SYNTHESIS R13PORT

FOR PUBLICATION”

CONTRACT N“ : BREU-CT91 -0548 (RZJE)

PROJECT No : SE -4538

TITLE :
Solution of Electrostatic ProbleIns in

Powder Handling and Processing

,
PROJECT
CO-ORDINATOR : Chilworth Technology Ltd.
Beta House - Chilw-orth Rese ~ch Centre
SOUTHAMPTON S016 I’N:,
England.

PARTNERS : L.O.M.
Alenza 1 y2
-
28003 Madrid
ESPAGNE

L. C.I.E.
33 avenue de General Lecler:
92260 FONTENAY AUX RQSES
-. FRANCE
“) CEMENTOS REZOLA
Avenida de Anorga
36/2009 SAN SEBASTIAN
ESPAGNE

INERIS
Pare Technologique ALATA
B.P. N“.2
60550 VERNEUIL - EN ~~ HALATTE
FRANCE

STARTING DATE : 1992-01 -01 DURATION :36 MONTHS

——.-.-.—-—..————— -— -—-—-.-,— —
PROJECT FUNDED BY THE EUROPEAN
Commission” UNDER THE
BRITE/EURAld P R O G R A M M E
 SOLUTION OF ELECTROSTATIC PROBLEMS

IN POWDER HANDLING

.4ND P r o c e s s i n g
~

ABSTRACT

Electrostatic tribocharging ofpowder causes it to be at !racted to, or repelled

ji-orn, a nearby surface or szu-rounding par[icles. This con lead to variations in
bulk density, choking of machines and a range of other u~zpredictable industrial
problems. Research work described by the report ~imed to improve the
economic eflciency of milling and mixing in the test-zase cement plant, by
reducing electrostatic powder adhesion. The jh-st stage of Ihe project was to
find the best powder categorisation methods. In the se(:ond stage, laboratory
test rigs lo model three relevant cement processing ma( hines were developed;
a pneumatic conveyor, a cement mill and a jluidised bed homogeniser. The
report deals principally with the obsenations andpredi( tions made using these
rigs. In the third stage, laborato~ charge control tec)miques were repeated
using the full-scale industrial machines, giving gener, d agreement with ~he
experimental resuits. Two important conclusions are that powders cannot
readily be classljied in terms of laboratory charge( lbili~ tests, and that
laboratory equipment which models a machine closely may allow predictions
of powder behaviour. Experience gained jl-om this p ~oject will be used to
improve similar industrial situations via ongoing constdtancy work.

--
‘,

—
 SOLUTION OF ELECTROSTATIC PROBLEMS

IN POWDER HANDLING

AND PROCESSING

Mr. Ian D. Pavey

CHILWORTH TECHNOLOGY Ltd

Beta house - ChiIworth Research Centre
SOUTHAMPTON S016 7NS
ENGLAND

~ Dr. Angel Vega Remesal

L.O.M.
Alenza 1 y2
28003 MADRID
ESPAGNE

Dr. Claude Menguy

L. C.I.E.
33avenue de Gerkral Leclerc ~
92260 FONTENAY AUX ROSES
FRANCE

) Snr. Juan Luis Querejeta

CEMENTOS REZOLA
Avenida de Anorga
36/2009 SAN SEBASTIAN
ESPAGNE

M. Dominique Guionnet

INERIS
Pare Technologique A L A T A
B.P. No.2
60550 Verneuil-en-Halatte
FRANCE
 CONTENTS
l’age No.

1. 1NTROI)UCTION 1

2. TECHNICAL DESCRIPTION 2

2.1 Setting Up the Equipment and Procedures

2.2 ‘ Chargeability Method for Powders and Fibres
2.3 Design of the Simulation Apparatus 3
i) Pneumatic Conveyor ‘
i~ Milling Test Apparatus
iii) Fluidised Bed for Mixing Homogeneity
2.4 Available Charge Control Techniques 4

