powders are used and where particular attention must be directed
towards control of dust explosion hazard include: plastics, food processing, metal
processing, pharmaceuticals, agricultural, chemicals and coal. Process steps
where fine powders are heated have a strong association with dust explosion;
examples include dilute pneumatic conveying and spray drying, which involves
heat and a dilute suspension.
In this chapter, the basics of combustion are outlined followed by the funda-
mentals specific to dust explosions. The measurement and application of dust
explosion characteristics, such as ignition temperature, range of flammable
concentrations minimum ignition energy are covered. Finally the available
methods for control of dust explosion hazard are discussed.

374 FIRE AND EXPLOSION HAZARDS OF FINE POWDERS
15.2 COMBUSTION FUNDAMENTALS
15.2.1 Flames
A flame is a gas rendered luminous by emission of energy produced by

chemical reaction. In a stationary flame (for example a candle flame or gas
stove flame) unburned fuel and air flow into the flame front as combustion
products flow away from the flame front. A stationary flame may be from
either premixed fuel and air, as observed in a Bunsen burner with the air hole
open, or by diffusion of air into the combustion zone, as for a Bunsen burner
with the air hole closed.
When the flame front is not stationary it is called an explosion flame. In this
case the flame front passes through a homogeneous premixed fuel–air
mixture. The heat released and gases generated result in either an uncon-
trolled expansion effect or, if the expansion is restricted, a rapid build-up of
pressure.
15.2.2 Explosions and Detonations
Explosion flames travel through the fuel–air mixture at velocities ranging from a
few metres per second to several hundreds of metres per second and this type of
explosion is called a deflagration. Flame speeds are governed by many factors
including the heat of combustion of the fuel, the degree of turbulence in the
mixture and the amount of energy supplied to cause ignition. It is possible for
flames to reach supersonic velocities under some circumstances. Such explosions
are accompanied by pressure shock waves, are far more destructive and called
detonations. The increased velocities result from increased gas densities gener-
ated by pressure waves. It is not yet understood what conditions give rise to
detonations. However, in practice it is likely that all detonations begin as
deflagrations.
15.2.3 Ignition, Ignition Energy, Ignition Temperature – a Simple

Analysis
Ignition is the self-propagation of a combustion reaction through a fuel–air

mixture after the initial supply of energy. Ignition of a fuel–air mixture can be
analysed in a manner similar to that used for runaway reactions (thermal
explosions). Consider an element of fuel air mixture of volume V and surface
area A, in which the volumetric concentration of fuel is C. If the temperature of
the fuel–air mixture in the element is Ti and if the rate at which heat is lost from
the element to the surroundings (at temperature Ts ) is governed by a heat
transfer coefficient h, then the rate of heat loss to surroundings, Qs is:
Qs ¼ hAðTi Ts Þ ð15:1Þ
COMBUSTION FUNDAMENTALS 375
The variation of the combustion reaction rate with temperature will be governed by
the Arrhenius equation. For a reaction which is first order in fuel concentration:

dC E
Vrmfuel ¼ VCrmfuel Z exp ð15:2Þ
dt RT
where Z is the pre-exponential coefficient, E is the reaction activation energy, R is

the ideal gas constant and rmfuel is the molar density of the fuel.
The rate Qa at which heat is absorbed by the fuel–air mixture in the element is:
dT
Qa ¼ V ½Crmfuel Cpfuel þ ð1 CÞrmair Cpair ð15:3Þ
dt
where Cpfuel and Cpair are the molar specific heat capacities of the fuel and air and
rmfuel and rmair are the molar densities of the fuel and air, respectively.
If Qinput is the rate at which heat energy is fed into the element from outside,
then the heat balance for the element becomes:

E
Q input þ ðHÞVCrm fuel Z exp
ð1Þ ð2Þ RTR
dTR
¼V ½Crm fuel Cpfuel þ ð1 CÞrmair Cpair þ hAðT Ri Ts Þ ð15:4Þ
dt ð3Þ ð4Þ
It is instructive to analyse this heat balance graphically for the steady-state

condition [term (3) is zero]. We do this by plotting the rates of heat loss to the
surroundings and the rate of heat generation by the combustion reaction as a
function of temperature. The former of course results in a straight line of slope hA
and intercept of the temperature axis Ts . The rate of heat generation by reaction
within the element is given by term (2) and results in an exponential curve. A
typical plot is shown in Figure 15.1. Analysing this type of plot gives us insight
into the meaning of ignition, ignition energy, ignition temperature, etc.
Consider initially the case where Qinput is zero. Referring to the case shown in
Figure 15.1, we see that at an initial element temperature Ti the rate of heat loss from
the element is greater than the rate of heat generation and so the temperature of the
element will decrease until point A is reached. Any initial temperature between TB
and TA will result in the element cooling to TA . This is a stable condition.
If, however, the initial temperature is greater than TB , the rate of heat generation
within the element will be always greater than the rate of heat loss to the
surroundings and so the element temperature will rise, exponentially. Thus initial
temperatures beyond TB give rise to an unstable condition. TB is the ignition
temperature, Tig , for the fuel–air mixture in the element. Ignition energy is the energy
that we must supply from the outside in order to raise the mixture from its initial
temperature Ti to the ignition temperature Tig . Since the element is continuously
losing energy to the surroundings, the ignition energy will actually be a rate of
energy input, Qinput . This raises the heat generation curve by an amount Qinput ,
reducing the value of Tig (Figure 15.2). The conditions for heat transfer from the
element to the surroundings are obviously important in determining the ignition
Heat
Rate of heat generated by
generation / reaction
loss (W)
B Heat loss
TS TA Ti TB Tig
Temperature (K)
Figure 15.1 Variation of rates of heat generation and loss with temperature of element.
temperature and energy. There are cases where the heat loss curve will be always
lower than the heat generation curve (Figure 15.3). Under such circumstances the
mixture may self-ignite; this is referred to as auto-ignition or spontaneous ignition.
In many combustion systems there is an appreciable interval (from milliseconds
to several minutes) between arrival at the ignition temperature and the apparent
onset of ignition. This is known as the ignition delay. It is not well understood, but
based on the analysis above it is related to the time required for the reaction in the
element to go to completion once the ignition temperature has been reached.
If there is adequate oxygen for combustion and the fuel concentration in the
element is increased the rate of heat generation by combustion will also increase.
Rate of heat
generation /
loss (W)
Q input
Temperature (K)
Tig 2 Tig 1
Figure 15.2 Variation in rates of heat generation and loss with temperature of element;
the effect on ignition temperature of adding energy.
COMBUSTION FUNDAMENTALS 377
Heat
Rate of heat generated by
generation / reaction
loss (W)
Heat loss
Temperature (K)
Figure 15.3 Variation in rates of heat generation and loss with temperature of element;
rate of heat generation always greater that rate of heat loss.
Whether the ignition temperature and energy will be affected depends on the relative
physical properties (specific heat capacity and conductivity) of the fuel and air.
15.2.4 Flammability Limits
From the above analysis it can be seen that below a certain fuel concentration
ignition will not occur, since the rate of heat generation within the element is
insufficient to match the rate of heat loss to the surroundings (Tig is never reached).
This concentration is known as the lower flammability limit CfL of the fuel–air
mixture. It is generally measured under standard conditions in order to give
reproducible heat transfer conditions. At CfL the oxygen is in excess. As the fuel
concentration is increased beyond CfL the amount of fuel reacting per unit volume
of mixture and the quantity of heat released per unit volume will increase until the
stoichiometric ratio for the reaction is reached. For fuel concentration increase
beyond the stoichiometric ratio, the oxygen is limiting and so the amount of fuel
reacting per unit volume of mixture and the quantity of heat released per unit
volume decrease with fuel concentration. A point is reached when the heat release
per unit volume of mixture is too low to sustain a flame. This is the upper
flammability limit, CfU. This is the concentration of fuel in the fuel–air mixture
above which a flame cannot be propagated. For many fuels the amount of fuel
reacting per unit volume of fuel–air mixture (and hence the heat release per unit
volume mixture) at CfL is similar to that at CfU showing that heat release per unit
volume of fuel–air mixture is important in determining whether a flame is
propagated. The differences between the values at CfL and CfU are due to the
different physical properties of the fuel–air mixtures under these conditions.
Thus, in general, there is a range of fuel concentration in air within which a
flame can be propagated. From the analysis above it will be apparent that this
range will widen (CfL will decrease and CfU will increase) as the initial
temperature of the mixture is increased. In practice, therefore, flammability limits

are measured and quoted at standard temperatures (usually 20 C).
Minimum oxygen for combustion
At the lower limit of flammability there is more oxygen available than is required
for stoichiometric combustion of the fuel. For example, the lower flammability
limit for propane in air at 20 C is 2.2% by volume.
For complete combustion of propane according to the reaction:
C3 H8 þ 5O2 ! 3CO2 þ 4H2 O
five volumes of oxygen are required per volume of fuel propane.

In a fuel–air mixture with 2.2% propane the ratio of air to propane is:
100 2:2
¼ 44:45
2:2
and since air is approximately 21% oxygen, the ratio of oxygen to propane is 9.33.
Thus in the case of propane at the lower flammability limit oxygen is in excess by
approximately 87%.
It is therefore possible to reduce the concentration of oxygen in the fuel–air
mixture whilst still maintaining the ability to propagate a flame. If the oxygen is
replaced by a gas which has similar physical properties (nitrogen for example)
the effect on the ability of the mixture to maintain a flame is minimal until the
stoichiometric ratio of oxygen to fuel is reached. The oxygen concentration in the
mixture under these conditions is known as the minimum oxygen for combustion
(MOC). Minimum oxygen for combustion is therefore the stoichiometric oxygen
equivalent to the lower flammability limit. Thus

mol O2
MOC ¼ CfL
mol fuel stoich
For example, for propane, since under stoichiometric conditions five volumes of
oxygen are required per volume of fuel propane,
MOC ¼ 2:2 5 ¼ 11% oxygen by volume
15.3 COMBUSTION IN DUST CLOUDS
15.3.1 Fundamentals Specific to Dust Cloud Explosions
The combustion rate of a solid in air will in most cases be limited by the surface
area of solid presented to the air. Even if the combustible solid is in particulate
COMBUSTION IN DUST CLOUDS 379
form a few millimetres in size, this will still be the case. However, if the particles
of solid are small enough to be dispersed in air without too much propensity to
settle, the reaction rate will be great enough to permit an explosion flame to
propagate. For a dust explosion to occur the solid material of which the particles
are composed must be combustible, i.e. it must react exothermically with the
oxygen in air. However, not all combustible solids give rise to dust explosions.
To make our combustion fundamentals considered above applicable to dust
explosions we need only to add in the influence of particle size on reaction rate.
Assuming the combustion reaction rate is now determined by the surface area of
solid fuel particles (assumed spherical) exposed to the air, the heat release term
(2) in Equation (15.4) becomes:

6 0 E
ðHÞVC Z exp ð15:5Þ
x RTR
where x is the particle size and rmfuel is the molar density of the solids fuel.
The rate of heat generation by the combustion reaction is therefore inversely
proportional to the dust particle size. Thus, the likelihood of flame propagation
and explosion will increase with decreasing particle size. Qualitatively, this is
because finer fuel particles:
more readily form a dispersion in air;
have a larger surface area per unit mass of fuel;
offer a greater surface area for reaction (higher reaction rate, as limiting);
consequently generate more heat per unit mass of fuel;
have a greater heat-up rate.
15.3.2 Characteristics of Dust Explosions
Consider design engineers wishing to know the potential fire and explosion
hazards associated with a particulate solid made or used in a plant which they
are designing. They are faced with the same problem which they face in gathering
any ‘property’ data of particulate solids; unlike liquids and gases there are few
published data, and what is available is unlikely to be relevant. The particle size
distribution, surface properties and moisture content all influence the potential fire
hazard of the powder, so unless the engineers can be sure that their powder is
identical in every way to the powder used for the published data, they must have
the explosion characteristics of the powder tested. Having made the decision, the
engineers must ensure that the sample given to the test laboratory is truly
representative of the material to be produced or used in the final plant.
Although there has been recent progress towards uniform international testing
standards for combustible powders, there remain some differences. However,
most tests include an assessment of the following explosion characteristics:
minimum dust concentration for explosion;
minimum energy for ignition;
minimum ignition temperature;
maximum explosion pressure;
maximum rate of pressure rise during explosion;
minimum oxygen for combustion.
An additional classification test is sometimes used. This is simply a test for

explosibility in the test apparatus, classifying the dust as able or unable to ignite
and propagate a flame in air at room temperature under test conditions. This test
in itself is not very useful particularly if the test conditions differ significantly
from the plant conditions.
15.3.3 Apparatus for Determination of Dust Explosion Characteristics
There are several different devices for determination of dust explosion character-
istics. All devices include a vessel which may be open or closed, an ignition
source which may be an electrical spark or electrically heated wire coil and a
supply of air for dispersion of the dust. The simplest apparatus is known as the
vertical tube apparatus and is shown schematically in Figure 15.4. The sample
dust is placed in the dispersion cup. Delivery of dispersion air to the cup is via a
solenoid valve. Ignition may be either by electrical spark across electrodes or by
heated coil. The vertical tube apparatus is used for the classification test and for
determination of minimum dust concentration for explosion, minimum energy
for ignition and in a modified form for minimum oxygen for combustion.
A second apparatus known as the 20 litre sphere is used for determination of
maximum explosion pressure and maximum rate of pressure rise during explo-
sion. These give an indication of the severity of explosion and enable the design of
explosion protection equipment. This apparatus, which is shown schematically in
Figure 15.5, is based on a spherical 20 litre pressure vessel fitted with a pressure
transducer. The dust to be tested is first charged to a reservoir and then blown by
air into the sphere via a perforated dispersion ring. The vessel pressure is reduced
to about 0.4 bar before the test so that upon injection of the dust, the pressure rises
to atmospheric. Ignition is by a pyrotechnical device with a standard total energy
(typically 10 kJ) positioned at the centre of the sphere. The delay between disper-
sion of the dust and initiation of the ignition source has been found to affect the
results. Turbulence caused by the air injection influences the rate of the combustion
COMBUSTION IN DUST CLOUDS 381
Perspex tube
Ignition
electrodes
Solenoid valve
Air
Dispersion One-way Air chamber

cup valve
Figure 15.4 Vertical tube apparatus for determination of dust explosion characteristics.
reaction. A standard delay of typically 60 ms is therefore employed in order to

ensure the reproducibility of the test. There is also a 1 m3 version of this apparatus.
The third basic test device is the Godbert–Greenwald furnace apparatus, which
is used to determine the minimum ignition temperature and the explosion
characteristics at elevated temperatures. The apparatus includes a vertical
electrically heated furnace tube which can be raised to controlled temperatures
up to 1000 C. The dust under test is charged to a reservoir and then dispersed
through the tube. If ignition occurs the furnace temperature is lowered in 10 C
steps until ignition does not occur. The lowest temperature at which ignition
Ignition leads
Dispersion
ring
Pressure
Ignition transducer
device
20 litre vessel
Pressurized
Base dust chamber
Figure 15.5 The 20 litre sphere apparatus for determination of dust explosion character-
istics (after Lunn, 1992).
occurs is taken as the ignition temperature. Since the quantity of dust used and
the pressure of the dispersion air both affect the result, these are varied to obtain
a minimum ignition temperature.
15.3.4 Application of the Test Results
The minimum dust concentration for explosion is measured in the vertical tube
apparatus and is used to give an indication of the quantities of air to be used in
extraction systems for combustible dusts. Since dust concentrations can vary
widely with time and location in a plant it is not considered wise to use
concentration control as the sole method of protection against dust explosion.
The minimum energy for ignition is measured primarily to determine whether
the dust cloud could be ignited by an electrostatic spark. Ignition energies of
dusts can be as low as 15 mJ; this quantity of energy can be supplied by an
electrostatic discharge.
The minimum ignition temperature indicates the maximum temperature for
equipment surfaces in contact with the powder. For new materials it also permits
comparison with well-known dusts for design purposes. Table 15.1 gives some
values of explosion parameters for common materials.
The maximum explosion pressure is usually in the range 8–13 bar and is used
mainly to determine the design pressure for equipment when explosion contain-
ment or protection is opted for as the method of dust explosion control.
The maximum rate of pressure rise during explosion is used in the design of
explosion relief. It has been demonstrated that the maximum rate of pressure rise in
a dust explosion is inversely proportional to the cube root of the vessel volume, i.e.

dP
¼ V 1=3 KSt ð15:6Þ
dt max
The value of KSt is found to be constant for a given powder. Typical values are
given in Table 15.1. The severity of dust explosions is classified according to the
St class based on the KSt value (see Table 15.2).
The minimum oxygen for combustion (MOC) is used to determine the maximum
permissible oxygen concentration when inerting is selected as the means of
Table 15.1 Explosion parameters for some common materials (Schofield, 1985).
Mean Maximum Maximum
particle size explosion rate of pressure rise
Dust ðmmÞ pressure (bar) (bar/s) KSt
Aluminium 17 7.0 572 155
Polyester 30 6.1 313 85
Polyethylene 14 5.9 494 134
Wheat 22 6.1 239 65
Zinc 17 4.7 131 35
CONTROL OF THE HAZARD 383
Table 15.2 Dust explosion classes based on 1 m3 test apparatus.

