5/2/2014 PARTICLE

TECHNOLOGY
LABORATORY REPORT

SUBMITTED TO
MUHAMMAD IRFAN AKRAM
SUBMITTED BY:
SONIA JABBAR 2011-BET-CHEM-02
NAWEED KHAN 2011-BET-CHEM-07
IRFAN ALI 2011-BET-CHEM-12
ZIA UR REHMAN 2011-BET-CHEM-14
KHUMAL SOHAIL 2011-BET-CHEM-22
 CHEMICAL ENGINEERING TECHNOLOGY

PARTICLE TECHNOLOGY LABORATORY LAYOUT

4
5 3

6 2
7 1

8
EQUIPMENT
1. Jaw crusher
2. Jar Mill / Pebble Mill
3. Ball Mill
4. Solid Handling Apparatus
5. Ultrafine Grinder (Universal grinder)
6. Cyclone Separator
7. Double Roll Crusher
8. Angle of Repose Apparatus

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EXPERIMENT # 1

Ball Mill
CONSTRUCTION AND PRINCIPLE OF BALL MILL
In its simplest form, the ball mill consists of a rotating hollow cylinder, partially filled with balls, with its
axis either horizontal or at a small angle to the horizontal. The material to be ground may be fed in through
a hollow trunnion at one end and the product leaves through a similar trunnion at the other end. The
outlet is normally covered with a coarse screen to prevent the escape of the balls.

The inner surface of the cylinder is usually lined with an abrasion-resistant material such as manganese
steel, stoneware or rubber. Less wear takes place in rubber-lined mills, and the coefficient of friction
between the balls and the cylinder is greater than with steel or stoneware linings. The balls are therefore
carried further in contact with the cylinder and thus drop on to the feed from a greater height. In some
cases, lifter bars are fitted to the inside of the cylinder.

The ball mill is used for the grinding of a wide range of materials, including coal, pigments, and feldspar
for pottery, and it copes with feed up to about 50 mm in size. The efficiency of grinding increases with the
hold-up in the mill, until the voids between the balls are filled. Further increase in the quantity then lowers
the efficiency.

The balls are usually made of flint or steel and occupy between 30 and 50 per cent of the volume of the
mill. The diameter of ball used will vary between 12 mm and 125 mm and the optimum diameter is
approximately proportional to the square root of the size of the feed, with the proportionality constant
being a function of the nature of the material.

During grinding, the balls wear and are constantly replaced by new ones so that the mill contains balls of
various ages, and hence of various sizes. This is advantageous since the large balls deal effectively with

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the feed and the small ones are responsible for giving a fine product. The maximum rate of wear of steel
balls, using very abrasive materials, is about 0.3 kg/Mg of material for dry grinding, and 1–1.5 kg/Mg for
wet grinding. The normal charge of balls is about 5 Mg/m3. In small mills where very fine grinding is
required, pebbles are often used in place of balls.

COMPOUND BALL MILL

In the compound mill, the cylinder is divided into a number of compartments by vertical perforated plates.
The material flows axially along the mill and can pass from one compartment to the next only when its
size has been reduced to less than that of the perforations in the plate. Each compartment is supplied
with balls of a different size. The large balls are at the entry end and thus operate on the feed material,
whilst the small balls come into contact with the material immediately before it is discharged. This results
in economical operation and the formation of a uniform product.

It also gives an improved residence time distribution for the material, since a single stage ball mill
approximates closely to a completely mixed system. In wet grinding the power consumption is generally
about 30 per cent lower than that for dry grinding and, additionally, the continuous removal of product
as it is formed is facilitated. The rheological properties of the slurry are important and the performance
tends to improve as the apparent viscosity increases, reaching an optimum at about 0.2 Pa.s. At very high
volumetric concentrations (ca. 50 volume per cent), the fluid may exhibit shear-thickening behavior or
have a yield stress, and the behavior may then be adversely affected.

OBJECTIVE
To determine the critical speed and magnitude of Ratting’s and Bond’s laws constants for the ball mill.

APPARATUS
 Ball mill with grinding medium
 Set of standard screens
 Scale
 Vernier Caliper for measurement

REQUIRED MATERIAL
Broken bricks of the size about 1/4 - 1/8 inch as obtained from the smooth roll crusher

PROCEDURE
 Measure the circumference of the cylindrical shell of ball mill with the help of string and hence
calculate its external radius.
 Measure the thickness of the shell with the help Vernier Caliper.
 Determine the diameter of balls of different sizes and hence calculate its mean size.
 Take 10 – 15 Kg of crushed bricks (or chalks) of 3. 6 mm.
 Empty the mill and load it with grinding medium
 Add pre weighed amount of persized feed in the ball mill
 Note the initial reading of energy meter
 Operate the loaded mill for 20 minutes.
 Switch off the mill and note the reading of energy meter.
 Unload the mill, carefully remove the product and determine its representative size.

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 Now operate the ball mill along with grinding medium for 30 minute and again note reading of
energy meter.
 Determine net and gross energies consumed during milling operation.
 Find out crushing strength of brinks from the literature.
 Calculate the critical speed, Rittinger’s law and Bond’s law constant using the following formulas.