3. PNEUMATIC CONVEYING TRIALS 6

3.1 Electrostatic Effects at Laboratory Scale

3.2 Single Point D.C. Neutraliser
3.3 On-Site Measurements. Surface Contamination of Pipes ‘7

4. MILLING TRIALS 8

4.1 Electrostatic Effects in Laboratory Scale Mill

4.2 On-Site Measurements. Milling Plant of the Inclustrial Partner
4.3 Research at Other Manufacturing Plants 9

5. IMPROVEMENTS IN MIXING AND MILLING

AT THE CEMENT PLANT 10

-. 5.1 Particle Size Determination

‘) 5.2 Mixing (Raw M’ix Homogenisation)
5.3 Cement Milling (Substitution and Improvement of Additives) 11

6. CONCLUSIONS 12

7. ACKNOWLEDGEMENTS 14

8. REFERENCES 14

9. FIGURES 15
 1 INTRODUCTION

Undesirable electrostatic charging eff+cts are invariably caused by the complex

phenomenon of contact electrification, that is, tribocharging. Even the most simple
process using a fairly res,istive powder may rapidly cre[:te very large fields and high
powder charges. Typical troublesome situations of this type exist where a powder
has been mixed, poured, ground, sieved, or micronised. One should be particulflrly
wary when the po~vder has been entrained within a mo-{ing air stream, for example
as occurs during pneumatic conveying.

A good example of an electrostatic side-effect concernt the variation in bulk

density of powder according to ambient humidity. In t} (O practical examples, bags
filled to the brim \vith food-stuff powder were sometin Ies found to be underweight;
a polymer powder transported by tanker filled to a particular level often had a bulk
density outside the specification. The ‘damp’ appearam :e of the powder in the
second case was a tell-tale sign of charging.

Unpredictability in the results of tribocharging originat ss from the fact that the
powder charge at any time is very susceptible to small changes in the features of a
plant, the humidity and the surface conditions. This being so, the best remedy for
an electrostatic powder handling problem will always I equire specific analysis of
each individual case, in terms of the above parameters Even so, there is often a
single, quite simple method which will remedy a wide array of different, unwanted
charging scenarios.

Test rigs of Laboratory scale were designed and built tl } reproduce the circumstances
leading to three different powder handling problems ir a cement manufacturing
plant. Electrostatic charging in the experimental machines (a fluidised bed, a
pneumatic conveyor and a grinding mill) was monitor(:d in order to gauge the
success of a series of neutralizing techniques.

The moiect
.- had three aims: firstly, to enable industry to recognise an electrostatic
cause in powder handling problems; secondly, to quantify the problem as best as
) possible; thirdly, to enable an appropriate form of soh Ition to be chosen.
‘Experience gained from the work wil[ be continually ind widely disseminated by
several partners, leading to a more widespread awareness in industry of the
phenomenon of tribocharging.

1 “
 L. TECHNICAL DESCRIPTION

2 . 1 Setting Up the Equipment and Procedures

In the first phases of the project, which occupie ~ the five partners for over a
year, the best available techniques of measurem mt, in terms of both
principles and equipment, were reviewed. The i litial plan was to categorise
po~vders according to their properties and therel )y create a database.
Resistivity’ and charge decay time, pernlittivity, cl~argeabi~ity, Particle $ize
and shape, adhesion and cohesion were the imp xtant parameters looked at.

. 2.2 Chargeability Method for Powders and Fibrus

The term ‘chargeability’, in this case refers to 1 he degree of charge on a

powder as a result of a simple, standard tribock arging process. No standard
test for chargeability y currently exists, and form i of equipment representative
of real conditions were evolved empirically by two of the partners. It was
fotind quite difficult to create a reasonably con’:rolled charge using fine
powders. Intuitively, one may expect that case: ding powder down an
I inclined stainless steel plane, connected to a se ~sitive ammeter recording the
streaming current, would be a useable system. [n practice, the powder
charging was much too aggressive, rapid, and ] esults unrepeatable.

Ultimately, chargeability of larger particles waj quantified by stirring them

in an earthed stainless steel blender. Powder 01’ finer granule size was
sprinkled fi-om a vibratory feeder to impact up m a metal plate. In both
cases, charging was followed with direct trader of the test material to a
Faraday Pail, connected to an electrometer set to the charge range.

