LAB MANUAL FLUID PARTICLE AND MECHANICS LAB (Fluid Particle Operations) B. Tech. III Semester (CBCS Scheme) Department of Chemical Engineering NATIONAL INSTITUTE OF TECHNOLOGY RAIPURccomaenictnesesiensnincstsiciiteseaieantte FLUID PARTICLE OPERATION (FPO) B MANUAL LIST OF EXPERIMENTS JBJECTIVES 1 2 4. To determine the Rittinger's & Kick’s constant in respect of the laboratory Jaw Crusher To determine Rittinger's & Kick’s constant in respect of the laboratory Roll crusher To determine arithmetic mean, surface mean, volumetric mean diameter, and specific area of ~ given sample. To find out the effectiveness of the screen at cut size. To find out the cross sectional area of the thickener required to concentrate slurry of known concentration, ¢ To study the settling velocity of slurries with different concentration of chalk dust (-28-35 mesh). , To determine the efficiency of a ball mill for grinding a material of known Wi. to find the critical speed of ball mill.xperiment No-O1 Objective: To determine the Rittinger’s & Kick's constant in respect of'the laboratory Jaw Crusher Requirements: Feed (approx | kg), standard séreens, weight box Theory: Jaw crushers do the heavy work of breaking large pieces of solid material into small lumps. IL is widely used in industry for coarse reduction of large quantities of solids. They operate hy compression and can break large lumps of very hard materials, as in the primary and secondary reduction of rocks and ores. They are very common in industry and have a wide application. In a Jaw Crusher feed of known size distribution is admitted between the two jaws, set to form a V open at the top. One jaw is fixed and the other one is movable (swinging jaw). The movable jaw makes an angle of 20° — 30° with the fixed jaw. It is driven by an eccentric so that a great compressive force is applied to lumps of solids caught between the jaws. Large lumps caught between the upper parts of the jaw are broken, drop into narrower space below and are re-crushed the next time the jaws close. Afier sufficient size reduction, they drop out from the bottom of the machine. A crusher cannot be expected to perform satisfactorily unless. A) The product is removed as soon as they are of desirable size. B) Unbreakable material is kept out of the machine. C) In case of heat sensitive products. the heat generated is removed on regular basis. Jaw crushers are of two types: Dodge Jaw Crusher and Blake Jaw Crusher. Prose iain Figure (a) Figure (b) In Dodge Jaw Crusher [figure (2), the swinging jaw is pivoted at the bottom of the V, due which ihere is maximum chances of chocking of particles. Whereas, in Blake Jaw Crusher [figure (b)] movable jaw is pivoted at the top of the V shape. Therefore, the greatest amount of motion is at the bottom of V, which means that there isa litle tendeney for a crusher of this kind to choke, though this may permit some uncrushed rock to pass through. Capacity of Blake crusher is more than Dodge crusher. olKICK’S LAW 1 states that the work required for crushing a given quantity of material is consiay , reduction ratio (that is the ratio of average size of the feed to the average size of "N irrespective of the original size, Mathematically, this law can be expressed as: Ow \ Pp arn Re Inge Where, ‘m = feed rote in tons/ he of material (capacity) P= Power required for erushing in kilowatts = RR (reduction ratio) Ky. = Kick’s constant, which depends on the type of machine and the material to be crushed. RR for coarse crushers is 3 to 7, whereas for fine grinders RR is as high as 100. Kick’s law cay applied without much serious error to coarse crushing where the feed size is quite large and the reduction ratio is quite low. Volume surface mean dia(D,) Experimental Procedure * Prepare a suitable feedstock of a solid material (maximum size 50 mm). You can take | to.2 Kg bricks as feed material. © Measure its size distribution. © Check all the connections. © Start the machine with no load condition and record the time taken for 10-20 Pulse energy meter for calculating power consumed by the machine. * Start feeding the solid material at a