Mechanical Process Engineering Particle Technology

Process Engineering Department summer semester 2017
Chair for Mechanical Process Engineering
Lecture: "Mechanical Process Engineering (Introduction into Particle Technology)"

We. 09:00 - 11:00 G05- H4
Tutorial: We. 11:00 - 13:00 G10-110
Handouts: http://www.mvt.ovgu.de/mvt/en/Lectures/Lecture+MPE.html, lecture manuscript with
chapters 0 – 8: *.pdf, tutorials, solutions, lab instructions.
date L/T content responsible

5.4. 2L introduction/disperse systems Hintz
5.4. 2T particle size distribution Hintz
12.4. 2L fundamentals of comminution Trüe
12.4. 2T comminution Trüe
19.4. 2L comminution Trüe
19.4. 2L particle characterisation techniques Hintz
26.4. 2L particle size distribution Hintz
26.4. 2T particle characterisation Hintz
3.5. 2L particle separation Trüe
3.5. 2T separation function/grade efficiency Trüe
10.5. 2L sieving Trüe
10.5. 2T sieving Trüe
17.5. 2L particle flow in a fluid Lukas
17.5. 2T particle flow in a fluid Lukas
24.5. 2L flow separation Lukas
24.5. 2T flow separation Lukas
31.5. 2L flow separators Lukas
31.5. 2T flow separators Lukas
7.6. 2L particle interactions/adhesion forces Müller
7.6. 2T particle interactions/adhesion forces Müller
14.6. 2L powder flow properties Müller
14.6. 2T powder flow properties Müller
21.6. 2L silo design Müller
21.6. 2T silo design Müller
28.6. 2L particle agglomeration Müller
28.6. 2T particle agglomeration Müller
5.7. 2L particle mixing Müller
5.7. 2T particle mixing Müller
written examination (120 min)
lab exercises: particle size measurement (Hintz), comminution (Jebelisinaki), fine particle flow separation
(Schlinkert)
Fig_MPE_2017 I.doc Mechanical Process Engineering – Particle Technology Prof. Dr. J. Tomas 05.04.2017
Recommended literature to Mechanical Process Engineering:
Editor Title Publishers Year

Perry, R.H., Green, Perry’s Chemical Engineers’ Hand- McGraw-Hill, New York 1999
D.W., Maloney, J.O. book (CD version)*
Rumpf, H. Particle Technology Chapman & Hall, London 1991
Coulson, J.M., Rich- Chemical Engineering, Vol 2 Parti- Pergamon Press, Oxford 1991
ardson, J.F. cle Technology
Fayed, M.E., Otten, L. Handbook of Powder Science & Chapman & Hall, New York 1997
Technology
- Ullmann's Encyclopedia of Industri- VCH-Verlagsgesellschaft, Wein- 1988
al Chemistry heim
Gotoh, K. Powder Technology Handbook Marcel Dekker Inc., New York 1997
Schulze, D. Powders and Bulk Solids: Behav- Springer Berlin 2008
iour, Characterization and Flow
Schubert, H. Handbuch der Mechanischen Ver- Wiley-VCH, Weinheim 2003
fahrenstechnik
Schubert, H. Mechanische Verfahrenstechnik Deutscher Verlag für Grundstoff- 1990
industrie, Leipzig
Löffler, F., Raasch, J. Grundlagen der Mechanischen Ver- F. Vieweg Verlag, Braunschweig 1992
fahrenstechnik
Schubert, H. Aufbereitung fester mineralischer Deutscher Verlag für Grundstoff- 1989
Rohstoffe, Bnd I industrie, Leipzig
Schubert, H. Aufbereitung fester Stoffe, Bnd II: Deutscher Verlag für Grundstoff- 1996
Sortierprozesse industrie, Stuttgart
Schubert, H. Aufbereitung fester mineralischer Deutscher Verlag für Grundstoff- 1984
Rohstoffe, Bnd III industrie, Leipzig
Stiess, M. Mechanische Verfahrenstechnik - Springer Verlag, Berlin 2009
Partikeltechnologie 1
Stiess, M. Mechanische Verfahrenstechnik 2 Springer Verlag, Berlin 1994
Molerus, O. Principles of Flow in Disperse Sys- Chapman & Hall, London 1993
tems
Buhrke, H., Kecke, Strömungsförderer F. Vieweg Verlag, Braunschweig 1989
H.J., Richter, H.
Löffler, F., Raasch, J. Staubabscheiden Georg Thieme Verlag, Stuttgart 1988
* recommended
Aufbereitungs-Technik Bulk Solids Handling

