Beruflich Dokumente
Kultur Dokumente
Table of contents
Experiments:
1. Determination of apparent and real density of materials.
2. Granular analysis of material by sieving apparatus.
3. Solid handling bench apparatus experiment.
Angle of repose
Loading and unloading
V-blender
4. Crushing of material of required size by jaw crusher and doing sieve
analysis on that material.
5. Ball mill and Pebble mill.
6. Cake filtration.
7. Double roll crusher.
8. Cyclone separator.
9. Helical ribbon mixer.
PARTICLE TECHNOLOGY LAB REPORT 3
Experiment#1:
Determination of apparent and real density of materials.
Required Materials:
1. Measuring cylinder
2. Vibratory sieve
3. Solids object to study
Theory:
1. Density: Density is a characteristic property of a substance. The density of a
substance is the relationship between the mass of the substance and how
much space it takes up (volume). The mass of atoms, their size, and how
they are arranged determine the density of a substance.
Absolute density of material cannot be determined because of the empty
spaces(voids) present between the particle due to irregular shape of the particle.
As shown in the figure below
2. Apparent density: The mass per unit volume (or the weight per unit
volume) of a material, including the voids which are inherent in the
material is called apparent density.
PARTICLE TECHNOLOGY LAB REPORT 4
3. Material density: The mass per unit volume (or the weight per unit volume)
of a material, not including the voids which are inherent in the material is
called real density or material density.
4. Methods of measuring real & apparent density: There are basically two
methods used for measuring real and apparent density.
By using vibratory sieve apparatus: This method is preferred if the
solid material under study is water soluble e.g. sugar, salts etc.
By using water and measuring cylinder: This method is preferred if
the material under study is not water soluble e.g. sand.
Procedure:
1. First weight the given sample of the solid.
2. After that place the sample in the measuring cylinder and determine the
volume of the sample which It occupied without compacting.
3. Then calculate the apparent density of the material by using formula.
mass of particles
Apparent density = ρ =
Volume of particle without compacting
4. To calculate the real density of material, determine the nature of
compound whether it is water soluble or not.
5. If the material is water soluble put the measuring cylinder containing
material over the vibratory sieve shaker the material.
6. Again note the volume of material and determine the real density by using
formula.
mass of particles
Real density = ρ =
Volume of particle after compacting
7. If the substance is not water soluble then the placed the material in the
measuring cylinder and pour water in it, water compacted the material and
then again note the volume of material in the cylinder and calculate the
real density by using above formula.
8. In the end calculate the crushing ratio of material by using formula.
𝐴𝑝𝑝𝑎𝑟𝑒𝑛𝑡 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
Crushing ratio = Φ =
𝑅𝑒𝑎𝑙 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
PARTICLE TECHNOLOGY LAB REPORT 5
Result:
Apparent density of material = 𝜌𝐴 =1.43
Real density of material = 𝜌𝑅 = 1.51
Crushing ratio = Φ =0.947
Table of apparent and real density of some materials
Materials taken Apparent density Real density
1 Sand 1.43 1.51
2 Sugar
3 Salt
Industrial applications:
1. Bridge construction:
During construction of bridges soil erosion is the biggest problem which the
engineer faces. This is due to the empty pores present between the
particles of the soils which when come in contact of water results in
lowering of ground. If the bridge is constructed in such soil its pillars will
settle down into the soil which result in bridge destruction. That’s why
before constructing the bridge the first thing which is done is the
compacting of the soil to make a solid base.
PARTICLE TECHNOLOGY LAB REPORT 6
3. Crushing of material:
The material with high density is not easy to crush it required a large force
to crush them as compared to material with low density so the
determination of crushing ratio is very important.
PARTICLE TECHNOLOGY LAB REPORT 7
___________________________________________________________________
PARTICLE TECHNOLOGY LAB REPORT 8
Experiment#2:
Granular analysis of material by sieving apparatus.
