Particle Size Segregation Research Articles

Evaluation of laboratory methods to quantify particle size segregation using image analysis in landslide flume tests

Evaluation of laboratory methods to quantify particle size segregation using image analysis in landslide flume tests

Effects of particle size composition and burden ratio on burden segregation in the blast furnace throat based on DEM

In blast furnace charging, burden segregation affects the distribution of gas flow and the efficiency of chemical reactions, which in turn impacts the overall efficiency and quality of ironmaking. This work developed a bell-less top charging model based on the DEM to analyze burden segregation at the furnace throat under various particle size compositions, chute inclinations, and burden ratios. The results show that the burden exhibits a ring-like distribution around the furnace throat, with smaller particles concentrated in the inner ring near the center. When particle size difference of the burden is significant, adjusting the proportion of large or small particles has a more pronounced effect on particle size segregation near the center of the blast furnace. The smaller the chute inclination, the more serious the particle size segregation of the burden. Pellet tends to accumulate near the center of the blast furnace, with a segregation index reaching 0.8 in this region. Adjusting the burden ratio has a more pronounced effect on the segregation of sinter. This work provides theoretical support for charging optimization in blast furnace operation.

Study on particle size and density segregation law in the separating process of poor quality coal with high gangue content under the action of composite force field

ABSTRACT Thin-seam mining frequently captures a significant proportion of gangue and interbedded coal in surface coal mines. Consequently, raw coal has a broad range of particle size distributions and a high percentage of components with intermediate densities, which are complex and challenging to separate. This study aims to determine the method of product division and the segregation law of particle size and density of raw coal during the separation process using a vibration and airflow composite force field. A difference in the particle size segregation of the coal particles was evident. Particle-size segregation primarily occurs in the separation area. Large-particle-size coal has a wide distribution range, spreading over the entire bed and fully utilizing the bed to achieve separation. The material becomes increasingly displaced into the separation area as its particle size decreases, thereby weakening the separation effect. Large coal particles can undergo density segregation in the vertical direction, with low-density material placed in the upper layer. This ensures that low-density material is incorporated into the refined coal product. Regardless of density, the coal tended to tilt more toward the bottom layer as the particle size decreased. This results in a poor density stratification effect with refined coal products mixed with gangue and an increase in the mismatch content. The extent of fine coal discharge was determined to be two-fifths of the entire length of the discharge side. This ensures that the majority of refined coal is recovered and that there is no excessive gangue mixing with the refined coal output. Achieving a 55.54% yield, refined coal lowers its ash content by 16%, increases its calorific value by 1400 kcal/kg, and effectively separates coal with a high gangue concentration.

Effect of construction method and bench height on particle size segregation during waste rock disposal

ABSTRACT Waste rock segregation and heterogeneity can increase the hydrogeotechnical and geochemical instability of waste rock piles, but characterising segregation quantitatively in the field is difficult because of the large dimensions of these structures. In this study, a discrete element model (PFC3D) was calibrated on two real cases and used to simulate the flow behaviour of waste rock during disposal. The effect of the construction method, the bench height, and additional factors (e.g. mine truck payloads and push velocities) on particle segregation was investigated. Segregation degree and relative particle diameters of waste rock at different locations in the pile were compared to propose practical solutions and reduce segregation and heterogeneity during deposition. Results indicated that simulated bench heights and mine truck payloads had limited effect on segregation. A smaller proportion of large particles in the original waste rock can increase segregation. Lateral disposal and increasing the push velocity tend to reduce segregation.

Segregation–rheology feedback in bidisperse granular flows: a coupled Stokes’ problem

The feedback between particle-size segregation and rheology in bidisperse granular flows is studied using the Stokes’ problem configuration. A method of lines scheme is implemented to solve the coupled momentum and segregation equations for a normally graded particle size distributed bulk at constant solids volume fraction. The velocity profiles develop quickly into a transient state, decoupled from segregation yet determined by the particle size. From this transient state, the velocity profile changes due to the particles’ relative movement, which redistributes the frictional response, hence its rheology. Additionally, the particles’ relative friction is modified via a frictional coefficient ratio, by analogy with the particles’ size ratio. While positive values of this coefficient exacerbate the nonlinearity of the velocity profiles induced by size differences, negative values dampen this behaviour. The numerical solutions reproduce well the analytical solutions for the velocity profile, which can be obtained from the steady-state conditions of the momentum and segregation equations for the transient and steady states, respectively. Segregation–momentum balances and four characteristic time scales can be established to propose two non-dimensional quantities, including specific Schmidt and Péclet numbers that describe broadly the segregation–rheology feedback. The proposed scheme, theoretical solutions and non-dimensional numbers offer a combined approach to understand segregation and flow dynamics within a granular bulk, extensible across many flow configurations.

