DISPERSION

Meaning: It is called DISPERSION when one solid (or more) component is mixed with a liquid (or
more) component.

Solid component Liquid component

DISPERSION

If all components are in liquid form, we refer to this process as MIXING or AGITATION or
HOMOGENISATION

Therefore at least 1 component MUST BE SOLID (e.g.: powder)

Purpose: Stir the mixture in order to break up and reduce the size of the particles of the solid
component. These particles must become smaller in size. Dispersion process can reduce the particles'
size to 30 → 300 microns. Powders have a size ranging from 30 → 2,000 microns.

In the water based architectural paint industry a particles' size ranging from 30 to 50 microns is
generally acceptable.

Sometimes customer refer to this process as PREMIX, sometimes clients do not really know the actual
meaning of “dispersion”, therefore we need to make sure that at least 1 solid component is present
within the formula.

To break down the size of the particles, we need HIGH SPEED: anything above 500 RPM is
considered HIGH SPEED (mixers and agitators all rotate at lower RPM)
 EQUIPMENT
RULE OF THUMB FOR THE “PERFECT DISPERSION”

Product level

D x 1.5

D = Impeller diameter
D ¼ D to ½ D

3xD
The process of dispersion DOES NOT mean “cutting” the solid particles. Dispersion means
“SHEARING” the solid particles.

When adding RESIN to the formula (resin is a sticky material) this material will stick to the solid
particles and, during dispersion, the resin will help breaking apart the particles, thus reducing their size.
The thicker the product, the better.
Furthermore, the more viscous the product, the bigger the diameter of the impeller will have to be.

MAX PRODUCT VISCOSITY for single impeller disperser: 20,000 cP.

To achieve a good dispersion (doughnut effect):

1. No “chopping” of the material but high “shearing” effect instead
2. Play around with the viscosity of the product (pull back on solvents or water)
3. Play around with the diameter of the impeller, the quantity of the product inside the vessel and the
height of the impeller from the bottom of the vessel.
4. SPEED. The only speed which is really relevant is the “TIP SPEED” of the impeller, not the RPM
of the shaft
The bigger the diameter of the impeller the higher the tip speed, which is what really counts!

Example 1 Example 2

100 R.P.M. 100 R.P.M.

300 mm impeller 1,000 mm impeller

 HOW TO DETERMINE TIP SPEED PER SECOND

D = Diameter
D L = Circumference
Impeller ->
B = R.P.M. (revolutions x minute)
A = Distance run p/Min

L = ∏ (Pi) x D (L = 3.142 x D)
A=LxB
Tip Speed p/sec = A/60 = Tip speed in m/sec

Example 1 Example 2

L = 3.142 x 300 (mm) = 942.6 mm L = 3.142 x 1,000 (mm) = 3,142 mm

A = 942.6 x 100 (RPM) = 94,260 mm = 94.26 m/Min A = 3,142 x 100 (RPM) = 314,200 mm = 314.2 m/Min
Tip Speed p/sec = 94.26/60 = 1.57 m/sec Tip Speed p/sec = 314.2/60 = 5.23 m/sec

Good dispersion will take place: within 18 → 30 m/sec

 25 m/sec with good quality pigments
 30 m/sec with cheap pigments

During dispersion, the solid component is the PIGMENT, TITANIUM DIOXIDE (*) (TiO2),
CALCIUM CARBONATE (CaCO2), etc.

(*) If TiO2 is of good quality and already a size of +/- 30 microns, dispersion process alone can
bring it down to 6 → 8 microns.

During dispersion, the liquid component are: RESIN

ADDITIVES
WATER (if product is water based) or
SOLVENT (if product is solvent based)

During dispersion process we also need: WETTING AGENT (1)

DISPERSION AGENT (2)

(1) All solid particles tend to stick and lump together. The WETTING AGENT reduces the SURFACE
TENSION of the particles allowing them to move away from each other and therefore allowing the
RESIN to move in between the particles. Once dispersion has been done and the size of the
particles has been reduced, we need to avoid these particles to flock and lump back together again.
That is when we add the

(2) DISPERSION AGENT. This agent prevents the particles from lumping back together again

Therefore, in order to achieve a good dispersion we need:

a) Good disperser
b) Good overall geometry (all sizes must be in the correct proportions: quantity of the product inside
the vessel, vessel size, impeller size, impeller height, tip speed, etc.)
c) Wetting agent must be of good quality and correct quantity
d) Resin must be of good quality and correct quantity
e) Dispersion agent must be of good quality and correct quantity
 DISPERSION TIME: 20 to max 30 minutes

Whenever a dispersion time exceeding 30 minutes is required, something is not right.

