Problems Unit II

Unit- I Properties, Handling and Mixing of

Particulate Solids
Problems
 A certain set of crushing rolls has rolls of 1000
mm diameter and 375mm width face. They are set
so that the crushing faces are 12.5 mm apart. The
manufacturer recommends speed to be 50 to 100
r.p.m. They are employed to crush a rock having
specific gravity 2.35 and the angle of nip is 310 30l.
What is the maximum permissible size of the feed
and maximum actual capacity of rolls in tonnes per
hour if the actual capacity is 12% of theoretical?
 Theoretical capacity in t/h Q=4.352 X 10 -7

N.D.w.d.s
 2. Calculate operating speed of the ball mill
from the data given below:
Diameter of ball mill=800 mm, dia of mill=60
mm.
If (I) operating speed is 55% less than the
critical speed.
(II) Critical speed is 40% more than the
operating speed.
3. What should be the diameter of a set of
rolls to take feed of size equivalent to 38 mm
spheres and crush to 12.7 mm?
The co-efficient of friction is 0.35.
Properties, Handling and Mixing of
Particulate Solids 1st Unit
 Individual solid particles are determined by their
size, shape, density
 Particles of homogeneous solids have the same

density of the bulk material

 particles obtained by breaking up a composite

solid,
 Such as metal bearing ore, have various densities

,different from bulk material.

 Size and shape are easily specified for regular

particles, such as spheres and cubes, but for

irregular particles (sand grains, mica flakes).
Particle shape
 The terms size and shape are not so clear for irregular
particles.

Particle shape: The shape of an individual particle is expressed

in terms of the sphericity (фs) , which is independent of particle
size. For a spherical particle of diameter Dp, фs=1, for a non
spherical particle, the sphericity is defined by the relation
фs= 6vp/Dpsp
where

Dp =equivalent dia or nominal dia of particle

Sp = surface area one particle
vp = volume of the particle
Finding surface area
 The Equivalent diameter =(diameter of sphere
of equal volume)
For Granular materials , however , it is difficult
to determine the exact volume and surface
area of the particle
And Dp is to be taken the nominal size based
on screen analysis or microscopic examination.
The surface area is found from adsorption
measurements or from pressure drop in bed of
particles.
Sphericity (фs )
 Фs , for many crushed materials is between
0.6 and 0.8,
 But for particles rounded by abrasion Ф may
s
be as high as 0.95.
 For cubes and cylinders for which the length

L equals the diameter. The equivalent

diameter > length
 And Ф , found from the equivalent diameter
s
would be 0.81 for cubes and 0.87 for
cylinders.
 Nominal dimeter L for these shapes since the
surface-to-volume ratio is 6/Dp. Same as
sphere, this make = 1
 For column packings such as rings and

saddles the nominal size is also used in

defining Фs .

 Particle size. In general diameter may be

specified for any equidimensional particle .
Particles that are not equidimensional, i.e.
 Longer in one direction than in others , are
characterized by second longer major
dimension.
 For needlelike particles Ф would refer to the
s
thick ness of the particles , not their length.
 By convention , particle sizes are expressed

in different units depending on the size range

involved.
 Coarse particles are measured in inches or

millimeters.
 Fine particles in terms of screen size
 Very fine particles interms in micrometers or

nanometers.
 Ultrafine particles are some times described

in terms of their surface area per unit mass

usually in square meters per gram.
Mixed Particles and Size analysis
In a sample of uniform particles of diameter Dp
the total volume of the particles is m/ɠp
N= m/ɠpvp (2)
m=Total mass of sample
ɠp = density of particles
since volume of one particle is vp ,the number
of particles in the sample N is as given the above
The total surface area of the particles is from
equations 1 and 2.
A=Nsp = 6m/ Фs ɠp Dp -(3)
 To apply equations 2 and 3 to mixtures of
particles having various sizes and densities .
the mixture is sorted into fractions can then
be weighed or individual particles in it can be
can be counted or measured by any one of a
number of methods .
N(2) and A(3) equations can be applied to each
fraction and the results added.
Size Separation of solids
Screening
A method of separating solid particles according to
size alone is called Screening
On basis of size using screens of known openings
Is the separation of a mixture of solid particles of
various sizes into to or more fractions by means of
a screening surface.
In screening , a mixture of solid particles of various
sizes is dropped on a screening
surface/screen(surface of suitable openings) which
acts as a multiple go and no gogage
The material that passes through a given
screen/screening surface is called the
undersize or minus(-) material while the
material that remains on the screen
/screening surface is called the oversize (+)
material.
 Screening is used for dry materials and

