Lecture 2 - Particle Characterization & Size Reduction v2
Lecture 2 - Particle Characterization & Size Reduction v2
Lecture 2 - Particle Characterization & Size Reduction v2
LECTURE 2
PARTICLE CHARACTERIZATION
AND SIZE REDUCTION
Lecturer:
ENGR. MICHAEL ALLAN G. RAMOS
Department of Chemical Engineering
Technological Institute of the Philippines
1st Semester, A.Y. 2016-2017
PARTICLE CHARACTERIZATION
1) Particle Shape
q Use of a shape factor called sphericity, s
q For spherical particle, s = 1.0
q For non-spherical particle, sphericity is defined as:
PARTICLE CHARACTERIZATION
1) Particle Shape
q Use of a shape factor called sphericity, s
q For spherical particle, s = 1.0
q For non-spherical particle, sphericity is defined as:
PARTICLE CHARACTERIZATION
2) Particle Surface Area
q In a sample (mass m and bulk density p)
of uniform particles of size Dp:
q Total number of particles:
q Total surface area:
q For mixture of particles having different Dp and p ,
specific surface area, Aw is defined as :
xi = mass fraction in an
increment
Dpi = arithmetic average of
the smallest and largest
particle diameters in an
increment
PARTICLE CHARACTERIZATION
Bulk (or Apparent) Density, p
PARTICLE CHARACTERIZATION
3) Average Particle Size
i.
PARTICLE CHARACTERIZATION
3) Average Particle Size
iii. Mass Mean Diameter, Dw :
PARTICLE CHARACTERIZATION
4) Number of Particles in a Mixture
q The volume of a particle is proportional to its diameter
cubed
a = volume shape factor
(constant according to shape)
Example: /6 for sphere
PARTICLE CHARACTERIZATION
5) Screen Analysis of Particles smaller than 200 Mesh
Linearizing:
ILLUSTRATIVE PROBLEM
Example 1: Calculate the sphericity of a cylinder of 1 cm
diameter and 3 cm height.
Example 2: (From MSH / Ex 28-1) The screen analysis applies to
a sample of crushed quartz. The density of quartz is 2,650
kg/m3 and shape factors are a=2 and = 0.571. For the
material between 4 and 200 mesh, calculate:
a) Specific surface, mm2 / g
b) Ds , Dv , Dw
c) N for particles 150/200
ILLUSTRATIVE PROBLEM
4.699 mm + 3.327 mm
= 4.013 mm
2
3.327 mm + 2.362 mm
#2 =
= 2.8445 mm
2
$
0.0251
=
= 0.006255
6$
4.013
#$ =
2
0.1250
=
= 0.043944
62 2.8445
8
7
= 0.8284
68
q Common Applications:
1. Pharmaceutical micronization of API (Active
Pharmaceutical Ingredients) for better dissolution rate
and bioavailability; fast-acting drugs
2. Petrochemical increase in reactivity; pre-processing
prior to extraction for increased penetration of solvent
3. Mining minerals are extracted from earths crust as
rocks but the final product are usually represented as
fine powders (e.g. carbonates, limestone, silicates)
Impact
Attrition or Shear
Cutting
Principle
Size
Application
Example
Equipment
Nutcracker
Coarse solids;
reduction to about
3 mm
Crushing Rolls
Hammer
General purpose
Coarse, Medium,
Fine grinding
Hammer Mill
File
Fine pulverization;
reduction to
Disc Attrition Mill
micrometer range
Scissors
Produces particles
with definite size Rotary Knife Cutter
and/or shape
POWER REQUIREMENT
q TWO STAGES OF BREAKAGE:
1.
2.
