Jet Mill Research Articles

Study on Particle Acceleration Characteristics in Supersonic Jet Field of Fluidized Bed Opposed Jet Mill

Study on Particle Acceleration Characteristics in Supersonic Jet Field of Fluidized Bed Opposed Jet Mill

Mechanical processing of wet stored fly ash for use as a cement component in concrete

Wet storage effects on fly ash mean that processing may be necessary to achieve the physical properties required for use in concrete. This paper considers drying, de-agglomeration and milling of various wet stored fly ashes at laboratory and pilot/benchtop scales, towards meeting these. In the laboratory, different batch quantities and milling times with as-received/pre-screened materials were examined using a ball mill. Greater particle size reductions were obtained with increased milling time but at gradually reducing rates. Pre-screening and batch quantity had relatively minor effects on particle size reductions, with small differences also found between wet and dry stored fly ash. Extended milling time resulted in a darkening of colour; slight increases in loss-on-ignition, the main oxides content and crystalline components; reductions in water requirement (to a point); and greater reactivity. Similar effects were generally noted in concrete for the superplasticising admixture dose to achieve a target slump and compressive (cube) strength. At pilot/benchtop scale, a dryer-pulveriser and spiral jet mill were used, which gave general agreement with the behaviour noted in the laboratory, but with the effects tending to be less. Fineness levels in Standards were achievable, with subsequent performance in concrete, appearing to depend on the milling process used.

A Rapid Thermal‐Radiation‐Assisted Sintering Strategy for Nd–Fe–B‐Type Magnets

The green transition has spiked demand for high‐performance sintered Nd–Fe–B permanent magnets, necessitating advanced powder consolidation technologies to enhance production efficiency. This study explores the rapid sintering methodology for an Nd–Fe–B powder using a radiation‐assisted sintering approach. The case study material is an industrially used powder, prepared through strip‐casting, hydrogen decrepitation, and jet milling, with a mean particle size of 5.5 μm. The powder is sintered to full density in a modified spark plasma sintering furnace, achieving pressureless conditions and eliminating electrical currents in the sample to preserve grain alignment and prevent decomposition of the hard‐magnetic phase. Fully dense samples are obtained with heating rates ranging from 10 to 200 °C min−1 and up to 5 min of dwell time at 1100 °C. Rapid heating results in grain size and microstructure comparable to conventionally sintered magnets prepared from the same powder, without compromising magnetic performance after postsinter annealing at 520 °C for 120 min. This sintering method contributes to a novel strategy for optimizing magnet production by utilizing efficient thermal‐radiation heat transfer. The combination of rapid heating and pressureless sintering drastically reduces heat‐up and dwell times, providing a fundamental advantage over slow conventional sintering.

Development of a Formulation and In Vitro Evaluation of a Pulmonary Drug Delivery System for a Novel Janus Kinase (JAK) Inhibitor, CPL409116.

The pursuit of targeted therapies for cytokine-dependent diseases has led to the discovery of Janus kinase (JAK) inhibitors, a promising class of drugs. Among them, CPL409116, a selective dual JAK and rho-associated protein kinase inhibitor (ROCK), has demonstrated potential for treating conditions such as pulmonary fibrosis exacerbated by the COVID-19 pandemic. This study investigated the feasibility of delivering CPL409116 via inhalation, with the aim of minimizing the systemic adverse effects associated with oral administration. Two micronization methods, jet milling and spray drying, were assessed for CPL409116, with spray drying chosen for its ability to produce an amorphous form of the compound. Moreover, parameters such as the mixing energy, drug load, and force control agent significantly influenced the fine particle fraction (FPF), a critical parameter for pulmonary drug delivery. This study provides insights into optimizing the formulation parameters to enhance the delivery efficiency of CPL409116 to the lungs, offering potential for improved therapeutic outcomes in cytokine-dependent pulmonary diseases.