Dust explosion class KSt (bar m/s) Comments
St 0 0 Non-explosible
St 1 0–200 Weak to moderately explosible
St 2 200–300 Strongly explosible
St 3 >300 Very strongly explosible
controlling the dust explosion. Organic dusts have an MOC of about 11% if
nitrogen is the diluent and 13% in the case of carbon dioxide. Inerting requirements
for metal dusts are more stringent since MOC values for metals can be far
lower.
15.4 CONTROL OF THE HAZARD
15.4.1 Introduction
As with the control of any process hazard, there is a hierarchy of approaches that
can be taken to control dust explosion hazard. These range from the most
desirable strategic approach of changing the process to eliminate the hazardous
powder altogether to the merely tactical approach of avoiding ignition sources. In
approximate order of decreasing strategic component, the main approaches are
listed below:
change the process to eliminate the dust;
design the plant to withstand the pressure generated by any explosion;
remove the oxygen by complete inerting;
reduce oxygen to below MOC;
add moisture to the dust;
add diluent powder to the dust;
detect start of explosion and inject suppressant;
vent the vessel to relieve pressure generated by the explosion;
control dust concentration to be outside flammability limits;
minimize dust cloud formation;
Exclude ignition sources.

15.4.2 Ignition Sources
Excluding ignition sources sounds a sensible policy. However, statistics of dust

explosions indicate that in a large proportion of incidents the source of ignition
was unknown. Thus, whilst it is good policy to avoid sources of ignition as far as
possible, this should not be relied on as the sole protection mechanism. It is
interesting to look briefly at the ignition sources which have been associated with
dust explosions.
Flames. Flames from the burning of gases, liquids or solids are effective sources of
ignition for flammable dust clouds. Several sources of flames can be found in a
process plant during normal operation (e.g. burners, pilot flames, etc.) and during
maintenance (e.g. welding and cutting flames). These flames would usually be
external to the vessels and equipment containing the dust. To avoid exposure of
dust clouds to flames, therefore, good housekeeping is required to avoid a build-
up of dust which may generate a cloud and a good permit-to-work system should
be in place to ensure a safe environment before maintenance commences.
Hot surfaces. Careful design is required to ensure that surfaces likely to be in

contact with dust do not reach temperatures which can cause ignition. Atten-
tion to detail is important; for example ledges inside equipment should be
avoided to prevent settling of dust and possible self ignition. Dust must not be
able to build up on hot or heated surfaces, otherwise surface temperatures will
rise as heat dissipation from the surface is reduced. Outside the vessel care
must also be taken; for example if dust is allowed to settle on electric motor
housings, overheating and ignition may occur.
Electric sparks. Sparks produced in the normal operation of electrical power

sources (by switches, contact breakers and electric motors) can ignite dust
clouds. Special electrical equipment is available for application in areas where
there is a potential for dust explosion hazard. Sparks from electrostatic
discharges are also able to ignite dust clouds. Electrostatic charges are
developed in many processing operations (particularly those involving dry
powders) and so care must be taken to ensure that such charges are led to
earth to prevent accumulation and eventual discharge. Even the energy in the
charge developed on a process operator can be sufficient to ignite a dust
cloud.
Mechanical sparks and friction. Sparks and local heating caused by friction or
impact between two metal surfaces or between a metal surface and foreign objects
inadvertently introduced into the plant have been known to ignite dust clouds.
15.4.3 Venting
If a dust explosion occurs in a closed vessel at 1 atm, the pressure will rise
rapidly (up to and sometimes beyond 600bar=s) to a maximum of around 10 bar.
CONTROL OF THE HAZARD 385
Maximum
pressure
Pressure Unvented
developed
A
Small vent
Vessel
design
pressure
B
Larger vent
Vent
opening
pressure
Time
Figure 15.6 Pressure variation with time for dust explosions (A) unvented, (B) vented
with inadequate vent area and (C) vented with adequate vent area (after Schofield, 1985).
If the vessel is not designed to withstand such a pressure, deformation and

possible rupture will occur. The principle of explosion venting is to discharge
the vessel contents through an opening or vent to prevent the pressure rising
above the vessel design pressure. Venting is a relatively simple and inexpensive
method of dust explosion control but cannot be used when the dust, gas or
combustion products are toxic or in some other way hazardous, or when the rate
of pressure rise is greater than 600bar=s (Lunn, 1992). The design of vents is best
left to the expert although there are published guides (Lunn, 1992). The mass
and type of the vent determine the pressure at which the vent opens and the
delay before it is fully open. These factors together with the size of the vent
determine the rate of pressure rise and the maximum pressure reached after the
vent opens. Figure 15.6 shows typical pressure rise profiles for explosions in a
vessel without venting and with vents of different size.
15.4.4 Suppression
The pressure rise accompanying a dust explosion is rapid but it can be detected in
time to initiate some action to suppress the explosion. Suppression involves
discharging a quantity of inert gas or powder into the vessel in which the explosion
has commenced. Modern suppression systems triggered by the pressure rise
accompanying the start of the explosion have response times of the order of a few
milliseconds and are able to effectively extinguish the explosion. The fast acting
trigger device can also be used to vent the explosion, isolate the plant item or shut
down the plant if necessary.
15.4.5 Inerting
Nitrogen and carbon dioxide are commonly used to reduce the oxygen
concentration of air to below the MOC. Even if the oxygen concentration is
not reduced as far as the MOC value, the maximum explosion pressure and the
maximum rate of pressure rise are much reduced (Palmer, 1990). Total
replacement of oxygen is a more expensive option, but provides an added
degree of safety.
15.4.6 Minimize Dust Cloud Formation
In itself this cannot be relied on as a control measure, but should be

incorporated in the general design philosophy of a plant involving flammable
dusts. Examples are (1) use of dense phase conveying as an alternative to dilute
phase, (2) use of cyclone separators and filters instead of settling vessels for
separation of conveyed powder from air, and (3) avoiding situations where a
powder stream is allowed to fall freely through air (e.g. in charging a storage
hopper). Outside the vessels of the process good housekeeping practice should
ensure that deposits of powder are not allowed to build up on ledges and
surfaces within a building. This avoids secondary dust explosions caused when
these deposits are disturbed and dispersed by a primary explosion or shock
wave.
15.4.7 Containment
Where plant vessels are of small dimensions it may be economic to design them
to withstand the maximum pressure generated by the dust explosion (Schofield
and Abbott, 1988). The vessel may be designed to contain the explosion and be
replaced afterwards or to withstand the explosion and be reusable. In both cases
design of the vessel and its accompanying connections and ductwork is a
specialist task. For large vessels the cost of design and construction to contain
dust explosions is usually prohibitive.
WORKED EXAMPLE 15.1
It is proposed to protect a section of duct used for pneumatically transporting a plastic

powder in air by adding a stream of nitrogen. The air flow rate in the present system is
WORKED EXAMPLES 387
1:6 m3 =s and the air carries 3% powder by volume. If the minimum oxygen for
combustion (by replacement of oxygen with nitrogen) of the powder is 11% by volume,
what is the minimum flow rate of nitrogen which must be added to ensure safe
operation?
Solution
The current total air flow of 1:6 m3 =s includes 3% by volume of plastic powder and 97%
air (made up of 21% oxygen and 79% nitrogen by volume). In this stream the flow rates
are therefore:
powder: 0:048m3 =s
oxygen: 0:3259m3 =s
nitrogen: 1:226m3 =s
At the limit, the final concentration of the flowing mixture should be 11% by volume.
Hence, using a simple mass balance assuming constant densities,
volume flow O2 0:3259

¼ ¼ 0:11
total volume flow 1:6 þ n
from which, the minimum required flow rate of added nitrogen, n ¼ 1:36 m3 =s.
WORKED EXAMPLE 15.2
A combustible dust has a lower flammability concentration limit in air at 20 C of 0.9%
by volume. A dust extraction system operating at 2 m3 =s is found to have a dust
concentration of 2% by volume. What minimum flow rate of additional air must be
introduced to ensure safe operation?
Solution
Assume that the dust explosion hazard will be reduced by bringing the dust concentra-
tion in the extract to below the lower flammability limit. In 2 m3 =s of extract, the flow
rates of air and dust are
air: 1:96 m3 =s
dust: 0:04 m3 =s
At the limit, the dust concentration after addition of dilution air will be 0.9%, hence:
volume of dust 0:04

¼ ¼ 0:09
total volume 2þn
from which the minimum required flow rate of added dilution air, n ¼ 2:44 m3 =s.
WORKED EXAMPLE 15.3
A flammable dust is suspended in air at a concentration within the flammable limits and
with an oxygen concentration above the minimum oxygen for combustion. Sparks
generated by a grinding wheel pass through the suspension at high speed, but no fire or
explosion results. Explain why.
Solution
In this case it is likely that the temperature of the sparks will be above the measured
minimum ignition temperature and the energy available is greater than the minimum
ignition energy. However, an explanation might be that the heat transfer conditions are
unfavourable. The high speed sparks have insufficient contact time with any element of
the fuel–air mixture to provide the energy required for ignition.
WORKED EXAMPLE 15.4
A fine flammable dust is leaking from a pressurized container at a rate of 2 litre=min into
a room of volume 6 m3 and forming a suspension in the air. The minimum explosible
concentration of the dust in air at room temperature is 2.22% by volume. Assuming that
the dust is fine enough to settle only very slowly from suspension, (a) what will be the
time from the start of the leak before explosion occurs in the room if the air ventilation
rate in the room is 4 m3 =h, and (b) what would be the minimum safe ventilation rate
under these circumstances?
Solution
(a) Mass balance on the dust in the room:

rate of rate of flow rate of flow out
¼
accumulation into the room of room with air
assuming constant gas density,

dC
V ¼ 0:12 4C
dt
where 0.12 is the leak rate in m3 =h, V is the volume of the room and C is the dust
concentration in the room at time t.
Rearranging and integrating with the initial condition, C ¼ 0 at t ¼ 0,

0:12 4C
t ¼ 1:5 ln h
0:12
Assuming the explosion occurs when the dust concentration reaches the lower flamm-
ability limit, 2.22%
time required ¼ 2:02 h:

WORKED EXAMPLES 389
(b) To ensure safety, the limiting ventilation rate is that which gives a room dust
concentration of 2.22% at steady state (i.e. when dC=dt ¼ 0). Under this condition,
0 ¼ 0:12 FCfL
hence, the minimum ventilation rate, F ¼ 5:4 m3 =h.
WORKED EXAMPLE 15.5
Table 15W5.1 Combustion data for various fuels.

Lower flammability Upper flammability
limit (vol % of fuel in air) limit (vol % Standard enthalpy
Substance (20 C and 1 bar) of fuel in air) of reaction (MJ/kmol)
Benzene 1.4 8.0 3302
Ethanol 3.3 19 1366
Methanol 6 36.5 764
Methane 5.2 33 890
Using the information in Table 15W5.1, calculate the heat released per unit volume for
each of the fuels at their lower and upper flammability limits. Comment on the results of
your calculations.
Solution
As the concentration of fuel in the fuel–air mixture increases, the fuel burned per unit
volume of mixture increases, and hence, the heat released per unit volume of mixture
increases, until the point is reached when the fuel and air are in stoichiometric
proportions CFstoic. Beyond this point, there is insufficient oxygen to combust all the
fuel in the mixture. For fuel concentrations beyond CFstoic, therefore, it is the quantity of
oxygen per unit volume of mixture which dictates the quantity of fuel burned and hence
the heat released per unit volume of mixture.
Below CFstoic
Heat release does not occur below the lower flammability limit CFL since flame
propagation does not occur.
At CF volume of fuel in 1m3 mixture ¼ CF
n¼ P
Assuming ideal gas behaviour, molar density ¼ V RT
At 20 C and 1 bar pressure, molar density ¼ 0:0416 kmol=m3
So; heat released per m3 mixture ¼ ðHc Þ CF 0:0416 ð15W5:1Þ

Hence, at CFL the heat released per m3 mixture ¼ ðHc Þ CFL 0:0416
The results for the listed fuels are shown in Table 15W5.2.
Table 15W5.2 Heat released per m3 fuel–air mixture at CFL for various fuels.
Heat released per m3
Fuel CFL Hc (MJ/kmol) mixture (MJ/m3)
Benzene 0.014 3302 1.92
Ethanol 0.033 1366 1.87
Methanol 0.06 764 1.91
Methane 0.052 890 1.93
For the fuels listed in Table 15W5.2 the values of heat released per unit volume of
mixture at the lower flammability limit are quite similar (1:91 MJ=m3 2%) demonstrat-
ing that it is the heat released per unit volume which determines whether a flame will
propagate in the fuel–air mixture.
Below CFstoic
When CF increases beyond CFstoic oxygen is limiting. Therefore, the first step is to
determine the oxygen concentration (kmol/m3 mixture) for a given CF.
For 1 m3 of mixture: volume of fuel ¼ CF
and volume of air ¼ 1 CF
Taking air as 21 % oxygen and 79 % nitrogen, by volume,
volume of oxygen ¼ 0:21ð1 CF Þ
Assuming ideal gas behaviour, 1 m3 at 20 C and 1 bar holds 0.0416 kmol (see above),
Moles of oxygen per m3 in a fuel–air mixture at CF, nO2 ¼ 0:0416 0:21ð1 CF Þ kmol=m3
Hence, moles of fuel reacting per m3 in a fuel–air mixture at CF
¼ nO2 mol fuel reacting with every mol of oxygen
stoichiometric coefficient of fuel

¼ nO2
stoichiometric coefficient of oxygen
Hence, beyond CFstoic heat released per m3 fuel–air mixture
¼ 0:0416 0:21ð1 CF Þ RST ðHc Þ ð15W5:2Þ
where
stoichiometric coefficient of fuel

RST ¼
stoichiometric coefficient of oxygen
WORKED EXAMPLES 391
Stoichiometric coefficients:
Benzene : C6 H6 þ 7:5O2 ! 6CO2 þ 3H2 O; so RST ¼ 0:1333