Chemical Engineering Science Chemie-Ingenieur-Technik
Chemical Engineering & Technology Particle Characterization
Particulate Science & Technology Powder Technology
Powder Handling and Processing
TIZ International Powder Magazine
Content:
1. Introduction, characterisation of disperse material systems, particle charac-

terisation, particle size distributions, quantities, statistical moments, distribution
characteristics, surface, physical particle test methods, particle shape, packing
states
2.1 Particle processing by comminution, process objectives, solid bindings,
material behaviour and fracture mechanics, cracking, stressing modes, micro-
processes of comminution,
2.2 Evaluation and characteristics of macroscopic process performance, work
principles and applications of crushers and mills, machine design
3.1 Separation of particles, mechanical separation processes, evaluation of sep-
aration efficiency by separation function, evaluation of separation sharpness
3.2 Sieving (screening), particle dynamics, work principles and applications of
screens, machine design
4.1 Flow separation, particle flow in a fluid, fluid and field forces, stationary parti-
cle settling velocity,
4.2 Introduction into characterisation of turbulent flow, turbulent particle diffusion,
turbulent counter-current and cross-flow classification of particles in water and
air,
4.3 Separation models, work principles and applications of turbulent counter-
current and cross-flow separators, hydro cyclone design, air separators
5. Combination of comminution and separation processes
6.1 Transport and storage of particle systems, interactions, molecular bindings
and micromechanical particle adhesion forces,
6.2 Macroscopic stress states, flow properties, test methods, evaluation of flow
behaviour of cohesive powders,
6.3 Problems at practical powder handling, problem solutions by appropriate de-
sign of mass and funnel flow hoppers
7. Particle formulation by agglomeration, objectives of agglomeration and physi-
cal product design, agglomerate strength, work principles and applications of
pelletizing, briquetting and tabletting machines, roller press
8. Mixing of particles, stochastic homogeneity, mixing kinetics, work principles
and applications of solid mixers, rotating drum mixers and agitators, permeation
of fine particle packings and homogenisation in a fluidized bed.
Mechanical Process Engineering 4 SWS 6.0 Credit Points
Scope: The students are introduced into the fundamentals of particle technology. They should learn how
to produce particles or powders by size reduction, separation, mixing and agglomeration as a sequence of
typical operations. As the consequence, the lectures are designed to focus on the essential microprocesses,
particle characterisation and tailoring of the physical product properties of particulate solids.
Prerequisite: Mechanics, Fluid dynamics
Content:
0 Introduction,
0.1 Definitions,
0.2 Hierarchic order of processing plants,
0.3 General tasks
1 Dispersity of particulate systems,

1.1 About rocks, gravel, lumps, nuggets, corn, particles, nanoparticles and colloids
1.2 Particle characterisation - Granulometry,
1.3 Particle size distributions,
1.4 Physical particle properties
2 Particle production by comminution,

2.1 Fundamentals of material bonds
2.2 Strong and weak bonds in solids
2.3 Mechanical properties of solids
2.4 Solid cracking and breakage
2.5 Microprocesses of particle stressing and breakage
2.6 Crushing and milling processes and machines
3 Particle separation
3.1 Process principles of particle separation in particle technology
3.2 Evaluation of separation efficiency by separation probability (function)
3.3 Particle separation by sieving,
3.4 Fundamentals and microprocesses of sieving
3.5 Model of screening dynamics
3.6 Sieving machines and screens
4 Particle separation in a fluid flow