1
𝜂𝑜′ = 2
𝑔
2𝜋 (𝑅 − 𝑅 )
𝑖 𝑏
Determine the operating speed of ball mill

𝜂𝑜′ = (0.6 − 0.85)𝜂𝑟′ 𝑖𝑛 𝑐𝑎𝑠𝑒 𝑜𝑓 𝑏𝑎𝑓𝑓𝑒𝑙𝑒𝑑 𝑚𝑖𝑙𝑙

𝜂𝑜′ = 1.05𝜂𝑟′

FACTORS INFLUENCING THE SIZE OF PRODUCT

 The rate of feed. With high rates of feed, less size reduction is effected since the material is in the
mill for a shorter time.
 The properties of the feed material. The larger the feed the larger is the product under given
operating conditions. A smaller size reduction is obtained with a hard material.
 Weight of balls. A heavy charge of balls produces a fine product. The weight of the charge can be
increased, either by increasing the number of balls, or by using a material of higher density. Since
optimum grinding conditions are usually obtained when the bulk volume of the balls is equal to
50 per cent of the volume of the mill, variation of the weight of balls is normally effected by the
use of materials of different densities.
 The effect on grinding performance of the loading of balls in a mill has been studied by KANO et
al. (22), who varied the proportion of the mill filled with balls from 0.2 to 0.8 of the volume of the
mill. The grinding rates were found to be a maximum at loadings between 0.3 and 0.4. The effect
of relative rotational speed, the ratio of actual speed to critical speed, was found to be complex.
At loadings between 0.4 and 0.8, the grinding rate was a maximum at a relative rotation speed of
about 0.8, although at lower loadings the grinding rate increased up to relative speeds of 1.1 to
1.6.
 The diameter of the balls. Small balls facilitate the production of fine material although they do
not deal so effectively with the larger particles in the feed. The limiting size reduction obtained
with a given size of balls is known as the free grinding limit. For most economical operation, the
smallest possible balls should be used.
 The slope of the mill. An increase in the slope of the mill increases the capacity of the plant because
the retention time is reduced, although a coarser product is obtained.
 Discharge freedom. Increasing the freedom of discharge of the product has the same effect as
increasing the slope. In some mills, the product is discharged through openings in the lining.
 The speed of rotation of the mill. At low speeds of rotation, the balls simply roll over one another
and little crushing action is obtained. At slightly higher speeds, the balls are projected short
distances across the mill, and at still higher speeds they are thrown greater distances and
considerable wear of the lining of the mill takes place. At very high speeds, the balls are carried
right round in contact with the sides of the mill and little relative movement or grinding takes
place again. The minimum speed at which the balls are carried round in this manner is called the
critical speed of the mill and, under these conditions, there will be no resultant force acting on
the ball when it is situated in contact with the lining of the mill in the uppermost position, that is

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the centrifugal force will be exactly equal to the weight of the ball. If the mill is rotating at the
critical angular velocity ωc, then:
𝑟𝑤𝑐2 = 𝑔
Or:
𝑔
𝑤𝑐 = √
𝑟
The corresponding critical rotational speed, 𝑁𝑐 in revolution per unit time, is given by:
𝑤𝑐 1 𝑔
𝑁𝑐 = = √
2𝜋 2𝜋 𝑟
In this equation, r is the radius of the mill less that of the particle. It is found that the optimum
speed is between one-half and three-quarters of the critical speed. Figure below illustrates
conditions in a ball mill operating at the correct rate.

A ball mill operating at the correct speed

 The level of material in the mill. Power consumption is reduced by maintaining a low level of
material in the mill, and this can be controlled most satisfactorily by fitting a suitable discharge
opening for the product. If the level of material is raised, the cushioning action is increased and
power is wasted by the production of an excessive quantity of undersize material.

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EXPERIMENT # 2

JAW CRUSHER
CONSTRUCTION AND PRINCIPLE
Crushers are slow-speed machines for coarse reduction off large quantities of solids. The man types are
jaw crusher, gyratory crushers, smooth-roll crushers, and toothed-roll crusher, the first three operate by
compression and can break large lumps of very hard materials, as in the primary and secondary reduction
of rocks and ores. Toothed-roll crushers tear the feed apart as well as crushing it; they handle softer feeds
like coal, bone, and soft shale.

In a jaw crusher feed is admitted between two jaws, jet to form a V open at the top. One jaw, the fixed,
or anvil, jaw, is nearly vertical and does not move; the other, the swinging jaw, reciprocated in a horizontal
plane. It makes an angle of 20o to 30o with the anvil it is driven by an eccentric so that it applies great
compressive force to lumps caught between the jaws. The jaw faces are flat or slightly bulged; they may
carry shallow horizontal grooves. Large lumps caught between the upper parts of the jaws are broken,
drop into the narrower space below, and are re-crushed the next time the jaws close. After sufficient
reduction they drop out the bottom of the machine. The jaws open and close 250 to 400 times per minute.

The most common type of jaw crusher is the Blake crusher, shown in figure below. In this machine an
eccentric drives a pitman connected to two toggle plates, one of which is pinned to the frame and the
other to the swinging jaw. The pivot point is at the top of the movable jaw or above the top of the jaws
on the centerline of the jaw opening.

The greatest amount of motion is at the bottom of the V, which means that there is little tendency for a
crusher of this kind to choke. Some machines with a 1.8- by 2.4-m (72- by 96-in.) feed opening can accept
rocks 1.8m (6ft) in diameter and crush 1200 ton/h to a maximum product size of 250 mm (10 inch). Smaller
secondary crushers reduce the particle size of pre-crushed feed to 6 to 50 (1/4 to 2 inch) at much lower
rates of throughput.

OBJECTIVE
To report result of screen analysis for the product obtained from jaw crusher in the form of cumulative
and fractional distributional plots.

REQUIRED MATERIAL
 Scale
 Tray
 Vibrating sieve
 Set of the sieves with different mesh no. (tyler series)
 Material

PROCEDURE
 Prepare the 5Kg of feed (red bricks) of size that can pass through a 4 inch hole and retain on 2
inch hole.
 Start the crusher and note the time for 2 revolution when crusher is unloaded by stopwatch.
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 Then start introducing feed in machine and noting time taken for two revolution when machine
is loaded by using stopwatch.
 Keep introducing feed pieces in machine and simultaneously noting total time taken for all the
feed to crush by stopwatch.
 When crushing is complete turn off machine and write down the time required for total
crushing.
 Analyze the material by sieving (preferably by using different mesh no. sieves) weigh out the
masses retained on each screen and in the pan.

OBSERVATION AND CALCULATION

𝐹𝑒𝑒𝑑 𝑡𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 = 3𝐾𝑔 = 3 × 10−3
𝑊𝑒𝑖𝑔ℎ𝑡 𝑓𝑜𝑟 𝑎𝑛𝑎𝑙𝑦𝑠𝑖𝑠 = 500 𝑔𝑟𝑎𝑚
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛1 ) 𝑤ℎ𝑒𝑛 𝑢𝑛𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡1 = 270 𝑠𝑒𝑐
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛2 ) 𝑤ℎ𝑒𝑛 𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡2 = 240 𝑠𝑒𝑐
𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 = 𝑇 = 100 𝑠𝑒𝑐
𝑟𝑒𝑣
𝐸𝑛𝑒𝑟𝑔𝑦 𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑁 = 50
𝐾𝑊ℎ

𝐸𝑛𝑒𝑟𝑔𝑦 (𝑒𝑥𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡)

𝑛2 𝑛1 𝑇 × 1000
𝐸=( − )
𝑡2 𝑡1 𝑁 × 𝑊
2 2 100 × 1000
𝐸=( − )
240 270 50 × 3 × 10−3
𝐾𝑊ℎ
𝐸 = 617.27
𝑡𝑜𝑛
𝑇𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 (𝑖𝑛𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑢𝑠𝑒𝑑 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑜𝑛𝑒 𝑡𝑜𝑛 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙.