Ethanol : C2 H5 OH þ 3O2 ! 2CO2 þ 3H2 O; so RST ¼ 0:3333
Methanol : CH3 OH þ 1:5O2 ! CO2 þ 2H2 O; so RST ¼ 0:6666
Methane : CH4 þ 2O2 ! CO2 þ 2H2 O; so RST ¼ 0:5
Table 15W5.3 gives the calculated values of heat released per m3 fuel–air mixture at the
upper flammability limit (CF ¼ CFU ) for these fuels [based on Equation (15W5.2)].
Table 15W5.3 Heat released per m3 fuel–air mixture at CFU for various fuels.
Heat released per m3
Fuel CFU H (MJ/kmol) RST mixture (MJ/m3)
Benzene 0.08 3302 0.1333 3.54
Ethanol 0.19 1366 0.3333 3.22
Methanol 0.365 764 0.6666 2.83
Methane 0.33 890 0.50 2.60
Amongst these fuels, the values for heat released per m3 of fuel–air mixture at the upper
flammability limit are of the same order (3:05 16%). Also, we note that the values at
the upper flammability limit are somewhat higher (but certainly the same order of
magnitude) than the values at the lower flammability limit. These differences are likely
to be due to the different physical properties (conductivity, specific heat capacity, for
example) of the fuel–air mixture at low fuel concentrations compared with the physical
properties at higher fuel concentrations.
WORKED EXAMPLE 15.6
Based on the information for methane in Table 15W5.1, produce a plot of heat released
per m3 of mixture as a function of fuel concentration for methane–air mixtures at
atmospheric pressure and 20 C. In the light of this, explain why fuels have an upper
flammability limit.
Solution
For CF < CFL and CF > CFU no heat will be released since no combustion takes place.
For CFL < CF < CFstoic (the fuel-limiting range) the heat released per m3 of fuel–air
mixture will be described by (See example 15.5):
ðHc Þ CF 0:0416 ð15W5:1Þ
For methane, the heat released per m3 of fuel–air mixture becomes:

37.02 CF MJ/m3.
For CFstoic < CF < CFU (the oxygen-limiting range) the heat released per m3 of fuel–air
mixture will be described by (See example 15.5):
0:0416 0:21ð1 CF Þ RST ðHc Þ ð15W5:2Þ

Heat released per m (MJ/m )

37.02CF
3
4
3.89(1-CF)
3
3
0
0 0.2 0.4 0.6 0.8 CF 1
CFL CFU
CFstoic
Figure 15W6.1 The heat released per m3 of methane–air mixtures as a function of

methane concentration CF.
For methane, the heat release per m3 of fuel–air mixture becomes:

3:89ð1 CF Þ MJ=m3
Determine CFstoic:
volume of fuel vol fuel

For 1 m3 : CF ¼ ¼
total volume of mixture vol fuel þ vol O2 þ vol N2
Taking air as 21 mol% oxygen and 79 mol% nitrogen,
vol fuel vol fuel

CF ¼ ¼
vol fuel þ vol O2 þ vol N2 vol fuel þ 4:762vol O2
At stoichiometric conditions (assuming ideal gas behaviour),
vol fuel mol fuel

¼ ¼ RST
vol O2 mol O2
vol fuel RST
So : CFstoic ¼ ¼
vol fuel RST þ 4:762
vol fuel þ 4:762
RST
For methane this gives CFstoic ¼ 0:095
Plotting these gives Figure 15W6.1.
TEST YOURSELF
15.1 List five process industries which process combustible particulate materials and in
which there is therfore the potential for dust explosion.
15.2 What is meant by the terms lower flammability limit and upper flammability limit?
EXERCISES 393
15.3 The lower flammability limits for benzene, methanol and methane are 1.4, 6.0 and
5.2 vol %, respectively. However, for each of these fuels, the heat generated per unit
volume of fuel–air mixture at the lower flammability limit is approximately 1.92 MJ/
m3. Explain the significance of these statements.
15.4 Explain why, for a suspension of combustible dust in air, the likelihood of flame
propagation and explosion increases with decreasing particle size.
15.5 List and define five explosion characteristics that are determined experimentally in
the 20 litre sphere test apparatus.
15.6 In decreasing order of desirability, list five approaches to reducing the risk of dust
cloud explosion.
15.7 Explain why a policy of eliminating ignition sources from a process plant handling
combustible powders cannot be relied upon as the sole measure taken to prevent a
dust explosion.
15.8 What factors must be taken into account when designing a vent to protect a vessel
from the effects of a dust explosion?
EXERCISES
15.1 It is proposed to protect a section of duct used for pneumatically transporting a food
product in powder form in air by adding a stream of carbon dioxide. The air flow rate in
the present system is 3 m3 =s and the air carries 2% powder by volume. If the minimum
oxygen for combustion (by replacement of oxygen with carbon dioxide) of the powder is
13% by volume, what is the minimum flow rate of carbon dioxide which must be added to
ensure safe operation?
(Answer: 1:75 m3 =s.)
15.2 A combustible dust has a lower flammability limit in air at 20 C of 1.2% by volume. A
dust extraction system operating at 3 m3 =s is found to have a dust concentration of 1.5% by
volume. What minimum flow rate of additional air must be introduced to ensure safe
operation?
(Answer: 0:75 m3 =s.)
15.3 A flammable pharmaceutical powder suspended in air at a concentration within the

flammable limits and with an oxygen concentration above the minimum oxygen for combus-
tion flows at 40 m/s through a tube whose wall temperature is greater than the measured
ignition temperature of the dust. Give reasons why ignition does not necessarily occur.
15.4 A fine flammable plastic powder is leaking from a pressurized container at a rate of
0.5 litre/min into another vessel of volume 2 m3 and forming a suspension in the air in the
vessel. The minimum explosible concentration of the dust in air at room temperature is
1.8% by volume. Stating all assumptions, estimate:
(a) the delay from the start of the leak before explosion occurs if there is no ventilation;
(b) the delay from the start of the leak before explosion occurs if the air ventilation rate in
the second vessel is 0:5 m3 =h;
(c) the minimum safe ventilation rate under these circumstances.
[(Answer: (a) 1.2 h; (b) 1.43 h; (c) 1:67 m3 =h).]
15.5 Using the information in Table 15E5.1, calculate the heat released per unit volume for
each of the fuels at their lower and upper flammability limits. Comment on the results of
your calculations.
Table 15E5.1 Combustion data for various fuels.

Lower flammability limit
(vol % of fuel in air) Upper flammability limit Standard enthalpy of
Substance (20 C and 1 bar) (vol % of fuel in air) reaction (MJ/kmol)
Cyclohexane 1.3 8.4 3953
Toluene 1.27 7 3948
Ethane 3 12.4 1560
Propane 2.2 14 2220
Butane 1.8 8.4 2879
15.6 Based on the information for propane in Table 15E5.1, produce a plot of heat released
per m3 of mixture as a function of fuel concentration for propane–air mixtures at
atmospheric pressure and 20 C. In the light of this, explain why fuels have an upper
flammability limit.
16
Case Studies
16.1 CASE STUDY 1
High Windbox Pressure in a Fluidized Bed Roaster
A fluidized bed for roasting mineral ores operates satisfactorily when fed
continuously with ore A. When the feed is switched to ore B, however, the
windbox pressure gradually rises and on occasions reaches unacceptable levels.
When this happens action is taken to prevent the blower which provides the
fluidizing air from overloading and perhaps tripping. The action usually taken is
to switch the feed back to ore A. When this is done the windbox pressure
gradually falls back to its original value.
Solids leave the fluidized bed by overflowing a weir. The internal configuration
of the fluidized bed is shown diagrammatically in Figure 16.1.
Ores A and B change particle size during the roasting process and so a
representative measure of the particle properties can only be obtained by
sampling the roasted product overflowing the weir. The measured particle
properties of the ores at this point are given in Table 16.1 The particles in ores
A and B are found to have similar shape and the particle size distributions are
also similar.
The bed operating conditions are independent of the ore being roasted (see
Table 16.2). Further details of bed geometry are shown in Table 16.3.
Possible causes of the increase in windbox pressure
The pressure in the windbox is determined by the pressure drop for flow of gas
downstream of the windbox. Downstream of the windbox is the distributor, the

396 CASE STUDIES
off gases
weir
ore feed
product
fluidizing air
Figure 16.1 Configuration of fluidized bed
Table 16.1 Particle properties of ores A and B
Ore Mean size (mm) Particle density (kg/m3)

A 130 3500
B 350 3500
Table 16.2 Fluidized bed operating conditions
Bed temperature ( C) 877

Superficial gas velocity (m/s) 0.81
Gas viscosity (kg/ms) 4.51 105
Gas density (kg/m3) 0.307
Table 16.3 Fluidized bed details

Bed diameter (m) 6.4
Nozzle diameter (mm) 6
Number of nozzles 3000
Air velocity in bed (m/s) 0.78
Bed height (weir setting) (mm) 1200
CASE STUDY 1 397
fluidized bed, gas cyclones and a baghouse (filter). Measurements of pressure

drops across the gas cyclones and the baghouse are found to change little when
the ore feed to changed from A to B, so the cause is not here.
The distributor is equipped with 3000 6 mm nozzles. If some of the nozzles
were becoming fully or partially blocked then this would lead to a rise in
distributor pressure since the gas volume flow delivered to the bed is effectively
constant. However, the fact that the windbox pressure gradually returns to
normal when the feed is switched back to ore A suggests that nozzle blockage
is not the most obvious cause of the problem (unless the blockage is reversible,
which seems unlikely).
This leaves us with an increase in bed pressure drop as the most likely cause of
the observed increase in windbox pressure. Let us look more closely at bed
pressure drop:
In a fluidized bed, the buoyant weight of the particles is supported by the
upwardly flowing gas, yielding the expression:
pbed ¼ Hð1 eÞðrp rf Þg ð7:2Þ
A further level of detail is introduced by considering the make-up of the bed – a

mixture of bubbles that contain essentially no particles and a dense emulsion
phase consisting of solids and gas in intimate contact (from the two phase theory
of fluidization – see Chapter 7). The overall bed density is thus a function of the
density of the particulate solids, the proportion of solids and gas in the emulsion
phase and the proportion of the bed occupied by bubbles.
pbed ¼ Hð1 ep Þð1 eB Þðrp rf Þg ð16:1Þ
where ep is the average particulate phase voidage and eB is the fraction of the bed
occupied by the bubbles.
In the specific situation of the case under consideration, two simplifications to the
above can be made: The bed height H is fixed by the overflow weir setting.
Hence, the bed is at its minimum height and fixed there as windbox pressure
continues to increase. This implies that for analysis, a fixed bed height can be
assumed (1.2 m in this case). A further simplification is that the particle density of
both ores A and B are the same (3500 kg/m3).
The bed height and particle density can therefore be eliminated as contributing
factors in the windbox pressure increase, since they are the same for both ores.
We therefore turn our attention to the bubble fraction and particulate phase
voidage in the fluidized bed. These properties are a combined function of the gas
flow rate through the bed and the particle shape, particle size and particle size
distribution.
Since both the volumetric flow of air to the fluidized bed and the bed
temperature are maintained constant during normal operation and the times of
excessive windbox pressure, both the superficial gas velocity and the gas
transport properties would be the same for both ores A and B (see Table 16.2).
398 CASE STUDIES
The remaining variables by which bed density (and hence bed pressure drop)
is influenced therefore relate directly to particle size and shape.
As indicated above, whether operating with ore A or B the particle size
distributions in the overflow have approximately the same shape. However,
the mean particle size in the overflow typically increases from around 130 mm to
350 mm during the high windbox pressure periods.
Referring to Equation (16.2), we therefore need to assess the effect of an
increasing mean particle size (i.e. from a mean size of 130 mm to 350 mm) on:
ep (average particulate phase voidage) and
eB (bubble fraction)
As a first approximation, we will the simple two phase theory of fluidization
(see Chapter 7), which means that the average particulate phase voidage will be
taken as the voidage at minimum fluidization emf and the bubble fraction will be
given by Equation (7.28):
ðU Umf Þ
eB ¼ B ð7:28Þ
U
where U B is the mean bubble rise velocity in the bed.

UB is taken as the arithmetic mean of the bubble rise velocity calculated at the
distributor (L ¼ 0) and at the bed surface (L ¼ H) from Equations (7.31) and (7.32)
for Group B powders:
0:54
dBv ¼ ðU Umf Þ0:4 ðL þ 4N 0:5 Þ0:8 ðDarton et al:; 1977Þ ð7:31Þ
g0:2
UB ¼ B ðgdBv Þ0:5 ðWerther; 1983Þ ð7:32Þ
where
8 9
< B ¼ 0:64 for D 0:1m =
B ¼ 1:6D0:4 for 0:1 < D 1m ð7:33Þ
: ;
B ¼ 1:6 for D > 1m
N is the orifice density of the distributor (in this case, 93 nozzles per square
metre).
D is the bed diameter or smallest cross-sectional dimension (in this case 6.4 m).
The depth of the bed in normal operation is 1.2 m (dictated by the weir setting).
In order to do these calculations, we need values for Umf and emf . Umf is estimated
using the Wen and Yu equation (Wen and Yu, 1966), which is appropriate for
both ores since they are Group B materials. emf is estimated using information,
given for a range of particles of different size and shape, in Kunii and Levenspiel
(1990) (page 69, Table C1.3). Such measurements, performed at the
normal operating temperature of the fluidized bed gave the results shown in
Table 16.4.
CASE STUDY 2 399
Table 16.4 Estimated values of Umf and emf for ores A and B
Ore Umf (m/s) emf
A 0.008 0.56
B 0.056 0.495
Table 16.5 Results of calculations of bed pressure drops

Value Ore A Ore B
Bubble size at distributor (L ¼ 0) (m) 0.155 0.151
Bubble size at distributor (L ¼ 1:0) (m) 0.459 0.448
Bubble velocity at distributor (L ¼ 0) (m/s) 1.97 1.95
Bubble velocity at distributor (L ¼ 1:0) (m/s) 3.40 3.36
Mean bubble rise velocity, U B (m/s) 2.68 2.65
Bubble fraction 0.299 0.284
Mean bed density (kg/m3) 1234 1446
Particulate phase voidage 0.56 0.495
Bed pressure drop (Pa) 12 107 14 181
The resulting calculations are shown in Table 16.5.

