Formulation of the particle size distribution effects on the rheology and hydraulics of highly-concentrated suspensions

A formulation was developed for the rheological characterization of highly concentrated suspensions, accounting for the physical effects of particle size distribution. A number of dimensionless parameters were developed signifying the physical characteristics of the solids and the vehicle fluid, and functionally related to the yield-stress and a flow parameter. Each of these expressions of the formulation contains an empirical dimensionless coefficient accounting for the interparticle and fluid/solid interactions that are not explained by the physical parameters involved. A formulation and a methodology were also developed for predicting the shear viscosity behavior of highly concentrated suspensions at low and high shear-rates through the use of three parameters signifying effects of particle size distribution. A number of applications were made using various non-coal and limited coal-liquid mixture data reported in the literature to demonstrate the general validity of the formulations.

A methodology was proposed for the analysis of the particle size distribution effects on the overall optimum energy efficiency during hydraulic transportation and particle size reduction. The computer model developed for this purpose was employed to evaluate the transportation energy consumption and the energy consumed in the grinding process to prepare the slurry, in pipes of various sizes and lengths for a coal slurry of various specified particle size distributions and concentrations. Correlations obtained indicated the sensitivity of transportation energy efficiency to various parameters including the maximum packing concentration, relative concentration, specific surface area of particles, surface area mean size, pipe size and length, and annual mixture throughput. The results of combined energy calculations have shown that the particle size distribution and related physical parameters can significantly affect the energy efficiency due to both grinding and transportation, and the delivered cost of slurry fuels.