BALL MILL

1. Objectives:
To find efficiency of ball mill for dry material with the help of Rittinger’s No.
and draw fractional and differential plot.

2. Theory:
The main body of the ball mill is a low speed rotary cylinder mounted on two
large bearings horizontally. Rotary part of the ball mill is driven at reducing
speed by motor through speed reducer and gear wheel or by low speed
synchronous motor through gear wheel. Inside the cylinder, feed properly
grinded by medium steel balls. The medium will be lifted to a certain height
under the action of centrifugal force and friction and drop or fall.
3. Experimental procedure:
● Feed is available in the form of lump so prepare feed to size of coarse powder
using jaw crusher.
● Perform sieve analysis on feed material and note different weight fraction
● Run ball mill at constant RPM without material for 15 min and note reading for
power calculation
● Charge feed in ball mill and again run for 15 min at same RPM and note energy
meter reading
● Now take out the product and carry out same sieve analysis as done on the feed

3.1 Schematic diagram:

3.2 Utilities:
The ball mill is used for grinding materials such as coal, pigments, and felspar for
pottery etc.
 Experimental observation:
● RPM :
● Energy meter reading without and with material :

Feed and product observation:

Feed observation Product observation

Feed Screen aperture Mass Product Screen Mass

Screen (mm) retained Screen aperture retained
(g) (mm) (g)
F7 6.7 48.5 P7 500 54.5
F6 4.75 43.5 P6 355 32.5
F5 3.35 28 P5 250 13.5
F4 2.36 18.5 P4 180 11.5
F3 1.7 13.5 P3 125 19.0
F2 1.18 15 P2 90 12.5
F1 0.85 9.5 P1 63 1.5
Result and discussion:
Calculation table:

For feed material:

Screen Screen Avg Dia. Mass Mass Mass fraction Ratio of

aperture retained fraction pass through sp. (xi*ni/ Dpi )
Dpi (mm)
(mm) (g) retained (xi) Surface
(ni)
F7 6.7 - 48.5 0.272 0.948 9.3 377.55
F6 4.75 5.725 43.5 0.247 0.8628 8.65 373.19
F5 3.35 4.05 28 0.159 0.7861 8.1 318.00
F4 2.36 2.856 18.5 0.1051 0.681 7.25 266.89
F3 1.7 203 13.5 0.0767 0.520 5.9 222.92
F2 1.18 1.44 15 0.0852 0.272 4.5 266.25
F1 0.85 1.1015 9.5 0.052 0 4.1 193.55
For product material:

Screen Screen Avg Dia. Mass Mass Mass fraction Ratio of

aperture retained fraction pass through sp. (xi*ni/ Dpi )
Dpi (mm)
(mm) (g) retained (xi) Surface
(ni)
P7 500 - 54.5 0.3578 0.9897 3.2 2405.12
P6 355 427.5 32.5 0.2241 0.9035 3.0 1572.63
P5 250 302.5 13.5 0.0931 0.7725 2.8 861.75
P4 180 215 11.5 0.0793 0.6932 2.7 995.86
P3 125 150.5 19.0 0.1310 0.6001 2.5 2147.54
P2 90 107.5 12.5 0.0862 0.3760 2.34 1876.35
P1 63 76.5 1.5 0.0103 0 2.2 296.21

Fractional plot: Fractional plot is drawn between mass fraction retained and average diameter of
particle for feed and product data and validate your graph with standard graph
Cumulative plot: Cumulative plot is drawn between mass fraction pass through and screen
aperture for feed and product data and validate your graph with standard graph.
Plate and Frame Filter Press
number of plates =8
ELUTRIATOR
 ELUTRIATOR

1. Objectives:

​ To investigate the working of a standard elutriator and to analyze its separation abilities.
​ To separate particles from a mixture into three different fractions in three
elutriating columns and find out the separation efficiency of each column.

2. Theory:

The separation of solid particles into several fractions based on their terminal velocities is called
classification. Elutriator is the simplest device that works on the principle of classification. If two
particles having different settling velocities are placed in a rising current of water and the water
velocity is adjusted to a value between the terminal velocities of the two particles a separation
will result.
An elutriator is a device used to separate particles into two or more groups. In an elutriator
containing three columns the feed is entered in the column 1 having the smallest diameter. The
diameter gradually increases in column 2 and column 3.
When the particles are introduced, often through a side tube, the smaller particles are carried
away with the fluid stream while the larger particles settle against the upward current.
 .

