An improved estimation of size distribution from particle profile measurements

Several methods are available to measure particle size. The majority of them, such as sieving, are off-stream techniques where samples must first be separated from the main stream for analysis.Therefore, the search for on-line particle size analysis systems has provided the impetus for the introduction of image-based particle size analysers to the mineral industry in the past three decades. Generally, the estimation of particle size distribution on the basis of image analysis depends on measuring a single parameter of particle profile. For example the equivalent area diameter (d_A) or mean Feret's diameter (d_F) distributions, then transforming this data to the equivalent size distribution. However, due to the irregularity of particles being analysed, it is believed that this kind of analysis may increase the error in estimation of particle size distribution since profiles of irregular particles carry more information than can be represented by a single parameter.In this paper, a proposed technique which measures two parameters, equivalent area diameter (d_A) and mean Feret's diameter (d_F), for each particle profile has been developed. The accuracy of the technique has then been investigated in the laboratory by successfully estimating (unfolding) the size distribution, where size refers to sieve size, of three samples of different particle shapes with known size distribution.     

Use of computer assisted image analysis for the determination of the grain-size distribution of sands used in mortars

A quantification procedure for constructing the sieving curves of sands used in mortars, from two-dimensional data obtained by image analysis of thin sections, has been developed. To test the suitability of this procedure, thin sections were made from ten fluorescent epoxy-impregnated mortars, containing five different sands of which the sieving curves had previously been determined. Whereas previous investigations were typically based on independent and individual micrographs, a new approach has been adopted in which measurements are performed on single composite images. Two stereological models, based on cubic and spherical particles respectively are applied to the examples and the results compared with the sieving curves. The results obtained show a reliable congruence, especially for the spherical model and when shape factors of sectioned grains are high. Sieving curves and grain-size distribution curves established from image analysis may have virtually the same precision, but the latter has a lower reproducibility.     

An experimental study of immiscible liquid–liquid dispersions in a pump–mixer of mixer–settler

Drop size distribution(DSD) or mean droplet size(d32) and liquid holdup are two key parameters in a liquid–liquid extraction process. Understanding and accurately predicting those parameters are of great importance in the optimal design of extraction columns as well as mixer–settlers. In this paper, the method of built-in endoscopic probe combined with pulse laser was adopted to measure the droplet size in liquid–liquid dispersions with a pump-impeller in a rectangular mixer. The dispersion law of droplets with holdup range 1% to 24% in batch process and larger flow ratio range 1/5 to 5/1 in continuous process was studied. Under the batch operation condition, the DSD abided by log-normal distribution. With the increase of impeller speed or decrease of dispersed phase holdup, the d32 decreased. In addition, a prediction model of d32 of kerosene/deionized system was established as d_(32)/D = 0.13(1 + 5.9φ)We~(-0.6). Under the continuous operation condition, the general model for droplet size prediction of kerosene/water system was presented as d_(32)/D = C_3(1 + C_4φ)We~(-0.6). For the surfactant system and extraction system, the prediction models met a general model as d_(32)/D = bφ~nWe~(-0.6).     

Monodisperse Droplet Generators as Potential Atomizers for Spray Drying Technology

Spray drying is a widely used unit operation for manufacturing powders of different characteristics. Many technological improvements have been made in the last few decades, and a great amount of research work is still being conducted. Recently, the hybrid spray-drying technique was reported, which combines the ink-jet technology with spray drying in order to produce particles of uniform characteristics.^[1-4¹, ², ³, ^4] The monodisperse droplet generators (MDGs) have certain features that make them attractive for use as atomizers in spray-drying operations. In this article, a comprehensive introduction to a variety of monodisperse droplet generators is provided. The advantages and limitations of these generators are discussed. The fundamental equations for predictions of the average droplet size are summarized. The discussion given in this study is aimed at the development of a hybrid technology that marries a suitable MDG with the existing spray-dryer technique (yet with some modifications) to manufacture the product with uniform characteristics containing micro- to nanosized particles.     

Monodisperse Droplet Generators as Potential Atomizers for Spray Drying Technology