Required Materials:
1. Stack of Sieves including pan and cover
2. Balance
3. Mechanical sieve shaker
4. Sample material under study
Theory:
A sieve analysis (or gradation test) is a practice or procedure used to separate
particle on the basis of particle size distribution (also called gradation) of a
granular material. The size distribution is often of critical importance to the way
the material performs in use.
This test is performed to determine the percentage of different grain sizes
contained within a soil. The mechanical or sieve analysis is performed to
determine the distribution of the coarser, larger-sized particles.
Procedure:
1. Take the dried sample of soil that weighs about 500 g.
2. Determine the mass of sample accurately. Wt. (g)
3. Prepare a stack of sieves. sieves having larger opening sizes (i.e.
lower mesh numbers) are placed above the ones having smaller
opening sizes (i.e. higher sieve numbers).
4. Make sure sieves are clean, if many soil particles are stuck in the
openings try to poke them out using brush.
5. Then put the sample of sand in the top of sieve of sieve stack and
cover its top with a lid.
6. Now put the stack in the sieve shaker and fix the clamps, adjust the
time on 10 to 15 minutes, frequency 50Hz and get the shaker going.
7. When the shaker time is over measure the mass retained over each
sieve.
PARTICLE TECHNOLOGY LAB REPORT 9
0.4
0.3
0.2
0.1
0
0 0.2 0.4 0.6 0.8 1 1.2
Screen opening diameter(mm)
2.Comulative analysis:
Screen Mass Percentage Cumulative Cumulative
Sieve opening retained mass w.t % w.t%
# diameter in retained undersize oversize
(mm) screen
(g)
1 0 0 100 0
7
0.5 80 15.93625498 84.06374502 15.93625498
6
0.355 156 31.07569721 52.98804781 47.01195219
5
0.212 220 43.8247012 9.163346614 90.83665339
4
0.15 30 5.976095618 3.187250996 96.812749
3
PARTICLE TECHNOLOGY LAB REPORT 11
100
80
60
40
20
0
0 0.2 0.4 0.6 0.8 1 1.2
Screen opening diameter(mm
wt −wf 505−502
Percentage mass loss during sieve analysis = ×100 = ×100
wt 505
= 0.59%<<2%
PARTICLE TECHNOLOGY LAB REPORT 12
been stopped. There is also a critical speed which, if approached will diminish
blending efficiency considerably. As the revolutions per minute increase, the
centrifugal forces at the extreme points of the blender will exceed the gravitation
forces required for blending. Consequently, the powder shall tend to gravitate to
the outer walls of the blender shell. As the size of the blender increases, the
rotational speed decreases usually in proportion to the peripheral speed of the
blender extreme. V-Blenders are designed to operate at 50% to 80% of the critical
speed.
Discharge from the V-blender is normally through the apex port which is fitted
with a discharge valve.
Principle of V shape blender:
The basic principle of v shape blender is tumbling action the cylinder is rotatable
first material are lifted up with the motion of blender and then allow to fall freely
due to gravity this is the basic principle used in “V” shape blender.
Applications of V-Blenders:
V-Blenders designs are most often used for the dry blending of free flowing solids.
This blender is often used for pharmaceuticals, but the mixing action's slight shear
limits the blender's use for some very soft powders or granules. V-Blenders are
generally used for the following:
Food products Ceramics Powders
Gravity also affects the angle of repose grater the gravitational force lesser
the angle of repose
Internal friction also affects the angle of repose greater the internal friction
more the angle of repose as shown below
This is because moist sand has greater cohesive forces as compared to the
dry sand
Methods in 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
PARTICLE TECHNOLOGY LAB REPORT 19
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 cylinder 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.
