Powder Pointers Fall 2007 Volume 1 No C

Brought to you by:

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Material Flow Solutions, Inc.
3536 NW 97 Blvd. Gainesville, FL 32606 Phone: 352-303-9123 E-mail: [email protected]

In This Issue
Understanding Segregation Feature Article:
Understanding Segregation
Mechanisms Mechanisms
Specialized Seminars now available
1
1
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Generalizing the relationship between
In process design, the solution to a segregation problem can be attacked inter-particle forces and bulk
from two angles. The process can be modified to accommodate unconfined yield strength of
segregation patterns caused by the various mechanisms or changes can be poly-disperse powders 3
Learning the Trade:
made to the process to reduce the cause of segregation. In either case, Bulk Unconfined Yield Strength 4
understanding segregation mechanisms is critical to developing robust
processes to handle segregating materials.
Material Flow Solutions
Sifting Segregation. Materials segregate when handled for a variety of announces availability of
reasons. Many solids flow practitioners quickly identify the potential for Specialized Seminars
fine material to sift through the matrix of coarse particles as material
slides down a pile. Indeed, sifting segregation is a predominant cause of
separation during handling of differently sized particles. This mechanism Material Flow Solutions has
usually results in a radial segregation pattern where fines accumulate near prepared a set of seminar topics
the center of a pile while the coarse material is predominately at the pile’s specifically for your process and
edge. However, severe sifting segregation can cause a top-to-bottom product engineers to help them
segregation pattern where the fines are beneath the coarse particles. This design material handling systems,
is especially true if inter-particle motion is induced within the material by design better products, and
some external means such as vibration. Typically, particle size differences successfully select unit operations
greater than three to one are enough to produce significant sifting that are compatible with critical
segregation problems. material properties. This proven
approach allows your engineers to
Repose Angle Segregation. Sifting segregation is by no means the only optimize plant performance and
mechanism that causes separation of particulate material during handling. increase your plant and operation
Some particles have differences in inter-particle friction and, thus, form productivity. Our seminars are
piles with different repose angles. Formation of piles within process available in one- two- or three-day
equipment causes the less frictional particle to slide further down the pile venues. Customize your seminar
accumulation at the pile’s edge. This mechanism results in a radial by choosing from a wide range of
segregation pattern. Materials with an angle of repose difference of more available topics that best meet
than two degrees can show significant repose angle segregation. Repose your company’s needs. You may
angles of only two degrees difference cause significant segregation. further optimize your seminar by
adding a half- or full-day plant
Air Entrainment Segregation. Air currents caused during filling may visit that will include an on-site
carry fine material to regions where the air currents decrease sufficiently review of your current process.
to deposit the fine material. This air entrainment segregation can produce
a radial pattern or a side to side pattern depending on the position of the For more information and a list of
seminar topic options, please turn
Continued on page 2 to page 3 of this newsletter.
Understanding Segregation Mechanisms 2
Continued from page 1

inlet and the geometry of the vessel. hours. Coarse particles entering radial segregation pattern will
Generally, fines accumulate near the bin during this time can be helped by converting the bin
process vessel walls with this impact on this fluidized material to mass flow. Material will
segregation. Figure 1 depicts a and penetrate the top layer of leave the bin as it entered the
typical profile for air entrainment fluidized solid before coming to hopper. There will be a
segregation where the fines rest below the top surface. This segregation profile across the
accumulate near the wall. However, results in a top-to-bottom outlet, but at least the material at
it is important to point out that this separation of particles in the bulk each cross-section will be the
figure also shows the result of sifting mixture, thereby creating layers correct consistence. If better
segregation where the fines of fines and coarse material. mixing than this is required,
accumulate near the drop point. additional in-line blenders
Figure 1 also indicates that several Customized Situations Equal should be added to the process
segregation mechanisms can occur at Customized Results. Many to achieve blend consistency.
the same time producing a complex solids flow practitioners promote
overall segregation pattern. the concept that mass flow will Summing Up. Knowing the
always solve a segregation segregation mechanism as well
problem. This is a short-sited as the flow profiles in your
view. The flow pattern within a process equipment is critical to
given piece of process equipment solving potential segregation
must be matched with the problems. Simple tests can be
segregation profile to achieve a performed to measure the
process to minimize segregation magnitude and type of
during handling. For example, segregation occurring in your
suppose that the material systems. Flow properties can
Figure 1. Typical Air Entrainment Segregation segregated by impact also be measured to determine
fluidization, forming layers when the flow patterns in your process
Impact Fluidization Segregation. placed in a bin or a hopper. equipment. Using this
If the bulk material is very fine and Placing a typical steep mass flow information, a reliable solution
compressible, then it may become hopper on this bin would not to complex segregation
fluidized during filling of a process help the segregation, but would problems can be designed to put
vessel. This fluidization is not significantly enhance the you on track for quality
persistent as it would be in a fluid separation of bulk materials. The production.
bed where there is an external source uniform velocity induced by a
of air. The material begins to lose its typical well designed mass flow If you would like additional
entrained air soon after completion of bin would cause the coarse information on segregation and the
problems accompanying it, contact:
the filling process. However, these material to exit, followed by the
materials retain their fluid-like fines, making the segregation CLICK HERE
behavior for several minutes or even problem worse. Conversely, a [email protected]

