CHE 509: INTRODUCTION TO PARTICLE TECHNOLOGY

LECTURE 2
PARTICLE CHARACTERIZATION AND
SIZE REDUCTION

Lecturer:
ENGR. MICHAEL ALLAN G. RAMOS
Department of Chemical Engineering
Technological Institute of the Philippines
2nd Semester, A.Y. 2018-2019
PARTICLE CHARACTERIZATION

1) Particle Shape
q Use of a shape factor called sphericity, ϕs
q For spherical particle, ϕs = 1.0
q For non-spherical particle, sphericity is defined as:
PARTICLE CHARACTERIZATION

1) Particle Shape
q Use of a shape factor called sphericity, ϕs
q For spherical particle, ϕs = 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 ρp)
of uniform particles of size Dp:

q Total number of particles:

q Total surface area:

q For mixture of particles having different Dp, 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, ρp

q Total mass per unit of total volume of sample
q not intrinsic characteristic of material
q varies with the size distribution of the particles
q differs from the true density of the material due to the
presence of void spaces
PARTICLE CHARACTERIZATION

3) Average Particle Size

i. Volume-Surface Mean Diameter, Ds :

ii. Arithmetic Mean Diameter, DN :

PARTICLE CHARACTERIZATION

3) Average Particle Size

iii. Mass Mean Diameter, Dw :

iv. Volume Mean Diameter, DV :

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: π/6 for sphere

 ILLUSTRATIVE PROBLEM

Example 1: Calculate the sphericity of a cylinder of 1 cm

diameter and 3 cm height.

Example 2: 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
!"0 = = 2.8445 mm
2
3# 0.0251
= = 0.006255
!4# 4.013
30 0.1250
= = 0.043944
!40 2.8445

36
5 = 0.828147 7789
!46
ILLUSTRATIVE PROBLEM

!" #$%&' () /!" #$%&'

,-
+ 0 = 8.8296 7780
./-
ILLUSTRATIVE PROBLEM

!" ∗ $% &'()

* +, -., = 1.6773 55
PRINCIPLES OF SIZE REDUCTION

q Unit operation that uses diverse forces to deform

a solid piece until it tears or breaks to produce
smaller particles from larger ones.

qSmaller particles are the desired product either

because:
q Larger surface area
q Shape
q Size
q Number
PRINCIPLES OF SIZE REDUCTION
q Criteria for Size Reduction:
1. Have a large capacity
2. Require a small power input per unit of product
3. Yield a product of the desired single size distribution

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 earth’s crust as
rocks but the final product are usually represented as
fine powders (e.g. carbonates, limestone, silicates)
 Different Methods According to
Types of Forces Used

Size Example
Force Principle
Application Equipment
Coarse solids;
Compressive Nutcracker reduction to about Crushing Rolls
3 mm
General purpose –
Impact Hammer Coarse, Medium, Hammer Mill
Fine grinding
Fine pulverization;
Attrition or Shear File reduction to Disc Attrition Mill
micrometer range
Produces particles
Cutting Scissors with definite size Rotary Knife Cutter
and/or shape
 SIZE REDUCTION EQUIPMENT

CRUSHING ROLL

q PRINCIPLE:
coarse materials are crushed by the
stress applied thru rotating heavy
wheels, mullers or rollers.

q APPLICATION:
Crushing seeds before extraction of
fixed oil; used to crush soft tissues – to
improve solvent penetration
 SIZE REDUCTION EQUIPMENT

HAMMER MILL

q PRINCIPLE:
Material is impacted by/with rapidly
moving hammers attached in a rotor

qAPPLICATION:
Milling dry materials, Wet filter press
cakes, ointments, slurries, etc. Brittle
materials are best fractured by
impaction.
 SIZE REDUCTION EQUIPMENT

DISC ATTRITION MILL

q PRINCIPLE:
consist of two discs having clearance
in between. Materials are sheared
by rotating one of the discs.

q APPLICATION:
preparation of colloidal particles for
suspension, emulsion, and
ointments
 SIZE REDUCTION EQUIPMENT

ROTARY KNIFE CUTTER

q PRINCIPLE:
consist of sharp-edged knives which
cuts the material

q APPLICATION:
tough and fibrous materials such as
animal tissues, medicinal plants, etc.
 POWER REQUIREMENT
q TWO STAGES OF BREAKAGE:
1. Initial fractures on existing fissures within the structure of the
material
2. Formation of new fissures followed by fractures along these
fissures

q HIGHLY ENERGY INEFFICIENT

small percentage of the actual energy supplied to the equipment is used in
the breakdown operation (figures of less than 2% efficiency has been
quoted by Richardson et. al, 2002)

q ENERGY LOST is mostly present in:

(a) deforming the particles within their elastic limits; and
(b) inter-particle friction and mechanical friction losses within the moving
parts of the equipment
 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
 RITTINGER’S 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 = Rittinger’s Constant (function of equipment and material)
x1 = average initial feed size
x2 = average final product size
 KICK’S 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 = Kick’s Constant (function of equipment and material)
x1 / x2 = size reduction ratio
 BOND’S 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
à 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.
 BOND WORK INDEX, Ei

Obtained from laboratory crushing tests of the feed material

q Defined as the energy required to reduce a unit mass of
material from an infinite particle size to a size such that 80%
passes a 100 µm sieve
q Refer to Table 21-8 / Perry’s HB 8th Edition
 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 Bond’s Law
 ILLUSTRATIVE PROBLEM

a) Using Rittinger’s Law

1 1 Dp After 1st
! = #$ − Mesh mean crushing
&
'() '&(+ 20/28 0.2945 7.07
28/35 0.503 16.6
First crushing: 35/48 0.356 14.02
6 :; − <= 48/65 0.2515 11.82
! = = 89 65/100 0.1775 9.07
2̇ >?@ 100/150 0.1255 7.62
&(+ = 5 12 = 34 55
' 150/200 0.089 33.8

1 -.
1 A = B. 8DEF 55GH
&()
' = - = = 4. H393 55 &/.
'
. 6.3498 22 G+
∑&
'/.

1 1 :; − 55
37 = #$ − PQ = 3. FD3D
0.1575 50 >R<
 ILLUSTRATIVE PROBLEM

a) Using Rittinger’s Law

After 2nd
1 1 Mesh Dp mean crushing
! = #$ −
&
'() '&(+ 20/28 0.2945 0
28/35 0.503 0
Second crushing: 35/48 0.356 0
48/65 0.2515 2.32
89 − 55 65/100 0.1775 14.32
#$ = 3. 6737
:;< 100/150 0.1255 13.34
&(+ = 0. 2343 55 150/200 0.089 70.02
'
-.
1 1 I = J. 6GJ7 55B2
&() =
' &/.
'
-. = 9.8294 AAB+ = 0. 2024 55
∑&
'/.

1 1 89
! = 5.8454 − F = G0. H7
0.1017 0.1575 :;<
 ILLUSTRATIVE PROBLEM
')*
(
b) Kick’s Law ! = #$ ln
')+
(
First crushing:
')* = 42 66
( 50
37 = #$ ln
')+ = 2. 3454 66 0.1575
(
;< − 66
7 ;< − >? CC = D. EF:3
! = = :5 @G>
9̇ @AB

Second crushing:
0.1575
')* = 2. 3454 66
( ! = 6.4231 ln
0.1017
')+ = 2. 3235 66
( ;<
;< − 66 K = F. L2D
#$ = D. EF:3 @G>
@G>
 ILLUSTRATIVE PROBLEM
1 1
c) Bond’s Law ! = #$ −
&()
' &(+
'
First crushing:
&(+ = ,- ..
' (all particles are uniform in size; 80% will pass a 50mm screen)

& 9: : CSA (smaller) vs. Dp

E/01203456 57 8
1.2

1
Mesh Dp xi
20 0.833 0 0.8

28 0.589 0.0707 0.6

35 0.417 0.166
48 0.295 0.1402 0.4

65 0.208 0.1182
0.2
100 0.147 0.0907 &() = -. =, ..
'
150 0.104 0.0762 0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
200 0.074 0.338
 ILLUSTRATIVE PROBLEM
1 1
c) Bond’s Law ! = #$ −
&()
' &(+
'
First crushing:
&(+ = ,- ..
'
1 1
! = 2(0.1581)(9.45) −
&() = -. 0, ..
'
0.45 50
>?
!1 = 2. 0, (From Table 21-8)
; = 0. -<=
@AB
 ILLUSTRATIVE PROBLEM
1 1
c) Bond’s Law ! = #$ −
&()
' &(+
'
Second crushing:
&(+ = ,. ./ 00
'

CSA (smaller) vs. Dp

& ;< :
E123425678 79 : 1.2

CSA 1

Mesh Dp xi (smaller)
20 0.833 0 1 0.8

28 0.589 0 1 0.6
35 0.417 0 1
48 0.295 0 1 0.4

65 0.208 0.0232 0.9768

0.2
100 0.147 0.1432 0.8336 &() = ,. >? 00
'
150 0.104 0.1334 0.7002 0
200 0.074 0.7002 0 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
 ILLUSTRATIVE PROBLEM
1 1
c) Bond’s Law ! = #$ −
&()
' &(+
'
First crushing:
&(+ = ,- ..
'
1 1
! = 2(0.1581)(9.45) −
&() = -. 0, ..
'
0.45 50
>?
!1 = 2. 0, (From Table 21-8)
; = 0. -<=
@AB
Second crushing:
&(+ = -. 0, ..
'
1 1
! = 2(0.1581)(9.45) −
&() = -. C< .. 0.13 0.45
'
>?
!1 = 2. 0, (From Table 21-8)
; = <. E<<
@AB
END.