We see that the predicted increase in bed pressure drop when changing the
feed ore from A to B is 2074 Pa. In practice, the increase was a little more than
predicted and it turns out that the blower was under rated for the job. As a result
the blower came close to its upper limit on a number of occasions. The analysis
shows that the most likely cause of the increase in bed pressure drop in switching
from ore A to ore B is the increase in bed pressure drop caused by an increase in
mean bed density.
So what is the solution? One option is to reduce the bed pressure drop by
2074 Pa when feeding ore B. This could be done by reducing the weir height so
that the bed depth reduces. This means a 14.6% (2074/14181) reduction in bed
level. This change would, of course, reduce the residence time of the ores in the
bed and may not be acceptable. However, the change could be made and the
product tested. If the tests show that reduction in residence time is not
acceptable, then the blower must be uprated to enable it to deliver the required
14 181 Pa bed pressure drop with some to spare.
16.2 CASE STUDY 2
Inappropriate Use of an L-valve
There is a market for high purity calcium carbonate and one method of making
this is to calcine limestone by heating it to between 800 C and 900 C to remove
the CO2 and produce a pure lime which is then put into a tank containing
demineralised water. The combustion gas rich in CO2 is stripped of its dust
400 CASE STUDIES
CO2 and N2 to
limestone cyclone and filters warm air
to filters
L-valve
calciner
cooler
rotary
valve
air
warm air cold air lime
Figure 16.2 Original layout of calciner and cooler with L-valve
content by passing it through cyclones, cooled, given a final cleaning in a

baghouse and then introduced through spargers to the bottom of the tank
containing the slaked lime to give a very pure CaCO3 suitable for use as an
additive in pharmaceutical and food products.
A new plant using this process (Figure 16.2), was designed to calcine crushed
limestone by feeding it to a fluidized bed heated by burning natural gas. The lime
so produced is transferred to a long rectangular cooler fluidized by cold air. The
hot combustion gases enriched by the CO2 from the calciner are dedusted in a
cyclone and cooled in a heat exchanger by the air that fluidizes the bed of lime
and limestone. The cooled gases then pass into a baghouse. Some attrition of the
lime particles occurs in the fluidized bed lime cooler and these entrained particles
are removed in another baghouse before the warm air is discharged to a chimney.
The lime product is removed continuously from the end of the cooler remote
from the feed point and, because its temperature is below 200 C, a rotary valve
can be used to control the removal rate. The hot lime particles overflow from the
calciner onto an inclined chute leading to the cooler, but because of the high
solids temperature (800–900 C) the use of a motorized rotary valve to control the
flow and provide a gas seal was impossible. The designers therefore decided to
use an L-valve to provide both a seal against hot gas passing to the fluidized
cooler and to control the solids discharge rate.
Brief description of how the L-valve works
The principle of the L-valve has been around for a long time. The first patent for a
means for controlling the flow of particulate solids from one vessel to another, or
into a pipeline, using only small flow rates of gas, was taken out by ICI in the
1930s. Interest in controlling the flow of fine powders (<100 mm) in dilute phase
conveying systems grew considerably with the advent of Fluid Bed Catalytic
Cracking, but it took the large synthetic fuels R&D programme in the USA in the
CASE STUDY 2 401
late 1970s and in the 1980s to stimulate interest in controlling the flow of
relatively coarse solids at high temperatures, and this led to the re-invention of
the L-valve.
Experimental work carried out by Knowlton and co-workers (Knowlton and
Hirsan, 1978) at the Institute of Gas Technology in Chicago established some of
the empirical principles of L-valves, sometimes called non-mechanical valves, but
the first paper setting out a step-by-step design procedure (based on experiments
with sands in 40, 70 and 100 mm diameter valves) was written by Geldart and
Jones (1991). Arena et al. (1998) added more data to the literature and confirmed
that the basic approach of the earlier workers is sound.
Although the L-valve appears to be quite a simple device, its hydrodynamics
are quite complicated, and only a basic explanation is given below.
Knowlton and Hirsan (1978) established that the best position for the injection
of the aeration gas is in the vertical leg (sometimes called the downcomer or
standpipe) about 1.5 pipe diameters above the centreline of the horizontal leg. This
is because gas is needed to reduce friction between the particles and the pipe at
the inside corner of the elbow, and if the gas is injected on or below the centreline,
less is available to perform this function. This gas then streams along the top of
the bed of powder lying in the horizontal leg carrying particles with it in a mode
of transport that resembles dense phase pneumatic conveying. As the aeration
gas flow is increased the depth of the flowing stream of powder increases and the
mass flow rate of solids increases. Eventually the whole depth of powder may
become active with the solids velocity increasing from bottom to top of the
horizontal leg.
Moving the solids requires a force to overcome friction and that is provided by
a pressure drop along the horizontal pipe. This pressure drop is a function of the
solids rate, the pipe diameter, and the mean size and bulk density of the powder.
The pressure is a maximum at the point of gas injection. The minimum gas flow
rate to initiate solids flow depends on the minimum fluidization velocity of the
powder, Umf , and when this minimum gas flow rate is exceeded, solids flow
starts at the minimum controllable solids flux, G. The solids flux then increases
linearly with the ratio Uext =Umf , where Uext is the volumetric flow rate of aeration
gas divided by the cross-sectional area of the horizontal leg. However, there is
limit to the maximum solids flow rate that can be attained and this depends on
the pressure balance. If the gas finds it is easier to flow upwards through the bed
of solids in the standpipe it will do so and less will be available to transport the
solids horizontally. Since the particles have the same characteristics in both
vertical and horizontal legs, the resistance to gas flow in the standpipe depends
primarily on the depth of powder in it. As a rule of thumb, the height of the
standpipe must be at least equal to the length of the horizontal leg. In practice,
the criterion is that the pressure drop in the horizontal section (that required to
move the solids) divided by the depth of solids in the standpipe must be lower
than the pressure gradient in a fluidized bed at minimum fluidization. If it is
equal to, or higher than this, the solids in the vertical leg may start to fluidize
(since the applied pressure gradient is greater than that required for fluidization)
and flow instabilities will occur. These take the form of a cessation of solids flow
followed by flushing of the solids through the L-valve.
402 CASE STUDIES
One of the problems of operating an L-valve system is that small changes in the
aeration gas flow rate can cause quite large variations in the solids flow rate so a
method of control is needed to match the solids efflux rate to the rate at which the
solids enter the standpipe. This might take the form of pressure measurements in
the standpipe linked to a flow controller on the aeration air. Fortunately, provided
the standpipe is long enough, it is possible to operate an L-valve in automatic
mode. The aeration rate is set at a value high enough to fluidize the solids above the
aeration point whilst the solids below are in packed bed mode. If the solids flow
rate into the standpipe increases, the level of fluidized solids in the standpipe rises
and more gas flows downwards causing the solids discharge rate to increase. If the
solids rate decreases the level of solids in the standpipe falls, more gas flows
upwards and less downwards, causing the solids discharge rate to decrease.
Unfortunately, in the application shown in Figure 16.2, because of limitations in
the vertical height available between the overflow weir in the side of the calciner
and the lime cooler the solids transfer system installed could not operate as a stable
L-valve because (a) the vertical leg was shorter than the horizontal leg, and (b) the
aeration point was not positioned above the centreline of the elbow. Moreover, the
discharge end of the horizontal section was higher than the level of the fluidized
bed in the cooler. It also turned out that the valve diameter (200 mm) was so large
that the minimum controllable solids flow rate was almost seven times the design
production rate. Reducing the aeration rate below the minimum value resulted in
no solids flow at all, so in order to make the system work at all, the operators of the
plant installed an additional aeration line on the centreline of the horizontal leg and
then operated the aeration system intermittently. When the bed level in the calciner
became too high and the red hot solids filled the overflow chute, the aeration air
was turned on fully, causing the solids in the short vertical leg to fluidize. This
altered the pressure balance in the system and caused the entire contents of the L-
valve to suddenly flush into the cooler, leaving a clear passage for the hot
combustion gases to blow through to the space above the bed in the cooler. This
resulted in the destruction of the baghouse when it caught fire.
CO2 and N2 to
limestone cyclone and filters warm air
to filters
Loop
calciner seal
cooler
air
warm air cold air lime
Figure 16.3 Modified calciner and cooler layout using a loop seal to transfer solids and
prevent gas flow from cooler to calciner
CASE STUDY 3 403
The solution to the problem was to replace the L-valve by a loop seal
(Figure 16.3), which is essentially a fluidized bed divided by a vertical baffle
except for a gap at the bottom to allow solids to pass between the two side-by-
side beds, fluidized by separate air supplies. Hot lime particles fall into the bed
nearest to the calciner, flow under the vertical baffle into the second bed adjacent
to the cooler driven by the higher pressure in the first leg of the loop. The solids
in the second bed then overflow into the cooler. This system operates like two
arms of a manometer and there are fluidized solids present at all times in the loop
preventing hot gas from passing direct into the cooler.
16.3 CASE STUDY 3
Fluidized Bed Dryer
Solving one problem may cause another that could not have been anticipated.
One stage in the manufacture of a water treatment chemical involved feeding
cube-shaped, slightly damp particles into a fluidized bed dryer. The distributor
was rectangular in plan view, about 3 m long by 1 m wide and contained many
drilled holes. The fluidizing air was supplied by a centrifugal fan and passed
through a heat exchanger before entering the plenum chamber through a duct
positioned about 1 m from the solids feed point. The fluidized solids formed a
bed about 1 cm deep. The warm product overflowed from the far end of the
bed into a chute which directed them to a bagging machine where the product
was packaged into 50 kg batches. In the customers‘ warehouses the paper or
plastic sacks were stored on top of each other before use, and in some sacks the
product particles became stuck so firmly together that they formed a solid
block that resembled a tombstone and so the particles could not be poured
out.
Although the damp feed was fed to the dryer and removed continuously,
samples taken at the solids exit showed that the moisture content was unaccep-
tably variable. Visual inspection of the fluidized bed through several of the
hatches in the wall of the steel expanded section above the bed surface revealed
that the bed was unevenly fluidized with large areas of unfluidized solids
remaining virtually motionless on the plate.
In poorly fluidized beds it is common for the defluidized and well fluidized
regions to change randomly and it seemed likely that from time to time that
static areas having higher moisture contents might suddenly become mobile
and flush through to the bed exit. Measurements of the pressure drop across
the air distributor plate were made in the absence of a bed and found to be
only 5 mm water gauge (49 Pa), much too low for a system having a very
small aspect ratio (bed depth/bed length or for a cylindrical bed, bed depth/
bed diameter). The consultant recommended that the distributor plate be
replaced by one having a pressure drop at least equal to that across the
fluidized solids.
This was done, and when the dryer was started up again, visual observation
showed that the entire bed was uniformly well fluidized. However, it was
404 CASE STUDIES
Flow path of baffle

solids
Figure 16.4 Plan view of dryer with baffles inserted
found that virtually none of the samples of the product had a moisture content
within specification. With hindsight it was deduced that the defluidized
regions had acted like baffles in causing the well-fluidized solids to take a
tortuous path along the plate, so increasing their residence time in the system
to allow some particles to dry thoroughly. When the plate was changed to give
a really well fluidized bed, all the particles flowed too rapidly through the
equipment to give a low moisture content. One solution was to insert a series of
baffles (see Figure 16.4) at right angles to the direction of solids flow, which
would cause the bed to operate nearer to plug flow, increasing the mean
residence time and reducing the range of residence times. An alternative
solution would be to insert a weir at the solids exit so as to increase the
mean residence time in the dryer and rely on the length to width ratio of the
bed to minimize backmixing of solids against the solids flow direction – and
hence reduce the range of residence times.
16.4 CASE STUDY 4
Aeration of a Hopper Leads to Air Shortage at a Coal Plant
Peter Arnold, University of Wollongong, Australia
In a coal preparation plant three ‘fine’ coal feed silos were fed with a common
rotary plough feeder – a device for delivering coal from the silo at a regular
rate. Arching of coal at the hopper outlet resulted in problems achieving stable
discharge of the silos. To overcome the arching problems at the hopper outlet a
sophisticated aeration system had been installed to the outlet slot. Since the
coal was size was ‘minus 12 mm’ (i.e. it has passed though a 12 mm sieve) a lot
of air was required for the aeration system. The result was that the rest of the
coal plant was starved of air and plans were being made to increase the
compressed air capacity. The injected air actually had little effect on
the arching problem. The problem was the result of a simple mismatch
between the hopper outlet and the feeder caused by the presence of a number
of structural columns protruding into the outlet area. At intervals along the
CASE STUDY 5 405
stainless steel
lining
fill
gate
plough
feeder
protruding column
(a) (b)
Figure 16.5 (a) Profile through the hopper slot outlet showing the offending columns and
(b) modifications to the geometry
slot, the structural columns protruded out from the hopper back wall and
prevented the plough feeder from fully activating the hopper outlet slot. The
plough blades had to avoid the columns and hence could not plough coal off
the full shelf width, effectively leaving coal to build up on the unploughed
shelf between the protruding columns. The solution was to implement the
philosophy ‘if you can’t get the plough to the back wall of the hopper then
bring the back wall to the plough!’ (Figure 16.5). Bringing the back wall
towards the plough feeder has reduced the steepness of the hopper wall and
so if that is all we did there would be a risk of compounding the arching
problem. However, to overcome this potential risk the new hopper wall is clad
with stainless steel, which would have far lower wall friction than the original
concrete wall. As a result of this simple modification the flow was stabilized
and the aeration air was no longer needed.
16.5 CASE STUDY 5
Limestone Hopper Extension Overloads Feeder
Peter Arnold, University of Wollongong, Australia
A limestone hopper at a cement plant was duplicated and uprated (the hopper
slot was lengthened in an attempt to increase delivery rate). As Figure 16.6
shows, the hopper was wedge-shaped and fed by an apron feeder. The hopper
fed from the rear of the feeder and required the feed material to be dragged
CASE STUDY 6 406
hopper walls
apron feeder
Plan view
dead region
flow hopper
channel
apron feeder
belt
Figure 16.6 Initial design of limestone hopper with apron feeder. A high proportion of
the length of the hopper slot is not active
under ‘dead’ or stagnant material, thereby overloading the feeder. In an initial

attempt to overcome this problem, higher capacity motors and gearboxes were
tried with the result that the apron feeder itself was overstressed. The solution
finally adopted was a redesign of the hopper–feeder interface to achieve a fully
active hopper outlet (Figure 16.7). The outlet slot was redesigned to increase
along its length. This eliminated the region of stagnant solids, reducing the force
applied to the feeder and so overcoming the problems of overloading the apron
feeder. The feeder power required after the modification was less than that
originally specified.
16.6 CASE STUDY 6
The Use of Inserts in Hoppers
Lyn Bates, Ajax Equipment, UK
It may seem strange that placing obstructions in the flow path of bulk solids can
offer any form of advantage but, in practice, a wide range of operating benefits
can be gained by the use of inserts in bulk storage installations. The fact is that the
change of flow path created by an insert forms new flow channel shapes that
CASE STUDY 6 407
hopper slot
Plan
flow
apron
Figure 16.7 Plan view of the solution to the problem. Note that the width of the outlet slot
is redesigned to increase along its length. This eliminates the dead region and so avoids
the problems of overloading the apron feeder
have more favourable flow characteristics than the original. Some modifications
are simple and self-evident, like inserting a device to catch lumps before they
reach and block the silo outlet. Others are more sophisticated and call for a
greater degree of technical competence and expertise, although the principles
involved can be readily understood from a basic appreciation of the technology.
There are many different reasons for fitting inserts into storage silos; a summary
of the main ones is given in Table 16.6. It must be pointed out that this is not a
field for the amateur. The obvious task of securing the required performance may
itself require a degree of expertise. It is even more important to ensure that these
fittings do not introduce adverse consequences to the operation or integrity of the
equipment, to the condition or fitness for use of the product, to hygiene,
maintenance, or other factors that may detract from overall efficiency and
economics of the plant.
The economic benefit of incorporating an insert in an original design is rarely
considered in the primary hopper selection process of determining the appro-
priate flow regime for a bulk storage facility even though, at this stage, they
enlarge the scope for optimization of an integrated design. By contrast, retrofits
are usually compromised by the constraints of the installed plant. Whilst these
may limit the options available, it is commonly found that inserts offer one of the
most promising routes available to address many of the problems encountered in
bulk storage applications.
408 CASE STUDIES
Table 16.6 Reasons for fitting hopper inserts

