Beruflich Dokumente
Kultur Dokumente
Dhanasekaran 1
UNIT - I
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
2
•
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
6
• diameter:
Volume mean
1/ 3
1
DV
Nx
i
3
i 1
D pi
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
10
vp aDp3
where
a = volume shape factor (a =0.5236 for sphere, 0.785 for
ashort cylinder (height = dia.), 1.0 for a cube)
Assuming that a is independent of size
•
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
13
Microscopy
Sedimentation Techniques
Screen Analysis
• The first two columns give the mesh size and width of
opening of the screen; the third column is the mass fraction
of the total sample that is retained on the designated
screen Xi, where i is the number of the screen starting at
the bottom of the stack; thus i = 1 for the pan, and screen
i+1 is the screen above i.
• Dpi means the particle diameter equal to mesh opening of
screen i.
• The last two columns show the average diameter in
each increment and the cumulative fraction smaller than
each value of Dpi
• In screen analysis cumulative are sometimes written
starting at the top of the stack and are expressed as the
fraction larger than a given size.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
22
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
23
• Cumulative plot is shown in the following figure from column
2 and 5 of the table
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
24
•
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
27
•
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
28
•
Mechanical Operations Unit - I notes - Dr. K. Dhanasekaran 29
PARTICLE-SIZE-DISTRIBUTION DATA
• presented in the form of a table
Mesh Screen Opening, Mass % Mass
Dpi Retained on Retained,
(mm) Screen,
(g)
14 1.400 0.000 0.00
16 1.180 9.12 1.86
18 1.000 32.12 6.54
20 0.850 39.82 8.11
30 0.600 235.42 47.95
40 0.425 89.14 18.15
50 0.300 54.42 11.08
70 0.212 22.02 4.48
100 0.150 7.22 1.47
140 0.106 1.22 0.25
Pan - 0.50 0.11
Total 491.00 100
Eg. mass fraction of 0.0186 passes thru’ a screen of 1.4mm aperture but being
retained at 1.180mm aperture, ave. of these two apertures =(1.4 + 1.18)/2 = 1.29mm
Mechanical Operations Unit - I notes - Dr. K. Dhanasekaran 31
• bec. 0.11 wt% particle retained on the pan, cumulative wt% undersize
0 & cumulative wt% oversize 100
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
33
CUMULATIVE SCREEN ANALYSIS
• two curves (mirror images of each other) cross at a median size where
50wt. % is larger in size & 50wt.% is smaller
• A log scale for the cumulative wt% preferred if an appreciable fraction of
the data points lie below 10%
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
34
Example 1 (page 11 in note)
Mesh Screen Opening, Mass
Dpi Fraction
Calculate (a) average particle diameter,
(mm) Retained, (b) cumulative fraction smaller than Dpi
xi
(c) plot the graph cumulative analysis of
4 4.699 0.000
part (b)
6 3.327 0.0251
8 2.362 0.1250
10 1.651 0.3207
14 1.168 0.2570
20 0.833 0.1590
28 0.589 0.0538
35 0.417 0.0210
48 0.295 0.0102
65 0.208 0.0077
100 0.147 0.0058
150 0.104 0.0041
200 0.074 0.0031
Pan - 0.0075
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
35
Solution for Example 1
vp aDp3
where
a = volume shape factor (a =0.5236 for sphere, 0.785 for
ashort cylinder (height = dia.), 1.0 for a cube)
Assuming that a is independent of size
Mechanical separations
Techniques used to separate one material from the other
are called separation.
Separations are extremely in chemical manufacture.
In fact, much processing equipment is devoted to separate
one phase or one material from the other.
Types of Separation
Diffusional Separation
Mechanical Separation
Diffusional Separation
Membrane separation can also be used for homogeneous
mixtures of macromolecules such as proteins or polymers
that are larger than the pores in the membrane.
This separation involves the transfer of the material
between the phases.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
47
Mechanical Separation
It for heterogeneous mixtures include methods of separating
solids from gases or liquids, separating liquid drops from
gases or other liquids, and separating one type or size of
solids from a mixture of particles.
These are based on the physical properties of the particles
such as size, shape or density, and on the density and
viscosity of the liquid.
Two general methods are (i) the use of a screen, septum, or
porous membrane that retains one component and allows the
other to pass and (2) the utilization of differences in
sedimentation rates as particles or drops move through a gas
or liquid.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
48
Screening
Separation of mixture of particles of various sizes into two or
more fractions by a screening surface is called screening.
This method is only based on the size of particles.
Over size material
Material that retain on the screening surface is called over
size material.
Under size material
Material that passes through the screening surface is called
under size material.
Intermediate material
When two screens are used for screening, the material that
retain on the second screen is called the intermediate
material.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
49
Unsized function
A single screen can make a single separation into two
fractions i.e. under size and over size. Such type of functions
is called the unsized function.
Sized function
When the material is passed through the series of screens
then it is divided into many fractions. Such type of function is
known as sized function.
Mesh
Hole of the screen is called the mesh.