𝑛2 𝑇 × 1000
𝐸=( )
𝑡2 𝑁 × 𝑊
2 100 × 1000
𝐸=( )
240 50 × 3 × 10−3
𝐾𝑊ℎ
𝐸 = 5555.55
𝑡𝑜𝑛

Fractional distribution plot Cumulative distribution plot

Mesh Weight Average Stated Cumulative fraction
Wight retained
No. fraction particle size particle size less than stated
(g)
(x) (mm) (mm) particle size
3 78 0.156 - 1
8 256 0.512 4.555 0.844
10 52 0.104 2.03 0.332
14 30 0.06 1.435 0.228
20 12 0.024 1.0155 0.168
25 10 0.02 0.774 0.144
pan 62 - - 0.124

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EXPERIMENT # 3

DOUBLE ROLL CRUSHER

INTRODUCTION
Two rolls, one in adjustable bearings, rotate in opposite directions as shown in Figure 1 and the clearance
between them can be adjusted according to the size of feed and the required size of product. The machine
is protected, by spring loading, against damage from very hard material. Both rolls may be driven, or one
directly and the other by friction with the solids.

The crushing rolls, which may vary from a few centimeters up to about 1.2 m in diameter, are suitable for
effecting a small size reduction ratio, 4:1 in a single operation, and it is therefore common to employ a
number of pairs of rolls in series, one above the other. Roll shells with either smooth or ridged surfaces
are held in place by keys to the main shaft. The capacity is usually between one-tenth and one-third of
that calculated on the assumption that a continuous ribbon of the material forms between the rolls.

An idealized system where a spherical or cylindrical particle of radius r2 is being fed to crushing rolls of
radius r1 is shown in Figure 2 is the angle of nip, the angle between the two common tangents to the
particle and each of the rolls, and 2b is the distance between the rolls. It may be seen from the geometry
of the system that the angle of nip is given by:

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OBJECTIVE
To report different types of diameters for the product obtained from double roll crusher. Such as Bond’s
diameter, volume mean diameter, mean volume diameter, surface mean diameter and mean length
diameter.

REQUIRED MATERIAL
 Scale
 Tray
 Vibratory sieve
 Set of sieves with different mesh no.
 Material (red bricks)

PROCEDURE
 Prepare 2Kg of feed (red bricks) of size that pass through a 2 inch hole and retain on a 1 inch hole.
 Start double roll crusher and note the time for two revolution when crusher is unloaded suing
stopwatch.
 Start introducing feed pieces and note time taken for 2 revolution of energy meter when crusher
is loaded.
 Keep introducing material in crusher and note total time required for crushing 2kg of feed.
 When crushing is completed stop the stopwatch and turn off the machine, note down the total
time required for crushing.
 Analyze the material by sieving (using different mesh no.) and weigh out the mass retained on
each sieve and in the pan.

OBSERVATION AND CALCULATION

𝐹𝑒𝑒𝑑 𝑡𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 = 2𝐾𝑔 = 2 × 10−3
𝑊𝑒𝑖𝑔ℎ𝑡 𝑓𝑜𝑟 𝑎𝑛𝑎𝑙𝑦𝑠𝑖𝑠 = 800 𝑔𝑟𝑎𝑚
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛1 ) 𝑤ℎ𝑒𝑛 𝑢𝑛𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡1 = 95 𝑠𝑒𝑐
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛2 ) 𝑤ℎ𝑒𝑛 𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡2 = 94 𝑠𝑒𝑐
𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 = 𝑇 = 122 𝑠𝑒𝑐
𝑟𝑒𝑣
𝐸𝑛𝑒𝑟𝑔𝑦 𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑁 = 50
𝐾𝑊ℎ

𝐸𝑛𝑒𝑟𝑔𝑦 (𝑒𝑥𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡)

𝑛2 𝑛1 𝑇 × 1000
𝐸=( − )
𝑡2 𝑡1 𝑁 × 𝑊
2 2 122 × 1000
𝐸=( − )
94 95 50 × 2 × 10−3
𝐾𝑊ℎ
𝐸 = 273.23
𝑡𝑜𝑛

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𝑇𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 (𝑖𝑛𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑢𝑠𝑒𝑑 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑜𝑛𝑒 𝑡𝑜𝑛 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙.

𝑛2 𝑇 × 1000
𝐸=( )
𝑡2 𝑁 × 𝑊
2 122 × 1000
𝐸=( )
94 50 × 2 × 10−3
𝐾𝑊ℎ
𝐸 = 25957.44
𝑡𝑜𝑛

Differential Analysis
Average 𝒙𝒊 𝒙𝒊 𝒙𝒊
Mesh Mass Opening Mass ̅ 𝒑 . 𝒙𝒊
particle ̅ ̅ ̅ 𝑫
No. retained of sieve fraction 𝑫𝒑𝒊 𝑫𝟐𝒑𝒊 𝑫𝟑𝒑𝒊 𝒊
size
(g) (mm) ̅ 𝒑 (mm) (𝒙𝒊 )
𝑫 𝒊
4 198 4.76 - 0.2475 - - -
8 280 2.38 3.57 0.3500 0.098 0.0275 0.007692 1.2495
10 72 1.68 2.03 0.0900 0.0443 0.0218 0.01076 0.1827
14 60 1.19 1.435 0.0750 0.05226 0.0364 0.0254 0.107625
20 10 0.841 1.015 0.0125 0.01231 0.01212 0.01195 0.012688
25 26 0.707 0.774 0.0325 0.0419 0.0543 0.070091 0.025155
pan 154 - - 0.1925 - - - -
𝒙𝒊 𝒙𝒊 𝒙𝒊
̅ 𝒑 . 𝒙𝒊 = 𝟏. 𝟓𝟕𝟕
∑𝑫 ∑ = 𝟎. 𝟐𝟒𝟖𝟗 ∑ 𝟐 = 𝟎. 𝟏𝟓𝟐𝟏𝟎𝟕 ∑ 𝟑 = 𝟎. 𝟏𝟐𝟓𝟖𝟕𝟔
𝒊 ̅𝒑
𝑫 ̅𝒑
𝑫 ̅𝒑
𝑫
𝒊 𝒊 𝒊