Angle of repose of different materials:
Material Angle of repose (Degree)
Wheat 27
Urea 27
Sand 45
Ashes 40
Bark 45
Corn flour 30-40
Wheat flour 45
PARTICLE TECHNOLOGY LAB REPORT 20
Applications:
The angle of repose is sometimes used in the design of equipment for the
processing of particulate solids. For example, it may be used to design an
appropriate hopper or silo to store the material, or to size a conveyor belt
for transporting the material. It can also be used in determining whether or
not a slope (of a stockpile, or uncompact gravel bank, for example) will
likely collapse; the talus slope is derived from angle of repose and
represents the steepest slope a pile of granular material will take. This
angle of repose is also crucial in correctly calculating stability in vessels.
It is also commonly used by mountaineers as a factor in analyzing avalanche
danger in mountainous areas.
Angle of internal friction and angle of repose
Angle of repose
The angle of repose is the maximum angle that a surface can be tilted from
the horizontal, such that an object on it is just able to stay on the surface
without it sliding down. let us first look at the diagram of the situation.
When the object is just about to move, the size of friction is given by
Fr = uR. The object is also in equilibrium (the object is about to move, but
PARTICLE TECHNOLOGY LAB REPORT 21
it is not moving yet!) so taking the forces acting along the plane, we can
say,
Hopper
There are basically two types of flow pattern which usually observe in hoppers or
silo:
1. Mass flow
2. Funnel flow
Mass flow
In a mass flow hopper, all the material inside the hopper moves down the walls
and exits. The flow is based upon a first-in, first-out principle and is uniform and
reliable upon discharge. Moisture content, temperature, age, oil content, and
PARTICLE TECHNOLOGY LAB REPORT 23
solid levels must be regulated to ensure effective flow. The basic flow pattern of
USAGE
Mass flow hoppers are used in virtually every type of industry and come in a
variety of sizes. Hoppers are most often used for raw material and product
storage as well as feeders for different processes.
Sr.# Diameter of hopper Time to flow out Flow type Mass flow rate
(s)
3
PARTICLE TECHNOLOGY LAB REPORT 24
FUNNEL FLOW:
In funnel flow, the material along the funnel walls remains stationary, while
the material in the center falls through the outlet creating a rat hole, or
channel. Funnel flow hoppers have a greater angle from the center of the
cone as shown below.
USAGE
Funnel flow is versatile and can be used in many of the same applications as mass
flow. A funnel flow design is most effective when the solid particulate is coarse,
free-flowing and not prone to caking. Also, funnel flow is used when segregation
is not important.
There are two types of hoppers, conical and wedge-shaped. The hopper shown
below to the right is conical whereas a wedge-shaped hopper is a trough with a
narrow slit, as shown to the left. Conical hoppers must be steeper to promote the
same amount of flow but wedge-shaped hoppers require a conveyer to collect the
materials that exit from it.
PARTICLE TECHNOLOGY LAB REPORT 25
PARTICLE TECHNOLOGY LAB REPORT 26
Experiment:
Crushing of material of required size by jaw crusher and doing sieve
analysis on that material
Required Materials:
1. Stack of Sieves including pan and cover (ASTMA) standard.
2. Jaw crusher
Theory:
Crusher is size reduction equipment. A crusher is a machine designed to reduce
large rocks into smaller, more manageable particles. Crusher is a machine which is
used to crush heavy size particle into small size, also it’s a primary size reducer.
Crusher are low speed machine for coarse reduction of large particles Approx. size
of reduced of material from a crusher ranges from 150mm to 250 mm.
Types of crusher
Jaw crushers
Gyratory crushers
Double role crushers
Jaw crusher
Jaw crusher is a type of crusher which produces coarse particle. Feed size of the
jaw crusher is 1500mm-40mm and the product size is from 50mm-5mm. Rpm for
jaw crusher is between 200-400.
Jaw crushers are heavy duty machines and hence need to be robustly
constructed. The outer frame is generally made of cast iron or steel. The jaws
themselves are usually constructed from cast steel. They are fitted with
replaceable liners which are made of manganese steel.
