Why does dispersion not become uniform? An explanation of the causes of aggregation residuals and distribution variability, as well as design points to achieve uniform dispersion.
澁谷工業 メカトロ統轄本部
In dispersion engineering, there are many cases where, although the appearance seems mixed, the particles are not actually uniformly dispersed. One of the causes of this is that the aggregation between particles has not been sufficiently resolved. When there is insufficient dispersion energy, the particles do not break down to primary particles, and aggregates remain. Additionally, if the shear conditions or flow state are uneven, the dispersion state can vary locally, resulting in variations in particle size distribution. This is particularly true in high-viscosity systems or high solid content slurries, where low flowability makes it difficult for energy to be transmitted uniformly, leading to dispersion inconsistencies. Furthermore, in batch processing, variations in mixing uniformity and residence time tend to make it difficult to maintain a uniform dispersion state throughout the process. To achieve uniform dispersion, it is important to design dispersion energy according to particle characteristics and to maintain uniform flow conditions in the process design. By maintaining consistent shear conditions, as in inline continuous processing, it is possible to achieve a uniform dispersion state and reproducible quality. The order of input, the wettability of the powder, and the initial mixing state of the dispersion also have a significant impact on uniformity. In particular, if local clumps or uneven distribution occur during powder input, it becomes difficult to resolve them in subsequent dispersion processes, leading to dispersion inconsistencies.
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To achieve uniform dispersion, it is important not only to consider dispersion energy and shear conditions but also to focus on the flow state and the overall design of the process. Our company offers process engineering that includes optimizing dispersion conditions according to particle characteristics and ensuring reproducibility during scale-up, centered around inline continuous processing. We will introduce specific design points to achieve uniform and stable dispersion quality.
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