CHAPTER 6

MIXING AND SEGREGATION

6.0 Introduction
Achieving good mixing of particulate solids of different size and density is important
in many of the process industries, and yet it is not a trivial exercise. For free-flowing
powders, the preferred state for particles of different size and density is to remain
segregated. This is why in a packet of muesli the large particles come to the top as
a result of the vibration caused by handling of the packet. An extreme example of
this segregation is that a large steel ball can be made to rise to the top of a beaker
of sand by simply shaking the beaker up and down this has to be seen to be
believed! Since the preferred state for free flowing powders is to segregate by size
and density, it is not surprising that many processing steps give rise to segregation.
Processing steps which promote segregation should not follow steps in which
mixing is promoted. In this chapter we will examine mechanisms of segregation and
mixing in particulate solids and briefly look at how mixing is carried out in practice.

6.1 TYPES OF MIXTURES

A perfect mixture of two types of particles is one in which a group of particlestaken
from any position in the mixture will contain the same proportions of eachparticle as
the proportions present in the whole mixture. In practice, a perfectmixture cannot be
obtained. Generally, the aim is to produce a random mixture,i.e. a mixture in which
the probability of finding a particle of any component isthe same at all locations and
equal to the proportion of that component in themixture as a whole. When
attempting to mix particles which are not subject tosegregation, this is generally the
best quality of mixture that can be achieved. Ifthe particles to be mixed differ in
physical properties then segregation may occur.In this case particles of one

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component have a greater probability of being foundin one part of the mixture and
so a random mixture cannot be achieved.

Fig 6.1 Types of mixtures

InFigure 6.1 examples are given of what is meant by perfect, random andsegregating
mixtures of two components. The random mixture was obtainedby tossing a coin
heads gives a black particle at a given location and tails gives awhite particle. For
the segregating mixture the coin is replaced by a die. In thiscase the black particles
differ in some property which causes them to have agreater probability of appearing
in the lower half of the box. In this case, in thelower half of the mixture there is a
chance of two in three that a particle will beblack (i.e. a throw of 1, 2, 3 or 4)
whereas in the upper half the probability is onein three (a throw of 5 or 6). It is
possible to produce mixtures with better thanrandom quality by taking advantage of
the natural attractive forces betweenparticles; such mixtures are achieved through
ordered or interactive mixing.

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6.2 SEGREGATION

6.2.1 Causes and Consequences of Segregation

When particles to be mixed have the same important physical properties
(sizedistribution, shape, density) then, provided the mixing process goes on for
longenough, a random mixture will be obtained. However, in many commonsystems,
the particles to be mixed have different properties and tend to exhibitsegregation.
Particles with the same physical property then collect together in onepart of the
mixture and the random mixture is not a natural state for such asystem of particles.
Even if particles are originally mixed by some means,theywill tend to unmix on
handling (moving, pouring, conveying, processing).Although differences in size,
density and shape of the constituent particles of amixture may give rise to
segregation, difference in particle size is by far the mostimportant of these. Density
difference is comparatively unimportant except in gas fluidization where density
difference ismore important than size difference. Many industrial problems arise
fromsegregation. Even if satisfactory mixing of constituents is achieved in a
powdermixing device, unless great care is taken, subsequent processing and
handling ofthe mixture will result in demixing or segregation.This can give rise to
variations in bulk density of the powder going topackaging (e.g. not possible to fit 25
kg into a 25 kg bag) or, more seriously, thechemical composition of the product may
be off specification (e.g. in blending ofconstituents for detergents or drugs).

6.2.2 Mechanisms of Segregation

Four mechanisms (Williams, 1990) of segregation according to size may be

identified:

1. Trajectory segregation.
A particle of diameter 2x would travel four times as far than a particle of diameter x
before coming to rest. This mechanism can cause segregation where particles are

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caused to move through the air. This also happens when powders fall from the end
of a conveyor belt.

2. Percolation of fine particles.

If a mass of particles is disturbed in such a way that individual particles move, a
rearrangement in the packing of the particles occurs. The gaps created allow
particles from above to fall, and particles in some other place to move upwards. If
the powder is composed of particles of different size, it will be easier for small
particles to fall down and so there will be a tendency for small particles to move
downwards leading to segregation. Even a very small difference in particle size can
give rise to significant segregation. Segregation by percolation of fine particles can
occur whenever the mixture is disturbed, causing rearrangement of particles. This
can happen during stirring, shaking, vibration or when pouring particles into a heap.
Note that stirring, shaking and vibration would all be expected to promote mixing in
liquids or gases, but cause segregation in free-flowing particle mixtures. Figure 6.3
shows segregation in the heap formed by pouring a mixture of two sizes of particles.
The shearing caused when a particle mixture is rotated in a drumcan also give rise
to segregation by percolation. Segregation by percolation occurs in charging and
discharging storage hoppers. As particles are fed into a hopper they generally pour
into a heap resulting in segregation if there is a size distribution and the powder is
free-flowing. There are some devices and procedures available to minimize this
effect if segregation is a particular concern. However, during discharge of a core
flow hopper sloping surfaces form, along whichparticles roll, and this gives rise to
segregation in free-flowing powders. If segregation is a cause for concern, therefore,
core flow hoppers should be avoided.