Construction of Tb-rich shells via novel interdiffusion approach to tackle coercivity-remanence trade-off

The strategic introduction and efficient utilization of heavy rare earth elements within Nd-Fe-B-based permanent magnets are instrumental in achieving an optimal balance between remanence (Br) and high coercivity (Hcj). Herein, we propose a novel interdiffusion approach based on hydrogen decrepitation (HD) for the cost-effective and high-performance sintered Nd-Fe-B magnets. With the aim of generating continuous Tb-rich shells on the grain surface, which favors high Br and high Hcj, strip cast (SC) flakes homogeneously mixed with 0.9 wt% Tb were processed by the HD. It is shown that the formation of (Nd, Tb)-Fe-B by the interdiffusion of Nd-Fe-B and Tb during de-hydrogenation, as well as the interdiffusion of Nd-Fe-B and (Nd, Tb)-Fe-B during sintering and tempering, is the key to the construction of Tb-rich shells. As a result, a magnet (Mag-Tb&HD) with maximum magnetic energy product ((BH)max) of 52.21 MGOe was achieved, which is superior to magnet prepared form SC flakes containing 0.9 wt% Tb (Mag-Tb&SC, (BH)max=49.36 MGOe) and the magnet prepared by adding 0.9 wt% Tb to the jet milling (Mag-Tb&JM, (BH)max=50.41 MGOe).

Characterization and biological activity evaluation of water-soluble resveratrol complexes obtained by spray drying, ball milling and jet milling

To increase the water solubility of resveratrol (RES) and explore the possibility of solid-phase preparation technology as an alternative to traditional spray drying technology. In this study, herein, three resveratrol-stevia glycoside-hydroxypropyl-β-cyclodextrin (RES-STE-HP-β-CD) complexes were prepared by jet milling, ball milling and spray drying. The three complexes were subjected to saturation solubility determination, characterization (SEM, XRD, FT-IR and 1H NMR), antioxidant activity evaluation and in vitro cytotoxicity assay. The results demonstrated that RES was successfully complexed with STE and HP-β-CD, and the crystalline state of RES was changed after the complexation. The water solubility of RES increased about 30 times, and the saturated solubility of the complexes prepared by jet milling reached the highest of 993.32 μg/mL. Meanwhile, RES could interact with STE through hydrogen bonding, and also could be probably inserted into the cavities of HP-β-CD. Moreover, the complexes prepared by different methods possessed good antioxidant activity and did not exhibit significant cytotoxicity. In conclusion, STE&HP-β-CD can effectively solubilize RES, and solid-phase preparation technologies (e.g., jet milling) have the potential to prepare water-soluble complexes. The complex powders can be used as raw materials for nutraceuticals or pharmaceuticals.

Effect of antioxidants on the efficiency of jet milling and the powder characteristics of Sm2Co17 permanent magnets

Abstract This study investigated the effect of antioxidants on the grinding efficiency, magnetic powder characteristics, microstructure, and magnetic properties of 2:17 type SmCo permanent magnet materials. The results show that adding antioxidants helps improve the dispersion among magnetic powders, leading to a 33.3% decrease in jet milling time and a 15.8% increase in magnet powder production yield. Additionally, adding antioxidants enhances the oxidation resistance of the magnetic powders. After being stored in a constant temperature air environment at 25 °C for 48 h, the O content in the powder decreased by 33% compared to samples without antioxidants. While in the magnet body, the O content decreased from 0.21 wt.% to 0.14 wt.%, which helps increase the effective Sm content and domain wall pinning uniformity in the magnet. Excellent magnetic properties were obtained in the magnet with added antioxidants: B r = 11.6 kGs, SF = 79.6%, H cj = 16.8 kOe, and (BH)max = 32.5 MGOe.