constant rate (tons/h). © Again record the time taken for 10 or 20 Pulses of energy meter for calculating power Collect the product and perform the screen analysis. © Repeat the experiment for different opening of jaws,no Dee + The crushed material is transferred to a sieve stack and mechanically agitated for 10-15 minutes. * The quantity of sample retained on each ‘sieve is weighed and tabulated as shown in the lable. The screen analysis data is used fo determine the volume surface mean diameter of the products. Observation: * Quantity of feed sample = + Feed size, Du * Time taken for | complete revolution (no load) Time taken for | complete revolution (on load) = .....hr * Total time the mill is put to operation + Energy meter constants for Jaw Crusher (To be observed from the Experimental Setup) = Tabulation for size analysis of Feed and Product S. ]MeshNo. | Opening | Average Particle dia | Mass Mass [X/Dp, | No. diameter | Dp; (mm) retained | fraction | D, (mm) (gms) | FORMULAE : Energy required for crushing E=[n)-n] + [m x EMC] kW hr/Tones Where ¢ ‘ny is the no, of revolutions of the energy meter disc during the mill operation under on load condition. + ‘n’ is the no, of revolution of the energy meter disc during the mill operation under no load condition, + ‘m’ ismass of sample in tones. * EMC is Energy meter constant Volume surface mean diameter of the feed and product can be calculated by using the form, Volume surface mean dia(D,) = 3) Lil 03tts Kick's constant (Ky) PL Rittinger’s constant (K,) “bso al RESULT: The crushing law constants are determined as under: + Rittinger’s Constant + Kick’s Constant =re Ex No-02 Objective : To determine Rittinger's & Kick’s constant in respect of the laboratory Roll crusher Requirements: Roll crusher setup, Feed sample, Sieves, Sieves Shaker. Stop - watch and the weighing balance. Theory: Roll crushers are classified as secondary crushers and used in the industry to reduce the particle size of materials to fine particles. It consists of two cylindrical rolls revolving toward each other. They have relatively narrow faces and are larger in diameter. The clearance between them can be adjusted according to the size of feed and the required size of the product. Rock fed from the above is nipped between the rolls, crushed, and discharged at the bottom. The forces of compression and friction between the rolls and particles are responsible for size reduction. provided the combined forces exceed the compressive strength of the particle Experimental Procedure: * Adjust the gap between rolls to produce the required product size. + Prepare a suitable feedstock of a solid material, + Measure its size distribution * Start the machine with no load condition and record the time taken for 10-20 pulse of enerzy meter for calculating power consumed by the empty machine. * Start feeding the solid material at a constant rate (m, ton/h) * Again, record the time taken for 10-20 pulses of energy meter for calculating power consumed by machine at loaded condition: Observation: © Quantity of feed sample = .......Tones + Feed size, Di mm © Time taken for 1 complete revolution (no load} © Time taken for | complete revolution (on load) ‘© Total time the mill is put to operation = ......hr © Energy meter constants for Roll Crusher (To be observed from the Experimental Setup) 3200 Pulses! br chr ‘Tabulation for size analysis of Feed and Product ST Mesh] Opening diameter | Average Particle [ Mass retained [ Mass 'No,_| No. Dp. (mm) dia Dy (mm) | (gms) fraction = | osov Formulae for Energy Calculation: # Energy required for crushing E=[n-n] « [mx EMC] kW hr/Tones, i Where ; * “ni is the no. of revolutions of the energy meter dise during the mill operation under on condition, * ‘nis the no. of revolution of the energy meter disc during the mill operation under no hoa condition, + ‘m’ is mass of sample in tones, EMC is Energy meter constant Volume surface mean diameter of the feed and product can be calculated by using the formulae Volume surtace mean dia(D,) = Kiek’s Constant (K,) ¥ Kl Dsa mk" \ DSB Rittinger’s constant (K,) RESULT: The crushing law