Ex-situ characterization and simulation of density fluctuations evolution during sintering of binder jetted 316L

Efficient density evolution during sintering of the as-printed component is vital to reach full densification and required properties of binder jet (BJT) components. However, due to the high porosity and brittle nature of the green compact, analysis of the microstructure development during sintering is very difficult, resulting in lack of understanding of the densification process. Density development from green state (57 ± 1.6 %) up to full density (99 ± 0.3 %) was characterized by high-resolution synchrotron X-Ray computed tomography (SXCT) on BJT 316L samples from ex-situ interrupted sintering tests. Periodicity of density fluctuations along the building direction was revealed for the first time and was related to the layer thickness of ∼ 42 µm during printing that decreased down to ∼ 33 µm during sintering. Sintering simulations, utilizing a continuum sintering model developed for BJT, allowed to replicate the density evolution during sintering with a mean error of 2 % and its fluctuation evolution from green (1.66 %) to sintered (0.56 %) state. Additionally, simulation of extreme particle size segregation (1 µm to 130 µm) suggested that non-optimized printing could lead to undesirable density fluctuation amplitude rapid increase (∼10 %) during sintering. This might trigger the nucleation of defects (e.g., layer delamination, cracking, or excessive residual porosity) during the sintering process.

Particle-size segregation patterns in a partially filled triangular rotating drum

In this paper a fully coupled particle-size segregation model for granular flows (Barker et al., J. Fluid Mech., vol. 909, 2021, p. A22) is used to simulate the development of the patterns in a triangular rotating drum. The results are compared with the experimental patterns formed with bidisperse and tridisperse granular mixtures, and with varying compositions and fill heights. In all cases the agreement between the simulations and experiments is remarkably good. The experimental patterns are generated in a narrow gap between transparent front and back sidewalls. These prevent three-dimensional motion, but also impose friction on the flow, making it thinner and faster than it would otherwise be. This promotes segregation, as it simultaneously increases the shear rate and reduces the local pressure. To obtain the correct flow dynamics and segregation, width-averaged sidewall friction is incorporated into the two-dimensional simulations, which are performed in OpenFOAM $^{\circledR}$ . The free-surface avalanche forms a boundary layer within which all the segregation occurs. Material in the lower reach of the avalanche is continuously deposited into an underlying solid body of grains, which rotates with the drum, and is eventually re-entrained into the avalanche along its upper reach. The changing geometry of the granular region (as the drum rotates) implies that the avalanche is constantly adjusting its length, position and depth. This generates a complex quasi-periodic flow, which when combined with particle-size segregation generates amazing patterns in the solid rotating granular body after only two drum rotations.

External field-driven property localization in liquids of responsive macromolecules.

We explore theoretically the effects of external potentials on the spatial distribution of particle properties in a liquid of explicitly responsive macromolecules. In particular, we focus on the bistable particle size as a coarse-grained internal degree of freedom (DoF, or "property"), σ, that moves in a bimodal energy landscape, in order to model the response of a state-switching (big-to-small) macromolecular liquid to external stimuli. We employ a mean-field density functional theory (DFT) that provides the full inhomogeneous equilibrium distributions of a one-component model system of responsive colloids (RCs) interacting with a Gaussian pair potential. For systems confined between two parallel hard walls, we observe and rationalize a significant localization of the big particle state close to the walls, with pressures described by an exact RC wall theorem. Application of more complex external potentials, such as linear (gravitational), osmotic, and Hamaker potentials, promotes even stronger particle size segregation, in which macromolecules of different size are localized in different spatial regions. Importantly, we demonstrate how the degree of responsiveness of the particle size and its coupling to the external potential tune the position-dependent size distribution. The DFT predictions are corroborated by Brownian dynamics simulations. Our study highlights the fact that particle responsiveness can be used to localize liquid properties and therefore helps to control the property- and position-dependent function of macromolecules, e.g., in biomedical applications.