Effects of rotational speed of the classifying wheel during jet milling on magnetic properties and thermal stability of sintered Nd-Fe-B magnets

Sintered Nd-Fe-B magnets with different grain sizes are prepared by adjusting rotational speed of the classifying wheel during the jet milling process. The microstructures of the magnets, the element contents of the magnets, the relationship between powder particle size and grain size and the magnetic properties of the magnets are studied by X-ray diffracton (XRD), scanning electron microscopy (SEM), optical microscopy (OM), electron backscattered diffraction (EBSD), inductively coupled plasma (ICP) and permanent magnet tester. The effect of grain size on thermal stability is characterized by the temperature coefficient of coercivity from room temperature to working temperature and the irreversible magnetic flux loss of the magnet at high temperature. The results show that the particle size of the alloy powder decreases with the increase of the rotational speed of the classifying wheel. When the alloy powder is formed and sintered, it is found that the grain size of the prepared magnet decreases with the decrease of the particle size of the alloy powder. The finer the grain size of the magnet, the clearer the grain boundary. As the grain size of the magnet decreases, the coercivity of the magnet increases, the remanence of the magnet decreases slowly and the thermal stability of the magnet becomes better. For the magnet with a rotational speed of the classifying wheel of 4900 r/min, the average grain size of the magnet is 4.70 μm, the coercivity (Hcj) is 15.47 kOe, and the remanence (Br) is14.09 kGs. At a temperature of 80 °C, the coercivity temperature coefficient of the magnet reaches −0.745 %/°C, and the irreversible loss of magnetic flux hirr is 16.49 %. In addition, the magnet prepared by the tail material produced a large number of voids and pores due to the high oxygen content. Tail material is not good enough in terms of magnetic property as well as thermal stability.

Modification of cement-based circulating fluidized bed combustion slag: Physical grinding and chemical excitation

This study investigates the effects of physical grinding (ball, impact, and jet milling) and chemical modification (using various dosages of Na2SO4, CaO, triethanolamine (TEA), and their composite modifiers) on CFBCS. The fluidity, flexural strength, compressive strength, and expansion rate of different modification methods were tested. Microstructural and phase composition analyses were conducted using X-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy, mercury intrusion porosimetry, and thermogravimetry-differential thermogravimetry. The results indicated that impact milling improved mortar fluidity by 2.9 % compared to ball milling, while jet milling reduced it by 5.7 %. Chemical modifications decreased paste fluidity but increased mortar strength and reduced expansion rates. Impact milling and jet milling improved 28-day compressive strength by 13.76 % and 16.01 %, respectively, and reduced the 90-day expansion rate by 0.007 % and 0.012 %, respectively. Composite chemical modification (CM-C) enhanced 28-day compressive strength by 23.88 % and reduced the 90-day expansion rate by 0.019 %. Microscopic analysis shows that modification reduced the pores and pore size of the mortar while increasing the hydration products. After TEA modification, rod-shaped AFt forms a reticulated structure, with C–S–H gel and CH crystals adhering to it. The hydration products of CFBCS mortar formed a network after jet milling, and the addition of composite modifiers resulted in a layered, dense structure.

Effect of Nozzle Quantity on the Flow Field Characteristics and Grinding Efficiency in a Steam Jet Mill

A steam jet mill (SJM), which employs industrial waste heat steam as a gas source, is a widely utilized apparatus for the pulverization of fly ash. To achieve elevated single-machine grinding capacity, efficiency improvement research based on structural optimization should be conducted. In this study, numerical simulations and industrial experiments are carried out on SJMs equipped with three and six nozzles (hereinafter referred to as N3 and N6, respectively) to study the influence of nozzle quantity on the flow field and grinding efficiency. The numerical simulation results indicate that, under the N3 structure, particles can achieve a higher impact velocity in the comminution area and improve the kinetic energy of a single impact. In the conveying area, the airflow diffusion is better, resulting in an upward flow field that is more uniform. The classification area shows an increase in the uniformity of the flow field and a significant reduction in the local vortex structure, which is beneficial for accurate particle classification. In the interim, industrial experiments demonstrate that the N3 structure can markedly enhance the processing capacity and energy efficiency of the system. The smaller the feed particle size, the more pronounced the efficiency improvement.