In the hopper outlet region
To aid the commencement of flow
To secure reliable flow through smaller outlets
To increase flow rates
To improve the consistency of density of the discharged material
To secure mass flow at reduced wall inclinations
To expand the flow channel
To improve the extraction pattern
To reduce overpressures on feeders
To save headroom/secure more storage capacity
To counter segregation
To blend the contents on discharge
To improve counter-current gas flow distribution
To prevent blockages by lumps or agglomerates
In the body of the hopper
To accelerate the de-aeration of dilated bulk material
To reduce compaction pressures
To alter the flow pattern
To counter ‘caking’ tendencies
At the hopper inlet
To reduce segregation
To reduce particle attrition
An understanding of the flow regimes, mechanisms of stress systems and

behaviour characteristics of loose solids, provide a background for the selection
of an appropriate insert type for specific functions and offers a sound basis for
their design. The performance of inserts interacts with the hopper geometry, the
type of feeder or discharge control, ambient and operating conditions. Design
considerations for inserts, hopper and feeder therefore require an overall systems
approach. With rare exceptions, most insert techniques have been developed and
introduced by industry, rather than arising from fundamental research. Some
forms of insert are covered by patent, registered designs or similar restrictions.
Availability of design data on applications is therefore somewhat restricted.
There remains open a wide avenue of research to optimize the design of different
techniques and develop an improved basis for their selection and integration
with hopper forms and flow aid techniques.
It will be seen that many interests are served by the placement of inserts in the
outlet regions of hoppers. This is because the flow pattern governing the behaviour
of material within the hopper is initiated in this region. Whereas the outlet region is
relatively small, divergence of the hopper walls quickly attains a size of cross-
section where flow problems are not an issue. It is therefore commonly possible to
fit flow-modifying inserts in this larger cross-section above the outlet that do not in
themselves cause any flow impediment, but usefully change the flow pattern in the
hopper and shelter the underlying regions to considerable advantage.
By way of example, two situations are described that show how the overall
behaviour of material in storage can be dramatically changed by comparatively
CASE STUDY 6 409
small inserts. More particularly, the properties of the discharged product are
made more suitable for the specific requirements.
Loss-in-weight make-up
One means of controlling the rate at which solids are fed to a step in a process is
known as loss-in-weight feeding. The storage silo holding the solids is mounted
on load cells and the weight of the solids in the vessel is continually monitored as
solids are discharged, so that the amount delivered or rate of delivery is known.
Loss-in-weight feeders require regular replenishment within a short period. In
this particular case, the unit handling delivering a fine powder feed under weight
control over a period of about 2 minutes was required to be re-filled from a
conical, mass flow hopper with quick-acting slide valve in 10–15 s. The problem
was that re-fill was very slow to start; it took over a minute for the powder to
emerge (Figure 16.8). Also, when it did emerge, the powder was so highly
aerated that it flushed through the feeder and was not in a suitable condition for
the next step in the process. Headroom, holding capacity, supply route and
general plant construction was, of course fixed in stone, so changes were only
permissible within the existing equipment geometry.
Fine powders usually have highly variable flow conditions. When settled, they
are cohesive and it is often difficult to initiate flow. One reason is that the close
proximity of the particles enables various molecular scale forces to attain
significance to resist particle separation. Fine cohesive powders therefore can
exhibit significant strength as compaction is increased. Expansion is also inhib-
ited by the rate at which air can percolate through the fine interstices between the
particles of fine powders. However, once a fine powder becomes expanded and
flow does occur, aeration tends to be excessive and the powder may become
effectively self-fluidized. De-aeration of the powder in such a state is slow, again
due to the minute size of the escape passages, so the bulk may take some time to
settle to a stable condition. Fluidized products have no strength to resist
Figure 16.8 Original arrangement of loss-in-weight make-up hopper

410 CASE STUDIES
deformation but are subjected to hydrostatic pressure that, combined with their
loose nature, makes them very searching for flow routes.
Every converging flow channel develops a velocity gradient across its cross-
section because, even in a mass flow channel, it is far easier for material
immediately above the outlet to move down than it is for product alongside to
move diagonally towards the outlet. This faster moving region in the feed
hopper creates a depression in the local surface that was more readily filled
by the fresh powder than by the more stable material previously loaded into the
loss-in-weight hopper. As this loose material progresses down towards
the outlet its hydrostatic pressure resists the entry of less free-flowing product
to the more rapid region of flow, to further increase the flow velocity differential.
The resulting small cross-section of rapidly moving fluid material quickly
penetrates the depth of the bed of powder to flush, without control, from the
machine outlet.
The retrofit task was twofold. It was necessary to accelerate the re-fill to deliver
powder quicker, and at the same time deliver the material in a more stable
condition. The first thing to recognize is that, provided flow takes place, the rate
of flow from mass flow hoppers is invariably slower than from hoppers with the
same size outlets that are not mass flow. The basic reason is that particles
disengage from the mass to accelerate in 0 free fall0 from a higher dynamic arch
in non-mass flow hoppers, so are travelling faster as they pass through the outlet.
It should also be noted that a flow stream travelling in an unconfined condition
can attain a high velocity, and it is therefore possible to achieve large rates of flow
through relatively small orifices. To secure a much higher flow rate in a less dilate
condition through the same size of opening therefore calls for an increase in the
area of the initial flow outlet and/or disturbance of the settle bulk to encourage
initial failure of the bulk state.
The solution adopted was to replace the quick acting slide valve with an
internal ‘cylinder and cone’ valve that fitted into the conical hopper some
distance above the hopper outlet (Figure 16.9). This comprises a short cylinder
with a superimposed cone, the bottom edge of which seats on the inner conical
wall of the hopper. This fitting was lifted by means of an air cylinder attached to
the top of the hopper. The action of lifting the insert exposed an annular gap. The
immediate flow channel above this circular slot had a vertical inner surface and a
conical outer shape. The action of lifting the valve disrupted the bulk resting on
the cone section above the vertical wall, whilst movement of the cylindrical
surface reduced local wall slip and left the local wedge-shaped annulus
of product without internal support free to fall away with minimum
deformation.
As the area of the annular gap increases as the square of the diameter, it is
practical to provide a greater flow area in this annulus than was given by the final
outlet. Upward movement of the valve disrupted material that was resting
between the hopper wall and the bottom of the conical portion of the valve.
The collapse of the bulk around this gap was therefore precipitated and occurred
at a greater span and cross-sectional area than the flow annulus exposed, so
material flowed through in a denser condition and at a much greater rate than the
original opening. The resulting flow was focused through the final hopper outlet
CASE STUDY 6 411
Figure 16.9 Modified loss-in-weight make-up hopper showing cylinder and cone insert
closed (a) and open (b)
as a virtually unconfined stream, so accelerating to a velocity that allowed the

higher rate to pass without either restraint or excessive dilation. As a result, the
make up quantity to the loss-in-weight hopper was supplied in a few seconds by
the bulk material in a stable, non-fluid, flow condition.
Segregation in mass flow hopper
It is commonly suggested that a mass flow hopper will overcome segregation

problems. The thinking is that any segregation taking place during the filling of a
mass flow hopper will be redressed by re-mixing of the solids from all regions of
the cross sectional area as the hopper discharges. Mass flow will restore the blend
of the silo cross section while extraction takes material from the parallel body
section of the silo and the surface level moves down uniformly. The problem
arises when the level of the contents fall to the hip of the conical transition.
412 CASE STUDIES
Around this point the surface dips due to the higher central velocity and there is
no longer any make-up product from an above central region. Progressively, the
core region is preferentially extracted until the final portion of material dis-
charged is predominately comprised of coarser fractions of product that pre-
viously rested in the top peripheral regions of maximum segregation. This effect
may not be highly significant in either scale or the intensity of the segregation in a
tall silo, where most of the stored contents are held in the body section. However,
a feature of mass flow is that the wall hopper walls of the converging section are
relatively steep and in some cases the converging section holds a large proportion
of the total hopper contents. This means that a higher proportion of the contents
is vulnerable to this form of segregation.
An example concerns a 20 tonnes fine mineral storage application, where the
discharged product particle size distribution was required to fall within narrow
bounds. The hopper design was such that 90% of the holding volume was
contained in the steep-walled conical section. It was found that, whilst the input
supply stream complied with the tight product specification, the final 2 tonnes of
product discharged from the hopper contained an unacceptable proportion of
coarse fractions and was rejected by quality control. The fact that the cross section
of the feed stream on the belt conveyor supplying the silo held a higher
proportion of fines in the lower centre and excess coarse fractions at the outer
edges was not a contributing factor to this maldistribution.
It was recognized that a single point fill was a prime cause of repose slope
segregation so a protracted effort was made to distribute the fill around the cross
section of the silo (segregation of free-flowing powder pouring into a heap – see
Chapter 11). The first stage was to fit an inverted cone under the inlet. The
intention was that solids fed into the cone would overflow evenly from its large
perimeter into the hopper – thus avoiding the disadvantages of the single fill
point. The cone had a central hole to allow it to be self-draining. The problem
encountered was that the repose pile of solids in the inverted cone, which
formed a reasonably concentric conical heap, would not spill evenly over the
circular ridge in the manner of a liquid weir as expected. It was first thought that
the circumferential bias was due to an eccentric fill point. However, after
working on this meticulously to direct the feed to a precise central location, it
was seen that the repose surface of the cone did not grow as a smooth rate but
increased as a succession of radial avalanche surges down the path of least
resistance.
The deposit of each surge increased the local resistance in the formative pile
stage, so the next surge found a different route around the periphery of the pile.
Alas, when the pile filled the inverted cone, the surge that first overflowed the
rim did not build up the local surface to offer increased resistance, so following
surges took the same biased path.
Protracted efforts were made to obtain an even overflow around the circumfer-
ence by fitting a castellated rim with adjustable weir gates and successive ’tweak-
ing‘ of their settings. Many miserable and dusty hours later, defeat was eventually
conceded as it slowly occurred to the engineers that the path that offered the least
resistance would always attract the following surges down the same part of the
repose slope and so the overflow from the cone would never be even.
CASE STUDY 6 413
Main support Flat plate: end radius

ribs to self-seat to leave annular gap
in hopper against hopper wall
Figure 16.10 Central insert to expand flow channel
Time to call a specialist!

The equipment layout did not permit the adoption of an effective fill geometry that
would counter segregation, so attention was directed to modifying the discharge
pattern. An insert system (Figure 16.10) was developed that prevented central
discharge and provided instead a ‘tributary’ collecting system. This allowed
multiple flow channels to develop at various radial and circumferential locations
in proportion to the relevant cross section of the silo that they served. An important
feature of this construction was that baffles above the outlet port prevented the
development of preferential flow from any of the sectors. The equipment included
a triangular, pyramid shaped insert that had three ribs to self-seat the device in the
bottom cone of the hopper above the outlet. The walls of this pyramid left spaces at
the bottom for one-third of the outflow to pass through each opening.
Three sets of plates were placed on the hopper cone, the lower edges of which
rested against the faces of the central pyramid insert to allow discharge from
underneath the plates. These plates were spaced apart by ribs, to provide extra
flow routes for the hopper contents to pass from different radii of the hopper
cross-section to the openings provided by the insert.
The initial draw down pattern was completely even until the surface reached
the top of the conical section. Thereafter, the surface profile reflected multiple,
preferential extraction points from different areas of the silo cross-section, but as
these represented the correct proportion of the different grades of fractions, the
discharged product was of the required particle size distribution.
The importance of detail and comprehensive route review was emphasized
when a second hopper of similar construction was similarly adapted. Initial
414 CASE STUDIES
results were surprisingly unsatisfactory, with marked segregation as the contents

approached the end of the hopper discharge. It was found that, whereas the first
hopper was fitted with a valve that fully opened, the second hopper had a
different valve, which was opened only partially. This preferentially emptied one
side of the hopper contents and meant that segregation once again became a
problem particularly in the final portion of material emerging from the hopper.
Modification to the valve mechanism overcame this difficulty.
16.7 CASE STUDY 7
Dust Emission Problems during Tanker Unloading Operations
A company is experiencing dust emission problems during the pneumatic lifting

of soda ash from a 28 m3 road tanker to the receiving bin shown in Figure 16.11.
For example, large amounts of dust are escaping from the access door, silo-saver
(pressure relief valve) and filter housing flanges. Also, the bin is occasionally
over-filled (causing more dust emissions).
The specification for the unloading system is summarized below:
solids conveying rate, ms 22 t/h;
air mass flow rate, mf 0:433 kg/s (from blower performance curves, which
show intake volume 21:7 m3/min at air density rf ¼ 1:2 kg/m3);
inside diameter of pipe, D ¼ 150 mm; total length of conveying pipeline,

L ¼ 35 m (including total length of vertical lift, Lv ¼ 20 m);
maximum air temperature (into receiving bin), t 70 C;
Figure 16.11 Pneumatic unloading of road tanker

CASE STUDY 7 415
particle size range of soda ash, 50 d 1000 mm;
median particle diameter, d50 ¼ 255 mm;
solids particle density, rs ¼ 2533 kg/m3;
loose-poured bulk density, rbl ¼ 1040 kg/m3;
volumetric capacity of tanker ¼ 28 m3;
initial pressure in tanker ¼ 100 kPa g (i.e. before opening discharge valve/s);
steady-state pressure drop ¼ 70 kPa (as seen by the blower);
blower is positioned on site – pressurizes the tanker vessel, which acts like a
blowtank.
The existing dust filter has a filtration area of 15 m2 (Figure 16.12) and is fitted
with a fan and polyester needle-felt bags. From performance curves, the fan
can extract 33.3 m3/min of air at 150 mm H2O ¼ 1.5 kPa. At first glance, this
appears to cover quite adequately the blower capacity of 21.7 m3/min. However,
transient effects and filtration efficiency also have to be evaluated.
Evaluation of Unloading Operation
Dust emissions occur during both the end-of-cycle purge sequence and especially
the subsequent clean-blow cycle (required to clean out the tanker). Note:
dust emissions do not occur during steady-state operation (namely, constant

pressure, air flow, conveying rate);
both ‘air-only’ operations are unavoidable (i.e. a new ‘self-cleaning’ tanker

cannot be used).
Figure 16.12 Receiving bin with existing 15 m2 filter

416 CASE STUDIES
The company was asked to take pressure measurements with respect to time.
The pressure decay in the tanker (during either air-only operation) was approxi-
mately linear and the maximum rate was found equal to ð90 kPa g – 35 kPa g)/
(11 s) ¼ 5 kPa/s. Note, this ‘supply’ of air may occur during an end-of-cycle
purge sequence and hence, is additional to the steady-state air flow rate of
0.433 kg/s. The filter has to cope with this maximum possible flow rate of air
(including dust loading).
Steady-State Operating Conditions
The following steady-state parameters are calculated from the specification given
above:
density of air in bin, rfe ¼ 1:028 kg/m3;
air flow, mf ¼ 0:433 kg/s;
flow rate of air into bin, Qfe 25:3 m3/min;
air velocity into bin, Vfe ¼ 23:8 m/s. This is not considered excessive for dilute-
phase conveying of soda ash, as long as sufficient volumetric capacity is
available in the bin for the air to expand;
existing filter opening (aperture) ¼ 0:7 m2.
Therefore, the velocity of air into the filter upstand, Vup ¼ 0:6 m/s. Based on
experience with similar materials and on the results of free settling tests, this is
considered to be quite acceptable and the dust loading should be only moderate.
However, if the bin is filled above the high-level mark, which is 2.5 m from
the top of the bin, then additional turbulence may cause increased loading on the
filter – this is considered in more detail later (when selecting a new filter). For the
present study, it is assumed that filling ceases when the high-level is reached
(i.e. ideal situation). Using appropriate values of ideal filtration velocity and
correction factors for temperature, particle size, dust loading, etc., then:
effective filtration velocity, Eff. Vfilt ¼ 2:0 m3/min/m2 ¼ ‘air-to-cloth’ ratio;
minimum filter area, Afilt ¼ 13 m2.
Hence, the existing fan and filter (Afilt ¼ 15 m2) should be adequate for steady-
state operation (as long as the receiving bin is not filled above its high level).
Air-Only Operations and New Filter
Maximum pressure decay ¼ 5 kPa/s (in addition to steady-state flow – worst