The simple picture of jaw crusher is shown on the next page.
PARTICLE TECHNOLOGY LAB REPORT 27
Crushing chamber
The volume or cavity between the two jaws is called the crushing chamber. The
movement of the swing jaw can be quite small, since complete crushing is not
performed in one stroke. The inertia required to crush the material is provided by
a weighted flywheel that moves a shaft creating an eccentric motion that causes
the closing of the gap.
PARTICLE TECHNOLOGY LAB REPORT 28
Angle between two jaws is between 20-30 degree. Larger lumps caught between
upper part of the jaw and broken into small piece by impact force. Small pieces
come to narrower space at the bottom where compressive force do a sufficient
size reduction and product obtained.
Types of jaw crusher:
1. Blake crusher-the swing jaw is fixed at the upper position
2. Dodge crusher-the swing jaw is fixed at the lower position
3. Universal crusher-the swing jaw is fixed at an intermediate position
0.5
Mass fraction retained
0.4
0.3
0.2
0.1
0
0 0.05 0.1 0.15 0.2 0.25
sieve opening diameter(inches)
2.Comulative analysis:
Sieve Screen opening Mass Percentage Cumulative Cumulativ
# diameter(inches retained in mass wt% e wt%
) screen(g) retained undersize oversize
3 0.2 0.83 52.299936 47.7000630 52.299936
1
4 0.187 0.12 7.5614366 40.1386263 59.861373
7 4
7 0.111 0.28 17.643352 22.4952741 77.504725
2
8 0.937 0 0 22.4952741 77.504725
10 0.0787 0.004 0.2520478 22.2432262 77.756773
8 1
14 0.0555 0.125 7.8764965 14.3667296 85.633270
3 8
25 0.028 0.03 1.8903591 12.4763705 87.523629
Pan 0 0.198 12.476370 0 100
PARTICLE TECHNOLOGY LAB REPORT 31
0 Total 1.587 1
Chart Title
120
100
80
60
40
20
0
0 0.05 0.1 0.15 0.2 0.25
screen opening diameter(inches)
PARTICLE TECHNOLOGY LAB REPORT 32
Principle
Both works on the principle of Tumbling action i.e. impact and attrition: size reduction is done
by impact as the balls drop from near the top of the shell.
Explanation
A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell may
be either horizontal or at a small angle to the horizontal. It is partially filled with balls. The
grinding media is the balls, which may be made of steel (chrome steel), stainless steel, ceramic,
or rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistant
material such as manganese steel or rubber. Less wear takes place in rubber lined mills. The
length of the mill is approximately equal to its diameter.
History
The general idea behind the ball mill is an ancient one, but it was not until the industrial
revolution and the invention of steam power that an effective ball milling machine could be
built. It is reported to have been used for grinding flint for pottery in 1870.
Working
In case of continuously operated ball mill, the material to be ground is fed from the left through
a 60° cone and the product is discharged through a 30° cone to the right. As the shell rotates,
the balls are lifted up on the rising side of the shell and then they cascade down (or drop down
on to the feed), from near the top of the shell. In doing so, the solid particles in between the
balls and ground are reduced in size by impact.
PARTICLE TECHNOLOGY LAB REPORT 33
Varieties
Aside from common ball mills there is a second type of ball mill called a planetary ball mill.
Planetary ball mills are smaller than common ball mills and mainly used in laboratories for
grinding sample material down to very small sizes. A planetary ball mill consists of at least one
grinding jar which is arranged eccentrically on a so-called sun wheel. The direction of
movement of the sun wheel is opposite to that of the grinding jars (ratio: 1:-2 or 1:-1 or else).
The grinding balls in the grinding jars are subjected to superimposed rotational movements, the
so-called Coriolis forces. The difference in speeds between the balls and grinding jars produces
an interaction between frictional and impact forces, which releases high dynamic energies. The
interplay between these forces produces the high and very effective degree of size reduction of
the planetary ball mill.