Smoothed particle hydrodynamics modelling of particle-size segregation in granular flows

In this work, smoothed particle hydrodynamics (SPH) is employed to investigate the segregation evolution in granular flows. We first provide the Lagrangian description-based governing equations, including the linear momentum conservation and the segregation–diffusion equation. Then the hybrid continuum surface reaction scheme is introduced to formulate the concentration-related inhomogeneous Neumann boundary condition on the free and wall surfaces. We follow a two-stage strategy to advance boundary particle searching and normal direction identification. Moreover, $C^1$ consistency is considered based on the Taylor series to obtain accurate segregation flux gradient along the boundary. Our SPH model is validated with a shear box experiment. The model is then applied to investigate the segregation mechanism in bidisperse-sized granular flows in a rotating drum.

Characterization of particle size segregation and heterogeneity along the slopes of a waste rock pile using image analysis

Large amounts of waste rock are produced during mining operations and often disposed of in large piles. Particle size segregation usually occurs during waste rock disposal, which can lead to high variations of particle size distribution (PSD) along the pile slope, increasing the risk for hydrogeotechnical instabilities. Determining segregation in situ is, therefore, critical to implement control measures and optimize deposition plans. However, characterizing PSD at field scale remains challenging because of the large dimensions of the pile, the instability of the blocks and the steep slopes. In this study, images, covering a 1400 m wide and 10 m high section of a waste rock pile, were taken and analyzed using image analysis to characterize segregation along the slope of the pile. PSD curves in different sections along the slope were determined and the segregation degree and characteristic diameters (e.g., D10, D50, D80,D95) were quantitatively compared. Results allowed to quantify segregation along the vertical direction of the pile, showing that segregation degree increased from − 0.77 ± 0.39 in the top (finer zone) to + 0.4 ± 0.14 in the bottom (coarser zone). Significant lateral heterogeneity was also observed with maximum diameters varying between 80 and 180 cm in the bottom section. Such segregation and lateral heterogeneity could induce significant variations of waste rock properties, with, for example, hydraulic conductivities varying by more than 2 orders of magnitude within the pile.

Application of radiotracers as tools to determine feed flowrate imbalances and particle size segregation in industrial flotation circuits

This publication presents the application of radiotracers in the characterization of industrial flotation circuits. Two examples are showcased: the detection of feed flow rate imbalances and the characterization of particle size segregation in automatic mineral-cutting machines. The feed pulp distribution was determined from the mean residence times. Particle size segregation was measured by sampling the cutting machines (≅ 25 grams samples) using coarse, intermediate, and fine-sized radiotracer particles. Radiotracers were injected into the feed streams and measured at various points of the circuit using nuclear instruments, allowing for non-invasive and real time detection. Results show that in the rougher flotation stage, the feed flow is distributed almost evenly in lines 2 and 3 (approximately 38% of the flow goes to each line) and to a lesser extent towards line 4 (approximately 24%). In lines 1 and 2 of the scavenger stage, a higher percentage of the flow goes towards line 1 (approximately 59%) and a lower percentage towards line 2 (41%). Line 6 of the rougher flotation is the fastest of the circuit (shortest residence time). In addition, the inlet mineral-cutting machine of the rougher stage segregates particles with a bias for fine sizes (11.4 % more fine-sized particles than coarse ones). This work is an example of how radiotracer technology can be applied to improve metal production and processes. Radiotracers provide reliable information to be used in combination with other metallurgical data to properly assess flotation circuits.

Effect of cohesion on structure of powder layers in additive manufacturing

Producing a consistent layer quality for different raw-materials is a challenge for powder-based additive manufacturing. Interparticle cohesion plays a key role on the powder spreading process. In this work, we characterise the structure of deposited layers in the powder-base additive manufacturing process by numerical simulations using the discrete element method. The effect of particle cohesion on the quality of powder layers is evaluated. It is found that higher interparticle cohesion lead to poor spreadability, with more heterogeneous powder layer structure and enhances particle size segregation in the powder layer. We also compare the powder layer quality deposited on a smooth substrate with that on a powder layer. Deposition on a powder layer leads to inferior layer quality of powder layer with higher heterogeneity and higher particle size segregation effects.Graphical abstract

