PENCAMPURAN/MIXING

TOPICS
INTRODUCTION
MIXING MECHANISM
STATISTICAL APPROACH OF SOLID MIXING
POWDER MIXER
SELECTION AND DESIGN CRITERIA
 INTRODUCTION
Objective
Mixing : liquid-liquid; solid-liquid; solid-solid
The closer the ingredients are in size, shape and density, the easier
the mixing operation and the greater intimacy of the final mix
Application:
Blending of grain prior to milling
Blending of flour and incorporation of additives into flours
Preparation of custard powder and cake mixes
Blending of soup mixes
Blending of spice mixes
Incorporation of additives into dried powder
Preparation of baby formula
 MIXING MECHANISM
MIXING : LIQUID-LIQUID ------ IRREVERSIBLE
MIXING : SOLID-SOLID ---------- REVERSIBLE
Three mechanism : Convection, Diffusion and Shear
One or more mechanism involved in mixing operation
Convection
Masses or group of particles transfer together from one location to
another
Circulating flow: rotational motor of a mixer vessel, an agitating
impeller(such as a ribbon and a paddle) or gas flow
Beneficial for bulk mode operation but gives unfavorable effect for
continuous mode mixing
For macroscopic mixing of bulk powder mixture
 MIXING MECHANISM
Diffusive
Individual particles are randomly distributed over a surface
developed within the mixture.
Microscopic homogenization
In fluid, diffusion is spontaneous but in particulate system :
due to gravity, tumbling, shaking, vibration and etc.
Shear
Group of particles are mixed through the formation of
slipping planed developed within the mass of the mixture
Kelompok partikel dicampur melalui pembentukan tergelincir
direncanakan berkembang dalam massa campuran tersebut
Sometimes considered as a part of the convective mixing
MIXING PROCESS

Equilibrium : mixing
vs segregation
 STATISTICAL APPROACH OF SOLID
MIXING
The best mixing---random distribution of the ingredients ---
the probability of finding a particle of a constituent of the
mixture is the same for all its points
In practical mixing applications, an ideal mixture may be
regarded as the one produced at minimum cost and which
satisfies the product specifications at the point of use
An fine powder ( < 30 m) the interparticle forces generated
by electrostatic charging, van der wall forces and forces due to
moisture are large compared with the gravitational and
inertial forces of the particle.
Segregation major factors =different sizes
Classification of Powder Mixture

Non
interactive segregating
interactive
 SAMPLING
The sample must be representative of the mixture and post
sampling handling must not alter it.
Factors involved : method of sampling, the number of
samples, the size of the sample, the location in the bulk
material from which the sample is taken.
Most representative sampling====infinite number of samples.
In practical, samples = 50, not less than 20, 5-15, at least 25.
Mixture quality : Mixing index and Mixing rate

Standard deviation

Mixing Index (Lancey),

practical value =0.75-1

so complete segregation
sr complete randomization or the min imum s tan dard deviation attainable

Mixing Index (Poole)

for two component system Theoritical

a upper lim it (completely segregated ) : so2 x c (1 x c )
x c (1 x c )
b lower lim it (randomly mixed ) : sr2
n
n the size of sample number of particles in each sample
 Mixing Index (Boss)

Mixing time=time needed for the concentration

variance to drop below some specified value

Ci is the concentration of the ith sample at time t, C is the

concentration afte infinite mixing

Y=standard deviation
RATE OF MIXING

dM
k (1 M )
dt
kt
M 1 e
 POWDER MIXER
1. Tumbler Mixer
2. Horizontal and Vertical Trough Mixer
3. Vertical Screw Mixers
4. Fluidized Bed Mixers
5. Hopper Blenders
6. Continuous Blenders
Tumbler
Mixer
Free flowing non segregating
powder maybe readily mixed in
batch by use of tumble mixers.
Operate by tumbling the mass of
solid inside a revolving vessel
Various form of vessel
Maybe fitted with baffles
Speed up to 100 rev/min
Working capacities 50-60 % of
the total vessel volume

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Horizontal and Vertical Trough Mixer

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Horizontal and Vertical Trough Mixer
Vertical Screw
Mixers
Materials are lifted from the bottom
to the top of the hopper and then
exchanged with material on the way
up.
Particularly useful for mixing small
quantities of additives with large
masses of material
 Fluidize Bed
Mixer

Passing air through the

material
Material to be mixed :
relatively free, fairly narrow
in their size distribution , not
too cohesive
 Hopper Blender
When a hopper discharge, there is a pronounced velocity
gradient across any horizontal section.
If the outflow from the hopper is recycled then there will be
considerable mixing
The recycled------ pneumatic or mechanical means
Applied only to very free flowing powder
 Continuous Mixer
Continuous only :
High value production needed
When a limited number of streams (two or three) are to be blended
and less degree of homogeneity is expected.
For particle similar in size, shape and density that differ slightly in
color or some other characteristic from batch to batch.
Requirement to provide a gradual rather than step change.
Commonly performed by using a cone-in cone blender type
 SELECTION AND DESIGN CRITERIA
Not based on well established scientific principles and no
general organized argument is available for the methodology
of selecting the target mixer.
Trial and error process --- previous experience
Main consideration
Rate of mixing
Power requirement
Efficiency
Design method
Scale up criteria
Others (cost, etc).
Factors Affecting Equipment Design
Mixing homogeneity
Ingredients and operating condition
Residence time
Loading and discharge arrangements
Power requirement
Equipment cleaning
Dust formation
Equipment wear
Equipment capacity
Equipment selection
Construction material
Auxiliary equipment
 Mixer Selection Based on Flow
Properties
Three condition ----- blender operate efficiently
The blender must have no stagnant regions.
The blender must promote different flow velocities in various section
of the blender
Blender operation must not segregate or demix, mixture ingredients.
 LIQUID MIXING
The dispersion of fine solid particles in liquid
media
The gas in liquid media
Liquid liquid mixing
 Dispersion of fine particles in liquid
media
4 stages of dispersion
1. Incorporation
2. wetting
3. Breakdown of particle cluster (aggregates and
agglomerates)
4. Possible flocculation of the dispersed particles
Milling used ---- 4 stages exist simultaneously
Application in Industry
Mixer Types
Mechanically Agitated-vessel
 Special
Type of for gas
In liquid
Impellers

The propeler,
turbine and paddle
used for
relatively low
viscosity liquid and
operate at high
rotational speed
Type of
Impellers
Jet Mixer
In Line Static Mixer
In-Line Dynamic Mixer
Mills
Mills
High Speed Dispersing Unit
Valve Homogenizer
Ultrasonic Homogenizer
Extruder
Extruder