These methods permit the measurement of cha rgeability of powders under

climatic controlled conditions, and are;
)
- reproducible
- valid for substances with high charge ~bility
- useable with small qu~tities of fine (lusts, fibres and pellets
- completed in a short time.

In addition, information from the tests;

- highlights the effect of ambient cond tions

- enables study of side effects such as adhesion and agglomeration.

The effect of solid and liquid additives on the specific charge of powders
was most usefully anal yzed by the blender m( :thod.

2
 2.3 Design of the Simulation Apparatus

The three experimental rigs will be introduced sc paratel y.

i) Pneumuiic Conveyor (See Figw-e 1.)

Charging of a material being transported in a stfi iight pipe depends partly

upon the orientation of the pipe with respect to the ,,force of gravity. As a
consequence, horizontal, vertical up and vertical down flow sections were
designed into the rig. Fittings, particularly those giving rise to a change in
flow direction, were anticipated to have a significant effect on powder
charge. To limit the number of possibilities, fitti ~gs used were restricted to
90° elbow bends. Taking all these points into consideration led to the basic
square circuit in the vertical plane, all pipework being 30mm internal
diameter stainless steel tubing.
I

The system was run below atmospheric pressure, by using suction on the
cyclone air outlet. Separate pipe sections were j( )ined with simple insulating
push fittings. Sensors and other items of equipment could pass through the
I pipe walls without risk of powder escaping into the lab. The upstream end
of the circuit was open to atmosphere, and powt ler fed directly into the pipe
I from a vibratory feeder. The rig was constructed i in such a way that any part
could be electrically isolated, allowing streamirq~ currents, and consequently
the local powder charging effect, to be monitort d. To ensure a reproducible,
quantified air flow, an orifice plate and water rr anometer was fitted
I immediately downstream of the cyclone.

iiy ~ Milling Test Apparatus (See Figures 2 & 3)

Figure 2 shows a schematic diagram of the exp a-imental mill in relation to

I
the electrostatic instrumentation. The mill itself is depicted from the side by
Figure 3..

,/)
A small cement mill, for evaluating electrostatic: charge behaviour and
developing the best control techniques, was bui .t to laboratory scale.
Instrumentation comprised specially designed field meters, electrometers and
a device to measure and record the power cons~mption. The machine has
been installed in a climatically controlled enclosure having a metaliic screen
like a Faraday Cage. Relative humidity can be ~djusted to any point
between 30’%0 and 60?L0, and the temperature to between 18°C and 30°C.

Principally, the mill used a revolving steel cylinder, 60cm in length and
diameter 30cm, closed by two end caps and driven through gearing by an
electric motor. One cap supported a robust tra,i in the entrance for the
removal of processed material. Blasting by san{i,jet removed every trace of
oxide or paint from all surfaces. Inside the mil , an additional tray was
located, the purpose of this being to remove th t output of grinding balls
( a l s o t e r m e d g r i n d e r heads).

I
 Above a critical velocity, all of the grinding ball:, will remain attached to
the inner wall by a centrifugal effect. In normal :]se, the mill turns at 65-
70% of critical velocity, nominal speed being 42 r.p.nl. ,

The number of grinder heads and their diametral size is shown below:

100 of 20mm; 100 of 25nm~; 100 of 30mm; 25 of 35nml; 18 of 40 nm.

All mechanical connections to, and supports of, 1 he mill were made from
PTFE (Teflon) to obtain high insulation with res ~ect to surrounding
grounded metallic parts. Insulation resistance bet ween the mill and the
motor was greater than 100 GigaOhm.

ii~ FIuidised Bed for Mixing Homogeneip (See Figure 4)

Mixture quality is a major concern of many ind~ stries, such as chemical

product manufacture (gas-solid reaction) and ph: rmaceuticals. The major
.,
‘difficulties in sohd-solid mixing operations are s segregation and the inability
of mixers to break down agglomerates. A segregation or de-mixing process
I always occurs in competition with homogenizing. The mixing quality
depends upon the dynamic equilibrium between mixing and segregation. A
mixture is homogeneous if any sample of the mixture has the same
composition and properties as any other.