constants are determined as under: # Rilttinger’s Constant = + Kick’s Constant | |n diameter, and pjective: To determine arithmetic mean, surface, mean, volumetric m peste area of given sample, Apparatus Required: Standard screens, weight box, weighing balance, e theory: The fine particles are generally specified accordingly to their screen analysis. A screen ed analysis of a material is carried out by using testing sieves. A set of standard screens are arrang serially in a stack in such a way that the coarsest and finest of the screens is at the top and bottom respectively. An analysis is carried out by placing the sample on the top screen and shaking in a {| definite manner, either manually or mechanically, for a definite period of time. The material retained on each screen is to be removed and weighed. The amount of material retained on each screen is expressed as the weight fraction of the total sample. Procedure: Standard screens are arranged as per their mesh no. in such a way that coarsest screen is atthe top and finest screen at the bottom. F * A weighed amount of material is placed on the top screen and the screen assembly is £ shaken manually for a sufficient period of time (approx 20 min). © After that the fines are removed from the bottom pan and the pan is also removed from the assembly. + The shaking is resumed to see whether any fines are coming out of last screen. When no material appears in the bottom, it indicates that screening is over, ‘© The screen is disassembled and individual fractions are weighed. Diameter of opening of screen is taken from the table. * Mass fractions are calculated and graph is plotted between: i, Average diameter of particles and mass fraction ii, Average diameter of particles and cumulative mass fractions Observation and Tabulation-Differential analysis Mesh | Screen Mass Mass | Average no, | opening | retained | fractio | particle dia(D,) | onscreen | nx, | dia, it @ it oFFormulae a 1. Arithmetic mean diameter Where. si mass fraction of increment and Dy; ~ Average diameter of particle Il, Volume surface mean diameter IIL Volume mean diameter \ IV. Specific surface area Result/ Calculation © Arithmetic mean diameter = Volume surface mean diameter Volume mean diameter = ‘© Specific surface are: Precautions +The individual sereen should be cleaned with brush to remove the trapped particles in t sereen. + Screen should be arranged with the screen having larger aperture on the top and smal aperture at the bottom, + The loss of particles should be least to the possible extent while shaking the screens4 gpject: To find out the effectiveness of the sereen at eu.size Requirements: Standard Sereens, sample, weight box. Theory: The effectiveness of screen is a measure of the success of the sercen in separating material { Aand B. If the screen functions perfectly, all the material A would be in overflow and material 1 would be in underflow, A common measure of screen effectiveness is the ratio of the oversize material A actually in the overflow to the amount of material A entering the feed. ‘These quantities are Dxy and fx respectively. Thus, E4= Dxp/ Fxe. where, Eq is the screen effectiveness based on the oversize. Similarly, an effectiveness based on the undersize material is given by- E9= [B(1-x5)] / [F(- Overall efficiency SY (E) = [B Dxo (1-x0)] / [F°xe (1-x1)] Now, DIF = (xr-xa) /(0-X8) and B/F = (Xp-Xr) / (Xo-Xe) .f Hence, E = [(xp-x5)(Xp-%F) Xo(1-X0)] / [(0-¥0)"(1-Xr) 84] Where, mass flow rate of feed. D = mass flow rate of overflow. mass flow rate of underflow. mass fraction of material A in feed Xp= mass fraction of material A in overflow. xg = mass fraction of material A in underflow, (J-xp) = mass fraction of material B in feed. (1-xp) = mass fraction of material B in overflow. (1-x%g) = mass fraction of material B in underflow. OBSERVATIONS: Sample taken = Sand Weight of sample =1Kg. Cut size for (effectiveness) = 22 mesh (Say)S.No. | Mesh T+ ame Melee ee! Mass Fraction Retained (mm) Feed | Overflow | Underflow (gm) F D B 7 | z 3 4 3 6 7 = i Graph: It is plotted between diameter of screen opening and cumulative mass fraction