Particle Technology & Screening Processes Particle Properties

PARTICLE TECHNOLOGY 1. Density

2. Flowability
Introduction
3. Chargeability
 Characterization 4. Adsorption
 Formation
 Processing
 Utilization PARTICLE SIZE DISTRIBUTION
IMPORTANCE

*concern:  Predict particle behavior

 Particle classification
 Particles
 Predict how to engineer the particle
 Powder
 Particulate Solids
Measurement of Particle Size
*scope (additional):
 Mechanical Analysis (used in 0.075 mm dia)
 Nanoparticles
 Hydrometer Analysis (used in <0.0075 mm dia)
 Aerosols
 Liquid droplets
 Emulsion Screening
 Bubbles
-separation of mixture of particles of various
sizes into two or more fractions by a screening surface
*Ways to characterize a particle
~ Particle Morphology *Perry’s Chemical Engineers’ Handbook
1. Size Definition 7th Edition: Section 19, pp. 19-18 to 23
2. Sizing Methods
Tables:
3. Size Distributions
4. Shape 19-5: Types of Screening Operations
5. Porosity 19-6: US Sieve Series & Tyler Equivalents
19-7: Slotted Opening Factors
Particle morphology: Size Definition Figures 19-21 & 19-22: Unit Capacity & Open
Spherical Particles Area Factor

 Diameter
 Radius SCREENING TYPES
1. Dry Screening
Non-Spherical Particles  Treatment of a material containing a natural
amount of moisture or a material that has been
 Equivalent Diameter *discussed DAW noong dried before screening.
momentum
2. Wet Screening
Particle Morphology: Sizing Methods  Operation when water is added to the material
being treated for the purpose of washing fine
 Mechanical (Sieving)
material through the screen.
 Optical (TEM, SEM, Doppler Shift Method,
Fraunhofer Diffraction)
 Electronic (Coulter Counter) General Terminologies:
 Dynamic (Sedimentation)  Oversize Material (material that retain on the
 Physical screening surface)
 Chemical  Undersize Material (material that passes
through the screening surface)
  Intermediate Material (when two screens are  Length (relates the efficiency)
used for screening, the material that retain on the Mesh Number Determination
second screen is called the intermediate
material) M ( A+ D )=1
 Unsized Function (a single screen can make a M – Mesh Number
single separation into two fractions [undersize A – Aperture
and oversize]. Such types of functions is called
D – Diameter
the undersize functions)
 Sized Function (when the material is passed
through the series of screens then it is divided Sample Problem: (Mesh Number Determination:
into many fractions. Such types of function is Example # 1)
known as sized functions.)
Find the diameter of mesh number 10 screens
 Mesh Number (number of openings/holes per
with 0.065 inches aperture.
linear inch)
 Screen Aperture (maximum clear space
between the edges of the screen opening) Given:
 Screen Interval (relationship between the M = 10
successive sizes of screen openings in a series)
A = 0.065 in.
D=?
Construction of Screens
M ( A+ D )=1
 Woven wire cloth *most common
 Silk bolting cloth
10 ( 0.0065+ D )=1
 Punched plates D=0.035∈.
 Bar screens

Methods of Reporting Size Fraction

Standard Screens In terms of aperture:
 U.S. Tyler / Tyler Standard Sieve Series Oversize, ¼ in +1/4 +1/4
o Fixed ratio of sqrt(2) on screen openings Through ¼ in on 1/8 in -1/4 + 1/8 1/4 / 1/8
o Based on 200 mesh screen
Through 1/8 in on 1/16 in -1/8 + 1/16 1/8 / 1/16
 U.S. ASTM / U.S. Sieve Series
Undersize, 1/16 in -1/16 -1/16
o Fixed ratio of screen openings
asaadsasadsasadsadsaa Passed Fractional
o Based on 200 mesh screen
through Form
 International Test Sieve Series then
retained
Testing Sieve Shakers
 Ro-Tap Sieve Shaker In terms of Mesh Number:
 End Shak Oversize, 4 mesh +4 +4
 Dynamic Sieve Shaker Through 4 mesh on 8 mesh -4 + 8 4/8
Through 8 mesh on 10 mesh -8 + 10 8/10
Classes of Screening Equipment Through 10 mesh on 14 mesh -10 + 14 10/14
Through 14 mesh on 20 mesh -14 + 20 14/20
 Grizzly Screens
Undersize, 20 mesh -20 -20
 Revolving Screens
 Shaking Screens
 Vibrating Screens
 Oscillating Screens