During dispersion, temperature will go up to +/- 60° (within 20 Min dispersion time).

If 60° is too much for the product we are handling, there are 2 solutions:

1. Dispersion tank must be equipped with a cooling jacket

2. Product viscosity can be reduced. Temperature will not increase but the dispersion time will and
dispersion quality will not be very good.

VACUUM DISPERSERS – WHY?

If product is thick, it will tend to trap air within itself during dispersion process. In this way, air bubbles
will be trapped inside the product.
Furthermore the vacuum will remove all air which is already contained within the solid parts. Upon air
removal, the liquid components will take its place thus making the shearing process easier and faster.
Vacuum dispersers are rather expensive but for high viscosity products this is the only choice.
Offset inks do not require vacuum dispersers because the product will still go through 3 rolls mills
which will eliminate all air bubbles anyway.
For the production of putty, for example, vacuum dispersers are the only choice.

MOBILE TANKS USED FOR DISPERSION – POINTS TO CONSIDER:

1. We must avoid the tank to spin together with the product (especially if the product is viscous)!
Vessels on wheels must be avoided

2. Vessels must be secured using CHAINS or CLAMPS

If tank is not secured, tank might move and hit the impeller and this can be particularly dangerous if we
are handling solvent based products.

When taking the measurement of a tank, the tank HEIGHT is therefore very important, in order to size
up the disperser and determine the height of the impeller within the tank itself.

Capture the total height is

not enough! We need to
know the height of the legs
too, in order to determine
the height of the impeller
from the bottom of the tank.

This measure is important!

 MIXING
Meaning: It is called MIXING when ALL component are liquids

Liquid component Liquid component

MIXING

Products to be mixed can be high or low viscosity.

A mixture of solvent/s and resin/s is normally referred to as a “CLEAR”

During the mixing process, the Unlike the process of dispersion,

flow of the liquids must follow during mixing it is not possible
the drawing on the left hand side (or necessary) to achieve the
“doughnut effect” which is
instead required during dispersion
stage.

Instead when products are mixed, the more “agitated” they are, the better will be the mixing process.
That is the reason why there are few solutions to generate a better turbulence. Following are the most
followed solutions:

4 x buffer plates
positioned at 90°
with one another

Shaft is slanted
to increase
turbulence.
Unsuitable Shaft is installed
with long and off-centre
heavy shafts
 IEC EQUIPMENT

HIGH SPEED DISPERSERS (H.S.D.) & MIXERS

FLOOR MOUNTED (IEC catalogue – Page 1 & 8)

IEC STRONG POINTS – MAJOR DIFFERENCES/COST FACTORS:

Transmission by PULLEYS and BELTS

a) PULLEYS and BELTS: high quality

components ONLY:
 PULLEYS: Adjustable type (Tapper
Lock) unlike China Made ones that are
hammered into place.
 Brand: UNIDRIVE – Germany - or
 FENNAR – France
 BELTS: Anti static. Replacement time:
3 years (high usage) – 5 years (max,
with moderate usage).
 Brand: UNIDRIVE – Germany

b) BEARINGS:
Brand: SKF or FAG ONLY.
Sealed & greased for life. China Made
sometimes are open and require regular
greasing & maintenance.

c) SHAFT: FORGED S/S ONLY

(hammering process increases strength and
density of material).
STEEL GRADE: AISI 304
China Made are generally made in Mild
Steel; they may look similar but they are
far weaker. Furthermore, China Made are
normally cast, not forged and with smaller
diameters. IEC diameter is calculated
according to industry standards.