Revolutionizing ITO waste recycling: Dynamic evolution of ultrafine pulverization and densification

In order to recycle ITO waste targets (R-ITO) efficiently, this study explores the dynamic evolution of ultrafine pulverization of R-ITO particles in jet mills. The R-ITO microparticles obtained by utilizing jet mill pulverization and combining them with the PBM model were used to prepare the R-ITO nano slurry with different average particle sizes with sand milling technology. Furthermore, the R-ITO green compacts were prepared via a pressure-slip casting process. The Brook kinetic model calculated the R-ITO grain growth activation energy to be 570 kJ/mol. Ultimately, the R-ITO target with a relative density of 99.9 % and average grain size of 2.42 μm was attained under a flowing oxygen sintering at 1550 °C for 0.5 h.

Process-Induced Crystal Surface Anisotropy and the Impact on the Powder Properties of Odanacatib.

Crystalline active pharmaceutical ingredients with comparable size and surface area can demonstrate surface anisotropy induced during crystallization or downstream unit operations such as milling. To the extent that varying surface properties impacts bulk powder properties, the final drug product performance such as stability, dissolution rates, flowability, and dispersibility can be predicted by understanding surface properties such as surface chemistry, energetics, and wettability. Here, we investigate the surface properties of different batches of Odanacatib prepared through either jet milling or fast precipitation from various solvent systems, all of which meet the particle size specification established to ensure equivalent biopharmaceutical performance. This work highlights the use of orthogonal surface techniques such as Inverse Gas Chromatography (IGC), Brunauer-Emmett-Teller (BET) surface area, contact angle, and X-ray Photoelectron Spectroscopy (XPS) to demonstrate the effect of processing history on particle surface properties to explain differences in bulk powder properties.

Coercivity enhancement of sintered NdFeB magnets by powder Refinement, lubricant increment and Hydrogen-Containing sintering manufacturing

This study investigates powder refinement, lubricant increment, and hydrogen-containing sintering procedures to develop high coercivity in NdFeB magnets. To improve the intrinsic coercivity iHc of sintered NdFeB magnets, it is proposed to control the average particle size and distribution of the magnetic powder by increasing the classification wheel speed of the jet mill during the jet milling process. Additionally, the incremental addition of lubricant is carried out in the additive mixing stage after the magnetic powder is refined. Through the increase of lubricant, the amount of lubricant is enough to completely cover the surface of the powder; hence, the alignment of the powder in the magnetic field forming process is improved, thereby increasing the maximum magnetic energy product (BH)max of the magnet. However, the magnetic properties of the magnet are improved through the refinement of the powder and the increase of the lubricant, but it also leads to the residue of impurities inside the magnet, which actually deteriorates the iHc. Different from the traditional process, this study moved the dehydrogenation procedure to the sintering process, thus reducing the residue of impurities inside the magnet, which is beneficial to the improvement of the magnetic properties of the magnet. Herein, we report a new commercial-scale process (100 kg batches) integrating all the above-modified procedures that reached the best experimental results of iHc = 20.79 kOe, (BH)max = 44.46 MGOe and BHH = 65.25 (i.e., BHH= iHc + (BH)max). The iHc, (BH)max, and BHH of the NdFeB magnet obtained by the new process proposed in this study are 16.47 %, 0.33 %, and 5 % higher than the traditional process, respectively. As a result, iHc has been greatly improved, making NdFeB magnets more conducive to meeting a wide variety of end-user applications, including high-coercivity (>20 kOe) sintered magnets suitable for equipment operating in high-temperature environments.

Mannan-rich Holocellulose nanofibers mechanically isolated from spent coffee grounds: Structure and properties

Spent coffee grounds (SCGs) contain abundant polysaccharides consisting of mannose (29 %), galactose (11 %), and glucose (11 %) and are a promising source of holocellulose nanofibers (HCNFs). In this study, the mannan-rich HCNFs were isolated from the SCG holocellulose in the yield of 52 % SCGs using an ultrahigh-pressure wet jet mill. The HCNF was refined by passing the suspension through a high-pressure homogenizer with a 95 μm nozzle 1–15 times. The 5-pass HCNFs were 2.4 nm wide and 0.7 μm long with 143 viscosity-average degrees of polymerization and contained mannan I crystals (5–10 nm in size) on cellulose microfibrils. The delignification process in water at 75 °C based on the Wise method allowed recrystallization of mannan on a cellulose microfibril substrate. The once-freeze-dried HCNFs had 30–50 nm widths and were not fully nanofibrillated in water when shaking the HCNF/water suspensions but exhibited comparable viscosities to those prepared by mechanical milling. The SCGs-derived HCNFs have a high potential for application in the food industry.