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Coming Next Quarter - Degradation Future Topics

Many unit operations involve particle size degradation. Degradation plays a • Optimal blender choices
key role in milling and agglomeration, segregation prevention, and product
• Milling issues
quality issues. Particle size degradation occurs through abrasion, fracture
and fatigue, to name a few. Each process or set of unit operations induces a • Erratic flow rates
certain set of comminuting mechanisms characteristic to your unique • Successful
process. Unit operation success often depends on matching the degradation agglomeration
test method with the process conditions. We will discuss how to accomplish
this task with minimal material and greater accuracy.
Specialized Seminars 3
Continued from page 1
See us at the
Our engineers assist you in designing a customized seminar to optimize Annual AIChE Meeting
your time and personnel investment, and assist you in increasing your in Salt Lake City
company bottom line. Simply choose from our shopping list of topics and
you are on your way to enhanced company profit and productivity: Dr. Kerry Johanson will present:
Generalizing the Relationship Between
Successful powder plant design Inter-particle Forces & Bulk Unconfined
Successful powder product design Yield Strength of Poly-disperse Powders
Segregation prevention Enhance your Wednesday, November 7, 2007 at
Bin and hopper design company profit 8:30 a.m., Suite F at the Marriott
Feeder design and productivity Salt Lake City.
Optimal blender selection with customized
Minimizing attrition seminars Dr. Johanson will also serve as a
Agglomeration unit operations member on the panel discussion:
Legacy of A. Jenike’s Silo Theory and
Blender operation Future Challenges for Silo Design
Mill operations Tuesday, November 6, 2007 in the
Grand Ballroom of the Salt Palace
For more information or to schedule your customized seminar: Convention Center at 12:30.
CLICK HERE [email protected]

Generalizing the relationship between inter-particle forces and

bulk unconfined yield strength of poly-disperse powders
The Problem. Engineers are often faced with the daunting task to create a production process without actually
producing and testing a representative sample of the material that will pass through the process. Ideally we would
test the materials that would pass through the process and then specify the design based on sound scientific models
relating the measured flow properties to process behavior. However, often that material does not exist until the
process system is designed and in full operation.

Flow behavior through a process depends on certain key properties of bulk material. One fundamental property is
the material’s unconfined yield strength. This key property affects hang-ups in process equipment, blending,
segregation, agglomeration, milling, flow rates, and adhesion to system surfaces. Thus, understanding what
parameters affect strength and how strength affects processing provides guidance on how to design processes
without having representative samples to test.

Strength can be described in the framework of a bulk continuum where it is the stress required to initiate yield of a
bulk material. However, a more useful framework would be to relate bulk strength to inter-particle forces. The net
effect of all inter-particle forces is to provide a resistance to shear. Thus, understanding the dynamics of this
adhesion process, and the relationship between shear and particle assembly structure, provides the basis of
predicting bulk yield strength from inter-particle forces.

The Solution. In a nut shell we must determine the number of particles involved in shear, the forces acting
between these particles, and the structure of the particle assembly. Past researchers have been able to provide us
with very simple models that predict strength only for processes where all the particles within the system are the
same size. Poly-disperse systems are significantly more complex as they result in shear zones that do not cause
inter-particle motion between all particles within the pore structures. Instead, some particles within the pore
structure simply translate with the surrounding larger matrix of particles. Understanding this complex structure
allows us to create new models that relate cohesive yield strength material with a range of particle sizes, thereby
allowing engineers to predict the strength of real material systems. Join us as we discuss these new models at the
up coming AIChE meeting.
 Learning the Trade 4

It is necessary to know and an unconfined (unsupported) state acting normal to any free surface
understand several fundamental to fail in shear. It is the primary is zero. However, stresses acting
material flow properties in order flow property that governs the along the free surface may not be
to characterize flow behavior in development of hang-ups in zero. In a hang-up condition, the
process equipment. In each of process equipment and is generally material on a free surface is
our quarterly newsletters, we a significant function of the supported by stresses that act
will discuss one of these key compaction pressure which has along the free surface and are
flow properties and its industrial been applied to the material in equal to the unconfined yield
application in detail. order to induce failure. It is used strength of the material. There-
to compute critical arching and rat- fore, measured values of material
Bulk Unconfined Yield Strength hole dimensions for a given strength under stress (unconfined
material in a hopper or bin. All yield strength) are critical to
Bulk unconfined yield strength is hang-ups in process equipment proper design and utilization of
the major principle stress level result in formation of a free both process system equipment
that will cause bulk material in surface. By definition, the stress and product characterization.

Please contact us with any comments, suggestions or inquiries you may have regarding our services.
We also encourage and welcome your suggestions for powder flow topics which you would like to see
included in future editions of Powder Pointers.

[email protected]

Material Flow Solutions, Inc.

3536 NW 97th Blvd.
Gainesville, FL 32606