Spray drying is a widely used unit operation for manufacturing powders of different characteristics. Many technological improvements have been made in the last few decades, and a great amount of research work is still being conducted. Recently, the hybrid spray-drying technique was reported, which combines the ink-jet technology with spray drying in order to produce particles of uniform characteristics.^[ 1-4 Patel , K.C. ; Chen , X.D. ; Lin , S.X.Q. Development of a laboratory ink-jet spray dryer . Chemeca 2006 , Auckland , New Zealand , September 17–20, 2006 (CD-Rom) . Patel , K.C. ; Chen , X.D. Drying of aqueous lactose solutions in a single stream dryer (S²D) . Transactions of the IChemE: Food and Bioproduct Processing 2007 , accepted . Patel , K.C. ; Chen , X.D. Production of spherical and uniform-sized particles using a laboratory ink-jet spray dryer . Asia-Pacific Journal of Chemical Engineering 2007 , 2 ( 5 ), 415 – 430 . Patel , K.C. ; Wu , W.D. ; Chen , X.D. Review on generation of monodisperse sprays for manufacturing micro-size uniform particles using a spray drying technology . In Proceedings of Asia-Pacific Drying Conference , Hong Kong , China , August 13–15, 2007 .  ^] The monodisperse droplet generators (MDGs) have certain features that make them attractive for use as atomizers in spray-drying operations. In this article, a comprehensive introduction to a variety of monodisperse droplet generators is provided. The advantages and limitations of these generators are discussed. The fundamental equations for predictions of the average droplet size are summarized. The discussion given in this study is aimed at the development of a hybrid technology that marries a suitable MDG with the existing spray-dryer technique (yet with some modifications) to manufacture the product with uniform characteristics containing micro- to nanosized particles.     

Statistical modeling of the geometrical structure of the system of artificial air pores in autoclaved aerated concrete

The geometrical structure of the system of artificial air pores in autoclaved concrete is studied, based on samples from laboratory and industry. The single pores are approximated by spheres, the corresponding radius distribution is determined by means of stereological methods. The resulting distribution is not a classical standard distribution, but instead requires a mixture of three components, one of them Gaussian. The pore system as a whole is approximated by the penetrable-concentric-shell or “cherry-pit” model, which consists of spheres that are partially penetrable. The corresponding hard cores form a random packing of hard spheres. The goodness-of-fit of the model is tested by means of information available from planar sections: the section profile radius distribution and the pair correlation function of profile centers.     

Electrostatic destabilization of water-in-crude oil emulsions: Application to a real case and evaluation of the Aibel VIEC technology

In the current study, the Aibel Vessel Internal Electrostatic Coalescer (VIEC) technology was tested for a real case scenario encountered in the production train of a UK oil field. Depressurized samples were collected both upstream and downstream of the first stage separator. The separation performance was discussed with respect to water cut and droplet size distribution of the emulsions, and the effect of chemical treatment. Issues with respect to representative sampling and testing have been discussed. The application of an external AC electrical field has been shown to significantly enhance the separation of the aqueous phase from tight emulsions, both when it was used alone and in combination with a commercial demulsifier. By using the VIEC technology, the time for separation could be reduced from 8 min to 2 min and the overall BS&W in the emulsions was improved from 45% or 60% to a residual water content of 5-20%. Destabilization of a 45% water-in-oil emulsion by electrical and chemical treatment (20/40 ppm) produced oil in the 2-7% BS&W range whereas the corresponding tests without applying an electrostatic field led to a BS&W greater than 25%. The achieved results strongly suggest that the VIEC technology can resolve the stable emulsion bands encountered in the Schiehallion train and add flexibility or increased production rate to the process. The results also suggest the importance of further studies on the destabilization performances achieved by electrostatic means.     

Automated air void analysis of hardened concrete — a Round Robin study

The RapidAir is an automatic system for analysing the air void content of hardened concrete. The analysis requires polishing of the concrete surface as described in ASTM C 457 as well as a contrast enhancement of the surface. The system can automatically analyse the air void system according to the ASTM C 457 and EN 480-11 standards.The sample preparation includes contrast enhancement steps ensuring white air voids in black concrete (aggregate and paste). For a well-lapped sample of good quality concrete the contrast enhancement procedure requires approximately 5-10 min to perform. The air content can be analysed in less than 15 min traversing 2413 mm (95 in.) — a significant improvement compared to several hours normally required to perform a manual linear traverse analysis.This paper describes the method and technique required for automatic analysis using the RapidAir system as well as data from a Round Robin study. Three samples were circulated to 7 different laboratories for automatic air void analysis. Prior to the automatic analysis the samples were analysed manually using linear traverse and point counting methods. The results of the Round Robin study showed very good repeatability and reproducibility of the RapidAir system but large variations when using manually performed analysis.     

Prediction of droplet size distribution in sprays of prefilming air-blast atomizers

Droplet size distribution is a crucial parameter of atomization process besides droplet mean diameter. In this paper, the finite stochastic breakup model (FSBM) of prefilming air-blast atomization process has been proposed according to the self-similarity of droplet breakup. There are four parameters in FSBM, which are the initial droplet diameter D₀, the maximum stable droplet size D_c, the minimum mass ratio of a sub-droplet to the mother droplet a, and the droplet breakup probability P(D). The simulation results of droplet size distribution with this model agreed well with the experimental results of prefilming air-blast atomizers. With this model, the nonlinear relationship between the mean droplet diameters and droplet size distribution of the air-blast atomization process can be predicted exactly.     

