Solids Mixing, Blending & Handling

An in-depth, two-day course focusing on the mixing, blending, and subsequent handling of powders and their blends. Offered upon sufficient request.

Topics include differences of mixing free-flowing powders versus cohesive powders; the impact of powder characteristics; ordered versus random mixes; main mixer types & their selection & scale-up; mixer performance based on mix variance; proper system design to enhance and maintain a quality mix; proper sampling techniques; segregation issues and fixes in transporting blends, as well as related topics in solids handling and reblending.

Course content includes fundamental differences of mixing free-flowing versus cohesive powders; the impact of powder flow characteristics on effective mixing; particle mobility; ordered versus random versus segregated mixes; main mixer types, common combinations, and mixer selection; using mixture variance to measure a mixer’s performance; proper system design to enhance a quality mix; impact of scale of scrutiny on mixture variance; effect of moisture and sprays on mixture variance; proper sampling techniques; fundamental approaches to mixer scale-up; segregation issues and fixes in transporting blends.
Mixtures should be preserved, so additional lectures will address the causes of de-mixing; proper handling of the final mixture; evaluation of samples to determine if the mixer or the process is affecting mix quality; and solutions to de-mixing if it occurs, as well as related topics in solids handling and reblending.

Course material:

• Day 1 –  Free-flow powders, cohesive powders, powder flow characteristics as they apply to mixers, random versus segregated mixing, mixer types & selection, mixture variance, scale of scrutiny, system design.

• Day 2 – Statistics of mixing, hands-on calculation examples, sampling techniques, analysis considerations, mixing scale-up. Proper sampling to understand mixer versus downstream process affects, correct downstream design, segregation and its causes, solving segregation issues, related solids handling topics.

• Evening sessions – Flow characterization demonstrations, DEM modeling & simulations