POWER REQUIREMENT
q Energy required to produce a change in size of the material is
theoretically expressed as a power function of the initial size
of material:
where:
dE = change in energy
dx = change in size
K = constant
x = initial size of the material
RITTINGERS LAW
The energy required should be proportional to the new surface
produced (n = 2)
Integration with n = 2:
where:
E = power per unit mass required for production of a new surface
K = Rittingers Constant (function of equipment and material)
x1 = average initial feed size
x2 = average final product size
KICKS LAW
The energy required for a given size reduction was
proportional to the size reduction ratio (n = 1)
Integration with n = 1:
where:
E = power per unit mass required for production of a new
surface
K = Kicks Constant (function of equipment and material)
x1 / x2 = size reduction ratio
BONDS LAW
The work necessary for reduction was inversely proportional
to the square root of the size produced (n = 1.5)
Integration with n = 1.5:
where:
E = power per unit mass required [kWh/ton]
x1 = average initial feed size [mm]
x2 = average final product size [mm]
Ei = Bond Work Index
the gross energy requirement in kW-hr / ton of feed needed to reduce a
very large feed to such a size that 80% of the product passes a 100-micrometer
screen.
ILLUSTRATIVE PROBLEM
Example 3: Bauxite is crushed in a jaw crusher and the
average size of the particle is reduced from 5 cm to the first
crushing DSA in the table, with consumption of energy at the
rate of 37 kW-hr/ton. What will be the consumption of energy
necessary to crush the same material from the 1st crushing
DSA to the 2nd crushing DSA. The mechanical efficiency
remains same.
a) using Rittinger's law
b) using Kick's law
c) using Bonds Law
ILLUSTRATIVE PROBLEM
a) Using Rittingers Law
= ;
First crushing:
1
1
< <
=> =@
= =
<=@ = 5 =
Dp
After 1st
Mesh mean crushing
20/28 0.2945
7.07
28/35 0.503
16.6
35/48 0.356
14.02
48/65 0.2515
11.82
65/100 0.1775
9.07
100/150 0.1255
7.62
150/200 0.089
33.8
1
1
<
=> = =
V@ = .
8
6.3498
<68
37 = ;
1
1
0.1575 50
7 < 8 = . V
68
= .
ILLUSTRATIVE PROBLEM
a) Using Rittingers Law
= ;
1
1
< <
=> =@
Second crushing:
; = .
<=@ = .
<=> =
Mesh
20/28
28/35
35/48
48/65
65/100
100/150
150/200
1
1
8 = 9.8294 V@ = .
<68
1
1
= 5.8454
0.1017 0.1575
Dp mean
0.2945
0.503
0.356
0.2515
0.1775
0.1255
0.089
After 2nd
crushing
0
0
0
2.32
14.32
13.34
70.02
7 < 8 = . V
68
= .
ILLUSTRATIVE PROBLEM
b) Kicks Law
= ]
First crushing:
<=@ =
<=> = .
= =
<=@
ln <
=>
50
37 = ] ln
0.1575
= .
Second crushing:
<=@ = .
<=> = .
] = .
= 6.4231 ln
= .
0.1575
0.1017
ILLUSTRATIVE PROBLEM
c) Bonds Law
= `
<6>
1
<6@
First crushing:
<6@ =
(all particles are uniform in size; 80% will pass a 50mm screen)
< :
E
Mesh
20
28
35
48
65
100
150
200
Dp
0.833
0.589
0.417
0.295
0.208
0.147
0.104
0.074
xi
0
0.0707
0.166
0.1402
0.1182
0.0907
0.0762
0.338
<6> = .
0.2
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
ILLUSTRATIVE PROBLEM
c) Bonds Law
= `
1
<6>
1
<6@
First crushing:
<6@ =
<6> = .
= 2(0.1581)(9.45)
= .
1
0.45
50
ILLUSTRATIVE PROBLEM
c) Bonds Law
= `
1
<6>
1
<6@
Second crushing:
<6@ = .
< :
E
Mesh
20
28
35
48
65
100
150
200
Dp
0.833
0.589
0.417
0.295
0.208
0.147
0.104
0.074
xi
0
0
0
0
0.0232
0.1432
0.1334
0.7002
CSA
(smaller)
1
1
1
1
0.9768
0.8336
0.7002
0
<6> = .
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
ILLUSTRATIVE PROBLEM
c) Bonds Law
= `
1
<6>
1
<6@
First crushing:
<6@ =
<6> = .
= 2(0.1581)(9.45)
= .
1
0.45
50
Second crushing:
<6@ = .
<6> = .
= 2(0.1581)(9.45)
= .
1
0.13
1
0.45