PARTICLE TECHNOLOGY LAB REPORT 34
Efficiency
If the energy to produce new surface by single-particle
breakage is used as the basis for evaluating efficiency,
then the efficiency of ball milling has a more realistic
value of about 15% for the comminution of quartz and
soda-lime glass. In a second approach, comminution
efficiency is based on comparing the energy to produce
some size distribution parameter of the product from
ball milling with that by single-particle breakage. For
both materials, dry ball milling efficiency was found to
be in the range of 25%.
Power consumption
Grinding media consisting of steel balls, with typical
diameters from 25 to 75 mm, is already present in the mill along with any rock that has not yet
overflowed through the discharge end. Typical power consumption for a 5-m diameter by 7-m-
long ball mill is between 2.5 and 3.5 MW.
Critical speed
The "Critical Speed" for a grinding mill is defined as the rotational speed where centrifugal
forces equal gravitational forces at the mill shell's inside surface. This is the
rotational speed where balls will not fall away from the mill's shell.
PARTICLE TECHNOLOGY LAB REPORT 35
Cake Filtration
Introduction
Cake filtration is basically a solid-liquid separation technique. Although we have
different filtration technique for the separation of solid and liquid but why we require cake
filtration technique? In normal filtration techniques like membrane filtration when we separate
solids with a higher percentage of solids like slurries by a filter membrane which is porous it
results in the formation of a layer of solids over the membrane which reduces or stop the
filtration process. In this case, we have to replace the membrane at some regular intervals. So in
this case, we required a special filtration technique called cake filtration.
Principal of cake filtration
The principal of cake filtration is very interesting and simple the slurry type
material which is required to be filtered is pressed between the plates to extract the liquid from it
in this way we can separate solids from liquid economically and effectively.
Cake filtration equipment
The equipment used for cake filtration are as follows:
1. Shell and leaf filter.
2. Rotary vacuum filter.
Operation & working
1. Shell and leaf filter
The labeled diagram of the shell and leaf filters are shown in the figure below
PARTICLE TECHNOLOGY LAB REPORT 36
The material which is to be filtered is pumped into these machines and the compressional force is
applied to extract all the liquid from it as shown below:
When all the water is removed from the slurry then the compressional force is removed and then
the dried cake is also removed in the form of blocks. As shown below:
PARTICLE TECHNOLOGY LAB REPORT 37
3. Centrifugal filters
A centrifuge is a piece of equipment that puts an object in rotation around a fixed axis (spins it in
a circle), applying a potentially strong force perpendicular to the axis of spin (outward). The
centrifuge works using the sedimentation principle, where the centripetal acceleration causes
denser substances and particles to move outward in the radial direction. At the same time, objects
that are less dense are displaced and move to the center
Clarifying Filters
Clarifying filters are the filters that removes all the small amounts of solids and liquid from
either liquid or gases. The particles are trapped inside the filter medium or on porous surfaces.
Clarification differs from screening in that pores in the filter medium are larger sometimes much
larger than the particles to be removed the particles are caught by surface forces and immobilized
on the surfaces or within the flow channels where they reduce the effective diameter of the
channel but usually do not block them completely.
Clarifiers are of two types:
Liquid clarifiers
Gas clarifiers
Liquid clarifiers:
PARTICLE TECHNOLOGY LAB REPORT 39
Thickeners and clarifiers are both used to separate liquids and solids by settling. Thickeners are
used to concentrate solids, while clarifiers are used to purify liquids. The most common type of
clarifier used is circular clarifier.
Thickeners and clarifiers use slowly rotating rake arms to separate solid particulate. A liquid feed
with suspended solids is fed into a tank with a diameter of 5 to 500 feet. As the particles settle,
angled rake arms move the concentrated slurry toward the center of the tank, where it is
removed. Clear liquid overflows the top of the tank and is collected in a trough.