In table 1 values of Re’ are given as a function of log {(R’2/ρu2)Re’-1}. In order to determine
the terminal falling velocity of a particle is evaluated and the corresponding value of
and hence of the terminal velocity can be calculated

Table 1. Values of log (Re’) as a function of log {(R’2/ρu2)Re’2} for spherical particles.

log {(R’2/ρu2)Re’2} 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

2 .620 .720 .819

1 .919 .018 .117 .216 .315 .414 .513 .612 .711 .810

0 .908 .007 .105 .203 .301 .398 .495 .591 .686 .781

1 .874 .967 0.008 0.148 0.236 0.324 0.410 0.495 0.577 0.659

2 0.738 0.817 0.895 0.972 1.048 1.124 1.199 1.273 1.346 1.419

3 1.491 1.562 1.632 1.702 1.771 1.839 1.907 1.974 2.040 2.106

4 2.171 2.236 2.300 2.363 2.425 2.487 2.548 2.608 2.667 2.725

5 2.783 2.841 2.899 2.956 3.013 3.070 3.127 3.183 3.239 3.295
 Table 2. Values of log Re’ as a function of log {(R’2/ρu2)Re’-1} for spherical particles.

log {(R’2/ρu2)Re’-1} 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9

5 3.401

4 3.316 3.231 3.148 3.065 2.984 2.903 2.824 2.745 2.668 2.591

3 2.517 2.443 2.372 2.300 2.231 2.162 2.095 2.027 1.961 1.894

2 1.829 1.763 1.699 1.634 1.571 1..508 1.496

1 0.963

1 .969 .919 .865 .811 .760 .708 .656 .605

2 .554 .503 .452 .401 .350 .299 .249 .198 .148 .097

3 .047 .996 .946 .895 .845 .794 .744 .694 .644 .594

4 .544 .493 .443 .393 .343 .292

3. Experimental Procedure:
​ 200 gm feed is prepared and its particle size analysis is done.
​ Terminal setting velocities of the particles are calculated using equation 4 and Table 1.
​ The flow rates are calculated using terminal settling velocities such that the largest
particle should settle in smallest diameter column and the smallest particle should
settle in largest diameter column.
​ Actual flow rate of the elutriator is set at 85% of the minimum value.
​ Flow rate of the Rotameter fixed and wait for 30 minutes.
​ The flow rate of water coming out of the exit is checked using a measuring cylinder and
stopwatch. It should meet the desired value.
​ The sample is fed through the hopper.
​ The whole setup is to operated for half an hour.
​ After that the pump is closed and again the setup is left for 1 hour for particles to settle
down in respective tubes of different diameter.
​ After the completion of the experiments the materials settled in each column are to
dried, filtered and screened to get the particle size analysis.
​ The materials are dried in oven after filtration.
 ​ Then weigh the particles and do particle size analysis for particles collected from each
column respectively.
​ Calculate cut particle diameter for each tube using equation 5 and Table 2.
​ Determine separation efficiency from cumulative plot of feed and products in each
column.

3.1 Schematic diagram:

Figure 1: SCHEMATIC DESCRIBING DESIGN AND OPERATION OF A STANDARD

ELUTRIATOR.
3.2 Utilities:

● Electric supply single phase AC, – socket with earth connection.

● Water supply (Initial fill).
● Drain required.
● Floor area required .
● Raw material for the feed (Silica).
● Oven for drying of product.
● Electronic weighing balance (2kg least count 0.1 gm.).

3.3 Experimental Observations:

Flow Rate (actual): 4 LPM

Table 1: FEED PARTICLE SIZE ANALYSIS

Screen Diameter Weight Retained Cumulative Mass

Mass Fraction
(µm) (gm) Fraction
600 47 0.235 0.0235
425 5 0.025 0.260
300 63.5 0.3175 0.5775
212 23.5 0.1175 0.695
150 42 0.21 0.905
106 3 0.015 0.92
75 9 0.045 0.965
PAN 5 0.025 0.99

Table 2: PRODUCT PARTICLE SIZE ANALYSIS FOR COLUMN 1

Screen Diameter Weight Retained Cumulative Mass

Mass Fraction
(µm) (gm) Fraction
600 1 0.0089 0.0089
425 2.5 0.022 0.0309
300 27 0.241 0.2719
212 23 0.205 0.4769
150 42 0.372 0.8489
106 9 0.080 0.8569
75 0.5 0.0044 0.8613
PAN 0.2 0.0017 0.8630
 Table 3: PRODUCT PARTICLE SIZE ANALYSIS FOR COLUMN 2

Screen Diameter Weight Retained Cumulative Mass

Mass Fraction
(µm) (gm) Fraction
600 0 0 0
425 0 0 0
300 1 0.0465 0.0465
212 0.5 0.0232 0.0
150 1.5 0.070 0
106 2 0.093 0.125
75 10 0.465 0.375
PAN 6 0.28 0.75

Table 4: PRODUCT PARTICLE SIZE ANALYSIS FOR COLUMN 3

Screen Diameter Weight Retained Cumulative Mass

Mass Fraction
(µm) (gm) Fraction
600 0 0 0
425 0 0 0
300 0 0 0
212 0 0 0
150 0 0 0
106 0.5 0.167 0.125
75 1 0.333 0.375
PAN 1.5 0.5 0.75
 PRESSURE DROP
THROUGH PACKED BED
Pressure drop through packed bed