d) ELECTRIC MOTOR:
Brand: MARELLI – Italy - or
ABB - France
All motors used by IEC are equipped with PTC (Platinum Temperature Coefficient), to stop motor
in case of over-heating. Clients in Asia generally refuse to connect the wires to Control Panel in
order to cut costs. In case of burned motor, if client did not connect the wires, warranty will not be
effective.
d) HYDRAULIC MOTOR: Oil filters (2)
Brand: ABB - France
Hydraulic motor is used to lift the disperser's
head up and down and to take the impeller out
of the mixing tank.
Hydraulic motors used by IEC are all fitted with
2 filters: 1 for the oil, 1 for the oil top up. China
made machines never include filters, thus
increasing the chances of spoiling the hydraulic
system.
Pressure release valve is included to avoid
pressure build up. This is also generally not
included in China Made models.
A 3-way valve diverts the oil to the shaft
chamber to lift the disperser. Valve is manually
operated.
A push button (which must be kept pressed) on
the motor. Head will not lift if the manual lever
is not in the correct position.

Manual lever to open oil flow Tube for slow release of oil into oil tank

Lowering of the disperser by slow release of the oil inside the shaft chamber back into the oil tank.
Speed is fixed and mechanically controlled by the size of the tube releasing the oil back into the oil
tank. Disperser lowering speed can not be adjusted; speed is fixed to follow basic safety standards.
 MOTOR ON TOP VS MOTOR BELOW

Air flow from top to

When the motor is placed on top, the air flow will
bottom
move from the top to the bottom (downward
movement). This is very good whenever we handle
solvent based products; in this case, in fact, solvent
vapours (which accumulate near the ground) will not be
sucked into the motor, and get in contact with any
electrical part, which might ignite the vapours.
Furthermore, the motor is comfortably sitting on top of
the disperser's arm, thus minimizing any problem
related to the stability of the motor itself.
The main problem is related to the additional roof space
required with this type of equipment when lifting the
equipment to take the impeller out of the tank. Some
customers do not have sufficient ceiling height to fit top
mounted type dispersers.

W
h
e
n

p
l
a
c
e
d

b
e
l
o
w, the motor will naturally suck the air from the
bottom, thus increasing the possibility of solvent
vapours being sucked inside. This increases the
possibility of potential explosion and fires.
Furthermore, the motor needs to be secured extremely
well as it is not sitting on anything but it is only
hanging from the structure of the disperser.
Although technically inferior to the top mounted
models, due to limitation in ceiling height, the below
mounted option is often preferred.
 Air flow from bottom to top

With the motor placed directly on top of the shaft, there

is no need for belts & pulleys; the transmission is direct,
from motor to shaft.
This system, though, presents the same problem as the
below mounted models: the solvent vapours coming from
the tank are directly under the motor and this, as
previously mentioned, is a potential danger.
The weight of the motor must be properly balanced with
the placing of a suitable counter weight.

Counter weight here

to balance motor weight

HIGH SPEED DISPERSERS (H.S.D.)

PLATFORM MOUNTED PM SERIES (IEC catalogue – Page 3)

These models can either fully or

partially move up & down

TANK MOUNTED TM SERIES (IEC catalogue – Page 4)

These dispersers are fixed, they can not be lifted

MULTI-SHAFTS DISPERSERS (IEC catalogue – Page 5)

MULTI-SHAFTS DISPERSERS are used for higher
viscosity products
 HIGH SPEED DISPERSERS ACCESSORIES (IEC catalogue – Page 2)

All these impellers are classified as “HIGH SHEARING”

All of them can perform; most of the time choice is based on client's personal preference, rather than
real technical advantages.