Impact of fluid path geometry and operating parameters on l/l-dispersion in interdigital micromixers

The dispersion of two immiscible fluids in interdigital micromixers was investigated using silicon oil/water and n-heptane/water as test systems. The experiments revealed the dependence of the average droplet size and size distribution on geometrical parameters of the micromixer and operating conditions. The mean droplet size was found to be correlated with total volume flow, volume flow ratio and corresponding pressure drop of the two liquids for a given micromixer geometry, which could be explained in light of the energy input. As a major focus, the effect of mixing chamber geometry and feeding system geometry was investigated with regard to droplet size distribution by systematically varying decisive dimensions in the mixer and by changing the feeding structure. It was shown that reducing the slit height and the number of feeding channels had a significant effect on droplet size distribution, leading to a smaller mean droplet size. Furthermore, the dispersion efficiency was also investigated by an extraction process.     

Predicting Droplet Size Distribution by Image Processing Technique for an Air Blast Atomizer

An image processing technique was used to predict the size distribution of the high speed, fine droplets at downstream of an air blast atomizer. The spray visualization setup consisted of UV lamps as light source, a stroboscope for slowing down the droplet motion, and a digital camera to capture the droplet images. The experiments were carried out at different liquid flow rates with various nozzle diameters. Two key unknown parameters (spray half angle and dispersion angle) of the air blast atomizer model in Fluent were obtained from these experiments. Using the obtained parameters and other structural parameters, the spray modeling was performed, and the Rosin–Rammler distribution was obtained and compared with those obtained from image processing technique through a diagnostic matrix. Regarding the kappa value, the agreement between predictions of the Fluent model and the image processing technique was moderate.     

CHARACTERISTICS OF MICROMETER AND SUBMICROMETER SIZE O/W EMULSIONS PRODUCED BY RAMOND SUPERMIXER®

A novel motionless mixer named the Ramond Supermixer® (RSM®) was employed to produce O/W emulsions composed of micrometer and submicrometer-size droplets. Liquid paraffin as dispersed phase, aqueous sucrose solution as continuous phase, and anionic sodium dodecyl sulfate as emulsifying agent were used as the model emulsification system. Pressure drop, droplet size distribution, Sauter mean diameter (d ₃₂), and geometric standard deviation of the droplet size distribution (σ_g) were investigated under the various combinations of process variables; superficial liquid velocity, number of mixing units, number of passages through RSM®, dispersed phase viscosity (η_d), continuous phase viscosity (η_c), and dispersed phase volume fraction. Different modes of droplet size variations with process variables were obtained, with respect to micrometer- and submicrometer-size ranges, and theoretical explanations are forwarded. For the micrometer-size range, maximum droplet diameter (d _max) was proportional to d ₃₂. For the submicrometer-size range, d _max varied with d ₃₂ in the range of 1.53–2.19-fold, and a correlation is proposed with K (=η_d/η_c); d ₃₂ and σ_g were well correlated with the process variables. Furthermore, a semi-empirical mechanistic model was developed for the formation of droplets obtained under inertial sub-range to interpret the effect of process variables.     

CHARACTERISTICS OF MICROMETER AND SUBMICROMETER SIZE O/W EMULSIONS PRODUCED BY RAMOND SUPERMIXER®

A novel motionless mixer named the Ramond Supermixer® (RSM®) was employed to produce O/W emulsions composed of micrometer and submicrometer-size droplets. Liquid paraffin as dispersed phase, aqueous sucrose solution as continuous phase, and anionic sodium dodecyl sulfate as emulsifying agent were used as the model emulsification system. Pressure drop, droplet size distribution, Sauter mean diameter (d₃₂), and geometric standard deviation of the droplet size distribution (σ_g) were investigated under the various combinations of process variables; superficial liquid velocity, number of mixing units, number of passages through RSM®, dispersed phase viscosity (η_d), continuous phase viscosity (η_c), and dispersed phase volume fraction. Different modes of droplet size variations with process variables were obtained, with respect to micrometer- and submicrometer-size ranges, and theoretical explanations are forwarded. For the micrometer-size range, maximum droplet diameter (d_max) was proportional to d₃₂. For the submicrometer-size range, d_max varied with d₃₂ in the range of 1.53-2.19-fold, and a correlation is proposed with K (=η_d/η_c); d₃₂ and σ_g were well correlated with the process variables. Furthermore, a semi-empirical mechanistic model was developed for the formation of droplets obtained under inertial sub-range to interpret the effect of process variables.