Effects of concentration of dispersions on particle sizing during production of fine particles in wet grinding process

Stirred media milling is a prospective technology for producing colloidal dispersions by means of wet grinding process. In the past, many researchers have studied the effects of different operating parameters such as size, shape, nature and quantity of grinding medium, the speed of agitator in grinding chamber, the feed rate of dispersions, etc. in stirred media mills. However, it is still less known how particle sizing which generates valuable information of particle size of the product to interpret, control and optimize the grinding process, is influenced by the concentration of the dispersion during stirred media milling where particles change their size from micron to colloidal range rapidly. One of the reasons of this lack had been our incapability in the past to study the particle size distribution of dispersions without dilution. The recent advent of acoustic attenuation spectroscopy is known to be capable of studying dispersions without dilution, under real process conditions and on line. The study employs acoustic attenuation spectroscopy to investigate the effects of concentration of dispersions of CaCO3 on its particle sizing during size reduction process in a stirred media mill (LabStar manufactured by NETZSCH). The dispersions of CaCO3 at 5%, 10%, 20% and 30% (m/m) were studied about six hours under a selected set of operating conditions. Contrary to the existing knowledge obtained through other techniques of particle sizing that are based on the principle of dilution, acoustic attenuation spectroscopy shows that, under certain grinding time at given operating conditions, increase in concentration of dispersion results in better grinding results yielding smaller particles. The causes behind the differences in results of acoustic attenuation spectroscopy and dynamic light scattering have been thoroughly investigated. We find certain limitations of acoustic attenuation spectroscopy in particle sizing. A typical phenomenon which causes misleading trends in particle sizing is multiple scattering in acoustic measurements. Multiple scattering, particularly, influences acoustic results when particles approach to fine size range during size reduction process.