Feasibility of High-Density and Non-Segregable Niobium Ore Tailings

Tailings disposal in the form of diluted slurries has a tendency for particle size segregation, where coarse particles settle near the discharge point, and finer particles are carried by the water flux to more distant regions. This causes a loss of reservoir capacity due to voids between the coarser particles and increased water content in the deposit. This work aimed to evaluate the feasibility of reaching non-segregable high-density slurries with fine tailings from the niobium oreflotation process and measure its disposal parameters. The innovation is to achieve increased solids percentage in the settled deposit and to avoid particle size segregation along the slurry path with niobium tailings. The study involved physical, chemical, and mineralogical characterization and semi-pilot thickening tests to produce enough volume of underflow with different bed heights and solids flux rates. Slump, rheology, and flume tests were performed to evaluate underflow disposal characteristics. The results indicated that the thickener bed height did not significantly influence the underflow solids content, yield stress, or slump. The solids flux rate, on the other side, had a greater influence—the higher it was, the lower the solids content, yield stress, and disposal angle, along with a higher slump. In flume tests, a high density of non-segregable tailings slurry was achieved with 1.96 t/m3, corresponding to an underflow with 66.8% solids, 43.9 Pa of yield stress with 0.5 (t/h)/m2, and 0.5 m of bed height.

Fuel-Appropriate Distribution of the Material Layer Based on Numerical Model of Sintering with Particle Swarm Optimization Algorithm

An optimization model for the fuel distribution of the material layer with mechanism models and algorithms is presented, which can reduce the fuel ratio of ore blending and enhance the fuel content in the upper layer to improve the homogeneity of the sinter quality. The actual fuel distribution of the material layer is analyzed through the granulation model and the theoretical fuel distribution for each unit is obtained using the numerical model. Then, the fuel particle size composition and segregation characteristics are optimized via the particle swarm optimization algorithm to bring fuel distribution close to the theoretical value, with a sum of their absolute values of 0.025. In comparison with the initial conditions, the fuel particle size composition conforms to a normal distribution with increased coarse particles, and the deviation of the granules from the vertical direction of the sinter layer decreases. Through this optimization method, the sinter bed with the ideal thermal profile can be achieved, namely uniform sintering along with a reduced coke ratio.

Three Experimental Common High-Risk Procedures: Emission Characteristics Identification and Source Intensity Estimation in Biosafety Laboratory.

Biosafety laboratory is an important place to study high-risk microbes. In biosafety laboratories, with the outbreak of infectious diseases such as COVID-19, experimental activities have become increasingly frequent, and the risk of exposure to bioaerosols has increased. To explore the exposure risk of biosafety laboratories, the intensity and emission characteristics of laboratory risk factors were investigated. In this study, high-risk microbe samples were substituted with Serratia marcescens as the model bacteria. The resulting concentration and particle size segregation of the bioaerosol produced by three experimental procedures (spill, injection, and sample drop) were monitored, and the emission sources' intensity were quantitatively analyzed. The results showed that the aerosol concentration produced by injection and sample drop was 103 CFU/m3, and that by sample spill was 102 CFU/m3. The particle size of bioaerosol is mainly segregated in the range of 3.3-4.7 μm. There are significant differences in the influence of risk factors on source intensity. The intensity of sample spill, injection, and sample drop source is 3.6 CFU/s, 78.2 CFU/s, and 664 CFU/s. This study could provide suggestions for risk assessment of experimental operation procedures and experimental personnel protection.

Particle-size segregation in self-channelized granular flows

Geophysical mass flows such as debris flows, dense pyroclastic flows and snow avalanches can self-channelize on shallow slopes. The confinement afforded by formed levees helps to maintain the flow depth, and hence mobility, allowing self-channelized flows to run out significantly farther than unconfined, spreading flows. Levee formation and self-channelization are strongly associated with particle-size segregation, but can also occur in monodisperse flows. This paper uses the monodisperse depth-averaged theory of Rochaet al.(J. Fluid Mech., vol. 876, 2019, pp. 591–641), which incorporates a hysteretic friction law and second-order depth-averaged viscous terms. Both of these are vital for the formation of a travelling wave that progressively deposits a pair of levees just behind the front. The three-dimensional velocity field is reconstructed in a frame moving with the front assuming Bagnold flow. This enables a bidisperse particle-size segregation theory to be used to solve for the large and small particle concentrations and particle paths in three-dimensions, for the first time. The model shows that the large particles tend to segregate to the surface of the flow, forming a carapace that extends over the centre of the channel, as well as along the external sides and base of the levee walls. The small particles segregate downwards, and are concentrated in the main channel and in the inner levee walls. This supports the contention that a low-friction channel lining provides a secondary mechanism for run-out enhancement. It is also shown that the entire theory scales with particle diameter, so experiments with millimetre-sized particles provide important insights into geophysical-scale flows with boulders and smaller rock fragments. The model shows that self-channelization does not need particle-size segregation to occur, but supports the hypothesis that particle-size segregation and the associated frictional feedback can significantly enhance both the flow mobility and the levee strength.