Volume mean diameter

𝟏 𝟑 𝟏
̅𝒗 =
𝑫 𝟑 = √ = 𝟏. 𝟗𝟗𝟓𝟑𝟒𝟕 𝒎𝒎
√ 𝒙 𝟎. 𝟏𝟐𝟓𝟖𝟕𝟔
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

Mean volume diameter

̅ 𝒑 . 𝒙𝒊 ) = 𝟏. 𝟓𝟕𝟕 𝒎𝒎
𝑫𝒗̅ = ∑(𝑫 𝒊

Surface mean diameter

𝟏
̅𝒔 =
𝑫 = 𝟒. 𝟎𝟏𝟗𝟕 𝒎𝒎
𝒙
∑ (̅ 𝒊 )
𝑫𝒑
𝒊

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Mean surface diameter

𝒙
∑ (̅ 𝒊 )
𝑫𝒑 𝟎. 𝟐𝟒𝟖𝟕𝟕
𝒊
𝑫𝒔̅ = = √ = 𝟏. 𝟒𝟎𝟓𝟕 𝒎𝒎
𝒙 𝟎. 𝟏𝟐𝟓𝟖𝟗
∑ ( ̅ 𝟑𝒊 )
√ 𝑫 𝒑𝒊

Mean length diameter

𝒙
∑ ( ̅ 𝟐𝒊 )
𝑫𝒑𝒊 𝟎. 𝟏𝟓𝟐𝟏𝟐
𝑫𝑳̅ = = = 𝟏. 𝟐𝟎𝟖𝟑 𝒎𝒎
𝒙 𝟎. 𝟏𝟐𝟓𝟖𝟗
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

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 CHEMICAL ENGINEERING TECHNOLOGY

EXPERIMENT # 4

ULTRAFINE GRINDER
INTERODUCTION
The ultrafine grinder is designed compactly with a wonderful appearance: it is small in size and light in
weight, reliable in operation and easy in maintenance. It has a large range of service and proves to be high
quality in crushing. In one word, this grinder will provide the best service to the users.

The machine is composed of the body and base. The body and valve form the crushing chamber. The main
shaft, supported by a roller bearing, passes through the bearing box of the body with a pulley on one end
of the crushing chamber. On the rotator there are lines of steel teeth crisscrossing with the gear wheel
fixed inside of the valve. Around the rotator, screen is fixed on the valve, there is an inlet, above which is
the hopper. The outlet is beneath the body.

PARTS OF ULTRAFINE GINDER

1. Hopper B 10. Small triangle belt wheel
2. Hopper A 11. Knuckle gear
3. Body 12. Pinion gear wheel
4. Inlet 13. Oblate gear
5. Rotator 14. Big gear wheel
6. Inner end cover 15. Sieve (screen)
7. Taper roller bearing 16. Vale
8. Outer end cover 17. Outlet
9. Main shaft 18. Base

ALPINE UNIVERSAL MILL

The Alpine pin disc mill shown in Figure is a form of pin mill and consists of two vertical steel plates with
horizontal projections on their near faces. One disc may be stationary whilst the other disc is rotated at
high speed; sometimes, the two discs may be rotated in opposite directions. The material is gravity fed in
through a hopper or air conveyed to the center of the discs, and is thrown outwards by centrifugal action
and broken against of the projections before it is discharged to the outer body of the mill and falls under
gravity from the bottom of the casing.

Alternatively, the pins may be replaced by swing beaters or plate beaters, depending on the setup and application.
The mill gives a fairly uniform fine product with little dust and is extensively used with chemicals, fertilizers and other
materials that are non-abrasive, brittle or crystalline. Control of the size of the product is effected by means of the
speed and the spacing of the projections and a product size of 20 μm is readily attainable.

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 CHEMICAL ENGINEERING TECHNOLOGY

The Alpine universal mill with turbine beater and grinding is suitable for both brittle and tough materials.
The high airflow from the turbine keeps the temperature rise to a minimum.

OBJECTIVE
To report differential analysis and cumulative analysis of product obtained from ultrafine grinder and
energy requirement to run the grinder.

REQUIRED MATERIAL
 Tray
 Sieve vibratory machine
 Set of sieve (preferably of different size)
 Stopwatch
 Material (corn cores)

PROCEDURE
 Weigh the 1Kg of corn core. It should pass 10cm hole
 Start grinder and simultaneously start stopwatch and note down time for two revolution of
energy meter, when grinder is unloaded.
 Start introducing corn core pieces through hopper and start stopwatch and noting time taken
for two revolution of energy meter when grinder is loaded.
 Keep introducing feed pieces and measuring the time take for total feed
 When grinding is complete turn of grinder machine and note the time for full grinding.
 Analyze product obtained from grinder by sieving in different mesh no. and weighing fractions
and making analysis.

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 CHEMICAL ENGINEERING TECHNOLOGY

OBSERVATION AND CALCULATION

𝐹𝑒𝑒𝑑 𝑡𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 = 1 𝐾𝑔 = 1 × 10−3
𝑊𝑒𝑖𝑔ℎ𝑡 𝑓𝑜𝑟 𝑎𝑛𝑎𝑙𝑦𝑠𝑖𝑠 = 200 𝑔𝑟𝑎𝑚
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛1 ) 𝑤ℎ𝑒𝑛 𝑢𝑛𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡1 = 60 𝑠𝑒𝑐
𝑇𝑖𝑚𝑒 𝑓𝑜𝑟 2 𝑟𝑒𝑣𝑜𝑙𝑢𝑡𝑖𝑜𝑛(𝑛2 ) 𝑤ℎ𝑒𝑛 𝑙𝑜𝑎𝑑𝑒𝑑 = 𝑡2 = 37 𝑠𝑒𝑐
𝑇𝑜𝑡𝑎𝑙 𝑡𝑖𝑚𝑒 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 = 𝑇 = 297 𝑠𝑒𝑐
𝑟𝑒𝑣
𝐸𝑛𝑒𝑟𝑔𝑦 𝑚𝑒𝑡𝑒𝑟 𝑓𝑎𝑐𝑡𝑜𝑟 = 𝑁 = 50
𝐾𝑊ℎ