case scenario). This equates to an additional air flow of 1.42 kg/s.
CASE STUDY 7 417
Hence, maximum Qfe ¼ 108 m3/min > existing filter capacity (i.e. a larger filter
is needed).
Assume new filter area 45 m2 with fan (108 m3/min at 150 mm H2O ¼ 1.5 kPa).
Standard aperture opening ¼ 1:84 m2.
This will generate Vup 1 m/s, which should be sufficient to provide above
moderate dust loading (especially if the bin is filled above the designated high
level). Also, due to high-velocity purging (and particle attrition), the dust level
may increase by up to 5% (especially in the 3 – 10 mm range).
Using appropriate values of ideal filtration velocity and correction factors, then:
effective filtration velocity, Eff. Vfilt ¼ 1:6 m3/min m2;
minimum filter area, Afilt 68 m2 (worst case scenario).
Hence, at least 50 m2 or preferably 60 m2 of filter area would be required (with

a larger capacity fan). However, if the following improvements are implemented,
then it may be possible to select a smaller filter.
Modifications to Filter and Bin
To reduce dust loading and improve filtration efficiency, the following modifica-
tions are recommended.
An upstand with a large as possible aperture (i.e. opening) should be custom-
built for the new filter (e.g. for a 45 m2 filter, the suggested 2005 mm 1220 mm
aperture provides a clearance of 200 mm between the bags and the side walls of
the upstand). Also, the upstand should be tall enough to provide a minimum of
1.5 m clearance between the underside of the bags and the top of the bin. These
modifications, together with a larger-diameter tee-bend at the end of the pipeline
to reduce conveying velocity, will reduce the dust loading (by reducing upflow
velocity, allowing more time for particle settling and allowing space for the new
velocity profile to develop in the upstand). This also reduces any damage to the
bags caused by turbulence (the splashing of particles upwards on to the filter
surface – due to high velocity particle stream leaving the pipeline impinging on
the material surface in the bin).
The maximum design pressure of the bin also should be determined, so that a
suitable (and reliable) silo-saver can be installed. Assuming a maximum possible
pressure of say, 5 kPa (i.e. before buckling), the silo-saver should be set at 4 kPa.
Note, a large-flow unit should be selected (e.g. 150 or 200 mm nominal bore).
Based on the above improvements, the filter requirements were re-calculated:
larger aperture opening 2:45 m2. This will generate Vup 0:7 m/s (maximum),
which is quite acceptable. The dust loading should be moderate.
Using appropriate values of ideal filtration velocity and correction factors, then:
effective filtration velocity, Eff. Vfilt ¼ 2:22 m3/min/m2.
minimum filter area, Afilt ¼ 49 m2 (worst case scenario).

418 CASE STUDIES
Figure 16.13 Modified Receiving bin with new 45 m2 filter
Hence, with a fan rated at say, 108 m3/min at 150 mm H2O¼1.5 kPa, a 45 m2
filter should be adequate, as shown in Figures 16.13 and 16.14, which includes
the modifications to the upstand and pipeline discussed previously. However,
if the bin is over-filled, there is still every possibility that material could block
Figure 16.14 Large-diameter tee-bend at end of pipeline

CASE STUDY 7 419
or restrict the flow path of the air, hence causing over-pressurization of the bin
(and subsequent dust emissions). To alleviate this situation, either this practice
has to be stopped or avoided (e.g. by making sure there is sufficient capacity
before the tanker arrives) or the volumetric capacity of the bin has to be
increased.
One final matter of consideration is the selection of the filter material. With the
larger upstand shown in Figure 16.13, it is recommended to use bags with a
Teflon coating, which should be better suited to higher temperatures and also
provide better cleaning and filtration efficiency. With the bottom of the bags at
least 1.5 m from the top of the bin and assuming that the bin is not over-filled, the
filter surfaces should be ‘safe’ from damage due to particle impact.
Outcome
The above modifications and recommendations were pursued by the company,

resulting in the complete elimination of dust emissions. Work in the vicinity of
the soda ash silo now proceeds without interruption (i.e. irrespective of tanker
unloading operations). This project was so successful, the company incorporated
the same principles and criteria into the design of a new production plant, as
shown in Figure 16.15.
Figure 16.15 Pneumatic tanker unloading system at new production plant

420 CASE STUDIES
16.8 CASE STUDY 8
Pneumatic Conveying and Injection of Mill Scale
Oxygen lances often are used in steel plants for hot metal pretreatment.
With the increasing cost of supplying compressed oxygen for such applica-
tions, one company investigated the possibility of recycling and injecting mill
scale (i.e. the waste material from rolling operations) into the hot metal
launders or directly into the ladles. Chemical tests demonstrated that the
mill scale contained sufficient oxygen for this purpose. Hence, it was required
to design a pneumatic conveying system according to the following
specification:
mill scale (sub 10 mm; loose powred bulk density, rbl ¼ 3500 kg/m3; particle
density, rS ¼6000 kg/m3);
mass of mill scale required for each tapping operation 300 – 3000 kg (depend-
ing on hot metal properties);
each batch size is to be delivered evenly during the tapping operation (usually
8 min);
noise generated during transportation must be less than 80 dBA at a distance of

1 m (due to the pipe work having to travel alongside a control room).
The above material delivery requirements equated to a steady-state conveying

solids mass flow rate, ms ¼ 2:25 – 22.5 t/h, depending on the level of oxidation
required. To determine reliable operating conditions (e.g. minimum air flows and
operating pressures) and generate sufficient steady-state data for modelling
purposes, several tests was carried out on fresh samples of mill scale using the
following test rig: Tandem 0.9 m3 bottom-discharge blowtanks (Figure 16.16);
mild steel pipeline (inside diameter of pipe, D ¼ 105 mm; total length of convey-
ing pipeline, L ¼ 108 m; total length of vertical lift, Lv ¼ 7 m; number of 90
bends, Nb ¼ 5).
Note, the bottom-discharge blow tanks used for this test program were not
considered appropriate for the final application (e.g. higher air flows needed to
cope with the heavy and flooding nature of this material; insufficient feed rate
control accuracy); however, they were found adequate for the purpose of
generating steady-state operating conditions.
Using a sound meter, sound levels also were recorded at various stages during
the test program. The readings were taken out in the open on top of the
laboratory roof approximately 1 m from the pipeline and found to be 66 dBA
(background noise prior to conveying) and 72 dBA (during conveying). The latter
level was considered sufficiently low for the final application.
By employing the test-design procedure described by Pan and Wypych (1992),
models were developed for: horizontal straight sections of pipe; vertical straight
CASE STUDY 8 421
Figure 16.16 Tandem 0.9 m3 blowtanks used for the test program
sections of pipe; 1 m radius 90 bends. The resulting ‘PCC Model’ and the Weber
A4 Model (Wypych et al., 1990) were employed to predict lines of constant ms for
the test rig pipeline and the various pipeline configurations being considered for
the two submerged arc furnaces.
To establish optimal operating conditions, it was realised that air flows could
be minimized by metering or controlling the flow rate of material into the
pipeline. This also would meet the requirement of achieving a turndown ratio
of 10:1 on conveying rate (namely, ms ¼ 22:5 – 2.25 t/h). The screw-feeding blow
tank (Wypych, 1995) shown in Figure 16.17 was found suitable for this material
and application.
Using the above models and method of feeding, the following optimal
operating conditions were predicted for the extreme case of maximum pipeline
length and maximum throughput. Note, a stepped-diameter pipeline was
selected to minimize pressure drop, air mass flow rate and hence, conveying
air velocities.
D ¼ 102=128 mm; L ¼ 120 m; Lv ¼ 22 m; Nb ¼ 5; t ¼ 20 C

ms ¼ 22:5 t=h; air mass flow rate; mf ¼ 0:46 kg=s
Total pipeline air pressure drop; pt ¼ 180 kPaðPCC ModelÞ--205 kPa
ðWeberA4ModelÞ
Superfacial air velocity; Vf ¼ 16--38 m=sðD ¼ 102 mmÞ and 24
--30 m=sðD ¼ 128 mmÞ
422 CASE STUDIES
Figure 16.17 General arrangement of screw-feeding blow tank
Based on these concept design parameters, the plant was designed, installed and
commissioned and has been operating successfully ever since. The operators
confirmed that the blow tank pressure reached approximately 200 kPa g
when ms ¼ 22:5 t/h was selected for the furthest tapping point (namely,
L ¼ 120mÞ.
Figure 16.18 Schematic layout of mill scale pneumatic injection system

CASE STUDY 8 423
Figure 16.19 Screw-feeding blow tank
Figure 16.20 Fused alumina-zircon bends

424 CASE STUDIES
A schematic layout of the plant is shown in Figure 16.18 and one of the screw-
feeding blow tanks is shown in Figure 16.19 Special fused alumina-zircon bends
(Figure 16.20) were selected to handle this extremely dense and abrasive
material.
Notation
a exponent in Equation (13.13) —

a surface area of particles per unit bed volume m2
A cross-sectional area —
A cyclone body length (Figure 9.5) m
A surface area of element of fuel–air mixture m2
Af flow area occupied by fluid m2
Ap flow area occupied by particles m2
AðnÞ rate constant for granule
h attrition i m3/s
r ðr r Þgx3
Ar Archimedes number Ar ¼ f p m2 f —
b exponent [Equation (13.13)] —
B length of the cyclone cone (Figure 9.5) m
B minimum diameter of circular hopper outlet m
Bnuc ðnÞ rate of granule growth by nucleation m6 s1
c particle suspension concentration kg/m3
C fuel concentration in fuel–air mixture m3 fuel/m3
C length of cylindrical part of cyclone (Figure 9.5) m
C particle volume fraction —
C suspension concentration —
CB concentration of the reactant in the bubble mol/m3
phase at height h
CB suspension concentration in downflow section —
of thickener
CBH concentration of reactant leaving the bubble phase mol/m3
CD drag coefficient [Equation (2.5)] —
CF concentration of feed suspension —
CfL lower flammability limit m3 fuel/m3
CfU upper flammability limit m3 fuel/m3
Cg specific heat capacity of gas J/kg K
CH concentration of reactant leaving the reactor mol/m3

426 NOTATION
CL suspension concentration in underflow of thickener —

Cp concentration of reactant in the particulate phase mol/m3
Cpair molar specific heat capacity of air J/kmol K
Cpfuel molar specific heat capacity of fuel J/kmol K
CS sediment concentration —
CT suspension concentration in upflow section —
of thickener
CV suspension concentration in overflow of thickener —
C0 concentration of reactant at distributor mol/m3
C0 initial concentration of suspension —
C1 constant [Equation (6.22)] s/m6
D diameter of bed, bin, cyclone (Figure 9.5), —
pipe, tube [Equation (6.2)], vessel
dBV equivalent volume diameter of a bubble m
dBvmax equivalent volume diameter of a bubble (maximum) m
dBVS equivalent volume diameter of a bubble at m
the surface
dd average drop diameter m
De equivalent tube diameter [Equation (6.3)] m
ðdp=dtÞmax maximum rate of pressure rise in dust explosion bar/s
e coefficient of restitution for granule collision —
E diameter of solids outlet of cyclone (Figure 9.5) m
E reaction activation energy in Arrhenius equation s1
[Equation (15.2)]
E(S2) standard error (standard deviation of variance —
of a sample)
ET total separation efficiency —
Eu Euler number —
F cumulative frequency undersize mm1
F volumetric flow rate of feed suspension to thickener —
f friction factor for packed bed flow —
FD total drag force N
ff hopper flow factor —
fg Fanning friction factor —
Fgw gas-to-wall friction force per unit volume of pipe Pa/m
FN number of particles per unit volume of pipe m3
fp solids-to-wall friction factor [Equation (8.19)] —
fn fraction of nuclei formed by n drops —
Fp form drag force N
Fpw solids-to-wall friction force per unit volume of pipe Pa/m
Fs drag force due to shear N
Fv force exerted by particles on the pipe wall per unit N/m3
volume of pipe
Fvw van der Waals force between a sphere and a plane N
fw wall factor, UD =U1 —
fwet fraction of the powder surface welted by m2/m2
spray drops
NOTATION 427
f(x) differential size distribution dF/dx m1or mm1

g acceleration due to gravity m/s2
G solids mass flux ¼ Mp =A kg/m2 s
G(n) volumetric growth rate constant for coating m3/s
g(x) weighting function [Equation (1.5)] —
G(x) grade efficiency —
G(x) linear growth rate constant for coating m/s
h depth of sampling tube below surface m
[Equation (1.15)]
h heat transfer coefficient W/m2 K
h height of interface from base of vessel m
h thickness of liquid coating on a granule m
H height of bed m
H height of powder in bin m
H height of solids in standpipe m
ha measure of roughness of granule surface m
Hc depth of filter cake m
He equivalent length of flow paths through m
packed bed [Equation (6.3)]
Heq depth of cake equivalent to medium resistance m
hgc gas convective heat transfer coefficient W/m2 K
hgp gas-to-particle heat transfer coefficient W/m2 K
Hm thickness of filter medium m
hmax maximum bed-to-surface heat transfer coefficient W/m2 K
Hmf height of bed at incipient fluidization m
hpc particle convective heat transfer coefficient W/m2 K
hr radiative heat transfer coefficient W/m2 K
h0 initial height of interface from base of vessel m
h1 height defined in Figure 3.9 m
HðyÞ function given by HðyÞ ¼ 2:0 þ y=60 —
[Equation (10.5)]
j reaction order —
J length of gas outlet pipe of cyclone (Figure 9.5) m
k reaction rate constant per unit volume of solids mol/m3 s
K height of inlet of cyclone (Figure 9.5) m
KC interphase mass transfer coefficient per unit s1
bubble volume
kg gas conductivity W/m K
KH Hamaker constant [Equation (13.1)] Nm

Kih elutriation constant for size range xi at height h kg/m2 s
above distributor

Ki1 elutriation constant for size range xi above TDH kg/m2 s
KSt proportionality constant [Equation (15.6)] bar m s
K1 constant [Equation (6.3)] —
L height above the distributor m
428 NOTATION
L length of pipe m
L volumetric flow rate of underflow suspension m3/s
from thickener
L width of inlet of cyclone (Figure 9.5) m
LH length of horizontal pipe m
Lv length of vertical pipe m
M mass flow rate of solids feed to separation device kg/s
M mass of solids in the bed kg
MB mass of solids in the bed kg
mBi mass fraction of size range xi in the bed —
MC mass flow rate of coarse product at solids discharge kg/s
Mf mass flow rate of fines product at gas discharge kg/s
Mf gas mass flow rate kg/s
MOC minimum oxygen for combustion m3O2/m3
MP solids mass flow rate kg/s
n exponent in Richardson–Zaki equation —
[Equation (3.24)]
n number of cyclones in parallel —
n number of particles in a sample —
N diameter of gas outlet of cyclone (Figure 9.5) m
N number of granules per unit volume in the system —
N number of holes per unit area in the distributor m2
N number of samples —
NðtÞ total number of granules in the system at time t —
Nu Nusselt number (hgp x=kg ) —
Numax Nusselt number corresponding to hmax —
nðn; tÞ number density of granule volume n at time t m6
p pressure Pa
p proportion of component in a binary mixture —
pc capillary pressure [Equation (13.2)] Pa
Pr Prandtl number ðCg m=kg Þ —
ps pressure difference [Equation (6.29)] Pa
q gas flow rate m3/s
Q volume flow rate m3/s
Q volume flow rate of gas into bed ð¼ UAÞ m3/s
Q volume flow rate of suspension to thickener m3/s
Qa rate of heat absorption by element of fuel-air W
mixture
Qf volume flow rate of gas/fluid m3/s
Qin volume flow into granulator m3/s
Qinput rate of heat input to element of fuel–air mixture W
Qmf volume flow rate of gas into bed at Umf ð¼ Umf AÞ m3/s
Qout volume flow out of granulator m3/s
Qp volume flow rate of particles/solids m3/s
Qs rate of heat loss to surroundings W
r radius of curved liquid surface m
R radius of cyclone body m
NOTATION 429
R radius of sphere m
R universal gas constant J/kmol K
R0 drag force per unit projected area of particle N/m2
rc filter cake resistance [Equation (6.17)] m2
r1 , r2 radii of curvature of two liquid surfaces m
Re Reynolds number for packed bed flow —
[Equation (6.12)]
Remf Reynolds number at incipient fluidization —
(Umf xsv rf =mÞ
Rep single particle Reynolds number [Equation (1.4)] —
Ri rate of entrainment of solids in size range xi kg/s
rm filter medium resistance [Equation (6.24)] m2
Rp average pore radius m
s granule saturation —
S total surface area of population of particles m2
S estimate of standard deviation of a mixture —
composition
Sv surface area of particles per unit volume of m2/m3
particles
S2 estimate of variance of mixture composition —
SB surface area of particles per unit volume of m2/m3
particles
Stdef Stokes deformation number —
Stk Stokes number [Equation (13.4)] —
Stk critical Stokes number for coalescence —
Stk50 Stokes number for x50 —
t time s
tp drop penetration time s
T reaction temperature K
TDH transport disengagement height m
Tg gas temperature K
Tig ignition temperature K
Ts solids temperature K
u granule volume m3
u and v size of two coalescing granules m
U superficial gas velocity ð¼ Qf =AÞ m/s
UB mean bubble rise velocity m/s
Uc representative collision velocity in the granulator m/s
Uch choking velocity (superficial) m/s
UD velocity in a pipe of diameter D m/s
Uf actual or interstitial gas velocity m/s
UfH interstitial gas velocity in horizontal pipe m/s
Ufs superficial fluid velocity m/s
Ufv interstitial gas velocity in vertical pipe m/s
Ui actual interstitial velocity of fluid m/s
Uint interface velocity m/s
Um superficial velocity at which hmax occurs m/s
430 NOTATION
Umb superficial gas velocity at minimum bubbling m/s