Particle size segregation and diffusion in saturated granular flows: Implications for grain sorting in debris flows

Sorting of rocks, boulders, and silt/sand-sized particles according to their size is a characteristic feature of debris flow deposits and is an active process during flow which significantly affects the mobility. The degree at which size sorting occurs in debris flows depends on the relative magnitudes of granular processes such as particle size segregation and diffusion. Since debris flows are fluid-saturated phenomena, accurate modelling of size sorting requires the understanding of the influence of fluids on these processes, which have not been systematically studied. Here, we present simulation results and the associated empirical expressions for particle size segregation and diffusion which take into account fluid effects due to buoyant and drag forces. These expressions are developed through scaling analysis of data obtained from coupled granular-fluid simulations of saturated bi-disperse mixtures under simple shear. We further show that using these scaling relationships, an existing segregation-diffusion continuum equation can be extended to model particle sorting in debris flows with various types of fluids.

Numerical study of heat transfer for gravity-driven binary size particle flow around circular tube

As the primary working medium in moving bed heat exchangers, solid bulk materials are composed of multiple size particles. To clarify the effect of particle size distribution (PSD) on heat transfer, the discrete element method (DEM) is used to study the flow and heat transfer of binary size particle flow around a circular tube. The heat transfer model for multiple size particles is developed and coupled with DEM method. The particle flow characteristics with PSD width are analyzed in detail. The results show that particle size segregation, competitive flow and flow instability are the unique characteristics of binary size particle flow around a tube. Wider PSD will enhance these characteristics and have a positive effect on particle renewal in the stagnation zone, which could decrease the local heat resistance. The total heat transfer coefficient between particle flow and tube wall increases at most by 9.73% as PSD is wider. • Binary size particle flow around a circular tube is studied with DEM method. • Binary size particle flow can form local particle size segregation around tube. • Binary size particles can decrease the stagnation zone above the tube. • A wider binary particle size distribution can increase the flow instability. • A wider binary particle size distribution can enhance heat transfer performance.

Formation of dry granular fronts and watery tails in debris flows

Debris flows are particle-fluid mixtures that pose a significant hazard to many communities throughout the world. Bouldery debris flows are often characterized by a deep dry granular flow front, which is followed by a progressively thinner and increasingly watery tail. The formation of highly destructive bouldery wave fronts is usually attributed to particle-size segregation. However, the moving-bed flume experiments of Davies (N. Z. J. Hydrol., vol. 29, 1990, pp. 18-46) show that discrete surges with dry fronts and watery tails also form in monodisperse particle-fluid mixtures. These observations motivate the development of a new depth-averaged mixture theory for debris flows, which explicitly takes account of the differing granular and phreatic surfaces, velocity shear, and relative motion between grains and fluid to explain these phenomena. This poster presents the theory of Meng et al. (J. Fluid Mech., vol. 943, 2022, A19), which consists of four coupled conservation laws that describe the spatial and temporal evolution of the grain and water thicknesses and depth-averaged velocities. This system enables travelling wave solutions to be constructed that consist of (i) a large amplitude dry flow front that smoothly transitions to (ii) an under saturated body, (iii) an oversaturated region and then (iv) a pure water tail. It is shown that these solutions are in good quantitative agreement with Davies’ experiments at high bed speeds and slope inclinations. At lower bed speeds and inclinations, the theory produces travelling wave solutions that connect to a steady-uniform upstream flow, and may or may not have a bulbous flow front, consistent with Davies’ observations.

A numerical study on the effects of particle size distribution on run-out distance of granular flow

The discrete element method is a powerful numerical tool widely employed in granular flow simulations. To reduce computational costs, either monodisperse granular models or models with a limited number of particle sizes are used to estimate the risk of sediment-related disasters. This highlights the need for a thorough understanding on the effects of particle size distribution on the accuracy of granular simulations. In this study, a series of granular flow simulations was conducted with different particle size distributions. The results clearly indicate that the run-out distance strongly depends on the number of particle sizes and is underestimated in the conditions employed by the monodisperse granular model. The longest run-out distance was observed in case that the bidisperse granular model was employed, whereas run-out distance tends to a constant value when polydisperse granular model was employed. Because particle size segregation was observed during the flow, a series of vibration simulations was also conducted to estimate the degree of the size segregation. It was shown that each granular model has an inherent degree of size segregation. From the results of the granular flow simulations and vibration simulations, it was confirmed that the inherent degree of the size segregation clearly affects the run-out distance.