4.1 Single particle flow in a fluid and flow-around pattern
4.2 Micro- and macroturbulence
4.3 Particle diffusion in a dispersion medium
4.4 Dynamics of particle transport in turbulent fluids (turbulent particle diffusion)
4.5 Models of particle separation in a turbulent flow field
4.5.1 Separation efficiency by cross-flow separation model
4.5.2 Separation efficiency by counter-current separation model
4.5.3 Multistage cross-flow separation model
4.5.2.1 Separation function, cut point and separation efficiency
4.5.2.2 Utilization of separation stages
4.5.2.3 Examples of zigzag air separator
4.6 Machines and apparatuses of particle classification and dust collection
5 Combination of comminution and separation units
5.1 Basic elements of processing systems
5.2 Basic structures and element combinations of processing systems
5.3 Combination of comminution and classification units
6 Particle interactions, powder storage and flow

6.1 Dynamics of a flowing particle packing
6.2 Fundamentals of particle adhesion and adhesion forces
6.3 Mechanics of particle adhesion
6.4 Testing methods of particle adhesion
6.5 Flow properties of cohesive powders
6.6 Testing devices and techniques of powder flow properties
6.7 Applications in silo hopper design
7 Particle formulation by agglomeration,

7.1 Fundamental agglomeration principles
7.2 Agglomerate strength
7.3 Pelletizing of moist powder
7.4 Press agglomeration
7.4.2 Powder compression behaviour
7.4.3 Briquetting and tabletting
7.4.4 Roller press
8 Product tailoring by particle mixing,

8.1 Microprocesses and mixing efficiency of particles
8.1.2 Model of stochastic homogeneity
8.1.3 Mixing kinetics
8.2 Rotating vessels, kneaders and agitators
8.3 Pneumatic mixing
8.3.2 Permeation of particle beds
8.3.3 Fluidized bed mixer
Definitions
 Subject of Process Engineering:
• Engineering discipline with integrating character, including
- Energy process engineering (energy conversion)
- Information technology (system engineering, data processing)
• Subject is the sustainable, energetically efficient, ecologically
tolerable industrial material conversion for economic utilisation
and consumption
• Minor importance of exact product shape (⇒ subject of produc-
tion engineering)
 Material conversion (processing):

• Change of physical, physico-chemical and/or
• Chemical, bio-chemical material properties
 Mechanical Process Engineering:

• Focus on physical or physico-chemical material properties of sol-
id particles and droplets, bubbles (≈ 10 nm to 1 m)
• Material conversion by mainly mechanical energy input
 Comminution (size reduction), dispersion and agglomeration
 Separation and mixing
• statistically distributed material parameters (mainly particle size
dependent)
• stochastic process dynamics, efficiency and performance
• Particle Technology
Block Flow Chart of Material Processing System
Balance boundary of material, energy, information and costs flows
Raw materials
Main
Raw materials Pro- Store product
(R) Store duct A Product (A)
(R) Raw material Material formu- By-
Material Store
conversion Pro- lation
processing separation (B) product
Store duct B
Auxiliary Store
(H) Waste
materials (H) (W) Waste
Infor- Infor-
mation (I) Auxiliary Auxiliary mation
material material
supply processing
Energy
Energy (E)
Recycling process
Costs (K) Proceeds
Store (W) (Reuse)
Survey about Unit Operations in Particle Processing
Draft of operation principle Process Related processes Physical operation principle
Size reduc- Comminution of solids (irreversible)
tion Disintegration of weakly bonded agglomerates
(reversible)
Classifying Separation according to particle size

Sieving or screen- according to geometrical dimen-
ing sions
Fluid flow separa- according to settling velocity
tion
Sorting and Separation according to physical material properties

grading Density sorting According to density
Hand sorting Optical properties
Mech. sorting Mechanical properties (elasticity)
Magnetic grading magnetic properties
Electrical grading according to conductivity
Flotation according to wettability
Leaching Dissolution Soluble phase
Extraction Liquid-liquid phase transition
Crystalli- Crystallization Evaporation of liquid