occasionally for the wet materials

Materials for screens
 Industrial screens are made from metal bars,
woven wire cloth, silk bolting cloth,
perforated or slotted metal plates.
 Many varieties and types of varieties and the

types of screens
Importance of the screening
operation
 The screening operation is industrially carried out
in order to
 1.remove the fines from feed material before a
reduction equipment such as crusher, ballmill or
rod mill.
 Prevent an incompletely crushed materials(over
size) from entering into other unit operations.
 Produce a commercial or process-grade material
to meet specific particle size limits
 Remove the fines from a finished product prior to
shipping
Classification of screens on the basis
of performance
 Comparison of ideal and Actual screens
Ideal screen- is the one which sharply
separates the feed mixture as over (large+)and
under(small -)flow
The ideal separation defines a cut diameter Dpc
(a typical particle dimension) which makes the
point of separation between the undersize and
oversize fractions and nearly =mesh opening
of the screen.
 Actual screens do not yield a sharp
separation .
 Actual screens, the screen analysis of the

overflow and underflow

 The overflow is found to contain particles

larger than the cut diameter

 In standard testing screens , closest

separations in case of spherical particles.

 In this case also there is some overlap.
 In case of needle like fibrous particles or
particles which have tendency to aggregate
into clusters,
 Commercial screens give poorer performance

than testing screens of the same mesh

handling the same feed mixture.
Types of standard screen series
 A number of methods of particle-size
determination are available but most particle
–size determination are made by the screen
analysis(particles within size range)
 Tayler standard screen series U.S. Sieve series

analysis or Indian standard sieves are used.

 The testing sieves with square openings are

constructed of woven wire screens. The mesh

and dimensions of which are standardized
 Every screen identified in meshes per inch.
 In coarse screens, the term mesh refers to the
distance between adjacent wire or rods.
 While in fine screens , the mesh is the number

of openings per linear inch counting from the

center of any wire to a point exactly one inch
distant(e.g., a 200-mesh screen will have 200
openings per linear inch).
 The minimum clear space between the edges

of the opening in the screening surface is

termed as screen aperture or screen-size
opening.
 The Tayler standard screen series is based
on a 200 mesh screen with a wire 0.0053
mm(0.0021) in diameter, giving a clear
opening of 0.074 mm(1/200 -0.0021=
0.0029 in).
 The screen coarser than a 200 mesh screen

have their mesh and wire diameter adjusted

that the area of opening in any one screen is
approximately twice the are of opening in the
next finer screen.
 The linear size of the opening in any screen
to that in next finer screen is 1.41.
 There fore, a 150-mesh screen will have an

opening of 0.104mm=0.0041 in) with a wire

of 0.064 mm diameter.
 Testing sieves of the Tyler standard sieve

series are used to determine the efficiencies

of screening equipment's and work of
crushing and grinding machinery.
Types screen analysis.

 These are two methods of reporting screen

analysis
 1.Differential analysis
 2.Cumulative analysis
 Differential Analysis.
 The screen analysis in which the weight

fraction of material retained on each screen is

reported in a tabular or graphical form as a
fraction of the mesh size/screen opening is
called differential analysis.
Cumulative analysis

 The screen analysis in which the cumulative

weight fraction of the material retained
(cumulative over size) or passing through
(cumulative undersize) each screen is reported
in a tabular or a graphical from as a function of
the screen opening is called cumulative
analysis.
 Fine particles are generally specified according

to their screen analysis.

 A screen analysis of material is carried out by

using testing sieves.

 A set of standard screens is arranged serially
in a stack in such a way that the coarsest of
the screens is at the top and finest of the
screens is at the bottom.
 An analysis is carried out by placing the

sample on the top screen and shaking the

stack in a definite manner, either , manually
or mechanically, for a definite length of time.
 The material removed on each screen is

removed and weighed.