The fundamental aspects governing the mechani jm ‘of gas-flow within the
bed are not yet fully understood. The fluidisatio~ of divided solid particles
occurs in the form of bubbles, analogous to the upward flow of gas through
a column of liquid. Figure 4 shows the schemat c diagram of the
equipment; the actual set-up was designed more to simulate the phenomenon
at the Cementos Rezola cement milling plant.

The fluidised bed was divided into three stacket. parts. The lowest and
middle parts, separated by a porous membraqe, were again divided into four
,), compartments in which mean and sequential pressure could be applied. The ,,
mean pressure just fluidises all particles; sequential pulses of higher pressure
perform the mixing. In the uppermost section, the smallest particles were
removed. The air feed pressure was measured with a digital manometer, and
the aeration and fluidisation flow with two independent flow meters.

2.4 Available Charge Control Techniques

Quite a large proportion of the project time wa:: spent reviewing methods of “
electrostatic charge control, both in the literature and private
communications from experienced cement mini ~g operatives. The idea was
to use the laboratory scale equipment to rank charge control techniques in
. order of effectiveness, expose any side effects, md select the optimum for
trials in full scale equipment.

4
 ,

There were two important methods by which po’vder charge generation in

the three test rigs could possibly be subdued:

a) Powdered and liquid additives

b) High voltage neutralisers

A, small proportion of powdered additive can be mixed with the primary

material (i.e. cement powder) to reduce the volu ne resistivity. Liquid
additives comprised }vat er, in the form of ambie It humidity, and a well-
known cement milling additive, SAT. Both worl. by speeding the charge
decay time, allowing more rapid relaxation of the powder charge whenever
the particles contact a grounded surface.

The degree of success of each treatment strong]: r depends upon the primary
powder; several kinds of material were tested to =xpose these variations.

Commercially available high-voltage neutraliser: ~ usually take the form of a

set of points supplied with high voltage of alter] Lating polarity, or with each
alternate point positive and negative respective]). Corona discharge provides
I a stream of ions from each point, the dispersal i If ions often assisted with
air jets. Comparatively large charges of equal a~ Ld opposite polarity sprayed
at the powder overcome existing tribocharge le~ els.

Preliminary Trials

Prior to any experiment with the test rigs, the e !fect of additives upon
primary powder properties was investigated. Two powdered additives,
graphite and alumina, were used to treat three pimary powders, LDPE
fines, cement and sepiolite. An addition of 5% graphite to LDPE fines was
able to reduce the charge decay time from mor( ~ than an hour to less than
one second. Similar effects were observed in th a other two powders, and as
a consequence the chargeability much reduced, and improved, by graphite.
The chargeability of cement only could be reduced by addition of alumina.
)
For liquid additive testing, the concentrations u ;ed were 35% & 50% for
relative humidity, and 150 & 300 ppm for SAI”. For cement and sepiolite,
but not LDPE, an increase in relative humidity produced an important
reduction in resistivity. All powders were less [johesive/adhesive, in a higher
humidity atmosphere.

A liquid additive currently widely used to cont:ol charge in cement milling

was found to have no significant effect upon tl e electrical properties of any
primary powder, cement included.

It was hoped that the information given by these standard laboratory tests
would correlate with, and could therefore have predicted, the outcome of
more complex tests in industrial situations.

~,
5
 3. PNEUMATIC CONVEYING TRIALS

3.1 Electrostatic Effects at Laboratory Scale

Using untreated sepiolite as a primary powder, tile space charge developed

within this equipment soon became appreciable :md internal walls powder
coated. The resultant cyclone blockages are thou ght to occur because of an
intensified space charge density close to the inte ma] wal 1s. That is, powder
entrained in the internal vortex of air in the cyclone is centrifugal] y
compressed, giving particles an increased electrc static adhesion force.

Powdered Additive: Graphite

Concentrations of O. 5% and 5% graphite/primar:r powder were pre-mixed by
vigorous shaking. Three types of primary povvd~ :r were modified; cement,
sepiolite and LDPE fines.

I Liquid Additive: SAT

Mixing was achieved by electrostatically sprayir ~g the “SAT (using a solution
of 5°/0 volume of SAT in isopropyl alcohol) on the powder. Two types of
primary powder were modified; cement and sep iolite.