This is the most common

Normally called “cowls impeller” or
“saw tooth impeller” This design is possibly the
best in terms of flow but
this is based on IEC
internal testing only
 EXAMPLE OF MIXERS
Bearing house & dry-well

Mixers can be of different

type. With different motor
configuration and impellers
designs.
“Cheap” versions do not have
“Bearing Housing” and “Dry-
Well”, which are found in the
more expensive models.
Cheap models

Advantages:
1) Lower cost
2) Easy to dismantle
3) Ideal for low head-room
locations

Disadvantages:
1) Shaft tends to wobble due
to the rigid steel coupling (*)
connecting the shaft directly
to the gearbox
2) Early gearbox failure
3) Oil will eventually leak
from the gearbox due to
normal wear and tear and drip
into the product. If product is
cheap, no big deal, but if
contaminated product is
expensive, then the
contamination can result in
high monetary loss for the
company

(*) Models c/w Bearing Housing & Dry-Well” are supplied with a FLEXIBLE COUPLING, to
connect the shaft to the gear box. This putts less stress to the gearbox as it is the bearing housing which
will prevent the shaft from wobbling.
 Gear box

Flexible coupling Potential oil leaks from the gear

box will not reach the product.
The dry well will divert the oil
flow out of the bearing
housing.
Bearing Housing Dry-Well
Shaft
Bearings

MIXERS ACCESSORIES (IEC catalogue – Page 10)

Impeller on the left: Conventional type, suitable for a wide range of viscosity – Up to 5,000 cP

Impeller on the right: suitable for viscous products – Up to 15,000 cP

High performance and high efficiency impeller

Suitable for low viscosity products up to 1,500 cP only.

Recommended
for medium
viscosity
applications
Up to 10,000 cP
 MOTORS

Type of motors 50 Hz 60 Hz
Nominal Speed Nominal Speed
2- pole 3,000 RPM 3,600 RPM
4- pole 1,500 RPM 1,800 RPM
6- pole 1,000 RPM 1,200 RPM
8- pole 750 RPM 900 RPM

Hz are determined by national electricity company (e.g.: TNB for Malaysia)

Example

TNB 50 Hz Motor works @ fixed speed

400 Hz
Inverter Box
TNB Motor speed can vary (within limits)
Most motors are designed to go up to
60/75 Hz only even if inverters can go to
0 Hz 400 Hz (unless motor is special made)

120

100

80

60

40

20

0
5 Hz-300 RPM 10 Hz-600 RPM 20 Hz-1200 RPM 30 Hz-1800 RPM 40 Hz-2400 RPM 50 Hz-3000 RPM

Y = kW
If our motor is designed for 3,000 RPM @ 50 Hz, using an inverter we can adjust the Hz and control the
RPM.
Example: 50 Hz = 3,000 RPM → 40 Hz = 2,400 RPM (40 : 50 x 3,000 = 2,400)
Motor power is still not affected if we reduce from 50 to 40 Hz; we still can get its full 100 kW.
If we continue to reduce the Hz, though, the power output will progressively decrease until we reach a
point when the motor power will not be sufficient to guarantee enough torque.
To conclude, we can adjust the speed of the motor by using an inverter, but the variation can not be too
drastic
A workable range would be between 30 to 60 Hz, which would translate, in our example, into a speed
variation between 1,800 RPM to 3,600 RPM.

If we require a 100 kW motor but we need to use it at lower a speed (e.g.: +/- 500 RPM) we have 2
choices:

1) Use a 8 poles motor, which run @ lower RPM. Cons: rather expensive, especially if EX, and
particularly bulky.
2) Use a gear box of appropriate ratio in order to reduce the motor RPM without compromising on the
power output. Then an inverter can be added to further adjust the speed to the required level.

Example: 100 kW Motor - 3,000 RPM @ 50 Hz

Required working speed: between 500 to 600 RPM
3,000 : 600 = 5 → Required gear box ratio = 1 : 5
With this gear box, RPM decrease to 600, still maintaining 100 kW power @ 50 Hz
Then using an inverter, we can still adjust the speed between the required 500 to 600 RPM without
compromising on power and torque.