𝐸𝑛𝑒𝑟𝑔𝑦 (𝑒𝑥𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡)

𝑛2 𝑛1 𝑇 × 1000
𝐸=( − )
𝑡2 𝑡1 𝑁 × 𝑊
2 2 297 × 1000
𝐸=( − )
37 60 50 × 1 × 10−3
𝐾𝑊ℎ
𝐸 = 123081.08
𝑡𝑜𝑛
𝑇𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 (𝑖𝑛𝑐𝑙𝑢𝑑𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑡𝑜 𝑟𝑢𝑛 𝑡ℎ𝑒 𝑒𝑞𝑢𝑖𝑝𝑚𝑒𝑛𝑡 𝑢𝑠𝑒𝑑 𝑓𝑜𝑟 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔 𝑜𝑛𝑒 𝑡𝑜𝑛 𝑜𝑓 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙.

𝑛2 𝑇 × 1000
𝐸=( )
𝑡2 𝑁 × 𝑊
2 297 × 1000
𝐸=( )
37 50 × 1 × 10−3
𝐾𝑊ℎ
𝐸 = 321081.08
𝑡𝑜𝑛

Differential Analysis
Average 𝒙𝒊 𝒙𝒊 𝒙𝒊
Mesh Mass Opening Mass ̅ 𝒑 . 𝒙𝒊 Cumulative
particle ̅ ̅ ̅ 𝑫
No. retained of sieve fraction 𝑫𝒑𝒊 𝑫𝟐𝒑𝒊 𝑫𝟑𝒑𝒊 𝒊
Analysis
size
(g) (mm) ̅ (𝒙𝒊 )
𝑫𝒑𝒊 (mm)
7 80 1 - 0.40 - - - - 1
6 68 0.5 0.750 0.34 0.4533 0.6044 0.8059 0.2550 0.60
5 12 0.355 0.428 0.06 0.1404 0.3283 0.7680 0.0257 0.26
4 14 0.212 0.284 0.07 0.2469 0.8709 3.0721 0.0198 0.20
3 9 0.15 0.181 0.03 0.1657 0.9157 5.0592 0.0054 0.13
2 6 0.106 0.128 0.03 0.2344 1.8311 14.3051 0.0038 0.10
1 4 0.0603 0.083 0.02 0.2405 2.8927 34.7891 0.0017 0.07
Pan 10 - - 0.05 - - - - 0.03
𝒙𝒊 𝒙𝒊 𝒙𝒊
∑𝑫 ̅ 𝒑 . 𝒙𝒊 = 𝟎. 𝟑𝟏𝟏𝟒 ∑ = 𝟏. 𝟒𝟖𝟏𝟐 ∑ 𝟐 = 𝟕. 𝟒𝟒𝟑𝟐 ∑ 𝟑 = 𝟓𝟖. 𝟕𝟗𝟗𝟓
𝒊 𝑫̅𝒑 ̅𝒑
𝑫 ̅𝒑
𝑫
𝒊 𝒊 𝒊

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 CHEMICAL ENGINEERING TECHNOLOGY

Volume mean diameter

𝟏 𝟑 𝟏
̅𝒗 =
𝑫 𝟑 = √ = 𝟎. 𝟐𝟓𝟕𝟏𝟔 𝒎𝒎
√ 𝒙 𝟓𝟖. 𝟕𝟗𝟗𝟓
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

Mean volume diameter

̅ 𝒑 . 𝒙𝒊 ) = 𝟎. 𝟑𝟏𝟏𝟒 𝒎𝒎
𝑫𝒗̅ = ∑(𝑫 𝒊

Surface mean diameter

𝟏 𝟏
̅𝒔 =
𝑫 = = 𝟎. 𝟔𝟕𝟓𝟏𝟏 𝒎𝒎
𝒙 𝟎. 𝟒𝟖𝟗𝟏
∑ (̅ 𝒊 )
𝑫𝒑
𝒊

Mean surface diameter

𝒙
∑ (̅ 𝒊 )
𝑫𝒑 𝟎. 𝟒𝟖𝟗𝟏
𝒊
𝑫𝒔̅ = = √ = 𝟎. 𝟏𝟓𝟖𝟕𝟐 𝒎𝒎
𝒙 𝟎. 𝟓𝟒𝟓𝟖
∑ ( ̅ 𝟑𝒊 )
√ 𝑫 𝒑𝒊

Mean length diameter

𝒙
∑ ( ̅ 𝟐𝒊 )
𝑫𝒑𝒊 𝟎. 𝟒𝟖𝟓𝟒
𝑫𝑳̅ = = = 𝟎. 𝟏𝟐𝟔𝟓𝟗 𝒎𝒎
𝒙 𝟎. 𝟓𝟒𝟓𝟖
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

USES
 It is most desirable to crush various coarse grains and fodder, such as corn, soyabean, sorghum,
dried sweet—potato slices and soyabean cake. Each of these articles can crushed into “powder”
by one stroke without any residue.

 This machine is also popular in chemical industry, paper-making and medical industry, because it
can be used to crush various kinds of chemical raw materials, exercise beating in paper making
and process herbal medicine.

 It is also be used to crush fresh fruit, fresh sweet potato and soaked soyabean, which contain a
great deal of moisture content, the crushing result is very good and praised by the users.

PRECAUTIONS
 When grinder is driven by internal combustion engine or any other power machine, the
following two precautions must be kept in mind.
o The rotational speed require by the grinder must be guarded, therefore, if necessary the
pulley of driving mechanism can be replaced.
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 CHEMICAL ENGINEERING TECHNOLOGY

o To guarantee a smooth and steady operation, it is advisable to fix the base of the
grinder to a cement platform or other solid support.
 The material to be crushed or grind should be adopted and no tiny metal pieces and other
foreign materials should be allowed.
 During the course of operation, no repair is allowed. Once any trouble or abnormal noise is
found, operation should be stopped at once.

