Mixing and Blending: Volume 2 — Combining Powders and Bulk Solids


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For process operators throughout the chemical process industries (CPI), the need to effectively and efficiently mix and blend powders and other bulk solids presents many challenges. For instance, engineering challenges arise when it comes to selecting and specifying the most appropriate mixer or blender to meet the needs of the process and the physical and chemical attributes of the powders (and thus dictate bulk solids behavior), and there is always a need to protect workers and safeguard the environment during operation and maintenance of these systems.

This selection of practical tutorial-style engineering articles provides informative, actionable information for process engineers and other technical professionals throughout the CPI. Several topics discuss different mixer and blender options. Others provide targeted engineering recommendations on how to manage specific safety issues— such as the risk of dust explosions — that can arise when handling powders and other bulk solids.

All of these articles in this PDF guidebook were published in Chemical Engineering magazine between 2009 and 2020. Volume 1 of this series — entitled “Mixing & Blending: Volume 1 — Combining Liquids” — is available separately.

Delivered in a PDF format. 87 Pages.

Topics Include:

Taking Representative Samples in Solids Handling Processes

Non-representative sampling in solids processes has costly consequences. A better understanding of the mathematical basis for sampling and of acceptable quality levels can help to alleviate potential sampling issues and more closely approximate reality

Selection of Silos for Bulk Storage

To determine what kind of storage silo is best for your site and your materials, begin by answering the following five questions

Agglomeration Processes

Cost Engineering: Equipment Purchase Costs

A methodology and examples for estimating equipment costs are presented

Commercializing Process Technologies

New technologies can provide competitive advantages compared to established processes, but significant effort is required to transition a promising concept into a commercial reality

Incorporate Floating Solids Into Liquids

New and seasoned, these proven rules of thumb work hand in hand with achieving the desired drawdown

Disperse Difficult Solids

Recent advances in mixing technology offer increased efficiency in dispersing powdered additives into liquids for both low and high-viscosity applications

Lifecycle Costs for Capital Equipment in the CPI

Longterm equipment costs need to be fully considered in capital-cost assessments

Automating Your Weigh Batching System

Reductions in dust, lower costs and improved measurement accuracy for your ingredients are just some of the advantages

Materials Selection in the CPI

An overview of the many factors to be considered when selecting materials of construction

Guarding Against Fires and Explosions Caused by Self-Heating

The two experimental methods presented here can be used to quantify powder self-heating hazards in layer and bulk conditions in industrial processes

Blender Selection and Avoidance of Post-Blender Segregation

Proper blender selection can improve the mixing of bulk solids. Be sure to consider post-blending segregation problems.

Blending, Sampling and Segregation

These aspects of dry solids mixing represent three sides of the same coin. Do not discount them

Solids Discharge: Characterizing Powder and Bulk Solids Behavior

How shear-cell testing provides a basis for predicting flow behavior

Fundamentals of Bulk Solids Mixing and Blending

Learn about mixing technology, types of blending equipment and key sampling practices to meet today’s requirements for robust processes

Selecting, Handling and Maintaining IBCs

A number of factors are involved in selecting the right intermediate bulk container (IBC). An overview is presented here