SIZING OF THE MOTORS - RULE OF THUMB

Sizing of the motors for the MIXING OF PAINT (water or solvent based):

For every 500 Lt of product to be mixed → 7.5 kW

The sizing of the motors for the DISPERSION OF SOLVENT BASED PAINT:

For every 500 Lt of product to be dispersed → 11 kW

The sizing of the motors for the DISPERSION OF WATER BASED PAINT:

For every 500 Lt of product to be dispersed → 15 kW

For the mixing of THINNERS or water-like products:

For every 500 Lt of product to be mixed → 2 kW

1 Hp = 0.746 kW
 NOTES ON HAZARDOUS LOCATION & EXPLOSION PROOF (EX) MOTORS

In electrical engineering, a hazardous location is defined as a place where concentrations of

flammable gases, vapours, or dusts occur. Electrical equipment that must be installed in such
locations is designed and tested to ensure it does not initiate an explosion, due to arcing contacts or
high surface temperature of equipment.
For example a household light switch may emit a small, harmless visible spark when switching; in an
ordinary atmosphere this arc is of no concern, but if a flammable vapour is present, the arc might start
an explosion. Electrical equipment intended for use in a chemical factory is designed either to contain
any explosion within the device, or is designed not to produce sparks with sufficient energy to
trigger an explosion.
Many strategies exist for safety in electrical installations. The simplest strategy is to minimize the
amount of electrical equipment installed in a hazardous area, either by keeping the equipment out of the
area altogether or by making the area less hazardous by process improvements or ventilation with clean
air.
Intrinsic safety and non-incendiary equipment and wiring methods are practices where apparatus is
designed with low power levels and low stored energy, so that an arc produced during normal
functioning of the equipment or as the result of equipment failure has insufficient energy to initiate
ignition of explosive mixture.
Equipment enclosures can be pressurized with clean air or inert gas and designed with various
controls to remove power or provide notification in case of supply or pressure loss of such gases.
Arc-producing elements of the equipment can also be isolated from the surrounding atmosphere by
encapsulation, immersion in oil, sand, etc.
Heat producing elements such as motor winding, electrical heaters, including heat tracing and lighting
fixtures are often designed to limit their maximum temperature below the auto ignition temperature of
the material involved.
Both external and internal temperatures are taken into consideration.
As in most fields of electrical installation, different countries have approached the standardization and
testing of equipment for hazardous areas in different ways. As world trade becomes more important in
distribution of electrical products, international standards are slowly converging so that a wider range
of acceptable techniques can be approved by national regulatory agencies.
Area classification is required by governmental bodies, for example the U.S. Occupational Safety and
Health Administration and compliance is enforced.
Documentation requirements are varied. Often an area classification plan-view is provided to identify
equipment ratings and installation techniques to be used for each classified plant area. The plan may
contain the list of chemicals with their group and temperature rating, and elevation details shaded to
indicate Class, Division (Zone) and group combination.
The area classification process would require the participation of operations, maintenance, safety,
electrical and instrumentation professionals, the use of process diagrams and material flows, MSDS and
any pertinent documents, information and knowledge to determine the hazards and their extent and the
countermeasures to be employed.
Area classification documentations are reviewed and updated to reflect process changes.
 DIVISIONS OR ZONES (GASES)

In an industrial plant handling of large quantities of flammable liquids and gases creates a risk of leaks.
In some cases the gas, ignitable vapour or dust is present all the time or for long periods.
Other areas would have a dangerous concentration of flammable substances only during process upsets,
equipment deterioration between maintenance periods, or during an incident.
Refineries and chemical plants are then divided into areas of risk of release of gas, vapour or dust
known as divisions or zones.
The process of determining the type and size of these hazardous areas is called area classification.

SAFE AREA

An area such as a residence or office would be classed as safe area, where the only risk of a release of
explosive or flammable gas would be such things as the propellant in an aerosol spray.
The only explosive or flammable liquid would be paint and brush cleaner. These are classed as very low
risk of causing an explosion and are more of a fire risk (although gas explosions in residential buildings
do occur).
Safe area on chemical and other plant are present where the hazardous gas is diluted to a
concentration below 25% of its lower flammability limit (or lower explosive limit (LEL)).

DIVISION 2 OR ZONE 2 AREA

This is a step up from the safe area. In this zone the gas, vapour or mist would only be present under
abnormal conditions (most often leaks under abnormal conditions).
As a general guide, unwanted substances should only be present under 10 hours/year or 0–0.1% of
the time

DIVISION 1 OR ZONE 1 AREA

Gas, vapour or mist will be present or expected to be present for long periods of time under normal
running.
As a guide this can be defined as 10–1000 hours/year or 0.1–10% of the time.