zation Precipitation Generation of new insoluble solid
phase
Mixing and Homogenisation of various particle phases
blending Solid mixing Solid-solid mixing
Homogenization Temporary constant properties
Suspension Solid in liquid
Aeration Gas in liquid
Agglome- Adhesion of many primary particles to a few coarser
ration agglomerates (clumps)
Pelletizing Moist agglomeration
Press agglomeration under pressure (tabletting)
Sintering Contact fusion
Coagulation Liquid-liquid
Solid-liquid Thickening of all particles, clarifying of liquid
separation Sedimentation Particle settling
Filtration Retention of particles by semi-
permeable membrane
Drying Evaporation of liquid
Dust collec- Precipitation of all particles from gas
tion Absorption from emission sources
Gas cleaning Separation of all particles from
gas
Thermal Roasting Degassing of volatile phases

treatment Calcination Chemical reactions within solids
(e.g. lime)
Combustion Gasification of organic phases
Multiscale Hierarchic Order of Processing Industries
Process Explanation Scale, Examples
equipment
fundamen- Physical fundamentals of mate- nm- to µm- diffusive, convec-
tal princi- rial conversion, transport laws (ba- range tive transport of
ples, effects, sics of molar number, mass, momen- molecules and par-
laws tum and energy conservation), mo- ticles; creation, de-
lecular interactions, molecular to par- struction of inter-
ticle dispersion actions
Micropro- Material conversion in a typi- Contact Particle stressing,
cess cally microscopic-smallest ma- zone of ma- particle flow, parti-
terial element, particle dispers chine tools, cle agglomeration
mm-range
Subprocess Typical material conversion and Apparatus Feed zone, separa-
transport in macroscopic zone or sub- zones, cm- tion unit, discharge
chamber, range zone
(Macro-) Material conversion in a macro- Appa- Mill, mixer, classi-
Process, scopic process chamber of op- ratus, fyer, cyclon, filter,
unit operation eration unit machine centrifuge
Process group Primitive combination of processes Group of Cascade of classi-
(chain, parallel or circuit arrange- apparatuses fyers or mixers, mill-
ments, to 10 processes) ing circuit
Processing Partially independent system for ma- Subplant Waste recycling
unit terial conversion (to 50 processes) plant
Processing Independently operating, integrated Plant Central heating sta-
System System to make main- and by- tion, cereals mill,
products, waste; with raw material and brewery, pharmaceu-
product store, energy and auxiliaries tical plant
supply (to 300 processes)
Chain of pro- primitive combination of processing Plant com- Crude oil ⇒ raffi-
cessing sys- systems (vertical production line: raw plex nation ⇒ ethylen ⇒
tems material to final product, regional dis- polyethylen ⇒ PE-
tributed) products
Integrated pro- horizontal and vertical network of Integrated Chemical enterprise,
cessing system processing systems, single site plant system Power station
Integrated ma- Integrated site and material conversion Integrated Crude oil ⇒ raffi-
terial pro- system of different international pro- site system nation ⇒ basic
cessing net- ducers; integrated distribution, con- chemicals
work sumption and recycling
General Process Model of Mechanical Process Engineering
1. General formulation of quantity balance of a material component:
Accumulation = Σinput streams - Σoutput streams + sources – sinks (1)
Following fundamental principles are to consider:

• Directional particle transport (convection)
• Non-directional particle transport (thermal or turbulent particle diffusion)
• Sources and sinks: Creation and destruction of interactions between particles, macromol-
ecules, ions or atoms
⇒ Chemical reactions: Creation and failure of strong interactions (= major valence -
bonding: covalent, ionic, metallic bonds), e.g.: chemical syntheses and decomposition
reactions, rock crushing or particle size reduction, crystallisation and dissolution;
⇒ Creation and failure of weak interactions (= minor valence bonding: hydrogen bridg-
es, van der Waals, electrostatic bonds), e.g.:
Solidification and melting, condensation and vaporising, adsorption and desorption,
coagulation and dispersion, agglomeration and disintegration.
2. Discrete mathematical formulation of quantity balance of type mass or number of parti-

cle size or particle property fraction i:
∂[r b ⋅ µ i ] 
= div[r b ⋅ µ i ⋅ v i ] − div[Di ⋅ grad(r b ⋅ µ i )] ± G i (2)
∂t
rb Mass fraction of all particles in a volume element dV (= powder bulk density),
≡ total solid mass concentration in a suspension c s = ms /dV
µi mass fraction (= dQ 3 (d i )) of fraction i in the observed volume element dV
∂ [ρ b ⋅ µ i ]
Accumulation (storage) of fraction or class i in the observed volume or continuum
∂t
element dV=dx.dy.dz

vi Particle flow rate of fraction i by external field force or potential difference

