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City of Manila, Philippines
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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
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

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: /6 for sphere

PARTICLE CHARACTERIZATION
5) Screen Analysis of Particles smaller than 200 Mesh

where: x = weight fraction retained

Dp = mean particle diameter

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

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 earths 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
Force
Compressive

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

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.
2.

Initial fractures on existing fissures within the structure of the

material
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

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.

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 m sieve
q Refer to Table 21-8 / Perrys 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 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

CSA (smaller) vs. Dp

1.2
1
0.8
0.6
0.4

<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> = .

8 = . (From Table 21-8)

= 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

CSA (smaller) vs. Dp

1.2
1
0.8
0.6
0.4
0.2

<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> = .

8 = . (From Table 21-8)

= 2(0.1581)(9.45)

= .

1
0.45

50

Second crushing:
<6@ = .

<6> = .

8 = . (From Table 21-8)

= 2(0.1581)(9.45)

= .

1
0.13

1
0.45