3. Rise of coarse particles on vibration.

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If a mixture of particles of different size is vibrated the larger particles move
upwards. This can be demonstrated by placing a single large ball at the bottom of a
bed of sand (for example, a 20 mm steel ball or similarly sized pebble in a beaker of
sand from the beach). On shaking the beaker up and down, the steel ball rises to the
surface.

4. Elutriation segregation.
When a powder containing an appreciable proportion of particles less than 50 m is
charged into a storage vessel or hopper, air is displaced upwards. The upward
velocity of this air may exceed the terminal freefall velocity of some of the finer
particles, which may then remain in suspension after the larger particles have
settled to the surface of the hopper contents. For particles in this size range in air
the terminal freefall velocity will be typically of the order of a few centimetres per
second and will increase as the square of particle diameter (e.g. for 30 m sand
particles the terminal velocity is 7 cm/s). Thus a pocket of fine particles is
generated in the hopper each time solids are charged.

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Figure 6.2 Mechanisms of segregation

6.3 REDUCTION OF SEGREGATION

Segregation occurs primarily as a result of size difference. The difficulty of mixing
two components can therefore be reduced by making the size of the components as
similar as possible and by reducing the absolute size of both components.
Segregation is generally not a serious problem when all particles are less than 30
m (for particle densities in the range 20003000 kg/m3). In such fine powders the
interparticle forces generated by electrostatic charging, van der Waals forces and
forces due to moisture are large compared with the gravitational and inertial forces
on the particles. This causes the particles to stick together preventing segregation
as the particles are not free to move relative to one another.

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These powders are referred to as cohesive powders (Geldarts classification of
powders for fluidization is relevant here). The lack of mobility of individual particles
in cohesive powders is one reason why they give better quality of mixing. The other
reason is that if a random mixture is approached, the standard deviation of the
composition of samples taken from the mixture will decrease in inverse proportion
to the number of particles in the sample. Therefore, for a given mass of sample the
standard deviation decreases and mixture quality increases with decreasing particle
size. The mobility of particles in free-flowing powders can be reduced by the
addition of small quantities of liquid. The reduction in mobility reduces segregation
and permits better mixing. It is possible to take advantage of this natural tendency
for particles to adhere to produce mixtures of quality better that random mixtures.
Such mixtures are known as ordered or interactive mixtures; they are made up of
small particles (e.g. < 5 m) adhered to the surface of a carrier particle in a
controlled manner. By careful selection of particle size and engineering of
interparticle forces, high quality mixtures with very small variance can be achieved.
This technique is used in the pharmaceutical industry where quality control
standards are exacting. If it is not possible to alter the size of the components of the
mixture or to add liquid, then in order to avoid serious segregation, care should be
taken to avoid situations which are likely to promote segregation. In particular
pouring operations and the formation of a moving sloping powder surface should be
avoided.

6.4 EQUIPMENT FOR PARTICULATE MIXING

6.4.1 Mechanisms of Mixing

Lacey (1954) identified three mechanisms of powder mixing:
1. shear mixing;
2. diffusive mixing;
3. convective mixing.

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In shear mixing, shear stresses give rise to slip zones and mixing takes place by
interchange of particles between layers within the zone. Diffusive mixing occurs
when particles roll down a sloping surface. Convective mixing is by deliberate bulk
movement of packets of powder around the powder mass. In free-flowing powders
both diffusive mixing and shear mixing give rise to size segregation and so for such
powders convective mixing is the major mechanism promoting mixing.

6.4.2 Types of mixer

Tumbling mixers.
A tumbling mixer comprises a closed vessel rotating about its axis. Common shapes
for the vessel are cube, double cone and V. The dominant mechanism is diffusive
mixing. Since this can give rise to segregation in free-flowing powders the quality of
mixture achievable with such powder in tumbling mixers is limited. Baffles may be
installed in an attempt to reduce segregation, but have little effect.

Convective mixers.
In convective mixers circulation patterns are set up within a static shell by rotating
blades or paddles. The main mechanism is convective mixing as the name suggests,
although this is accompanied by some diffusive and shear mixing. One of the most
common convective mixers is the ribbon blender in which helical blades or ribbons
rotate on a horizontal axis in a static cylinder or trough. Rotational speeds are
typically less than one revolution per second. A somewhat different type of
convective mixer is the Nautamix in which an Archimedean screw lifts material from
the base of a conical hopper and progresses around the hopper wall.

Fluidized bed mixers.

These rely on the natural mobility afforded particles in the fluidized bed. The mixing
is largely convective with the circulation patterns set up by the bubble motion within
the bed. An important feature of the fluidized bed mixer is that several processing
steps (e.g. mixing, reaction, coating drying, etc.) may be carried out in the same
vessel.

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High shear mixers.

Local high shear stresses are created by devices similar to those used in
comminution; for example, high velocity rotating blades, low velocityhigh
compression rollers. In the high shear mixers the emphasis is on breaking down
agglomerates of cohesive powders rather than breaking individual particles. The
dominant mechanism is shear mixing.

Figure 6.3 Tumbling mixers: V-mixer; double cone mixer; and rotating cube
mixer

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