Equipment design is shown in the figure below:
The bridge-supported clarifier pictured above is used for primary wastewater treatment. After
large objects and grit have been screened out of the water, raw wastewater is fed into the primary
clarifier. In this stage, floating material and material that easily settles out will be removed,
resulting in a homogeneous effluent that can be further treated biologically in the secondary
clarifier, and a sludge discharge that can be treated or processed.
Uses:
Thickeners and clarifiers are often used in water and wastewater treatment plants to remove
solids, chemicals, microbes and other impurities. Thickeners and clarifiers are also used in the
paper industry, the uranium industry, and in alumina, coal, copper, and iron ore production.
Gas clarifiers:
Filter for gas cleaning includes pad filters for atmospheric dust and granular beds and bag filters
for process dusts. Air is cleaned by passing it through pads of cellulose pulp, cotton, felt. Glass
fiber, or metal screening; the pad material may be dry or coated with a viscous oil to act as a dust
holder; for light duty the pads are disposable; but in large scale gas cleaning they are frequently
rinsed and recoated with oil.
PARTICLE TECHNOLOGY LAB REPORT 40
Jaw crushers
Gyratory crushers
Double role crushers
Double roll crusher
It consists of two counter rotating rolls which are mounted
horizontally on a rigid frame. The crushing area of the rolls are
totally enclosed in a fabricated housing. One of the rolls is fixed
in position while the other is a floating roll which can move
relative to fixed roll to control product size and release un-
crushable material by spring action. Both vertical spindle and
horizontal spindle type gap adjustment system are available in MSEL range. The roll surface can
be smooth or beaded depending on the type and size of the
feed material. The crushing element is a single piece steel
casting Roll mounted on taper hubs at both ends. Two rolls
rotate in opposite direction by means of motor and belts with
or without gear box. Smooth Roll Crusher can be provided with
spring loaded roll scraper for removing sticky material from roll
surface. Roll grinding arrangement can be supplied as an
optional item for grinding the roll surface without removing the
rolls from the crusher frame. Motorized or hand operated
centralized grease lubrication system can be provided on request.
PARTICLE TECHNOLOGY LAB REPORT 42
The basic principle of crushing in double roll crusher is compressional force generated by narrow
gap between the moving rollers.
Frames
Rollers
Bearings
Belt
Drivers
Frame” A cast-iron or steel-plate frame is used. The steel-plate frame is fabricated by welding.
The Plummer blocks of fixed roll assembly are integral with the frame. The Plummer Block for the
movable roll assembly are elastically positioned in horizontal direction with high-strength coil
springs or hydraulic accumulators selected for the type of crushing duty. This elastic mounting
includes a means of adjusting the roll-to-roll clearance (roll setting) and serves as a protective
feature for preventing motor over load or damage to the crusher, as the roll will yield and back
away when it grips hard foreign matters like tramp iron.
Rollers: Roller tyres are of smooth type, corrugated type or toothed type, depending on the
crushing duty. In the standard design each roll assembly consist of a roll boss with hexagonal
outer shape rigidly mounted on the roll shaft which permits easy replacement of roll tyre. The
roll tyres are held tight by means of bolts. This arrangement provides for easy tyre replacement
and minimizes parts subject to wear. The roll tyres are made of high manganese steel.
PARTICLE TECHNOLOGY LAB REPORT 43
Bearings: Spherical roller bearings are used to support the rolls. The spherical roller bearings are
complete with labyrinth seals and packing for preventing entrance of dust and leakage of oil.
Belts: A belt is a loop of flexible material used to link two or more rotating shafts mechanically,
most often parallel. Belts may be used as a source of motion, to transmit power efficiently, or to
track relative movement.
Drive: The power of roll crusher motor is 2.2.KW, voltages are 400V and operated at 200RPM.