 For reporting the screen analysis , the amount
of material retained on each screen is
expressed as the weight fraction of the toal
sample.
 In screen analysis in tabular form, weight
fraction of the material retained on each screen
is function of the mesh size.
 As the particles retained on any one screen are
passed through the screen immediately above
it two numbers are needed to specify the size.
 One for the screen through which fraction
passes and the other for the screen on which
that fraction is retained.
 Hence the notation 10/14 means through 10

mesh and on 14 mesh(.i.e. the material is

that it passes through the screen of mesh
number 10 and collects on the screen of
mesh number 14). An analysis reported in a
tabular form in this manner is called
differential analysis.
 The average particle size of the material retained on any
particular screen is calculated as the arithmetic mean of
two screen openings used to obtain the fraction.
 The 2nd method is cumulative analysis, the cumulative
analysis is obtained from the differential analysis is
obtained from the differential analysis by adding
cumulatively.
 The individual weight fractions of material retained on
each screen, starting with that retained on the largest
mesh, and tabulating and plotting the cumulative sums
against the screen opening of the retaining screen under
consideration.


   we define equation △ф
If
 ф =△ф1+ △ф2+ △ф3+… + △фNT =
 Where △ф1, △ф2 , △ф3 are the weight fractions of
material retained on screen 1,2,3 … numbered
serially from top of the deck.
 Cumulative analysis is relation between ф and
screen opening.
 The quantity ф is the weight fraction of the sample
that consists of particles larger than the screen
opening.
 For the entire sample value of ф is unity.
 ф = cumulative fraction retained on screen
 1- ф = cumulative fraction passing through
the screen.
 A graphical presentation of screen analysis

can be done on ordinary graph papers but

more conveniently on semilogarthmic papers
where the size is plotted on a logarithmic
scale.
 A semilogarthmic papers where size is

plotted on a logarithmic scale .

 A semilogarthmic plot avoids the crowding of most
data into small section of the diagram.
 The results of screen analysis represented as
fractional or cumulative distribution curves are
shown in Fig a and b.
 Fractional distribution curve is a plot of the weight
fraction of material retained against the average
particle size and cumulative distribution curves
shown in Fig c. are obtained by plotting the fraction
of the total weight of particles having a size greater
than or less than a given screen opening against the
screen opening.
Capacity and effectiveness of screens
 The capacity and effective ness are measure of
the performance in industrial screening.
 The capacity of a screen is the mass of material

that can be fed per unit time to a unit area of the

screen.
 Capacity and effective ness in screening

operations are closely related .

 For obtaining maximum effectiveness the

capacity must be small.

 Large capacity attainable only by reduction in the

effectiveness.
 As the capacity and effectiveness are opposing factors. A
reversible balance must be done between them in actual
practice.
 One can control the capacity of a screen simply by
varying the mass flow rate of feed to the screening
equipment .
 For a given capacity, the effectiveness that can be
achieved depends upon the nature of the screening
operation.
 For a given undersize particle , the overall chance of
passage through the screen is function of the number of
contacts between the particle and the screen surface, and
the probability of its passage in single contact.
 When the screen is overloaded , the number
of contacts is small and probability of
passage on contact is reduced due to the
interference of the other particles.
 The effectiveness is improved by reducing the

capacity since then there will be more

contacts per particle and better chance for
passage on each contact.
The factor s of reduce the capacity
and effectiveness.
 Blinding
 Cohesion of particle to the screen surface,
 Oblique direction of approach of the particles

to the screening surface and interference of

bed particles with the motion of any one.
 The moisture content of the feed adversely

affects the screening operation as the damp

particles are prone to stick to the screen
surface and to each other.
Blinding of screen
 It refers to the phenomenon wherein
elongated, sticky ,etc. particles become wedged
into the openings during screening and thus
prevent other particles from passing through it.
 Thus ,the blinding of a screen means the
plugging of screen with solid particles.
 Due to blinding of appreciable fraction of the
screen becomes inactive.
 The blinding tendency is more pronounced with
fine screens than with the coarse screens.
Definition and derivation of the
effectiveness of a screen
 Material balance over a screen:

 Consider that the feed to a screen consists of

materials A and B, where A is the oversize
and B is the undersize material.

