Facts At Your Fingertips

Blending and Segregation Mechanisms for Solids

Department Editor: Scott Jenkins

I
n solids-handling, blending (com- allow individual particles to Jenike & Johanson

bining two or more materials to move relative to one another.

achieve a combined product) and Fluidization in fluidized-bed re-
segregation (the separation of par- actors or granulators results in
ticles into distinct zones according to diffusion. Mechanical blenders
particle size, shape, density or other move collections of particles
physical attributes) are competing by convection, but when the
processes. This one-page reference speed of the agitator is suffi-
outlines common mechanisms by cient to locally fluidize material,
which these processes occur. diffusion occurs.
Shear. Shear occurs in a flow- FIGURE 1. Sifting segregation, where particles of varying
Random and ordered blends ing granular solid as a result sizes separate due to gravitational forces, is particularly com-
A random blend occurs when the of a velocity gradient, and can mon in processes that involve piling materials or filling bins
blend components do not adhere or develop as either a discontinu- not spontaneously segregate when
bind with each other during motion ous shear (for instance, a shear or at rest, but will often readily segregate
through the blend vessel [1]. Particles slip plane) or as a continuous gradi- when allowed to move. For sifting to
that form random blends can be easy ent of velocity. In either case, there occur, material must be free-flowing,
to blend, because they move easily can be some overlap in what could have a range of particle sizes, have
relative to one another, but they also be called shear and what might be some fairly large (>100 mesh) par-
can readily separate from each other, characterized as convection. The ticles, and have some means of inter-
collecting in zones of similar particles important difference, as it applies particle motion [3].
when forces, such as gravity, airflow to solids blending, is in the intensity. Fluidization. This type of segregation
or vibration, act on the blend. Shear planes that develop in gravity results when finer, lighter particles rise
In most dry-blending applications, blending or in a tumble blender pre- to the top surface of a fluidized blend
particles have some tendency to in- dominantly result in mixing by con- of powder, while the larger, heavier
teract with one another via chemical, vection. Shear in a high-speed mixer particles concentrate at the bottom of
molecular, physical or other means is more effective in breaking up ag- the bed. The fluidizing air entrains the
such that individual particles can ag- glomerates of fine powders and dis- fines and carries them to the top sur-
glomerate, coat or bond to one an- tributing small-particle-size material face. This mechanism generally only
other [2]. When particle interaction with high surface activity. occurs with powders with an average
occurs, the blend is referred to as an particle size smaller than 100 µm [1].
ordered or structured blend. In most Segregation mechanisms Fluidization segregation is likely to oc-
industrial processes, the reality is Segregation can be driven by factors cur when fine materials are pneumati-
somewhere between the two blend including gravity, electrostatic forces, cally conveyed, when they are filled
types. Some particles of the blend fluid-drag forces and elastic forces. or discharged at high rates, or if gas
may have very little tendency to in- Common segregation mechanisms counter-flow occurs. The more cohe-
teract while other blend components are sifting, fluidization and dusting. sive the material, the less likely it will
may have significant interaction. Sifting. The most prevalent type of segregate by this mechanism.
segregation is sifting, which results Dusting. Particle entrainment or
Blending mechanisms in separation by particle size. Sift- dusting segregation occurs when fine
Three primary blending mechanisms ing segregation is the most com- particles in a blend are carried by air
are convection, diffusion and shear. mon means for particles to separate. currents (such as during transfer of a
Convection. Convection is the trans- It occurs when small, fine particles blend into a container) and then settle
fer of a collection of particles from move through large, coarser particles preferentially at the container walls.
one location to another. This can oc- (Figure 1). Sifting segregation occurs This mechanism requires four con-
cur as a result of material cascading to some degree in most bulk-solids ditions: difference in particle sizes;
in a tumble blender, material moving operations. Sifting will occur in mix- relatively large particles (average size
against the blade of a ribbon or pad- tures of different-sized particles when greater than 100 µm); free-flowing
dle blender or as a result of gas-pres- particles are sufficiently large that sur- material; and inter-particle motion. n
sure pulses in a pneumatic blender. face forces are weak relative to grav-
Diffusion. Diffusion is the random ity (usually larger than 100 μm), when References
redistribution of particles that oc- particles have mobility relative to one 1. Maynard, E., Blender Selection and Avoidance of Post-Blender
Segregation, Chem. Eng., May 2008.
curs as a result of increased particle another and when there is some
2. Troxel, T.G., Blending, Sampling and Segregation, Chem. Eng.,
mobility. Increased mobility typically mechanism to allow particles to October 2012, pp. 41–46.
occurs when the bulk density of the move relative to one another [2]. Col- 3. Marinelli, J., Will Mass Flow Solve All Your Segregation Prob-
material is decreased sufficiently to lections of different size particles will lems?, Chem. Eng., April 2006.

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