Comments
The most effective additive, either liquid or po~ {dered was graphite,
combined with the powder in a concentration o~” 5°/0. This managed to
reduce tribocharging levels on all the primary powders and stopped the
sepiolite cyclone blockages.

For sepiolite and cement, SAT seems unable to reduce, the charge level of
the powder. A comparison between the initial c ~argeability test results and
the charge developed during pneumatic transpo]t ruled out any accurate
predictions. Tribocharging occurring due to panicles impacting a plate did
not correlate with tribocharging from powder b own through pipework
entrained in a volume of air. Put another way, ndividual powder treatments
which appeared successful in the simple experi] nental model were not
reflected in “a different kind of charging scenario.

3.2 Single Point D.C. Neutraliser

The basic system comprised a needle connected to a high voltage power

supply protected by a plastic tube. Of the three powders tested, sepiolite,
cement and LDPE fines, a low local leveI of c~ mrge was measured. The
device reduced the electrostatic space charge o~’ sepiolite at the inlet to the
cyclone, hence preventing any blockages. The leutraliser was certainly more
effective than the additives, but a single point ~:ould ‘not control powder -
charge throughout the entire transport system.
 3.3 On-Site ,Measurements. Surface Contamination of Pipes

A 40m run of 80mm diameter stainless steel piping was used to convey fine ‘
metal oxide powder of 2 microns mean particle diameter by pneumatics.
The powder was fed into the system at the rate of 1 tonne/hour and
transported in an air flow of approximately 3601 n3/hour. After the operation,
‘up to 10kg could be, found adhering to the walk of the pipes.

Using the laboratory technique, streaming curre] Its from’ eight sections of
pipework, insulated from each other and also fn }m ground, were monitored
to record specific charge exchanged per unit length of pipe. Charge-driven
current from the receiving hopper, and the chaq ;e on the powder in the
hopper at the end of conveying, could also be n )easured with good
reproducibility.
I
As expected, under low humidity conditions the powder was much more
likely to acquire charge by triboelectrification, the degree being typical of
pneumatic transport.

An increase in the mass flow rate of powder le: ids to a decrease in the
specific charge on the powder, but this did not appear to have any influence
on the contamination problem. The most impor ant aspect of the results was
the hypothesis that the space ch~ge density of powder [pC/m3] is the
governing factor for powder charging. Space c1 arge density is a direct
function of streaming current and relatively ind tpendent of mass flow rate.
,
Where right-angled bends were included in the pipework, we found that the
polarity of powder charging was opposite to thtit in straight pipe sections.
This finding confirmed identical phenomena pr wiously observed in the
laboratory scale rig. Powder traveling around the inside of a bend will
become compressed against the inside wall, du~: to a centrifugal effect
similar to the operation of a cyclone. The spacl> charge density close to the
internal pipe surface will be much increased, zld as a consequence, the
) direction of the driving force for charge exchmlge could reverse,

We concluded that the charge levels [1 to 3 p{;/m3] measured on the

powder were enough to initiate powder adhesitm, and recommended that the
powder be conveyed under more humid conditions. Electrostatic charging
would then be implicated as the cause of the c mtarnination problem.

7’
I
 4. MILLING TRIALS

4.1 Electrostatic Effects in Laboratory Scale Mill

Typically, the problem associated with electrosta: ic charge generation during

milling is one of efficiency loss due to agglomer ~tion and adhesion of the
powder to milling elements. Additives and static eliminators neutralise the
powder charge and prevent sticking, saving ener~ :y and increasing
productivity.

A laboratory scale mill was the starting point for the study of the problems
associated with milling; also, to initiate solutions to be applied in the real
plant. The test rig was used for measurements of some effects and variables
described as follows:
,.
- Electrostatic charge of the powder subs~ antes during milling
- Electrical power consumption
- Effects of additives and neutralizers on power consumption
- Effects of ambient conditions (Relative Humidity, Temperature)

The well controlled conditions and systematic m tthods of operation of the

lab-scale mill have ciearly established that electrostatic effects are
responsible for loss of milling efficiency. It was useful to apply the same
solutions in the real plants. Additives, and the el actrostatic neutraliser probe
in the scale mill both decreased the electrostatic charge. Power consumption
was significantly lowered as a consequence.

