SOLIDS NOTES 9, George G.
Chase, The University of Akron
9. SEGREGATION
Separation articles by size, density, or other material properties occurs when
concentrations of one type of particle in a hopper or pile is much greater than the average
for the entire mass. The process of separating the particles into different relative
concentrations is referred to as segregation is the opposite. Segregation processes are the
opposite of mixing processes, which in the latter the particles are blended into relatively
uniform consistency.
Segregation is important in handling of powders because in many operations you want to
avoid concentrations of one particle type or another.
9.1 Mechanisms
We need to understand the mechanisms that cause segregation before we can design
systems to minimize the effect. Differences in size, density, shape and resilience all
contribute to segregation. By far, particle size difference is the most important
parameter.
Four primary mechanisms cause segregation:
• TRAJECTORY SEGREGATION. When a powder cloud is in flight, groups of
fine particles can travel farther than single large particles. For coarse particles,
the larger particles tend to travel the farthest.
• PERCOLATION OF FINES (also called sifting). If a mass of particles is
disturbed (by stirring, shaking, vibrating) such that the individual particles move
relative to each other, a rearrangement in the packing occurs.
If a powder has a size distribution, it is easier for smaller particles to move into
the void spaces between larger particles during the disturbance. Hence, in a
storage hopper there is a tendency for small particles to migrate downward in the
direction of gravity. A very small size difference is sometimes sufficient to cause
a measurable segregation.
Segregation upon pouring a powder into a pile occurs frequently due to the
percolation (as well as trajectory) mechanisms (Figure 9-1).
HIGHER
CONCENTRATION HIGHER
IN SMALLER CONCENTRATION
PARTICLES IN LARGER
PARTICLES
Figure 9-1. Segregation of particles when poured into a pile due to percolation.
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SOLIDS NOTES 9, George G. Chase, The University of Akron
• RISE OF COARSE PARTICLES UPON VIBRATION. This effect can be
demonstrated by submerging a large steel ball bearing in sand in a beaker. Upon
vibrating the beaker the ball bearing rises to the top of the sand. This occurs even
when the larger particle is much denser than the fine particles.
• ELUTRIATION SEGREGATION (also called fluidization). When a powder is
discharged from a hopper, or is poured into the top of a hopper, a large volume of
air is displaced. The air velocity may exceed the terminal velocity of the smaller
particles. This can cause the fines to suspend while the coarse particles settle out.
The fines eventually settle on top of the suspension and form a layer on top of the
powder that is concentrated in the fines.
9.2 Reduction in Segregation
Methods to reduce segregation are aimed at reducing the effects that cause segregation.
• Make sizes of components as close as possible to the same size.
• Reduce the absolute size of the particles. Usually segregation is not a problem for
particles smaller than about 30 microns for particle densities in the 2000 to 3000
kg/m3 range. For more dense particles the size must be smaller than 30 microns.
For very small particles the surface forces act to minimize the segregation effect
on individual particles. However, if the surface forces cause the particles to
agglomerate into larger particles, then segregation may become a problem again.
• A small amount of liquid may be added to a powder to increase its attractive
forces between particles and minimize fines migration.
• Avoid situations that promote segregation
o Avoid pouring where the powder forms a sloping surface,
o Avoid pouring into the core of a hopper,
o Avoid vibrations, shaking, stirring (unless done to promote mixing),
o Use mass flow hoppers.
• Use continuous mixing.
• Use materials with large aspect ratios. Fibers and flakes do not segregate as
easily as spherical shapes. Rough surfaces also reduce the segregation effect.
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SOLIDS NOTES 9, George G. Chase, The University of Akron
9.3 Example
A transport truck is loaded with a well mixed powder with a wide size distribution. The
truck delivers the product to a facility 20 miles from the its loading point.
Is the material likely to segregate?
Yes, due to vibrations from the transport.
What material will exit first? Last?
Fines are more likely to exit first and coarse to exit last.
What options do you have to minimize the segregation at the delivery site?
Additives to reduce segregation (liquid? Fibers?)
Do the mixing at the delivery site.
Change the particle size mixture at the supply site to a more uniform size.
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