Effect of Magnesium Stearate and Fines on Delivery of Dry Powder for Inhalation using Sucrose as a Carrier

Typically, lactose is utilised as carrier in Dry Powder Inhaler commercially. However, with the widening scope of DPI in therapeutic categories other than COPD and asthma, a need for the alternate carrier is arising. In this study, we used sucrose, a non-reducing sugar, as an alternate carrier. Effect of addition of fines and magnesium stearate was studied on powder flow properties and aerosolization performance. The air jet milling technique was used to generate sucrose fines. DSC and XRD studies showed no change in sucrose polymorph upon micronization. Levosalbutamol sulphate was used as a model drug, powder blends were prepared by low shear tumbling type blender. Powder formulations were studied for PSD, blend homogeneity, and flow properties. The percentage of particles smaller than 5 microns rose when fines were added as indicated by PSD data. SEM study revealed that the added fines get adsorbs on the coarse carrier, thus minimizing the adhesive interactions between drug and coarse carrier. In-vitro deposition was studied using low and high resistance devices on glass Twin Stage Impinger (TSI). Addition of fines and the magnesium stearate improves aerosolization performance showing higher Fine Particle Fraction (FPF) by almost 2 folds than the formulation containing coarse carrier alone.

Jet milling‐activated direct synthesis of octenyl succinic anhydride modified starch: an analysis of structural and application properties

SummaryThe synthesis of octenyl succinic anhydride‐modified starch was achieved through a fluidised bed activated by jet milling with graded revolution rates of 1200, 1800, 2400, 3000, and 3600 rpm. This study investigated the changes in the structural, physicochemical, and application properties of modified starch after jet milling. The results showed that modified starch can be synthesised using a one‐step jet milling process. The degree of substitution increased with a decrease in the starch particle size, resulting in a rough granule morphology. Structural analysis revealed that crystalline areas were destroyed in the modified starches. In the Fourier‐infrared spectrum, typical peaks appeared at 1724 and 1573 cm−1 upon introduction of the octenyl succinic anhydride group, whereas a new sodium peak appeared in the XPS spectrogram. The 1H‐NMR spectrum indicated that the esterification reaction mainly occurred on OH2 groups. The emulsification properties of the modified starch were significantly enhanced and increased with the crushing strength. The octenyl succinic anhydride‐modified starch has potential as a wall material for microcapsules, with good embedding rate and thermal stability. This novel synthesis method represents an innovative method for the synthesis of OSA‐starches.

Preparation and Evaluation of Inhalable Microparticles with Improved Aerodynamic Performance and Dispersibility Using L-Leucine and Hot-Melt Extrusion.

Dry-powder inhalers (DPIs) are valued for their stability but formulating them is challenging due to powder aggregation and limited flowability, which affects drug delivery and uniformity. In this study, the incorporation of L-leucine (LEU) into hot-melt extrusion (HME) was proposed to enhance dispersibility while simultaneously maintaining the high aerodynamic performance of inhalable microparticles. This study explored using LEU in HME to improve dispersibility and maintain the high aerodynamic performance of inhalable microparticles. Formulations with crystalline itraconazole (ITZ) and LEU were made via co-jet milling and HME followed by jet milling. The LEU ratio varied, comparing solubility, homogenization, and aerodynamic performance enhancements. In HME, ITZ solubility increased, and crystallinity decreased. Higher LEU ratios in HME formulations reduced the contact angle, enhancing mass median aerodynamic diameter (MMAD) size and aerodynamic performance synergistically. Achieving a maximum extra fine particle fraction of 33.68 ± 1.31% enabled stable deep lung delivery. This study shows that HME combined with LEU effectively produces inhalable particles, which is promising for improved drug dispersion and delivery.