4.3 On-Site Measurements. Milling Plant of the Industrial Partner

Measurements of electrostatic charge of powder: during a real process were

made using similar principles to those used to measure charge in laboratory
) tests. Simple equipment based on a Faraday cag~~ received powder collected
in the plant. This permitted immediate “on-line” knowledge of the specific
charge of the powder taken from a real stage of the process. The
measurements were carried out with or without ]owder additives and/or
neutralizers.

The following items summarise the schedule of the electrostatic audit:

- Determination of the critical measuring points

- Location of accessible points to collect the sample powder
- Careful collection of sample powder to avoid superimposed charges
Measurements of electrostatic charge o‘ the sample
Weighing the sample to ,calculate the specific charge
Complementary measurement of electri c field

8
 Electrostatic measurements in the plant, accord in,; to this systematic method,
illuminated the location of the problem and dem{lnstrated the results of
additives, neutralizers and other types of devices used to, improve
performance and reduce the power consumption.

/
4.4 Research at Other Manufacturing Plants

Two industrial plants were anaiyzed according tf the systematic techniques

developed during the work with our industrial p: rtner. These processes have
in common the use of fine powders with reco@i zed electrostatic problems,
as described below.

a) Sulphur plant with a great probler 1 of productivity loss due to

powder adhesion.

b) Large wheat flour plant with operational problems such as

shock discharges to personnel ‘and Ioss of productivity during
I sieving.

In both cases, an important problem not related [o the objective of the

programme was revealed; namely the explosive ~ehaviour of the powders.

A laboratory study of sulphur powder shows that a small proportion of

additive to powder drastically changes the electr sstatic behaviour. This
principle could be applied to plant to improve tile productivity, also to limit
stoppage of the process due to powder aggiome~’ation.

In the case of flour plants no electrostatic additives are permitted. The

research for these food powders was focused on the improvement of the
process based upon modifications of the plant. IJactors such as geometry,
materials in contact with the powder, climatic cmditions were researched
and changed. Also, the analysis of powders and material at laboratory scaIe
.) helped to solve problems in the plant.

1.,

I 9

1.
 5
-. IMPROVEMENTS IN MIXING AND MILLING AT ~,HE CEMENT PLANT

5.1 Particle Size Determination

Several interesting and useful comparisons betwc en different methods to

determine particle size \vere compiled by the inii ial research. As a result of
development in this area milled Quartz has been adopted as an internal
standard to verify periodically the laser granulon letry equipment. The
statistical study of this data confirms the repeata’’}ility and reproducibility of
the equipment. In a valuable outcome, particle .4 ze verification enables
better adjustment of granulometry set points on {he milling equipment.

5.2 Mixing (Raw Mix Homogenisation)

One of the characteristics most appreciated in th t cement industry is the

homogeneity, as much in the feedstock as in the final product. The main
feedstock in a cement factory is the raw mix which is fed to the kiln to
obtain the portland cement clinker. As a conseq~ Ience, all improvements in
raw mix homogeneity improve kiln performance, economy and final product
homogeneity.

In mixing by fluidisation, a technique has been >erfected to quantify the ‘

efficiency of the factory’s raw mix homogenisation silo in real work.
conditions. By the application of this technique, it has been shown that the
actual operating conditions of this silo allows a reduction of 4 to 5 times the
wiriation of the chemical composition between the entrance and exit of the
silo.

In the following table the results of two tests based on chemical

characterisation (characteristic studied: Lime S: ~turation Factor) are shown.

.)- Samples of the m-ix were taken from the entram:e and
homogeneisation silo.
, exit of the

0
Tests n“l Test n 2
L.S.F. Inlet L.S.F. Outlet L.S.F. inlet L.S.F. Outlet
M a x . 130,37 109,55 123,45 108,21
Min- 98,73 102,04 101,32 101,79
St. Deviation 9 , 1 6 2,14 7,22 1,54

Table 1. Lime Saturation Factor at entrance and exit to the silo.