Calculation: xr, xp and xgate taken from the graph at cut diameter and effectiveness is calcula! Result:i i i | 1 | | } | Experiment no. 05 Object: To find out the cross sectional area of the,thickener required to concentrate slurry of known concentration. , Data known: Feed sample = 1000 kg/hr; Initial concentration (C Final concentration (C,) =100gm/It. Requirements: One 500 mi measuring cylinder, CaCOs powder (-28'36 mesh), weight box. stopwatch: Theory: Sedimentation is cartied out continuously in equipment called thickeners. A thickener consists of cylindrical tank with opening for a slurry feed and product draw off. Dilute slurry is introduced into the tank and afier a certain period of time the liquid is decanted while the sludge is removed from the bottom In the case of a continuous thickener, the area required is determined by that concentration layer for which the solids handling capacity, expressed as weight of solids per (unit area) (unit time). is minimum, The material balance for a thickener, operating with a slurry feed of concentration Co and underflow concentration C, and containing no solids in the overflow, based on a slurry feed rate of F Volumes per unit time as follows. ‘Volume of solids entering thickener per unit time =FC, Since no solids leave in the overflow, if L represents the volume of underflow per unit time, FC)=LCy xO) [Mass Balance} F(1-C,) = LO-C,) + V 2) [Liquid Balance} So, FC/Cy=L substituting in (2) Hence, F(I-Cy)= {Fle (I-C,) Cy} + V OR FCC) =VCy Dividing by A (area of the thickener) or, F (Cy-C,/CyA = VIA or, FCQ/ALI/Cy - C= WA=¥ Where, V/A =¥, is the velocity with which the particles are thrown upwards which at equilibrium must be equal to downward velocity, and LC, represents the amount and concentration of slurry at any time, Again LCVA‘[I/C."MCyJ=v,, OR ‘A graph is plotted between » 44 and v grap = The lowest value of “+ is obtained from graph, Corresponding value of.vis also noted. WTime (see) | Heightiem) | ‘time(see) | Height(om) aaa —— Table:-2 seecay | #imimol iZ,/40 -V Timedoiny | Bieiny | Zitem) | ina { Result; The thickener area for the required duty is found to be «...... |. Plot graph between Zi and 6i 11, Plot graph between V vs C, os and “tvs V | | | c sqm. IIL. Take lowest value of LC1/A from graph and note corresponding value of V and then calct minimum thickener area, Lo = Lielw, Le ka - = diefho G > gle Co Mijpt oft integace Lo Jn Cems) Underpies Lg In” Lu = Wr [ha bo Cue Kg ue ——s Oj “Tinecswin) Ni sa)ninperiment no. 6 Objective: To study the setttin velocity of slurries with different concentration of chalk dus 28135 mesh), : eee ‘ Apparatus Required: 3 cylindrical jars (500ml) capacity, stop wateh, ¢ solution alk powder, ammonical Theory: Settling is the process by which particulates settle to the bottom of a liquid and form sediment, Particles that experience a force, either due to gravity or due to centrifugal motion wilh tend to move in a uniform manner in the direction exerted by that force. For gravity settling, this ‘means that the particles will tend to fall to the bottom of the vessel, forming sludge or slurry at the Vessel base. : : 357 Tocedure: Weigh three samples of chalk dust 17.5 gm, 20gm, 22.5gm to prepare slurry of 29% 40%, and 45% concentration, Put this weighed material to the respective cylindrical glass jars, add Water to make it 900 CC solution, Stir with the help of glass rod, thoroughly. The time rate of decrease in height of visible interface between supernatant clear liquid and slurry containing the Pantcles is recorded. ‘The graph for different concentration of slurry are plotted, height of the interface and time being the ordinates, Observation and Tabulation S.No, Time (Mi Concentration height (em.) 30% 40% ‘s% Bey. sass T ; = oS |__ Result/ Calculation © Graph is plotted between height and time of different concentration as Preeal '* Reading to be taken at the interval of 2 min till two readings match or whichever is earlier.Experiment no. 07 Objective: To determine the ¢ jency of a ball mill for grinding a material of known Wig the critical speed of ball mill,” * 1 