ZONE 0 AREA

Gas or vapour is present all of the time. An example of this would be the vapour space above the liquid
in the top of a tank or drum. The ANSI/NEC classification method considers this environment a
Division 1 area.
As a guide this can be defined as over 1000 hours/year or >10% of the time.
 EQUIPMENT CLASSIFICATION

Ex Notified Body Name Description Location Use

Code
Flame-proof d Will have a Equipment is robust, can stand Zone 1 if gas Motors, lighting,
CENELEC Hexagon an explosion from within, group & junction boxes
followed by without transmitting the flame temperature
apparatus group & to the outside. Equipment has class is correct
Safety Category flame-proof gaps
Increased e Will have a Equipment is very robust and Motors, lighting,
Safety CENELEC Hexagon components are made to a junction boxes
High quality. Casing is c/w seals
followed by to prevent vapours from
apparatus group & entering. Should vapours enter
Safety Category anyway (faulty seal, casing not
properly closed), casing will not
withstand the explosion and fire
will propagate outside too.
Oil Filled o Will have a Equipment components are Zone 2 or 1, Heavy current
CENELEC Hexagon completely covered with a layer depending on equipment
of oil edition of
followed by standard used
apparatus group &
Safety Category
Pressurised p Will have a Equipment is pressurised with a Zone 1 Analysers,
or purged CENELEC Hexagon positive pressure; gas cannot get motors, control
in for air is coming out or boxes,
followed by equipment is purged with a computers
apparatus group & diluting gas such as air. If air is
Safety Category used, it is ducted in from
outside the hazardous area.
Intrinsically i Will have a Any arcs or sparks in this 'ia': Zone 0 & 1 Instrumentation
safe CENELEC Hexagon equipment has insufficient measurement
energy (heat) to ignite a vapour. 'ib': Zone 1 and control
followed by Equipment can be installed in
apparatus group & ANY housing provided to IP54.
Safety Category A 'Zener Barrier' or 'opto isol' or
'galvanic' unit may be used to
assist with certification.

MULTIPLE PROTECTIONS

Many items of EEx rated equipment will employ more than one method of protection in different
components of the apparatus. These would be then labelled with each of the individual methods. For
example a socket outlet labelled “EEx'de'” might have a case made to EEx 'e' and switches made to EEx
'd'.

Same applies to motors, where, for example the control panel is EEx'e', while the body of the motor is
rated EEx'd'

This apparatus will then be labelled: EExde

WET MEDIA GRINDING

One of the most critical operation in the manufacturing process of paint and ink is the grinding process.
This is where the solid pigments are broken down into their finest particle size.
Wet media grinding is the process where a “media”, made by tiny “beads”, is agitated at a very high
speed within a “wet” environment (paint or ink, for example).
The purpose of this media is to progressively reduce the size of the other solid particles which are
contained in the product we need to refine.
The size of the solid particles contained in our product (example: paint) will be reduced by collision
with the “beads”. Just imagine an object subjected to the force generated by a sandstorm; the object’s
mass will progressively diminish by erosion and collision with the sand.
In order to maximise the grinding time, though, the size as well as the material of the beads must be
balanced with the size of the particles we need to grind. As a general rule, if the product contains large
particles, the beads must be bigger too. In any case a proper balance must be achieved.

EXAMPLES

→ Beads → Product's particle

Both beads and particles are of similar size

Grinding quality = GOOD

Beads are smaller than the particles

Grinding quality = POOR

Beads are FAR smaller than the particles

Grinding quality = VERY POOR

Beads are bigger than the particles

Grinding quality = POOR

Beads are FAR bigger than the particles

Grinding quality = VERY POOR

Beads and particles are both very small

Grinding quality = GOOD

Even the product's viscosity plays an important role; a high viscosity product will require bigger and
heavier beads, otherwise, even if the product is agitated, they will just remain in suspension without
actually moving within the product itself. Once again, a proper balance between viscosity of the
product, type and size of beads must be achieved.

The optimal viscosity range for grinding purposes is 600 to 1,500 cP

IEC mills can work with a product viscosity ranging from 300 to 5,000 cP.