10
 From these results, the homogenisation silo is clew] y not responsible ior our
problems in raw mix homogeneity. So, the other elements (such as transport
installations, intermediate storage silos etc. ) mus. be checked as suspect
mix segregation elements.

5.3 Cement Milting (Substitution and Improvement of Additives)

The specific electrical energy consumption in cer~ent milling is in the range

from 41 kW/ton to 67 kW/ton depending on the cement type. To reduce the
specific consumption, chemical milling aids are \lsually employed.

In this area, via experimental work carried out ir the plant, it has been
demonstrated (using a high voltage neutralizer) t!~at electrostatic phenomena
may be partly responsible for reduced efficiency in the process. This has led
to the partial replacement of chemical additive b{ an electric neutralizer in
I
the smaller cement production mill. -

On other hand, as a consequence of the project, :he use of the milling

additives in the factory has been rationalised. By co-operation with an
additive supplier, new and more economical add tives have been developed.

We can evaluate in a general way the influence lf the project on the milling
process. Energy consumption remains the same 1 Jut the costs of milling
additive in 1995 are more or less 10°/0 lower than in 1994, for the same
quantity of cement production.

11
,.
 ‘ 6. CONCLUSIONS

The work completed has a very wide application in an il]exhaustible number of

industrial situations. There are two or three solutions which may solve the majority
of unwanted charging effects, but each ‘case is different md inevitably creates its
own problems. For example, variations in surface conditions, materials and
humidity, or the geometric features of a plant, wi~l all r~:quire specific ana~ysis in
any case.

All powders cannot be categorised by chargeability, sim :e different charging

scenarios can cause quite unpredictable levels of charge Fine powders in particular
may give unrepeatable results for the same test. Even ii a detailed database of ~
material charging behaviour could be prepared, it will always be difficult to foresee
electrostatic problems using this knowledge alone. It is therefore important to seek
guidance from expert consultants if the situation is unddy complex, poorly
understood or at all hazardous.

I “’ Laboratory analysis of the powder was crucial to the u] ~derstanding of electrostatic

1“ problems and should be the first step in any research ri :Iated to powder handling.
Test-rigs to model each specific problem were used su~:cessfully to categorise
powder charge control techniques in order of effective~ less. In all cases the best
results could be repeated at large-scale in similar math ines.

There are a limited number of options for dealing witt static charge. Most often
used are additives, which lower the volume resistivity of the powder, or high-
voltage corona neutralisers which overcome the powder tribocharge with much
higher levels of positive and negative ions.
I The degree of success of additives in increasing condt .ctivity depends very much
on the primary powder. But there may be additional physical reasons to prevent
their adoption. Looking at the application to cement o niy, although the resistivity
can be usefully lowered by the addition of 5°/0 graphi’ e, there were two undesirable
side-effects. Firstly, the cement was unacceptably disc oloured; secondly, the
.) lubricating effect on the grinder heads reduced their efficiency.

Of the liquid additives tested with cement, water in t} [e form of relative humidity
was found to be most successful at modifying electri( al properties, and SAT not at
all. However, conditioning cement powder using humidity was not a practical
industrial treatment. The whole picture should alway: be considered.

Pneumatic conveying highlights one of the important differences between additives

and neutralisers; that is, their, different spheres of inf uence. A neutraliser can ord y
discharge the powder in its locaIity, and charge will :apidly be re-generated further
-., along the pipework. Local discharging by neutraliser in a key area such as just
‘before a cyclone has been shown to prevent cyclone blockages, so the device can
be an appropriate solution. Alternatively, modifying [he powder with an additive
will control charge build up through the whole syste .m. But we should bear in mind
that the powder will not necessarily be completely n mtral at any stage.
I
I 12
 Greater certainty can be expected from predictions of clinging when the physical
model is close to the real situation. For example, powdt:r charge levels in lab-scale
pneumatic conveying did not correlate with chargeabifit y recorded from simple
impact plate experiments. However, consider the impori ant finding that powder
\ travel ling around a 90” bend, and along straight pipes, ~ vill charge in the opposite
direction. This phenomena was observed in the both the small scale and industrial
pneumatic conveyers. In hindsight, it could have been predicted.