Introductio ipment Generally the ball mills are known as the secondary size reduction equipme ball mill is made in a great many types and sizes and can be used on @ EF er variety 0 materials than any other type of machines, ‘The feed must be non-abrasive with a hardness of less, A ball mill consists of a cylindrical slowly turning about a horizontal axis and filled to ab ae ae : ‘of its volume with solid grinding medium. When the ball mill is rotated, the grinding elemen carried to the le of the shell nearly to the top from where; they fall on the particles under gr 'n a ball mill, most of the size reduction is done by impact. The energy expands in Tifin srinding units are utilized in reducing the size of the particles. Ball mill ean accept a feed size range of SO pm. The speed of ball mill varies between 60-70 rpm as the product size become the capacity of a mill reduces the energy requirement in increases ‘Theory: A ball mill consists of a cylindrical shell slowly turing about a horizontal axis and fe | with solid grinding medium. Critical speed of a ball mi Me = Where, n. = critical rotational speed R = radius of the ball mill = radius of the ball For effective operations of the mill, the mill should be operated at 65 to 85% of eritieal spec the product size becomes finer the capacity of the mill reduces and the energy require increases. As the speed of the mill exceeds n. Ay Bonds crushing law and work index wal A more realistic method of estimating the power required for crush and grinding“Where, ky is a constant which depends upon the type of machine and on the material being S rushe, Dy in millimeters, pin Klowats and min tones per hour, Wis defined as the gros a requirement in kilowatt hour per tons of feed needed to redu very large feed. ths definition leads to a relation between ky and W. 1 ky = 03162 x w | | 1 p=mx0.1362 x w [| 4.- | Po Pra Description : The present laboratory ball mill is designed to crush particles to very fine (powder) particle. It can handle variety of material, the compact and rugged construction can handle general laboratory or small pilot plant requirement. The shell is fabricated from thick steel! and balls are also ‘of special steel. an opening and tightening arrangement is provided in the centre of the shell to feed ‘and to take of the material. Balls are provided along with the material Utilities Required: “Electricity supply-single phase, 220v AC, 50 Hz, 5-15 amp sockets with earth. Conneetion floor area required 1.5m*Im raw iaterial for feed 'sleves with sieve shaker for catalysis. Experimental Procedure: Prepare a uniform sized feed of material to be crushed, Fill the shell with the balls provided. ‘Tasure that all switches given on the panel are at off po: ‘Now switch on the main power supply. ‘Switch on the MCB and then starter to run the machine, Caleulate the power consume to run the machine at no load condition by determining the ‘time for 10 or 20 pulse on the energy meter. Switch off the starter and then MCB, Fill the feed in the ball mill. ‘SwitelON the MCB and then starter to run the machine at loaded conditions by thedetermining the time for 10 of 20 pulse on the energy meter. ® Run the mill for specific time and calculate the size distribution of the product, «Repeat the above steps for different’ RPM. Observation and Tabulation am | onmning | MORTRT] Mess Ty, - es erin ass —lolyae Penne | (gms) | retained | x, | Dar | Dar | X/Dri no. | dia, (mm) fraction (gms) | + 4 Calculation 1, Average feed diameter (Dpa) Il. Average product diameter (Dpp) Wl Total weight of feed = 5 IV. Without load (Py.) = kw. With load (P:) = kW V. w; for ash clinker = 24.2 ENC = pulse/kW. VI, Mass rate m w 60 mee * 700 me ton/hr, ky = Dpp XW KglVIL Power (?) 1 1 Poa = MX key X Poh ee om we ta ENC kw. Pace = kW, VIIl. Efficiency (n) = Pact 100 ie Peat a 1 %, Critical speed of ball mill (7,) Radius of ball mill (R) Radius of balls (r) c= __ tps. Result/ Calculation The efficiency of the ball mill is Precautions * Clean the balls and whole unit before and after its user with cloth. * Check all the electrical connections before starting the mill,