It is also possible to handle higher viscosity products but the efficiency and performance will be
affected.

Furthermore the energy of the agitation process must be adequate.

In any case, the particles' size of the dispersed (or Pre-Mixed) product can't be too big, for 2 main reasons:

1) If they still are, dispersion was not good in the first place. Dispersion stage is very important as solid particles
should be already reduced to a suitable working size in order to be further reduced during grinding process.
2) Grinding would take a much longer time, which is uneconomical.

BEADS TYPE
Price indication
 Glass Commonly used. Very cheap – Low performance +/- 5 USD p/Kg

 Zirconium Silicate Also referred to as “Ceramic Beads” due to their look, +/- 35 USD p/Kg
 Zirconium Oxide Zirconium beads are more expensive but offer a much +/- 140 USD p/Kg
better performance, with Oxide beads being the best
in terms of strength and weight. Zirconium Oxide
beads can be also extremely fine and they are therefore
very suitable to achieve the highest possible degree of
particles' size reduction.

 Rare earth Earth like brown material +/- 70 USD p/Kg

 Steel +/- 5 USD p/Kg

BEADS TYPE DETERMINATION – RULE OF THUMB

Finished product's max allowed particles' size: Recommended beads type Size

- 30 to 20 microns Glass 1.8 or 2.5

- 30 to 20 microns but product is thicker (eg: marine paint) Zirconium Silicate 1.8 or 2.5
Heavier than glass but not too expensive

- 20 to 10 microns Glass 1.2 or 1.8

- 20 to 10 microns but product is thicker Zirconium Silicate 1.2 or 1.8

- 10 to 5 microns Zirconium Silicate recommended 0.8 or 1.2

- 10 to 5 microns but product is thicker Zirconium Oxide 0.8 or 1.2

- “Off Gauge” (1 – 2 microns) Zirconium Oxide ONLY 0.4 or 0.8

It is generally rather difficult to determine the performance of any mill, without precise data on the
following items:

 Particles' size of the product

 Viscosity of the product
 Type of selected beads
 Size of selected beads

In order to achieve the best possible performance, the customer should be willing to work hand in hand
with the equipment manufacturer and eventually must be willing to adjust formulations, viscosity as
well as beads type and size.

To answer questions on equipment's performance without the above information would be almost
impossible as well as dangerous.

To summarize, when we are dealing with grinding process there are several factor we need to consider:

1) The energy of grinding

2) The density of the media (beads)
3) That small beads break the product's particles better than large beads of the same weight, provided the
product's particles size is compatible with the beads' size.
4) For large product's particles we need to use large beads
5) Products with higher viscosity require bigger and heavier beads
 HORIZONTAL MILL

A gap is left to let the product flow out of the grinding

chamber. Gap must be 1/3 of the beads size.
E.g.: Bead = 1.2 mm → Gap = 0.4 mm

Check valve (non-return valve)

Product in Product out
Filter
Grinding disks
Spacers
Fan blades

Bearings

Mechanical seals

Belt

Chilled H2O out Chilled H2O in

Cooling jacket
Plug for draining
Spiral for H2O
Grinding chamber
Motor

Product
Product's grinding can be performed in one single pass (product in → grinding → product out) or with
multiple passes. Product which has already been ground once can be put back into the original vessel in
order to go through the grinding process one or more times.

This is called CIRCULATION GRINDING

From mill
Purpose of the agitator is to ensure that:

1) All product goes through the mill - and

2) No sedimentation within the vessel

To mill

Flow rate is kept purposely high, as we need to achieve multiple passes; therefore the higher the flow
rate the faster this process will be.

NOTE: IEC mills can do this, unlike other mills,thanks to their bigger outlet.

PASSING GRINDING, instead, allow for the product to go through the mill one time only. From the
first vessel, the ground product is transferred to a receiving vessel. In this case either one single pass is
enough to achieve the desired result, or more mills are placed in-line, with the product travelling from
one mill to the next. In this case the mills are equipped with progressively smaller beads, in order to also
progressively reduce the particles' size of the product until the desired result is achieved.