The standard Double roll crusher has independent belt drives from two motors, one motor for
each roll. This arrangement eliminates the need for an intermediate drive transmitting device
resulting in less space utilization and reducing the no-load power loss. In our lab we used single
driver to rotate single roller and with belts and gears we drive the other roller.
Angle of nipping
For rollers which have equal radius and length, tangents are drawn at the point of contact
of particle and the tangent of two roller meet to form angle of nip(2θ). The figure shows
the diagram of angle of nip of two rollers.
Feed size
Crusher are usually classified on the basis of feed size i.e.
1. Primary
2. Secondary
3. Tertiary
A primary crusher receives the stone directly from a quarry after blasting, and produces
the first reduction in size. Then the output of the primary crusher is fed to a secondary
crusher, which further reduces the stone size. Some of the stone may pass through four
or more crushers before it is reduced to the desired size.
So the double roll crusher is secondary crusher which receive the feed crushed of the
jaw crusher.
In order to calculate the size of the feed which should feed into the crusher we use the
following formula
Size of particle feed=𝐷𝑝 = 0.045𝑅 + 𝐿
Size of roller
To solve for the radius of the rolls, it is
convenient to assume that the particle
to be crushed is spherical and roll
surfaces are smooth. The figure below
shows a spherical particle about to
enter the crushing zone of a roll
crusher. The nip angle is defined as
the angle that is tangent to the roll
surfaces at the points of contact
between the rolls and the particle.
Usually the nip angle is between 20 and 30 but in some large roll crushers it is up to 40
degrees. The formula used to calculate the radius of roller is shown below
𝐿 − 𝐷𝑐𝑜𝑠𝜃
𝑅=
2(𝑐𝑜𝑠θ − 1)
Here,
R is radius of the roll
L is distance between rolls
D is diameter of the feed
Θ is Nip angle
Crushing ratio
The Reduction Ratio is broadly defined as the ratio of the feed size to the product size in
any crushing operation. It is very useful in determining what a crusher can do, or is
doing, in the way of size reduction. It can also be used as a partial indicator of the
stresses the crusher will be subjected to during operation, an element in determining
the crusher capacity and as an indicator of crusher efficiency. However, there is no one
PARTICLE TECHNOLOGY LAB REPORT 45
method of calculation which will provide a useful figure for all of these considerations,
so there are various types of Reduction Ratios in use, depending on how technical you
wish to get. Crushing ratio of some of the equipment is shown below:
Equipment Reduction ratios
1. Jaw crusher 1:6
2. Gyratory crusher 1:8
3. Head cone crusher 1:7
4. Double roll crusher 1:4
5. Hammer or impactor Up to 10:1
Feed rate
Although in batch system we put the feed with our desire quantity so we can control the
flow rate whoever in batch system the feed rate depends on diameter of roller, width of
roller, roller speed distance between roller and bulk density of material to be crushed.
The formula used to calculate feed rate is shown below.
𝑄 = 60𝜋𝐷𝐿𝑊𝜔𝜌𝑏 (ton/h)
Calculation of double roll crusher efficiency
The efficiency of the double roll crusher can be calculated by taking the ratio of surface
energy crated to the energy absorb by the substance the formula is shown below:
𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑒𝑛𝑒𝑟𝑔𝑦 𝑐𝑟𝑒𝑎𝑡𝑒𝑑 𝑏𝑦 𝑐𝑟𝑢𝑠ℎ𝑖𝑛𝑔
𝜂𝑐 =
𝑡𝑜𝑡𝑎𝑙 𝑒𝑛𝑒𝑟𝑔𝑦 𝑎𝑏𝑠𝑜𝑟𝑏 𝑏𝑦 𝑎 𝑢𝑛𝑖𝑡 𝑚𝑎𝑠𝑠
Or
𝐸𝑠 (𝐴𝑠𝑠𝑝 − 𝐴𝑠𝑠𝑓 )
𝜂𝑐 =
𝑊𝑎
Here,
𝐸𝑠 is the surface energy per unit area.