Mesh number
It is defined as the numbers of holes per linear inch.
Aperture of screen
Aperture is the maximum clear space between the edges of
the screen opening. It is usually given in inches or mm.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
50
Standard Screens
U.S. Tyler
These are the U.S standard sieves and are available in mesh
number 4 – 325.
U.S. ASTM
It is “American Society of Testing Materials” standard sieves
series and are available in mesh number 4 – 325.
B.S.S
British standard sieve as available in mesh number 5 – 300.
I.M.M.S
Institute of Mining and Metallurgy standard sieves are
available in mesh number 5 – 200.
F.S.S
French standard sieves are available in mesh number 17 – 38.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
52
Screen equipment
Stationary screens and grizzlies
Mechanically Vibrating screens
Gyrating screens
Centrifugal Screens
Stationary screens and grizzlies
A grizzly is a grid of parallel metal bars set in an inclined stationery
frame. The slope and the path of the material are usually parallel to
the length of the bars.
Very coarse feed, as from a primary crusher, falls on the upper end
of the grid. Large chunks roll and slide to the tails discharge; small
lumps fall through to a separate collector. The spacing between the
bars is 2 to 8 in. (50 – 200 mm).
Stationery inclined woven-metal screens operate in the same way,
separate particles ½ to 4 in.(12 to 100mm) in size. These are
effective only very coarse, free flowing solids containing few fine
particles.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
56
Gyrating screens
Two screens, one above the other, are held in a casing inclined
at an angle between 16º to 30º with the horizontal.
The feed mixture is dropped on the upper screen near its
highest point.
Casing and screens are gyrated in a vertical plane about a
horizontal axis by an eccentric that is set halfway between the
feed the feed point and the discharge.
The rate of gyration is between 600 and 1800 r/min. the screens
are rectangular and fairly long.
Oversize particles fall from the lower ends of the screens into
collecting ducts; fines pass through the bottom screen into a
discharge chute.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
57
Vibrating screen
Screens that are rapidly vibrated with small amplitude are less likely
to blind than are gyrating screen. The vibrations may be generated
mechanically or electrically.
Mechanical vibrations are usually transmitted from high speed
eccentrics to the casing of the unit and from heavy duty solenoids
are transmitted to the casing or directly to the screens.
Ordinarily no more then three decks are used in vibrating screens.
Between 1800 and 3600 vibrations per minute are usual. A 48 by
120-in(1.2 to 3-m) screen draws about 4 hp(3kW).
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
58
Capacity of screen
The capacity of a screen is measured by the mass of
material that can be fed per unit time to a unit area of the
screen.
Capacity and effectiveness are opposing factors.
To obtain maximum effectiveness, the capacity must be
small
Large capacity is obtainable only at the expense of a
reduction in effectiveness.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
60
An ideal screen would sharply separate the feed mixture in such a way
that the smallest particle in the overflow would be just larger than the
largest particle in the underflow. Such an ideal separation defines a cut
diameter Dpc that marks the point of separation between the fractions.
Usually Dpc is chosen to be equal to the mesh opening of the screen.
Acutal screens do not give a perfect separation about the cut diameter.
The closet separations are obtained with spherical particles on standard
testing screens, but even here there is an overlap between the smallest
particles in the overflow and the largest ones in the underflow.
Sieving Method
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
63
Sieving
• Weight distribution
• Sieve analysis is performed using a nest or stack of sieves
where each lower sieve has a smaller aperture size than
that of the sieve above it.
• Sieves can be referred to either by their aperture size =
mesh size = sieve number
• The mesh size is the number of wires per linear inch.
250 μm = No. 60
125 μm = No. 120
• Approx. size range : 5μm - ~3mm
Standard woven wire sieves
Electroformed micromesh sieves at the lower end or range
(< 20μm)
Punch plate sieves at the upper range
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
64
Microscopy
• Optical microscopy (1μm - mm)
• Electron microscopy (0.001μ-)
• Number distribution
• Being able to examine each particle individually has led to
microscopy being considered as an absolute measurement
of particle size.
• Can distinguish aggregates from single particles
• Can be coupled to image analysis computers, each field can
be examined, and a distribution obtained.
• Most severe limitation of optical microscopy is the depth of
focus being about 10μm at x100 and only 0.5μm at x1000.
• With small particles, diffraction effects increase causing
blurring at the edges - determination of particles < 3μm is
less and less certain.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
65
Submicron particles
• For submicron particles it is necessary to use either:
TEM (Transmission Electron Microscopy) or
SEM (Scanning Electron Microscopy)
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
66
Diameters Measured
• Longest dimension:
a measured diameter equal to the maximum
value of Feret's diameter.
• Perimeter diameter:
the diameter of a circle having the same
circumference as the perimeter of the particle.
• Maximum chord:
a diameter equal to the maximum length of a
line parallel to some fixed direction and limited
by the contour of the particle.
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
68
•
Mechanical Operations Unit - I notes - Dr. K.
Dhanasekaran
71
Laser Diffraction
PCS