Factors in selecting Screening Equipment:

 Width (determines the capacity)
Sample Problem: (Methods of Reporting Screen (Fractional Way)

Analysis) 4 7g 0.07
6 10 g 0.10
8 23 g 0.23
Differential Screen Analysis of Fractional Plot
10 8g 0.08
Mesh Mass
100 grams 14 12 g 0.12
Number Fraction, xi
20 25 g 0.25
4 7g
Pan 15 g 0.15
6 10 g
8 23 g
*in fractional way, kung ano lang laman ng pan, yon na
10 8g
yong mass fraction.
14 12 g
20 25 g
Pan 15 g For Cumulative (On-Screen)
*report mesh number as +positive (referring as on-
Solution: screen)

100 g Mesh Number Mass Fraction, xi

+4 0.07
@ Mesh No. 4: 7g 93 g
+6 0.17 [0.10+0.07]
@ Mesh No. 6: 10 g 83 g
+8 0.40 [0.17+0.23]
@ Mesh No. 8: 23 g 60 g
+10 0.48 [0.40+0.08]
@ Mesh No. 10: 8g 52 g +14 0.60 [0.48+0.12]
@ Mesh No. 14: 12 g 40 g +20 0.85 [0.60+0.25]
@ Mesh No. 20: 25 g 15 g Pan 1.00 [0.85+0.15]

@ Pan: 15 g
For Cumulative (Through Screen)

One way to report: Mesh Number *report mesh number as -negative (referring as passed
through)
100 grams Mesh Number
Mesh Number Mass Fraction, xi
4 7g +4
-4 0.93 [1.00-0.07]
6 10 g -4 +6
-6 0.83 [0.93-0.10]
8 23 g -6 +8
-8 0.60 [0.83-0.23]
10 8g -8 +10
-10 0.52 [0.60-0.08]
14 12 g -10 + 14
-14 0.40 [0.52-0.12]
20 25 g -14 + 20
-20 0.15 [0.40-0.25]
Pan 15 g
Pan

Screen Effectiveness
 The measure of success of a screen in closely
separating materials
 Recovery of desired material in product and
rejection of desired material in product

Effectiveness of Screen CMB

For Mass Fraction, xi: F x F =P x P + R x R

100 grams Mass Fraction, xi
 P xP 6/8 0.075 0.080 0.020
Recovery of desired material in P =
F xF 8/10 0.125 0.145 0.055
10/20 0.100 0.170 0.090
( 1−X P ) P
Rejection of desired material in P = 1− 20/28 0.125 0.150 0.085
( 1− X F ) F
28/35 0.125 0.280 0.100
35/48 0.175 0.175 0.150
Screen Effectiveness = Recovery*Rejection
48/65 0.225 0.150
PxP ( 1−X P ) P
Form1 :
F xF (
1−
( 1− X F ) F ) 65/100
100/150
0.050 0.250
0.100

Desired Mat % @ mesh 35

*F = ( x P −x R ) & P = ( x F −x R )
Feed: xf = 0.175 + 0.225 + 0.050 = 0.45
P ( x F −x R )
From = Reject: xR = 0.175
F ( x P −x R )
Product: xP = 0.150 + 0.150 + 0.250 + 0.100 =
0.650
x P ( x F −x R ) ( 1−X P ) ( x F−x R )
Form2 :
(
x F ( x P −x R )
1−
( 1−X F ) ( x P−x R ) ) For one screen:
50 tons
P=
Effectiveness = effectiveness based on oversize
6 hr
particles * effectiveness based on undersize particles
Component Material Balance:

R x R ( 1−X P ) P F x F =P x P + R x R
E=
[
F x F ( 1−X F ) F ] P ( x F −x R )
=
F ( x P −x R )

Screen Capacity (it indicates how much material a 50

screen can handle 6 ( 0.45−175 )
=
F ( 0.65−0.175 )

Expressions of capacity can be: tons

F=14.3939
hr
1. Mass of Feed / Area-time [MT/day-ft2]
2. Mass of Feed / Area-time-aperture [MT/day-ft 2-
mm] Efficiency:

PxP ( 1−X P ) P
E=
F xF
1−
(( 1− X F ) F )
Sample Problem (Screening)
50 50
Limestone is crushed by 6 units operating in parallel and
the products separated by 35 mesh screens also in
parallel, into two fractions. The effective dimensions of
E=
6
(0.650)

14.3939(0.45)
1− (
( 1−0.650 ) ( )
6
( 1−0.45 ) (14.3939) )
each screen is 6’ by 20’. The common undersize from E=0.5282=52.82 % efficient .
the screen comes out at the rate of 50 tons/hr. Assume no
losses. lb
Capacity: in
24 hr−ft 2
1. The efficiency of the screening operation is __. tons
F=14.3939
2. The capacity of each screen in lbs/24h-ft2 is __. hr
lb
F=6333.316
Mesh Feed Size Overflow Underflow 24 hr−ft 2
Sample Problem (Screening)
1800 lbs of dolomite per hour is produced by crushing
and then screening through a 14-mesh screen. The screen
analysis is as follows:
Size Reduction
 Involves the production of smaller mass units
from larger mass units of the same materials.
 Ways in which particles of solids are cut or
broken into smaller pieces
 Size reduction is the operation carried out for
reducing the size of bigger particles into smaller
one of desired size and shape with the help of
external forces.

Feed: xf = 0.285 +0.086+0.057+0.0286 = 0.4566
Reject: xR = 0.24
Product: xP = 0.4 +0.3 +0.2 + 0.1 = 1.0
Hardness of Material
The hardness of the material as measured by
Mohs scale of (1) to (10) is a criterion of its resistance to
crushing and has significant effect on the wear and tear
of the size reduction device.

P = 1800 lb/hr
Soft Materials: (1) talc, (2) gypsum, (3) calcite
1800 ( 0.4566−0.24 )
= Intermediate: (4) fluorite (5) apatite (6) feldspar
F (1−0.24 )
Hard Materials: (7) quartz (8) topaz (9)
F = 6315.7895 lb/hr.
corundum (10) diamond

Efficiency:
Objectives
PxP ( 1−X P ) P
E=
F xF (
1−
( 1− X F ) F ) 1. Increase the surface area , because, in most
reactions involving solid particles, the rate of
reactions is directly proportional to the area of
1800 (1)
E= contact with a second phase
6315.7895( 0.45 66)
2. Break a material into very small particles in
E=0.6242=62.42 % efficient . order to separate the valuable amongst the two
constituents
3. Achieve intimate mixing
Size Reduction 4. To dispose solid wastes easily
5. To improve the handling characteristics
6. To mix solid particle more intimately
 In most reactions involving solid particles, the
rate is directly proportional to the area of contact
on the second phase. Advantages
1. Content uniformity
By the size reduction, it will also increase the surface 2. Uniform flow
and the reactivity of the solid particles will increase 3. Effective drying
4. Increase surface area or viscosity
5. Uniform mixing and drying
Must be size reduced to meet its size and shape 6. Improve rate of absorption
specification. 7. Improve dissolution rate