ρb µ i vi Convective (directional) mass flow of fraction i through the observed volume
element dV
Di Diffusion coefficient of fraction i
D i grad (r b µ i ) Diffusive (non-directional) mass flow of fraction i through the observed vol-
ume element dV
G i ∼ µ i µ j Particle interaction term = conversion rate ≡ change of mass content of fractions
.
i and j in the observed volume element dV by

• creation of particle interactions (agglomeration → 2nd order kinetics) or
• destruction of particle interactions (disintegration → 1st order kinetics G i ∼ µ i )
Symbols
a mm distance, separation
a m/s2 acceleration
A m2 area, apparatus area
Ar - ARCHIMEDES number
b mm characteristic width or breadth of volume element, zone width or breadth
b mm subprocess chamber width, apparatus discharge opening width
B - statistical fit
B m process chamber width
B Vs/m2 magnetic induction
Bo - BODENSTEIN number
c - constant, coefficient
c g/l mass concentration
c mol/l molar concentration
C As/V electric charge capacity
d µm particle size, diameter
d mm characteristic diameter of volume element, zone diameter
d mm subprocess chamber diameter, apparatus discharge opening diameter
dp nm pore size
D m process chamber diameter
D m2/s diffusion coefficient
e As electronic charge
E N/mm2 modulus of elasticity
E V/m electric charge strength
E Nm energy
Eu - EULER number
f - function
f s-1 frequency
ff - flow factor
ff c - flow function
F N force
Fr - FROUDE number
g m/s2 gravity acceleration
G N/mm2 shear modulus
h mm characteristic height of volume element
h mm subprocess chamber height, zone height
H m process chamber height
H A/m magnetic field strength
I A electric current
k - constant, co-ordination number
k s-1 reaction-rate constant
k kg/(m2*s) mass transfer coefficient
l mm characteristic length of volume element
l mm subprocess chamber length, zone length
L m process chamber length
Lj - LJA SC  ENKO number
m kg mass
m kg/h mass flow rate
M Nm moment
M g/mol molar mass
n - exponent,
n - compressibility index
n - particle number, molar number
-1
n min number of revolutions
N - total particle number
p kPa pressure
P kW power
q µm-1 frequency distribution
Q - cumulative distribution (quantil)
Q As electric charge