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 CHEMICAL ENGINEERING TECHNOLOGY

EXPERIMENT # 5

PEBBALE MILL
INTRODUCTION
A cylindrical cell slowly turning about a horizontal and filler to about half of its volume with a solid grinding
to make or forms a pebble mills. The shell is usually steel lined with high steel plate, porcelain, silica rock
or rubber. In the mill the grinding element are carried out of the shell nearly to the top from where they
fell on the part underneath. The energy expended in lifting the grinding unit utilize in reducing the size of
the particles.

A Pebble mill, a type of grinder, is a cylindrical device used in grinding (or mixing) materials like ores,
chemicals, ceramic raw materials and paints. Pebble mills rotate around a horizontal axis, partially filled
with the material to be ground plus the grinding medium. Different materials are used as media, including
ceramic balls, flint pebbles and stainless steel balls. An internal cascading effect reduces the material to a
fine powder. Industrial Pebble mills can operate continuously, fed at one end and discharged at the other
end. Large to medium-sized pebble mills are mechanically rotated on their axis, but small ones normally
consist of a cylindrical capped container that sits on two drive shafts (pulleys and belts are used to transmit
rotary motion).

The Pebble mill is a key piece of equipment for grinding crushed materials, and it is widely used in
production lines for powders such as cement, silicates, refractory material, fertilizer, glass ceramics, etc.
as well as for ore dressing of both ferrous non-ferrous metals. The pebble mill can grind various ores and
other materials either wet or dry. There are two kinds of pebble mill, grate type and over fall type due to
different ways of discharging material. There are many types of grinding media suitable for use in a pebble
mill, each material having its own specific properties and advantages. Key properties of grinding media
are size, density, hardness, and composition.

 Size: The smaller the media particles, the smaller the particle size of the final product. At the same
time, the grinding media particles should be substantially larger than the largest pieces of material
to be ground.
 Density: The media should be denser than the material being ground. It becomes a problem if the
grinding media floats on top of the material to be ground.
 Hardness: The grinding media needs to be durable enough to grind the material, but where
possible should not be so tough that it also wears down the tumbler at a fast pace.
 Composition: Various grinding applications have special requirements. Some of these
requirements are based on the fact that some of the grinding media will be in the finished product.
Others are based in how the media will react with the material being ground.
o Where the color of the finished product is important, the color and material of the
grinding media must be considered.
o Where low contamination is important, the grinding media may be selected for ease of
separation from the finished product (i.e.: steel dust produced from stainless steel media
can be magnetically separated from non-ferrous products). An alternative to separation
is to use media of the same material as the product being ground.
o Flammable products have a tendency to become explosive in powder form. Steel media
may spark, becoming an ignition source for these products. Either wet-grinding, or non-
sparking media such as ceramic or lead must be selected.
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o Some media, such as iron, may react with corrosive materials. For this reason, stainless
steel, ceramic, and flint grinding media may each be used when corrosive substances are
present during grinding.

OBJECTIVE
Calculate the angle 𝜶 to which the ball are carried against the wall of jar mill and give differential and
cumulative analysis of product.

MATERIAL REQUIRED
 Jar mill
 Pebbles
 Vibratory shakes and set of sieves
 Collecting tray
 Solid for study (coal)

PROCEDURE
 Measure the inside diameter of jar mill
 Measure the size of the ball with the help of Vernier caliper.
 Fill the jar mill to about half of its volume with balls of same diameter
 Feed the jar mill 250g mass of coal of homogenous size (obtained by screening) and note the
particle diameter.
 Before turning on the mill set the speed regulator to maximum.
 Measure the speed of rotation of the jar mill in revolution per minute
 Analyze the product with the help of screen and note the particle diameters.

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 CHEMICAL ENGINEERING TECHNOLOGY

OBSERVATION AND CALCULATION

Feed weight for analysis = 250 gram

Differential Analysis
Average 𝒙𝒊 𝒙𝒊 𝒙𝒊
Mesh Mass Opening Mass ̅ 𝒑 . 𝒙𝒊 Cumulative
particle ̅ ̅ ̅ 𝑫
No. retained of sieve fraction 𝑫𝒑𝒊 𝑫𝟐𝒑𝒊 𝑫𝟑𝒑𝒊 𝒊
Analysis
size
(g) (mm) ̅ 𝒑 (mm) (𝒙𝒊 )
𝑫 𝒊
8 160 2.38 - 0.64 - - - - 1
10 22 1.68 2.03 0.088 0.0433 0.0214 0.0105 0.1786 0.36
14 22 1.19 1.435 0.088 0.0613 0.0427 0.0298 0.1263 0.272
20 2 0.841 1.0155 0.008 0.0079 0.0078 0.0076 0.0081 0.184
25 8 0.707 0.774 0.032 0.0413 0.0534 0.0690 0.0248 0.176
Pan 36 - - 0.144 - - - - 0.144
𝒙𝒊 𝒙𝒊 𝒙𝒊
∑𝑫 ̅ 𝒑 . 𝒙𝒊 = 𝟎. 𝟑𝟑𝟕𝟖 ∑ = 𝟎. 𝟏𝟓𝟑𝟗 ∑ 𝟐 = 𝟎. 𝟏𝟐𝟓𝟑 ∑ 𝟑 = 𝟎. 𝟏𝟏𝟕𝟎
𝒊 𝑫̅𝒑 ̅
𝑫𝒑𝒊 ̅𝒑
𝑫
𝒊 𝒊

Volume mean diameter

𝟏 𝟑 𝟏
̅𝒗 =
𝑫 𝟑 = √ = 𝟐. 𝟎𝟒𝟒 𝒎𝒎
√ 𝒙 𝟎. 𝟏𝟏𝟕𝟎
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