𝐴𝑠𝑠𝑝 is the area per unit mass of feed.
𝐴𝑠𝑠𝑓 is the area per unit mass of feed.
𝑊𝑎 is the energy absorbed by the unit mass of solid.
References
https://www.scribd.com/doc/229884634/Double-Roll-Crusher-Machine-Design
PARTICLE TECHNOLOGY LAB REPORT 46
Cyclonic separation
Introduction
Cyclonic separation is a method of removing particulates from
an air, gas or liquid stream, without the use of filters, through
vortex separation. When removing particulate matter from
liquids, a hydrocyclone is used while from gas, a gas cyclone is
used. Rotational effects and gravity are used to separate
mixtures of solids and fluids. The method can also be used to
separate fine droplets of liquid from a gaseous stream.
Working
A high speed rotating (air)flow is established within a
cylindrical or conical container called a cyclone. Air flows in a
helical 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, then fall 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, thus
separating smaller and smaller particles. The cyclone geometry, together with flow rate, defines
the cut point of the cyclone. This is the size of particle that will be removed from the stream
with a 50% efficiency. Particles larger than the cut point will be removed with a greater
efficiency, and smaller particles with a lower efficiency.
Uses
Large scale cyclones are used in sawmills to remove sawdust from extracted air.
Cyclones are also used in oil refineries to separate oils and gases, and in the cement
industry as components of kiln preheaters.
Cyclones are increasingly used in the household, as the core technology in bagless types
of portable vacuum cleaners and central vacuum cleaners.
Similar separators are used in the oil refining industry (e.g. for Fluid catalytic cracking) to
achieve fast separation of the catalyst particles from the reacting gases and vapors.
Cyclones are also used in industrial and professional kitchen ventilation for separating
the grease from the exhaust air in extraction hoods.
PARTICLE TECHNOLOGY LAB REPORT 47
Separation factor
The ratio of the centrifugal force over force due to gravity is called separation factor:
2 2
𝐹𝑐 𝑚𝑢𝑡𝑎𝑛 /𝑟 𝑢𝑡𝑎𝑛
i.e. = =
𝐹𝑔 𝑚𝑔 𝑟𝑔
A large diameter cyclone has small separation factor so its efficiency is small.
The charging of material in the blender is generally through nozzles or feed-hoppers mounted
on the top cover of the blender. The inlet cover also provides maintenance and cleaning access
to the inside of the blender. An external jacket can also be provided on the blender container
for applications which require heating or cooling of product material.
Operation
During the blending operation, the outer ribbons of the agitator move the material from the
ends to the center while the inner ribbons move the material from the center to ends. Radial
movement is achieved because of the rotational motion of the ribbons. The difference in the
peripheral speeds of the outer and inner ribbons results in axial movement of the material
along the horizontal axis of the blender. As a result of the radial and the counter-current axial
movement, homogenous blending is achieved in short time. Blending is generally achieved
within 15 to 20 minutes of start-up with a 90 to 95 percent or better homogeneity. The particle
size and its bulk density have the strongest influence on the mixing efficiency of the ribbon
blender. Ingredients with similar particle size and bulk densities tend to mix faster as compared
to ingredients with variation in these attributes
Applications of Ribbon Blenders
Ribbon blenders can be designed to operate in both batch and continuous modes. Batch type
blenders can be built up to capacities of 50 m3. The ribbon blender’s versatility for blending
solids combined with it ability to perform heating, cooling, coating, and other processes make it
a very popular blender. The following are the applications of the Ribbon Blender:
Blending large volumes of dry solids.
Dry powder to wet phase mixing.
Mixing of bulk drugs, chemicals, and cosmetic powders.
Dry Blending of capsule formulations.
Lubrication of dry granules in large quantity.
Heating, cooling, and drying of materials.
Coating solid particles with small amounts of liquids to produce formulations.