Umf superficial gas velocity at minimum fluidization m/s
Ums minimum velocity for slugging m/s
Up actual particle or solids velocity m/s
UpH actual solids velocity in horizontal pipe m/s
Ups superficial particle velocity m/s
Upv actual solids velocity in vertical pipe m/s
Ur radial gas velocity m/s
UR radial gas velocity at cyclone wall m/s
Urel relative velocity ð¼ Uslip ¼ Uf ¼ Up ) m/s
jUrel j magnitude of Urel m/s
UrelT relative velocity at terminal freefall m/s
Usalt saltation velocity (superficial) m/s
Uslip slip velocity ðUf Up Þ m/s
UT single particle terminal velocity m/s
UT2.7 single particle terminal velocity for a particle 2.7 m/s
times the mean size
UTi single particle terminal velocity for particle size xi m/s
Uy particle tangential velocity at radius r m/s
UyR particle tangential velocity at cyclone wall m/s
U1 velocity in an infinite fluid m/s
n characteristic gas velocity based on D m/s
n granule volume m3
vs powder velocity in the spray zone m/s
V granulator volume m3
V volume of element of fuel–air mixture m3
V volume of filtrate passed m3
V volumetric flow rate of overflow suspension from m3/s
thickener
Vapp approach velocity of granules m/s
Vd volume of a drop m3
Veq volume of filtrate that must pass in order to m3
create a cake
w average granule volume defined in Equation (13.13) m3
w liquid level on dry mass basis g liquid/g
dry powder
ws width of the spray m
w critical average granule volume for coalescence m3
x granule or particle diameter m
x mean particle diameter m
x critical average granule volume for coalescence m
xa arithmetic mean diameter (Table 1.4) m
xaN arithmetic mean of number distribution m
xaS arithmetic mean of surface distribution m
xC cubic mean diameter (Table 1.4) m
xcrit critical particle size for separation [Equation (9.20)] m
xg geometric mean diameter (Table 1.4) m
NOTATION 431
xh harmonic mean diameter (Table 1.4) m

xhV harmonic mean of volume distribution m
xNL number-length mean m
xNS number-surface mean m
xp mean sieve size of a powder m
xp sieve size m
xq quadratic mean diameter (Table 1.4) m
xqN quadratic mean of number distribution m
xs equivalent surface sphere diameter m
xSV surface-volume diameter (diameter of a sphere m
having the same surface/volume ratio as
the particle)
xv volume diameter (diameter of a sphere having the m
same volume as the particle)
x50 cut size (equiprobable size) m
y gap between sphere and plane [Equation (13.1)] m
Yd dynamic yield stress of the granule —
factor [Equation (7.30)] —
yi composition of sample number i —
z log x —
z depth of penetration of liquid into powder mass m
Z Arrhenius equation pre-exponential constant s1
[Equation (15.2)]
Z0 Arrhenius equation pre-exponential constant mol fuel/
[Equation (15.5)] (m2 fuel s)
as factor relating linear dimension of particle to its —
surface area
aV factor relating linear dimension of particle to —
its volume
a significance level —
b coalescence kernel or rate constant s1
b ðU Umf Þ=U —
b0 coalescence rate constant [Equation (13.12)] —
b1 ðu; nÞ coalescence rate constant [Equation (13.12)] —
bðu; n u; tÞ coalescence rate constant for granules of s1
volume u and ðu nÞ at time t
g surface tension N/m
g cos y adhesive tension mN/m
d effective angle of internal friction deg
p static pressure drop Pa
ðpÞ pressure drop across bed/cake Pa
ðpc Þ pressure drop across cake Pa
e granule porosity or voidage —
eb porosity of voidage of powder bed —
emin minimum granule porosity or voidage reached —
during granulation
432 NOTATION
y dynamic contact angle of the liquid with the —

powder
m liquid viscosity Pa s
rg granule density kg/m3
rl liquid density kg/m3
rs solid density kg/m3
a dimensionless spray flux —
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Index
References to figures are given in italic type. References to tables are given in bold type.
20 litre sphere 380–381, 381 batch flux plot 56

for downwards-flowing liquid 62
abrasion for thickeners 64–66
in cyclones 257 alternative form 66–67
and particle size reduction 327 for upwards-flowing liquid 63
adsorption, and particle size worked example 73–76
enlargement 338 batch settling
aeration test 56–59
case study 404–405 worked example 73–76
in pneumatic systems 226–228 type 1 56–57
in standpipes 233 type 2 58
aerosols, drug delivery 367 bed density 172
air bends in pipelines 221–222, 222
behaviour of colloids in 130–131 Bernoulli equation 97
isoelectric point 125 Bingham fluids
air knife 226 worked example 112–113
alumina, isoelectric point 125 yield stress 99–100
aluminium, explosion parameters 382 blow tank, dense-phase pneumatic
alveoli 359–360 transport 228–229
drug permeability 367 blowers
particle interaction 365 dilute-phase pneumatic transport
Andreason pipette 15 222–223
applications rating, case studies 399
fluidized beds Bond’s law 316–317, 316–317
chemical processes 191–193, 400–404 breakage rate, and particle size
reactor model 194–198 reduction 319
as mixer 300–301 Brownian motion 118–120
physical processes 191 and particle diffusion 119–120, 119
granulation 337, 354–355, 355 and particle size determination 15
nanoparticles 144–145 in respiratory tract 364
assumptions, particle size measurement, worked example 145–146
sedimentation 13 bubble size, fluidization 177
bubbling flow 173–174, 173, 176–177
baffles, in fluidized bed 404 case study 398
ball mill 325–326 and particle density 180–181

442 INDEX
bubbling flow (Continued) shear thinning 141, 142

reactor modelling 194–198 surface forces 117–118, 120–121
in standpipes 232 EDL forces 124–127, 146–148
two-phase theory 180–181 van der Waals forces 121–124
bulk density, packed beds 173 viscosity 135–136
bypass line, and plug breakup 226 combustion, overview 374–378
combustion rate, dust 378–379
cake filtration comminution see size reduction
cake washing 159–160 concentration interface 54–56
compressible cake 160–161 in batch settling 56–58
filter resistance 159 height at time 59–60
incompressible cake 157–160 worked example 71–72
calcite, isoelectric point 125 containment, of hazardous
calcium carbonate, production 400 equipment 370
carbon dioxide, and explosion control 386 continuity, pneumatic transport
Carman-Kozeny equation 15, 19, 154–155, 216–217
156–157 convective mixer 300
carryover see entrainment core flow 266, 267
case studies Coulombic interaction 128–129
blowers 399 Coulter counter analysis, worked
dryer 403–404 example 20–23
fluidized bed 395–399 cracks, in particles 313–314
hoppers 404–405 crushers 321–322
feeder overloading 406 see also size reduction
catalysis, use of fluidized beds in 192, 193 crushing, definition 326
central tendency 7–10, 9 crystals, fracturing 312–314
centrifugal pumps 105–106 curved pipes 221
centrifuge cyclones 247–259
and Brownian motion 15 overview 247–248
in colloidal sediment concentration 134 abrasion 257
choking velocity, in dilute phase transport blockages 258
system design 219 design, worked example 259–260
coal slurry 92 in dilute-phase transport 222
coalescence rate, granulation 351–352 discharge hoppers 258
coarse crushing 326 efficiency 255–257
coarse particles, definition, and dust loading 257
entrainment 183 worked example 260–263
coarse product 249 in fluidized bed reactors 199
cohesive powders 298–299 in parallel 259
cohesivity rheology 249
and particle size reduction 327 scale-up 253–254
see also surface forces schematic diagram 248
colloid mill 325 separation efficiency 252–253
colloids in series 259
definition 117 theoretical analysis 250–252
in air 130–131 types 257
see also dust vortex radius 252
Brownian motion 119–120, 119
drag forces 131 Debye length 126
elasticity 143–144 deformation behaviour, and
sediment concentration 133–134 granulation 347–348
INDEX 443
dense-phase pneumatic transport 211, and particle shape 33–34

224–226 and Reynolds number 30, 34
overview 212 drugs, delivery systems, via respiratory
advantages 225 tract 367–369
continuous 224 dryer, case study 403–404
discontinuous 224–225 dryers 191
powder assessment 230 dune flow 224–225
system design 230 dust
deposition velocity, slurry 92–93, 104, combustion 378–379, 379–383
see also saltation emission, during tanker
design unloading 414–419
cyclones, worked example 259–260 explosions
dense-phase pneumatic transport analysis 381–382, 382–383
systems 230 equipment 381–382
hoppers 268–272 characteristics 379–380
summary 278 venting 384–385
pipes see also colloids
for dilute-phase pneumatic
transport 219–225 EDL
for slurries 103, 108 calculation, and surface forces 147
detonations 374 colloids 124–127
diameter (of particle) 1–3 worked example 146–148
and batch settling 54 and viscosity 140
equivalent sphere 3, 3 Einstein, Albert 119
worked example 17 elasticity, colloidal suspensions 143–144
and sieving, worked example 24 electrical double layer forces see EDL
surface-volume 3 electron microscopy 13
and terminal velocity 31 electrostatic forces
see also size and particle size enlargement 340
differential frequency distributions 4 in respiratory system 364
diffusion electrozone sensing 15
colloidal particles, due to Brownian elutriation see entrainment
motion 119–120, 119 entrainment
in respiratory tract 364 definition 182
dilatant flow 95 particle separation via 297
dilute-phase pneumatic transport rate 184–186
overview 212 equipment
closed-loop 223 dust explosion investigation 380–381
gas velocity 219 granulation 352–355
pipe design 219–225 hazardous, containment 370
pressure drop 217–218 protective 370–371
dimensions, regular particles 2 size reduction 320–326
diplegs 258 Ergun equation 155–156, 157
dipole moment, inter-atomic 122 erosion, of fluidization reactor 199
disengagement zone 183 errors
distribution curves electrozone sensing 15
conversion 5–7 particle size, sampling 16–17
worked example 18 sedimentation analysis of particle
downflow 63 size 15
drag 29–31 Euler number 249
colloids 131 explosion pressure, dust explosions 382
444 INDEX
explosions 374 fluidized beds

analysis 381–382, 382–383 applications
control 379–380, 383–386 calcium carbonate production, case
ignition energy 382 study 400–402
parameters for materials 382 chemical processes 191–193
and particle size 379 reactor model 194–198
dryer, case study 403–404
Fanning friction factor, turbulent flow, as mixer 300–301
power-law slurry 99 physical processes 191
feeder systems, dilute-phase fluids
transport 222 Bingham
Feret’s diameter 2 worked example 112–113
fibrous materials 327 yield stress 99–100
filtration 159–161 as carrier media for milling 328
in slurry de-watering 108 inertia 30
fine particles see colloids Newtonian
fine product 249 and colloids, flow behaviour 135–136
flames 374, 384 shear stress and shear rate 94
flammability limits 377–378 power-law, Reynolds number 98
flocculation 128 turbulent flow, transition velocity 98
and surface force control, colloids viscosity, and particle settling 51–52
127–128 yield-stress 100
flow flux plot
slurry 91–93 for batch settling, and height-time
homogeneous 93–94 curve 59–61
flow area, suspensions 52–53 for downwards-flowing liquid 62
flow behaviour see fluids; rheology for flowing fluids, worked example
flow rate 76–79
Bingham plastic slurries 101 thickeners 64–66
and cyclone efficiency 255–257 alternative form 66–67
in standpipes 235–236 for upwards-flowing liquid 63
fluid catalytic cracking (FCC) 192, 193, Fraunhofer theory 16
237 freeboard 183, 184
fluid energy mill 324 frequency distribution curves
fluid velocity, and particle separation, in comparison 5
fluidization, non-bubbling 178 conversion 5–6
fluidization size 4
applications, granulators 354–355, friction
355 between powder and hopper wall
bubbling 173–174, 173, 176–177 276–277
and particle density 180–181 internal to suspension, shear cell
reactor model 194–198 tests 276
two-phase theory 180–181 and pressure drop, in pneumatic
in dense-phase pneumatic transport 218
transport 228 solids-to-wall, dilute-phase pneumatic
homogeneity 403–404 transport 220
non-bubbling, bed expansion turbulent flow, power-law slurry 99
178–179 friction factor, definition 97
overview 169–171 fuel concentration
and standpipes 232–235 and flammability limit 377–378
and velocity 170 and ignition 376–377
INDEX 445
gas between bed and fluid surface

acceleration, and pressure drop, in 188–190
pneumatic transport 218 Hedstrom number, Bingham plastic
density, and choking velocity 214 slurries 102
flow height-time curve, batch settling, and flux
between system components, plot 59–61
prevention 402–403 hematite, isoelectric point 125
in bubbling fluidization 180–181, 180 Herschel-Buckley model, slurries 100
and fluidization 171 heterogeneous flow, slurry 92
loss 198 homogeneous flow, slurry 92
heat transfer to particles 186–187 homogeneous slurry, rheology 93–94
velocity, relation to particle hopper flow factor 269
velocity 215–216 conical channels 279–280
gas distributor, fluidizing reactor 198 determination from shear cell
Geldart powder classification 174–177, 176 tests 277–278
and dense-phase pneumatic transport 230 hoppers
Group A powders 182, 189 case study 404–405
heat transfer 189 feeder overloading 406
Group B powders 181–182 discharge aids 281
Godbert-Greenwald furnace 381–382 inserts 407–409, 408
granulation 341–355 and particle size segregation
equipment 352–355 412–413
liquid drop size 344 loss-in-weight feeding 409–410
overview 337–338, 341–342 mass flow 265
processes percolation 296
consolidation 342, 345–346 pressure on base 281–284
granule breakage 349 hydraulic characteristic, slurry 92, 93
growth 346–349 hydrodynamic volume 172
overview 342–343, 342 hydrophobic force 129
wetting 342, 343–345
rate of growth 350–351 ignition
in reducing health risks 370 definition 374
simulation 349–352 delay 376
granulators 352–355, 353 sources, dust explosions 384
grinding ignition energy
definition 326 definition 375
slurry 105 dust explosions, measurement 382
see also size reduction image analysis systems, particle size, and
microscopy 13
Hagen-Poiseulle equation 97 impaction, in respiratory tract 363,
Hamaker constant 123–124, 123 366–367
hammer mill 322–323 induction growth 347
hardness, and particle size reduction 327 inhalers
hazard control dry powder 368–369, 369
dry powders 369–371 metered-dose 367, 368
dust explosions 379–380, 383–386 interception, definition 364
containment 386 intermediate region (flow behaviour), and
inerting 386 shape 33
suppression 385–386 isoelectric point (IEP) 125
heat transfer
fluidized beds 186–188 Jenike shear cell 272
446 INDEX
Kick’s law 316, 317 mixture, types 294