Mean volume diameter

̅ 𝒑 . 𝒙𝒊 ) = 𝟎. 𝟑𝟑𝟕𝟖 𝒎𝒎
𝑫𝒗̅ = ∑(𝑫 𝒊

Surface mean diameter

𝟏 𝟏
̅𝒔 =
𝑫 = = 𝟔. 𝟒𝟗𝟕𝟕 𝒎𝒎
𝒙 𝟎. 𝟏𝟓𝟑𝟗
∑ (̅ 𝒊 )
𝑫𝒑
𝒊

Mean surface diameter

𝒙
∑ (̅ 𝒊 )
𝑫𝒑 𝟎. 𝟏𝟓𝟑𝟗
𝒊
𝑫𝒔̅ = = √ = 𝟏. 𝟏𝟒𝟔𝟗 𝒎𝒎
𝒙 𝟎. 𝟏𝟏𝟕𝟎
∑ ( ̅ 𝟑𝒊 )
√ 𝑫 𝒑𝒊

Mean length diameter

𝒙
∑ ( ̅ 𝟐𝒊 )
𝑫𝒑𝒊 𝟎. 𝟏𝟐𝟓𝟑
𝑫𝑳̅ = = = 𝟏. 𝟎𝟕𝟎𝟗 𝒎𝒎
𝒙 𝟎. 𝟏𝟏𝟕𝟎
∑ ( ̅ 𝟑𝒊 )
𝑫𝒑𝒊

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 CHEMICAL ENGINEERING TECHNOLOGY

EXPERIMENT # 6

ANGLE OF REPOSE
OBJECTTIVE
To measure the angle of repose of given sample.

APARATUS
 Rotary cylinder
 Solid objects to study (rice)
 Pneumatic conveyor
 Hooper
 Cyclone

THEORY
“The angel between the sloping side of the come and the horizontal in
the conical heap is called angle of repose.”

The angle of repose is the greatest angle to the horizontal made naturally by the inclined surface of
abrasive when poured from designated height. When we pile up a granular mean (think about a small
mount), the angle of repose that adopts will take value between 𝜃𝑣 and 𝜃𝑚 (by figure) under 𝜃𝑟 the salt
pile always is stable, and 𝜃𝑚 there will be avalanches on the surface spontaneously.

When bulk granular materials are poured onto a horizontal surface, a conical pile will form. The internal
angle between the surface of the pile and the horizontal surface is known as the angle of repose and is
related to the density, surface area and shapes of the particles, and the coefficient of friction of the
material. However, a 2011 study shows that the angle of repose is also gravity-dependent. Material with
a low angle of repose forms flatter piles than material with a high angle of repose.

The term has a related usage in mechanics, where it refers to the maximum angle at which an object can
rest on an inclined plane without sliding down. This angle is equal to the arctangent of the coefficient of
static friction μs between the surfaces.

When bulk granular materials are poured onto a horizontal surface, a conical pile will form. The internal
angle between the surface of the pile and the horizontal surface is known as the angle of repose and is
related to the density, surface area and shapes of the particles, and the coefficient of friction of the
material. However, a 2011 study shows that the angle of repose is also gravity-dependent.Material with
a low angle of repose forms flatter piles than material with a high angle of repose.

The term has a related usage in mechanics, where it refers to the maximum angle at which an object can
rest on an inclined plane without sliding down. This angle is equal to the arctangent of the coefficient of
static friction μs between the surfaces.

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MEASUREMENT

There are numerous methods for measuring angle of repose and each produces slightly different results.
Results are also sensitive to the exact methodology of the experimenter. As a result, data from different
labs are not always comparable. One method is the triaxial shear test, another is the direct shear test.

If the coefficient of static friction is known of a material, then a good approximation of the angle of repose
can be made with the following function. This function is somewhat accurate for piles where individual
objects in the pile are minuscule and piled in random order.

Where, μs is the coefficient of static friction, and θ is the angle of repose

METHOD OF DETERMINING THE ANGLE OF REPOSE

TILTING BOX METHOD

This method is appropriate for fine-grained, non-cohesive materials, with individual particle size less than
10 mm. The material is placed within a box with a transparent side to observe the granular test material.
It should initially be level and parallel to the base of the box. The box is slowly tilted at a rate of
approximately 0.3 degrees/second. Tilting is stopped when the material begins to slide in bulk, and the
angle of the tilt is measured.

FIXED FUNNEL METHOD

The material is poured through a funnel to form a cone. The tip of the funnel should be held close to the
growing cone and slowly raised as the pile grows, to minimize the impact of falling particles. Stop pouring
the material when the pile reaches a predetermined height or the base a predetermined width. Rather
than attempt to measure the angle of the resulting cone directly, divide the height by half the width of
the base of the cone. The inverse tangent of this ratio is the angle of repose.

REVOLVING CYLINGER METHOD

The material is placed within a cylinder with at least one transparent face. The cylinder is rotated at a
fixed speed and the observer watches the material moving within the rotating cylinder. The effect is
similar to watching clothes tumble over one another in a slowly rotating clothes dryer. The granular
material will assume a certain angle as it flows within the rotating cylinder. This method is recommended
for obtaining the dynamic angle of repose, and may vary from the static angle of repose measured by
other methods. When describing the angle of repose for a substance, always specify the method used.

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ANGER OF REPOSE OF VARIOUS MATERIALS.

Here is a list of various materials and their angle of repose. All measurements are approximated and not
exact.

Material (condition) Angle of Repose (degrees)

Ashes 40°
Asphalt (crushed) 30–45°
Bark (wood refuse) 45°
Bran 30–45°
Chalk 45°
Clay (dry lump) 25–40°
Clay (wet excavated) 15°
Clover seed 28°
Coconut (shredded) 45°
Coffee bean (fresh) 35–45°
Earth 30–45°
Flour (corn) 30–40°
Flour (wheat) 45°
Granite 35–40°
Gravel (loose dry) 30–45°
Gravel (natural w/ sand) 25–30°
Malt 30–45°
Sand (dry) 34°
Sand (water filled) 15–30°
Sand (wet) 45°
Snow 38°
Urea (Granular) 27°
Wheat 27°

PROCEDURE
 Take the sample of granular solids of particles size around sugar grains or similar like wheat or
rice and with a suitable humidity grade.
 Fill the rotary cylinder to half using the pneumatic conveyer system (sucking from a hopper and
separating the particles though a cycle.
 Turn the cylinder slowly clockwise until the very moment that particles start sliding
 Take note of the angle described by the solids
 Calculate the angle of repose as the means between these two measures.
 Repeat the test several time for better thoroughness of the data.