 Out of the total materials fed to the screen,

some part of it is removed as overflow and
remaining part of it is collected as underflow.
Material balance over a screen
 Consider that the feed to a screen consists of
materials A and B, where A is the oversize
and B is the undersize material .
 Out of the total materials fed to the screen

some part of it is removed as overflow and

remaining part of it is collected as underflow.
 Let F be the mass flow rate of feed(kg/h)
 D be the mass flow rate of overflow,(kg/h)
 B be the mass flow rate of underflow,(kg/h)

 x be the mass fraction of material A in feed.

F
 xD be the mass fraction of material A in
underflow.
 The mass fractions of material B in feed , overflow

and underflow are 1-xF , 1-xD, 1-xB respectively,

 The overall material balance over a screen is

F=D+B (1)
 The material balance of ‘A’ over a screen is are

xFF= xDD +xBB (2)

From equation (2)
we have F-B=D (3)
Substituting the value of D from equation into
equation ,(3) we get (2)
 xFF=xD (F-B)+xB.B
 xFF =xDF-xDB+xBB
 (xD -xF)F= (xD-xB)B
 B/F = (xD -xF)/ (xD -xB)
 Similarly , elimination of B from equations 1
and 2 gives
 D/F = (x -x )/(x -x )
F B D B
The effective ness of a screen (Screen
efficiency)
 Of a measure of the success of the screen in
closely separating undersize and oversize
materials.
 In the case of a perfectly functioned screen , all

the oversize material ‘A’ would be in the

overflow and all the undersize material would
be in the underflow.
 The screen effectiveness based on the over size

material is ratio of the amount of oversize

material actually in the overflow to the amount
of oversize material A in the feed.
Screen effectiveness
 Screen effectiveness based on material A = EA
=D.xD/F.xF

= Quantity of oversize in the overflow/Quantity of

over size in the feed
Similarly ,
The screen effectiveness based on the undersize
material is given by
E=B(1-xB)/F(1-xF)
The overall effectiveness of screen can be given by
E=EA .EB
 Where E is the overall effectiveness of a screen.
 Substituting the values of EA and EB from
equations EA and EB into E
 We get
E= D.B.xD (1-xB )/F2 xF (1-xF)

Substituting the values of D/F and B/F from

equations into E we get
E =(xD -xF)/ (xD -xB) X (xF-xB)/(xD-xB) X xD(1-
xB )/xF (1-xF)
 E= (xF-xB) (xD –xF) xD(1-xB )/ (xD-xB)2 xF (1-xF)
Factors affecting performance of
screens
 Variables in screening operations
 There are many variables in a screening

operation that can be very easily changed .

 The best combination of these variables

results into the excellent performance of

screening equipment.
 1. Method of feeding:
 In order to obtain the maximum capacity and

efficiency , the screening equipment must be

fed properly.
 The material should be spread evenly over a full
width of the screening surface and should approach
the screening surface in a direction parallel to the
longitudinal axis of the screen and must be fed at
low rate.
 2.Screening surface
 Use of single –deck screens in series results into the

most efficient operation as in case of multiple –deck

screens lower decks are not fed so that their entire
area is not used and each separation requires a
different combination of angle, speed, and
amplitude of vibration for the best performance.
3.Screen slope
 As the screen slope increases, the rate at which the
materials travels over the screening surface
increases and at the some time, it reduces the bed
thickness.
 The increase of rate of travel means an increase in
the quantity passing over the screen surface and
pass through it.
 However , the slope cannot be increased beyond a
certain value because beyond that value (limit) the
material will travel down the screen much faster
without getting screened and the screening
efficiency reduce drastically.
Vibration amplitude and frequency
 One has to select the proper amplitude of
vibration to prevent blinding of the screening
cloth and for long bearing life .
 The frequency of vibration affects the capacity of
the screening equipment by regulating the
number of contacts between material and the
screening surface.
 Moisture in feed:
 The moisture associated with the feed material
adversely affects the screening operation and
should be removed.