Controlling Product Density Through Proper Design
Material Flow Solutions, Inc.
One of the problems facing engineers handling bulk
solids is flow rate or density control. The lack of this
type of control can cause serious variations in a
packing facility, especially if the packing equipment is
based on volumetric control. There are two main
causes of density variation. One cause is separation
(segregation) of mixture components due to different
particle densities. This type of density fluctuation is
really due to segregation issues and our section on
segregation control will provide some guidance. The
other cause of density variation is differences in
compaction caused by gas effects or compression
effects. In this type of density control, the goal is
generally achieving the right compaction pressure con-
sistently or maintaining the right residence time to allow consistent product de-aeration. Ideally
one must control the amount of gas present in the solids voids. In these cases, it is essential to
maintain mass flow and to provide a means of either increasing or decreasing the amount of
entrained gas that is carried with the bulk solid during handling.
At Material Flow Solutions we approach these types of problems by, first, measuring the flow
properties of the bulk material(s). This data gives information to allow design of a feed system
that is compatible with mass flow. Using the flow properties and our proprietary computer
software we can compute the expected gas entrained in the process equipment at your range of
flow rates and process conditions. This allows us to predict when density fluctuation may be
experienced in your system and provide a means of designing either the material or the process
to mitigate erratic flow rates and allow uniform packing and consistent density control.
PRACTICAL APPLICATIONS of controlling product density include, but are not limited to:
Modification of particle size of spray dried clay particles to prevent surging
Use of gas injection to control cement flow rates
Use of de-aeration hoppers to control flow rates of pulverized limestone
Use of compaction screws to control soap powder packing variations
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