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OBSERVATION AND CALCULATION

ANGLE OF REPOSE OF RICE
Clockwise Anticlockwise
30o 31o
Mean angle of repose = 30.5o

ANGLE OF REPOSE FORE WHEAT

Clockwise Anticlockwise
38o 35o
Mean angle of repose = 36.5o

USES
 Angle of repose is used in the design of equipment for the processing of particulate solid e.g.
design of appropriate hopper or silo to store materials
 The angle of repose is also crucial in correctly calculating stability in vessels.
 It is also used by mountaineers as a factor in analyzing avalanche danger n mountainous area.

PRECAUTION
 The rotary cylinders should be filled up to marked level correctly.
 Keep your eye align with the rotary cylinder to accurately measure the angle of repose.

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EXPERIMENT # 7

CYCLONE SEPARATOR
OBJECTIVE
To calculate the solid masic flow separated by an erocyclone.

APPARATUS
 Pneumatic transport system
 Cyclone
 Hopper
 Solid for study
 Chronometer

WORKING PRINCIPLE
A high speed rotating (air) flow is established within a cylindrical or conical container called a cyclone. Air
flows in a spiral pattern, beginning at the top (wide end) of the cyclone and ending at the bottom (narrow)
end before exiting the cyclone in a straight stream through the center of the cyclone and out the top.
Larger (denser) particles in the rotating stream have too much inertia to follow the tight curve of the
stream and strike the outside wall, falling then to the bottom of the cyclone where they can be
removed. In a conical system, as the rotating flow moves towards the narrow end of the cyclone the
rotational radius of the stream is reduced, separating smaller and smaller particles.

THEORY
Most centrifugal separators for removing particles from gas streams contain no moving parts. They
typified by the cyclone separator shown in figure. It consists of a vertical cylinder with a conical bottom,
a tangential inlet near the top, and an outlet for dust at the bottom of the cone. The inlet is usually
rectangular. The outlet pipe is extended into the cylinder to prevent short-circuiting of air from inlet to
outlet.

The incoming dust-laden air travels in a spiral path around and down the cylindrical body of the cyclone.
The centrifugal force developed in the vortex tends to move the particles radially toward the wall, and the
particles that reach the wall slide own into the cone and are collected. The cyclone is basically a settling
device in which a strong centrifugal force, acting radially, is used in place of a relatively weak gravitational
force acting vertically.
2
𝑚𝑢𝑡𝑎𝑛
The centrifugal force 𝐹𝑐 at radius 𝑟 is equal to 𝑟𝑔𝑐
, where m is the mass of particle and 𝑢𝑡𝑎𝑛 is its
tangential velocity. The ratio of the centrifugal force to the force of gravity is then
2
𝑚𝑢𝑡𝑎𝑛
𝐹𝑐 ( 𝑟𝑔 ) 𝑢𝑡𝑎𝑛
2
= 𝑚𝑔𝑐 =
𝐹𝜃 𝑟𝑔
𝑔𝑐

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For a cyclone 1ft in diameter with tangential velocity of 50 ft/s near the wall, the ratio F c/Fg, called the
separation factor, is 2500/(0.5 × 32.2) = 155. A large-diameter cyclone has a much lower separation factor
at the same velocity, and velocity, and velocities above 50 to 70 ft/s are usually impractical because of the
high pressure drop and increased abrasive wear.

Small-diameter cyclones may have separation factors as high as 2500. To handle large gas flows, a number
of small-diameter cyclone may be grouped in single enclosure with common headers for the feed and
product gases and a single dust hopper.

The dust particles entering a cyclone are accelerated radially, but the force on a particle is not constant
because of the change in r and also because the tangential velocity in the vortex varies with r and with
distance below the inlet. Calculation of particle trajectories is difficult, and the efficiency of a cyclone is
generally predicted from empirical correlations.

For a given air flow rate and inlet velocity, however, moderate increases in cyclone diameter and length
improve the collection efficiency, because the increase in surface area offsets the decreased centrifugal
force.

The decrease in efficiency with decreasing particle size is actually more gradual than predicted by simple
theories. For small particles, the radial velocity and the collection efficiency should be a function of 𝐷𝑝2 ,
but agglomeration of the fines may occur to raise the efficiency for these particles. Because of the particle
size effect, the uncollected dust leaving with the gas has a much smaller average size than the entering
dust, which may be important in setting emissions limits. Also, the overall efficiency is a function of the
particle size distribution of the feed and cannot be predicted just from the average size.

The collection efficiency of a cyclone increases with the particle density and decrease as the gas
temperature is increased because of the increase in gas viscosity. The efficiency is quite dependent on
flow rate because of the 𝑢𝑡𝑎𝑛 term used in above equation. The cyclone is one of the few separation

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devices that work better at full load than at partial load. Sometimes two identical cyclones are used in
series to get more complete solids removal, but the efficiency of the second unit is less than the first,
because the feed to the second unit has much lower average particle size.

PROCEDURE
 Weigh some amount of solid such as salt or fine sand.
 Place the solid in the hopper with the discharge valve close.
 Turn on compressor and regulate the air inlet with the flow meter valve and note this value.
 Place the suction pipe in hopper precisely and the solid start to conveying from the hopper to the
cyclone.
 At the same time start the chronometer and place the particle discharge pipe of the cyclone to
another hopper with the discharge valve closed.
 When the conveying of solid is finished stop the chronometer.
 Calculate the solid masic flow.

OBSERVATION AND CALCULATION

Weigh of the box = 24g

Mass passing before Mass after passing

Mesh no. Efficiency %
erocyclone (g) erocyclone (g)
7 38 35 92
6 50 48 96
5 50 49 98
4 50 46 92

USES
 Cyclone are used for filtration in a wide variety of application like abrasive, coolant mists,
explosive, medical, fine-powder, metal working chips, toxic media and various production
exhaust.
 They are often used as an air pollution control.

PRECAUTION
 If material being handled by a process is combustible the dust it generated is likely to be explosive.
 Cyclone are frequently located inside the plant where explosive relief venting is impractical.
 Additionally their configuration makes explosion relief ventilation challenges since a smooth
inside wall and adequate Venetic is required. In such a system, explosion pressure detectors, on
the cyclone detect the pressure excursion from air impeding explosion. The detector transmit a
single to control panel which triggers high rate discharge. Extinguishers while simultaneously
shutting down the process.

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