In this case the purpose of the agitator is

only to ensure that no sedimentation
occurs inside the vessel

In this case flow rate must be

kept slow, 'cause product will
go through the mill only one
time and the maximum result
must be achieved within one
single pass.

To mill
 EXAMPLE OF PASSING GRINDING

Product = 300 micron

2mm 1 – 1.2mm 0.4 – 0.6mm

beads beads beads

Final product = less then 1 micron

Internal chamber is made of high hardness material

Outside of the grinding chamber there is a “COOLING

JACKET” where CHILLED WATER is pumped in.

Optimal temperature of the chilled water: 7°C.

Chilled water will prevent the temperature of the ground

product from rising.

HM Series (IEC catalogue – Page 15) vs. HE Series (IEC catalogue – Page 16) - Major differences:

1) Motor
2) Transmission belts
3) Seals
4) Control panel
5) Safety features
6) Grinding chamber material

SIZING OF THE MILLS – RULE OF THUMB

1 : 20 of the batch size in litres

Example: Average batch size: 200 Lt → Recommended mill size: 10 Lt

A 10 Lt mill can also grind bigger batches but it will take longer time. If the batch is too big, process
would become too slow and anti-economical.

On the other hand, if the batch is too small compared to the mill's size, the product will be “lost” inside
the mill's chamber resulting in yield loss.
 PARTICLES' SIZE OF MAJOR FINISHED PRODUCTS

SOLVENT BASED

Automotive coatings: Top coat: Max 1 micron

Primer: < 10 micron

Ink: 1 to 6 microns

Coil coatings: Top coat: 6 micron

Primer: < 15 micron

Enamel: 20 microns
40 microns

WATER BASED

Architectural paint: 30 to 50 microns (average 40 microns)

IEC vs BUHLER OR NETZSCH

In many occasion we'll have to compare IEC with its main European competitors, Buhler & Netsch.

Both have developed a different type of mills, called “Superflow” (Buhler) and “LMZ” (Netzsch)

It is worth highlighting that the quality of the final product, done with Buhler, Netzsch or IEC mills, is
absolutely identical, provided that in all machines the same type of beads are used and the comparison
is made using the same batch of product.

Productivity, though, is 20% higher with Buhler “Superflow” or Netzsch “LMZ” compared to IEC HM
or HE mills.

For productivity we intend the amount of time and the amount of grinding passes required in order to
achieve the same result.

On the other hand, IEC mills can handle products with a viscosity up to 5,000 cP, even though IEC mills
work very well up to 3,000 cP only, after which productivity starts to decline.

Buhler 'Superflow” can not handle products with a viscosity higher than 2,000 cP.

At the end of the day, what can be proposed to the client who is intentioned to buy Buhler or Netzsch, is
to purchase 2 or 3 IEC mills, put them in the condition to work in-line (passing grinding, see above) and
with progressively smaller, good quality beads.

Final result will be the same as with Buhler “Superflow” but with an even smaller investment.

Plus, the customer will have 3 mills available rather than 1, which is always a better option for
maintenance purposes and in order to avoid downtime due to sudden machine breakdowns.
 BASKET MILLS

Basket mills are very simple and straight-forward type of

machines.

Premix is delivered into a portable tank which is positioned

under the basket mill. The basket mill is lowered into the tank
and the process can start straight away.

BASKET MILL vs. HORIZONTAL MILL

PROs:

1. Easy to wash
2. Easy to change colour
3. Low maintenance (no mechanical seals), no leaking
4. Simple and intuitive
5. Large cooling area (vessel is jacketed. Grinding bowl can be jacketed too – Vibromac design)
6. Cheaper

CONs:

1. Can't change batch size

2. Can't be sure all product has gone through the grinding process
3. Particles' size can't go lower than 3 microns
4. Not recommended for high end products such as automotive coatings

IEC promotes this solution, c/w multiple openings. This design can
handle more viscous products

Below the grinding bowl an impeller pushes the product up and back into
the grinding bowl.

The “pins” options, compared to the “disks” options, offers better

performance.

For more details on grinding bowls option, pls refer to IEC catalogue – Page 18