*Perry’s Chemical Engineers’ Handbook Disadvantages

th
7 Edition: Section 20, pp. 20-5 to 20-7, 20-10 to 20-56 1. Drug degradation (strictly for pharmaceutical
th
8 Edition: Section 21, pp. 21-8 to 21-11, 21-45 to 21-73 companies)
 2. Contamination 2. Amount of energy/powder used
3. Particle size
4. New surface formed
Mechanism
Types of comminution (size reduction) equipment
1. Compression (crushing) *commonly used
- Particle disintegration by two rigid forces 1. Crusher
- Coarse reduction of hard solids to give 2. Grinder
relatively few fines Energy and Power Requirements: THEORIES AND
LAWS
2. Impact 1. Rittinger’s Law (1867)
- Particle concussion by a single rigid force 2. Kick’s Law (1885)
- Gives coarse, medium or fine product sizes
3. Bond’s Law (1952)

3. Attrition
- Arising from particles scraping against one POWER REQUIREMENT: RITTINGER’S LAW
another or against a rigid surface
- States that the work required in crushing is
- Yields very fine products from soft non-
proportional to the new surface created
abrasive materials
(n=2)

4. Shear (cutting) 1 1
- Produced when the particle is compressed
E=K R ( −
x2 x1 )
between the edges of two hard surfaces
X2 is the mean diameter of the product
moving tangentially
X1 is the mean diameter of the feed
KR is the Rittinger’s constant

POWER REQUIREMENT: KICK’S LAW

- The energy required for crushing is
proportional to the size reduction ratio (the
ratio of the initial particle size to the final
particle size [n=1])
X1
E=K K ln ( ) X2

Different Impact used to reduce the size of particle X2 is the mean diameter of the product

1. Gravity Impact X1 is the mean diameter of the feed

- The free-falling material’s moment is
momentarily stopped by the stationary
object
2. Dynamic Impact
- Most often used when it is necessary to
separate two material which have relatively
different friability
KK is the Kick’s constant
POWER REQUIREMENT: BOND’S LAW
- The work required to form particles from
very large size is proportional to the square
root of the surfaces to volume ratio of the
product ¿(n=1.5)

Disrupting Forces in Size Reduction

1.
2.
Compression
Impact
E=K B ( √1x )
2

3. Shear
X2 is the mean diameter of the product
4. Both compression and shear
KB is the Bond’s constant
Work Index (Ei)
Factors affecting size reduction
1. Hardness of feed
 - The work index required to reduce a unit 42.3 76.6
N c= N c=
weight from very large size to 80% passing √ D−d √ D−d
a 100 micrometer screen

P 1 1
T
=1.46 E i
(√ −
X2 √ X1 )
P 1 1
T
=0.3162 E i
(√ −
X2 √ X1 ) Sample Problem: Size Reduction
The critical speed of a ball mill in rpm whose diameter is
POWER REQUIREMENT: RITTINGER’S LAW 12” with grinding balls with diameter of 1/2” is
approximately __ rpm.
Work Index (Ei)
76.6
P A p − Af N c=
= 12 0.5
T N
√ −
12 12
N c =78.2475 rpm
Shape Factor
specific surface area
η= Sample Problem: Size Reduction
6
Dp It is desired to crush 10 tons/hr of iron ore hematite. The
size of the feed is such that 80% passes a 3” screen and
80% of the product is to pass a 1/8” screen. Calculate the
CRUSHING EFFICIENCY
gross power required.
- The ratio of the surface energy created by
P 1 1
crushing to the energy absorbed by the solid
T
=1.46 E i
( −
√ X2 √ X1 )
ε S ( A p− A f )
ε C= P 1 1
εA

MECHANICAL EFFICIENCY
10
=1.46(12.68)
(√ 0.125
12
−

√3
12
)
P=1443.6205 hp
- The ratio of the energy absorbed per energy
input
Settling and Sedimentation
εA
ε m=
εi

Crushing can be:

1. Closed circuit
- Operations where material is returned to the
crusher
2. Open circuit
- No oversize material returned to the crusher

Stages in Commercial Size Reduction

1. Coarse size reduction: feeds from 2” – 96” or
more
2. Intermediate size reduction: 1” – 3”
3. Fine Size reduction: 0.25” – 0.5”

Critical Speed for Mills