Kreiger-Dougherty model, colloidal mixture density, slurry 91
suspension flow behaviour mixtures
137–138 mean composition 302
mixing indices 303
L-valve 400–403 ordered 299
laminar flow quality assessment 301–302
Bingham slurries 101–102 types 293–294
particle behaviour in entrainment 183 variance of composition 302–303
slurries 96–97, 97–99 worked example 305–306
through packed beds 153–155, 155–156, MOC 378, 382–383
15 mode, of population particle size 7
lean phase flow see dilute-phase pneumatic Mohr’s circle 274–275
transport motion
lime 400–402 of solid particles
liquids, drop size, and granulation 344 drag 29–31
lungs 359–360 under gravity 31–32
muds, drilling 92
Martin’s diameter 1–2, 2
mass, distribution, conversion 5–6 nanoparticles 144–145
mass flow 265, 266 see also colloids
in hoppers 267 nasal airways 361, 361
rate 284–285 nebulizer 367, 368
MDI (metered-dose inhaler) 367 net interaction force 129
mean Newtonian fluids
determining appropriate 20 and colloids 136
equivalence of types 10–11 flow behaviour 135–136
harmonic 10 drag curve 30
of population particle size 8 and particle shape 33
arithmetic 8–9 shear stress 94
quadratic 9–10 terminal velocity 32
surface-volume, worked example 19 nitrogen, and explosion control 386
median, of population particle size 7–8 noise measurement 421
melting point, and particle size non-settling slurry 92
reduction 327 nucleation 343–345
Mie theory, laser diffraction 16
milk 94 oil, isoelectric point 125
milling oil separator, collection efficiency, worked
circuit types 328–329 example 36–38
definition 326 optical microscopy 13
see also size reduction ores, roasting 395–399
mills overflow 63
and material types 328 oxidation, particles 124–125
modes of operation 328 oxygen, concentration, and
minimum dust concentration, combustion 378, 382–383
analysis 382 oxygen lance 419–420
minimum oxygen for combustion
(MOC) 378, 382–383 packed beds
mixer granulators 354 depth, and voidage 179
mixers, types 300–301 expansion, non-bubbling 178–179
mixing, types 299–300 for filtration 157–161
INDEX 447
paper pulp 92 population

particles balance, in granulation 349–352
acceleration, and pressure drop, in particle size description by single
pneumatic transport 218 number 7–10
break-up, in cyclones 258 porous materials, particle density
coarse, definition in entrainment 183 measurement 172
colloids, definition 117 positive displacement pumps 106
density, in fluidization 172–173 powders
heat transfer from gases 187 assessment for dense-phase
homogeneity, and distribution transport 230
conversion 7 dry, surface forces 131
non-spherical, packed beds, and fine
156–157 fire risk, overview 373
segregation see size segregation health effects 369–371
size see size flow behaviour, in hoppers 269–270
pH fluidization, classification 174–177, 175
and colloidal surface forces 125, 129 health effects, on respiratory tract
and viscosity 141–143 359–367
and yield stress, colloidal shear cell test, performing 272–273
suspensions 142 power-law models, slurry flow 95–96
pharynx 361–362 power-law slurries, worked
pin mill 323–324 example 109–110
pipes pressure, in fluidized bed, case
bends 221–222, 222 study 395–399
design pressure drop
dilute-phase pneumatic and cyclone efficiency 255–257,
transport 219–225 255–257
slurries 103, 108 fluidization 169–170
flow, yield-stress fluids 100 and pipe bends 221
see also standpipes in pneumatic transport 218
piston pump 107 dense-phase, plug flow 225–226
planes of concentration 60 dilute-phase 217–218
plug flow 224 and system design 219–221
plug formation, avoidance 226–229 in standpipes 234, 235–237
plunger pumps 106 turbulent flow, Bingham plastic
pneumatic transport 211–230 slurries 102
dense-phase 211, 224–226 projected area diameter, calculation,
advantages 225 worked example 24
continuous 224 protective equipment 370–371
discontinuous 224–225 pseudoplastic flow 95
powder assessment 230 pumping, slurry 92
system design 230 pumps 105–108
dilute-phase
gas velocity 219 Quemada model 138
pipe design 219–225
and pressure drop 220 reaction rate, in fluidization reactor 196
vertical, choking velocity 212–214 regular particles, dimensions 2
polyester, explosion parameters 382 respiratory tract
polyethylene, explosion parameters 382 Brownian motion 364
polymers, and surface for reduction and fine powders
127–128 diffusion 364
448 INDEX
respiratory tract (Continued) settling

impaction 363–364, 365–366 batch 53–54
sedimentation 362, 365 in flowing fluids 61–67
flow behaviour 361–362, 361 worked example 76–79
overview 359–360, 360, 361 in still fluids 53–54, 53–61
sedimentation 365 worked example 68–70,
and Stokes number 366, 366 71–72
Reynolds number see also saltation
and drag coefficient 34 settling flux, and suspension
worked example 41, 42 concentration 53–54, 55
and fluidization velocity 171 sewage sludge 92
non-spherical particles 33 shape
and particle density in fluidization 179 constancy 7
power-law fluids 98 and terminal velocity 33–34
ranges 30 shear cell test
and Stokes’ law 29 analysis 274–278
through packed beds, worked worked example 285–287, 287–288
example 161–162 shear diameter 2
rheology shear rate, colloidal suspensions 136–137
definition 134 shear stress, Newtonian fluids 94, see also
colloidal suspensions 134–139 rheology
cyclones 249 shear thinning
in hoppers 268–269 colloidal suspensions 141, 142
slurries 93–94 slurries 95, 96
worked example 111–112 sieve diameter, calculation, worked
risk assessment example 24
fine powders 369–370 sieving 3
see also hazard control silica, isoelectric point 125
Rittinger’s postulate 315 size 1–3
colloids
salt, common 312 and flow behaviour 143
saltating flow, and dense-phase attractive particles 141
transport 225 and sedimentation rate 132–133
saltation determination, fluidization 173
and pipe bends 221 drop, an granulation 344
pneumatic transport 214–215 and dust explosions 379
slurry 92 and energy requirements for size
sampling 16–17 reduction 317
mixtures 302 measurement
Sauter mean 8–9 electrozone sensing 15
scale of scrutiny 301–302 laser diffraction 16
scale-up, cyclones 253–254 microscopy 13
sediment concentration 133–134 permeatry 15
sedimentation 3 worked example 19–20
colloids 133–134 sedimentation 13–15
in de-watering 108–109 worked example 20
in respiratory tract 365 sieving 12–13
segregation, causes and reduction, in cyclones 258
consequences 294–295 and respiratory tract interaction 366
separation, in gas cyclones, separation and size reduction mechanism
efficiency 249–250 choice 326, 327
INDEX 449
and terminal velocity 31 splash zone 183

see also Geldart powder classification Stairmand cyclones 255
size distribution 4–5 standpipes 231–237
arithmetic-normal 11 fluidized flow 232–235
conversion 5–7 in L-valve 401
in granulation 349 packed bed flow 231–232
log-normal 11–12, 12 pressure balance 235–237
and particle size reduction 318–320 steady growth 347
size enlargement see granulation steric repulsion 128
size reduction Stokes diameter 14
energy requirements 314–318 Stokes’ law 13
worked example 329–331 and Reynolds number 29
equipment 320–326 and suspensions 51
fracture mechanisms 312–314 Stokes’ law region
overview 311 drag curve 30
stressing mechanisms 320–321 and particle diameter, as function of
for transport 105 particle density, worked
size segregation 39–41, 294–295 example 35–36
batch settling test 56–59 and terminal velocity 31
in gas cyclones 247–248 Stokes number
in hoppers, and inserts 412–414 cyclones 253–254
mechanisms of action in granule growth 346–347
entrainment 297 and respiratory tract interaction 366, 366
percolation 295–296 stress, and particle cracking 313–314
trajectory segregation 295 superficial velocity 216
via vibration 296–297, 298 fluid 52
reduction 298–299, see also mixing particles 52
slip velocity, definition 215–216 and volumetric fluid flux 179
sludge, definition 91 surface diameter, calculation, worked
slugging 177 example 24
slurry surface forces
de-watering 108–109 calculation
definition 91 summing 129
flow, non-Newtonian models 94–95 worked example 146–147
heterogeneous, flow behaviours 103 colloids 117–118, 120–121
non-Newtonian models, power-law, effect on viscosity 136
pressure-drop predictions electrical double layer (EDL)
96–99 forces 124–127
preparation for transport 104–105 van der Waals forces 121–124
pumps 105–108 and flow behaviour 139–144
yield stress models 99–100 attractive forces 140–144
small particles see colloids repulsive forces 139–140
soda ash 414–415 and particle size enlargement 338–341
solid boundaries, and terminal reduction 127–128
velocity 34 and size segregation 298–299
solid bridges 340 surface tension
solids feeders 199 and particle enlargement 338–341
solids loading 217 and wetting 343
sparks 384 surface-volume mean 8–9
sphericity 33
for cubic particles 42 tankers, unloading 414–419
450 INDEX
temperature particle, in gas, and gas velocity 216

and combustion rate 375 saltation see saltation
and dust ignition 382 terminal see terminal velocity
and ignition energy 376 yield-stress slurries 101
terminal velocity ventilation 370
and diameter, worked example 41–43 and dust explosions 384–385
Newton’s law region 32 venting, explosions 384–385
and particle size 33 vertical tube apparatus 380, 381
of particle under gravity 31–32 vibration, and particle separation 296–297
of particles in suspensions 52 viscosity
and sedimentation velocity, in Bingham fluids 99
respiratory tract 362 colloidal suspensions 135–136
small particles 14 and attractive surface forces 141
and solid boundaries 34 power-law fluids 98
and Stokes’ law, worked example 38–39 slurry 94–95
and volume diameter, density, voidage
sphericity 43–44 packed beds 171
thickeners 63–66 in pneumatic transport, in terms of solids
critically loaded 64, 65, 68 loading and gas/particle
overloaded 65–66, 67–68, 67 velocity 217
underloaded 65 in standpipes 234
thixotropic fluid, definition 94 see also volume fraction
titania, isoelectric point 125 volume diameter, calculation, worked
toughness, and particle size reduction 327 example 23, 24
tumbling granulator 353–354 volume fraction
tumbling mixer 300 particle 54
turbulent flow colloids, and flow behaviour
Bingham plastic slurries 102–103 135–139, 139
particle behaviour in entrainment 183 and cyclone efficiency 257
slurries 97–99 and liquid cohesion 339
through packed beds 155–156 slurry, and mixture density 91
transition velocity void, fluidization 174
Bingham plastic slurries 102–103 see also voidage
power-law fluids 98 vortex radius, in cyclones 252
upflow 63 Washburn test 343

water, behaviour of colloids in 131–132
van der Waals forces 299 Wen and Yu equation 171
colloids 121–124 wheat, explosion parameters 382
worked example 146–148 workplace, dust hazard 369
and particle size enlargement 338
worked example 146–148 yield loci, shear testing 273
velocity yield stress
Bingham plastic slurries 101 hoppers 269
in Brownian motion 118–119 and pH 142
gas slurries 99–100
yield-stress fluids, worked example
and pressure drop in horizontal 110–111
pneumatic transport 215
and pressure drop in vertical zeta potential 126
pneumatic transport 213 zinc, explosion parameters 382
of impaction in respiratory tract 363 zirconia, isoelectric point 125

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Introduction to Particle

Technology – Second Edition

Introduction to Particle Technology, 2nd Edition Martin Rhodes

Telephone (þ44) 1243 779777

Email (for orders and customer service enquiries): [email protected]

Other Wiley Editorial Offices

About the Contributors xiii

3 Multiple Particle Systems 51

5 Colloids and Fine Particles 117

5.3.3 Adsorbing Polymers, Bridging and Steric Forces 127

6 Fluid Flow Through a Packed Bed of Particles 153

7.8 Applications of Fluidized Beds 191

8 Pneumatic Transport and Standpipes 211

9 Separation of Particles from a Gas: Gas Cyclones 247

9.6.4 Attrition of Solids 258

10 Storage and Flow of Powders – Hopper Design 265

11 Mixing and Segregation 293

11.5.1 Mechanisms of Mixing 299

12 Particle Size Reduction 311

13 Size Enlargement 337

14 Health Effects of Fine Powders 359

15 Fire and Explosion Hazards of Fine Powders 373

16 Case Studies 395

16.3 Case Study 3 403

Dr Karen P. Hapgood holds a BE and PhD in Chemical Engineering from the

George Vincent Franks holds a Bachelor’s degree in Materials Science and

Jennifer Sinclair Curtis received her BS degree in chemical engineering from

Martin Rhodes holds a Bachelor’s degree in chemical engineering and a PhD

It is 10 years since the publication of the first edition of Introduction to Particle

The objective of this textbook is to introduce the subject of particle technology to

Stirring a mixture of two free-flowing powders of different sizes may result in

systems. Mathematical modelling of particulate solids behaviour is a rapidly

point of pure benzene at atmospheric pressure can be safely assumed to remain

1.2 DESCRIBING THE SIZE OF A SINGLE PARTICLE

Regular-shaped particles can be accurately described by giving the shape and a

Introduction to Particle Technology, 2nd Edition Martin Rhodes

Table 1.1 Regular-shaped particles

Figure 1.1 Some diameters used in microscopy

Figure 1.2 Comparison of equivalent sphere diameters

Table 1.2 Comparison of equivalent sphere diameters

1.3 DESCRIPTION OF POPULATIONS OF PARTICLES

A population of particles is described by a particle size distribution. Particle size

Figure 1.3 Typical differential and cumulative frequency distributions

Figure 1.4 Comparison between distributions

surface and FM is the cumulative distribution by mass. In reality these distribu-

1.4 CONVERSION BETWEEN DISTRIBUTIONS

Many modern size analysis instruments actually measure a number distribution,

Size (cm) Number of objects % by number % by mass

convert the measured distribution into more practical distributions by mass,

Fraction of particles in the size range

Fraction of the total surface of particles in the size range

If N is the total number of particles in the population, the number of particles in

ðx2 aS ÞNfN ðxÞdx

where S is the total surface area of the population of particles.

fS ðxÞ / x2 fN ðxÞ or fS ðxÞ ¼ kS x2 fN ðxÞ ð1:1Þ

Similarly, for the distribution by volume

fV ðxÞ ¼ kV x3 fN ðxÞ ð1:2Þ

And for the distribution by mass

The volume of cuboid ¼ 1 2 4 ¼ 8 mm3

The surface area of the particle ¼ ð1 2Þ þ ð1 2Þ þ ð1 þ 2 þ 1 þ 2Þ 4 ¼ 28 mm2

Fv ¼ 1:096 105 x3 for x 45 mm

(a) Volume of the particle ¼ 5 3 1 ¼ 15 mm3