Synergism of jet milling and deep eutectic solvent pretreatment on grapevine lignin fractionation and enhancing enzymatic hydrolysis

Herein, we investigated the synergistic effects of jet milling (JM) and deep eutectic solvent (DES) pretreatment on the fractionation of grapevine lignin and the consequent enhancement of enzymatic hydrolysis. Grapevine, a substantial byproduct of the wine industry, was subjected to JM pretreatment to produce finely powdered particles (median diameter D50 = 98.90), which were then further treated with acidic ChCl-LA and alkaline K2CO3-EG DESs. The results revealed that the combined JM + ChCl-LA pretreatment significantly increased the cellulose preservation under optimal conditions (110 °C, 4 h, and 20 % water content), achieving removal rates of 74.18 % xylan and 66.05 % lignin, respectively. The pretreatment temperature and inhibitor production were reduced, resulting in a remarkable threefold increase in glucose yield compared to untreated samples. Moreover, the structural analysis of the pretreated lignin indicated an enrichment of phenolic units, leading to enhanced antioxidant and antibacterial activities, particularly in the JM pretreated samples. These findings underscore the promising potential of the synergistic JM and DES pretreatment in facilitating the efficient utilization of grapevine lignocellulosic biomass for sustainable biorefinery technologies.

Comparison of noodle-making performance of purple-colored whole wheat flour prepared with a jet mill and an ultra-centrifugal mill.

This study explores the impact of milling methods on the quality and noodle-making performance by comparing jet-milled (WF-JM) and ultra-centrifugally milled (WF-UM) purple-colored whole wheat flours. WF-JM exhibits smaller starch granules and a fragmented protein matrix attributed to the increased milling pressure. Physicochemical analyses reveal lower moisture and higher damaged starch in WF-JM. Rheological analyses show lower viscosity in the WF-JM blends. The mixograph results reveal weaker dough-mixing stability and strength for WF-JM. Cooked noodles from WF-JM are uneven, in contrast to uniform WF-UM strands. Blending WF-UM enhances noodle quality. Overall, the noodle-making performance for WF-JM was inferior compared to WF-UM, confirming the significantly negative impact of damaged starch and fragmented protein matrix in whole wheat flour than the positive effect of particle size. This study highlights the complex interplay between milling methods, particle size, and physicochemical attributes, providing insights for optimizing whole wheat flour processing and product quality.

Research on the Grinding Process of Superhard Particles in the Fluidized Bed Opposed Jet Mill Based on the CFD-DEM Methodology

The process of superhard particle breakage in the grinding zone of the fluidized bed opposed jet mill is investigated using the CFD-DEM (computational fluid dynamics-discrete element method) coupling method with the Tavares UFRJ Breakage Model in the present study. The effects of structural and operational parameters, such as target plate structure, nozzle position, air inlet velocity, and feed rate, on the equipment stress distribution, airflow velocity, pressure field, particle velocity, and cumulative particle size distribution are thoroughly studied to determine the optimal structural and operational parameters. Experimental validation is conducted, including scanning electron microscope (SEM) observation of particle morphology and analysis of particle size distribution of ground product particles. The simulation results indicate that the wear rate of the structure without a target plate is lower than that of the structure with a target plate in the grinding central zone. Therefore, the structure without a target plate is chosen for further investigation. The cumulative particle size distribution after grinding is influenced by nozzle position, air inlet velocity, and feed rate. The particle D50 is positively correlated with nozzle spacing and feed rate, while it is negatively correlated with air inlet velocity. The optimal grinding effect is achieved when the distance between the nozzle and the center of the grinding zone ranges from 52.5 mm to 72.55 mm, the air inlet velocity is 950 m/s, and the feed rate is 10.5 g/s. Through experimental investigation, it has been observed that when the feed rate is 10 g/s, the particle size distribution becomes more uniform. Furthermore, consistent trends in the cumulative particle size distribution in the experiment and simulation results can be found, which validates the present numerical model. It was observed that particles at low feed rates retain certain angular edges, while particle roundness increases at high feed rates.