Q J/s heat flow rate
r xy - correlation coefficient
r mm characteristic radius of volume element
r mm subprocess chamber radius, zone radius
R m process chamber radius
R kJ/(kmol*K) general gas constant
R V/A electric resistance
Re - REYNOLDS number
Rm kg/kg mass recovery
s - standard deviation
s mm distance, film thickness, wall thickness
s2 - variance
S m³/m³ pore (volume) saturation
S kg/(m2*h) particle mass flow rate related to cross-sectional area
Sc - SCHMIDT number
t h time
t mm thickness
T kg/kg separation function, grade efficiency curve
T K temperature
T s time constant
Tu - degree of turbulence
u m/s flow rate, fluid velocity
U m process chamber circumference
U V electrostatic potential
v m/s flow rate, particle velocity
V m3 process chamber volume
V m3/h volumetric flow rate
w mm mesh
W - probability
W kWh work
We - WEBER number
x - independent variable
x, y, z - co-ordinates
dx, dy, dz mm incremental dimensions of volume element
X kg/kg mass fraction
y - dependent variable
α - failure probability
α deg failure angle, wetting angle, angle
α m-2 filter medium resistance
β deg angle
β m-1 specific filter cake resistance
β kg/(s*m2) mass transfer coefficient
δ deg angle
∆ - difference
ε m³/m³ porosity
ε m/m normal strain
ε W/kg energy dissipation
ε0 As/(V*m) permittivity of vacuum
εr - permittivity
ϕ m³/m³ particle volume fraction
φ - partial pressure ratio
ϕ deg friction angle, angle
ϕ s-1 angle rate
Φ - probability distribution function
γ deg angle
γ m/m shear strain
γ s-1 shear rate gradient
η Pa * s dynamic (fluid) viscosity
κ - separation efficiency
κ - elastic-plastic particle contact consolidation coefficient
κ - exponent
κV - (volume related) magnetic susceptibility
κm m3/kg mass related magnetic susceptibility
λ - parameter
λ kPa/kPa lateral pressure ratio
λ µm micro-dimension of turbulence
Λ m macro-dimension of turbulence
µ kg/kg mass fraction
µ - friction coefficient
µ0 N/A2 magnetic field constant
µr - magnetic permittivity
ν - safety factor
ν - stoichiometric factor
ν m2/s kinematic (fluid) viscosity
θ °C temperature
θ deg contact angle
Θ deg process chamber inclination angle, cone angle
r kg/m3 density
σ - standard deviation
σ kPa normal stress
σ J/m2 surface energy (tension)
σ2 - variance
σc kPa uniaxial compressive strength (unconfined yield strength of powder)
σF kPa tensile strength (yield strength of material)
σ1 kPa major principal stress
σZ kPa isostatic tensile strength
σ2 kPa minor principal stress
τ kPa shear stress
τc kPa cohesion
τ0 kPa yield strength
ω s-1 circular frequency
Ω - Ω-number
ζ mV Zeta-potential
ξ - particle characteristic, variable
ψ - particle shape factor
ψ mV electric double-layer potential
Indices
a external, apex
A feed, output, area related
b bulk
B bottom, bubble
c compressive, critical
C COULOMB
d discharge
D pressure, diffusion, vapour, nozzle
e effective, electric
el elastic
E feed, input
f fluid
F fill, fines, filter, filtrat
g gaseous, limit
G coarse, gravity
ges total
h horizontal, homogeneous, hydraulic
H adhesion, major design, homogenisation
i running index of size fractions, internal
j running index of density fractions
k running index of constituents or material components, continous phase
krit critical
K particle contact, capillary, spherical, core flow
l liquid
ln logarithmic
L light material, storage, air, pneumatic
m mass related, medium
M mixture, mass flow, centre, model, magnetic
max maximum
min minimum
n number, normal state
N normal
0 non-loaded, initial state
o overflow, upper
p particle
pl plastic
P pore, packing, probe, power
r quantity, roughness
R ring, radius, margin
s solid, stationary
st stationary, steady-state
S surface, suspension, heavy material, shear
ST SAUTER
t time dependent, turbulent
T separation, tangential, inertia, surfactant
Tr suspension, mud
u underflow, below
v vertical, viscous
V volume related
w wall, resistance
W water
x x-axis
y y-axis
z centrifugal, circulation, z-axis
zul permissible
Z tensile, zone, cell, comminution
ε pore volume related
ϕ influenced by particle volume concentration
0 number as quantity (from l0)
1 length as quantity (from l1)
2 area as quantity (from l2)
3 volume or mass as quantity (from l3)

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Process Engineering Department summer semester 2017

Chair for Mechanical Process Engineering

Lecture: "Mechanical Process Engineering (Introduction into Particle Technology)"

date L/T content responsible

Editor Title Publishers Year

Aufbereitungs-Technik Bulk Solids Handling

1. Introduction, characterisation of disperse material systems, particle charac-

1 Dispersity of particulate systems,

2 Particle production by comminution,

4 Particle separation in a fluid flow

6 Particle interactions, powder storage and flow

7 Particle formulation by agglomeration,

8 Product tailoring by particle mixing,

 Material conversion (processing):

 Mechanical Process Engineering:

Classifying Separation according to particle size

Sorting and Separation according to physical material properties

Crystalli- Crystallization Evaporation of liquid

Thermal Roasting Degassing of volatile phases

1. General formulation of quantity balance of a material component:

Accumulation = Σinput streams - Σoutput streams + sources – sinks (1)

Following fundamental principles are to consider:

2. Discrete mathematical formulation of quantity balance of type mass or number of parti-

i and j in the observed volume element dV by

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