Space charge density, and not specific charge, correspol Ids directly to streaming
current in pneumatically conveyed powder; thought to Ee the govering factor for
tribocharging. Where powder flow is centrifugally conll messed, the space charge
density increases and the situation is likely to cause po~~der adhesion or choking.

In laboratory scale cement milling, electrostatic charge 1 las been isoiated as the
cause. of efficiency 10SS, mostly due to powder sticking :0 milling elements.
Neutralisers and additives were both successful at reduc ng power consumption at
small scale. The ultimate aim was to substitute current c heroical additives with a
more economical A.C. corona neutraliser at full scale. 1 unfortunately, the internal
.,
environment of a cement mill is very aggressive, and ar y ordinary neutraliser
would probably be destroyed by falling rocks, or erodec. A specially designed
high-power system would be necessary to tackle these problems.

L.O.M. have drawn upon their Brite EuRam experience in two post-project
consultancies. In both the sulphur plant and the wheat hour plant investigated, an
explosion risk has been identified, and in the second ca’ e, unsafe shocks have been
received by personnel. Using an accurate model of the relevant features of the
sulphur plant, L.O.M. predict that low productivity COU1 ~ be markedly improved,
simply by using specified additives. Where no chemical additives are permitted, as
in the case of wheat flour, the options are reduced to changing materials, geometry
and ambient conditions, backed up with laboratory anal>’sis of powder.

To Cementos Rezola, as an industrial partner, the most relevant aspects of the

whole project we~e those related to the mixing and miIli ng processes. As a direct
) result of. the research into the best methods of particle size measurement, Rezola
have adopted milled quartz as an internal standard. As a consequence, on-line
verification of their granulometry equipment has improved powder quality control.

Analysis of the raw-mix homogenisation silo has shown that although there may be
considerable static charge at the surface, this is probably insignificant compared to
the other forces, Because of the extremely large size of :he. silo (9.7m diameter and
23m height) neutralisation of the surface charge to redui:e the overall static build-
up would not be worthwhile.

Experience gained during the Iife of the” project will be continually disseminated to
clients through consultancy work on individual industria. problems as they arise.
Because of the permanent increases in productivity, or rt~ductions in power
consumption which may be achieved using the results, tile cost of the project “will
be recovered after a small number of successful solutions have been applied.

13
 7. ACKNOWLEDGEMENTS

The work described above could not have been carried i Jut without the support of
the European Community Brite-EuRam Programrne.

( C o n t r a c t N“. B R E U - C T 9 1 - 0 5 4 8 (RZJE); Project N“. 4538 .

The research opportunities opened up by this funding h: .ve been gratefully

appreciated by al i of the five partners.

8. REFERENCES
.
[1] British Standard B.S. 5958 “Code of Practice for Con, rol of Undesirable Static
Electric@”. (1980)

1 [2] GLOR, MARTIN. ““Electrostatic Hazards in Powder handling”, Research Studies

Press Limited, John Wiley and Sons inc. (1988)

[3] BAUDET, M. “Mines et Carridres”, (June 1990)

[4] COLE B.N., BAUM M. R., MOBBS F.R. “An investig~ lion of electrostatic
charging effects in high speed gas-solids pipe flow”, Prf )c. Inst. Mech. Eng., 184
(3C) (1969-1970), pp 77-83.

[5] EBADAT V., BAILEY A. G.” AND SINGH S. ‘The 1) !fluence of a Super-imposed
Electric fieid on Triboelectrfrcation of Powder Particle r in a Pneumatic Conveying
System”, Journal of Electrostatics, Vol. 3 (1990), pp 25”’-270

[6] CROSS J. A. “Electrostatics: Principles, Problems ana Applications”, Adam

Hilger (1987).

[7] BOSHUNG P:, GLOR, M. “Methods for Investigating the Electrostatic Behaviour
.) of Powders’: JournaI of Electrostatics; Vol. 8 (1980), p]) 205-219.

14
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I
Figure 4, Experimental Fluiclised Bed for Mixing Homogeneity Testing