1. Objectives:
To plot modified Reynold’s No. (NRe.m) vs. modified friction factor (f) and verify Ergun’s
equation

2. Theory:
Packed bed provides a large surface area of contact between two fluids and thus
extensively used in distillation, extraction, absorption etc. As the fluid pass through the
bed, it passes through the void present in the bed. The voids form continuous channels
throughout the bed. The flow may be laminar through some channels and turbulent in
other channels

.
 Where, h manometer reading
ρm density of manometer fluid
ρ density of water
L bed length
ε void fraction of bed
VP volume of single particle
V superficial velocity
SP surface of single particle
μ viscosity of fluid

ϕs sphericity

Dp equivalent diameter of particle

3. Experimental procedure:

● Determine surface area of one ring by taking average value of inside, outside
diameter and length of random 10 rings
● Determine volume of one ring experimentally with the help of measuring
cylinder
● Determine porosity of bed with the help of measuring cylinder
● Now on experimental setup, allow water to flow from bottom to top in a packed
bed. Regulate flow of water by means of pinch cork.
● Note the manometer reading at different flow rate
● For flow measurement, note collected outlet volume of water with time and
calculate flow rate
● Also note flow rate from rotameter and correlate with calculated water flow rate.
3.1 Schematic diagram:

3.2 Utilities:
In industry, a packed column is a type of packed bed used to perform separation
processes, such as absorption, stripping, and distillation. A packed column is
a pressure vessel that has a packed section.

3.3 Experimental observations:

Inside diameter of column
Effective height of packing L
Density of manometer fluid ρm
Density of water ρ
Viscosity of water μ
Inside diameter of packing
Outside diameter of packing
Length of packing
manometer reading flow rate Q Rotameter flow
h1, cm h2, cm Volume of water, L Time, s rate (LPM)

21 18.2 0.6 10 4
21.4 18 0.8 10 5
21.7 17.5 0.51 5 6
21.8 17 0.62 5 7
22.5 16.6 0.72 5 8
23 17.1 0.94 5 9
Manomete Flow Pressure Superficial Modified Friction Eargun’s
r Reading, rate, Q drop per velocity, Reynold’s factor, f equation,
Δh = h1-h2, m3/s length, V m/s no, NRe.m N/m
cm N/m

2.8 60 2884.14 0.03057324841 490.74235 22.85073221 783.9117503

3.4 80 3502.17 0.04076433121 654.3231334 15.60786619 1341.617865
4.2 102 4326.21 0.05197452229 834.2619951 11.86024163 2126.26686
4.8 124 4944.24 0.06318471338 1014.200857 9.171544069 3090.239185
5.9 144 6077.295 0.07337579618 1177.78164 8.359332838 4122.188816
5.9 188 6077.295 0.09579617834 1537.659363 4.904343756 6914.145872
4. Sources of error:

Since we have assumed Dp = 4 mm there are bound to be discrepancies.

SEDIMENTATION
 SEDIMENTATION

1. Objectives;

To study the batch sedimentation for limestone water slurry.

Use these data to calculate the area of a continuous thickener (S) in which limestone water slurry
equivalent to the slurry in your experiment is fed at the rate of 50 tons of dry solid per hour to
produce a slurry of 550 grams of limestone per liter?

2. Theory:

Sedimentation, or clarification, is the process of letting suspended material settle by gravity.

Depending on the particles concentration and the type of interaction between the particles,
sedimentation or settling can be described as of four types:
● Discrete Particle Settling: The particles settle without any interaction. This occurs under low
solids concentration.
● Flocculent Settling: This is defined as a condition where particles initially settle
independently, but flocculate in the depth of the clarification unit. The velocity of settling
particles usually increases as the particles aggregate.
● Hindered Settling: Inter – particle forces are sufficient to hinder the settling of neighboring
particles. The particles tend to maintain a fixed position with respect to each other. This type
of settling is typical in the settler for the activated sludge process (or a secondary clarifier).
● Compression Settling: This occurs when the particle concentration is so high that so that
particles at one level are mechanically influenced by particles on lower levels. The settling
velocity then drastically reduces.
Sedimentation used in industry can be mainly of two types:

Gravity Sedimentation: which uses gravitational force as a driving force for settling.

Centrifugal Sedimentation: which uses centrifugal force as a driving force for settling.

3. Experimental Procedure:

● Prepare limestone water slurry containing 250 g of solids in 1 litre water.

● Observe the height of interface between clear and suspended solid and note the height
of interface with time.
● Repeat this experiment at least three times.
 ● The ultimate height and ultimate concentration of the solid in the settled sludge (Cu) is to
be measured on the next day.

3.1 Schematic Diagram:

Figure 1: Schematic of a sedimentation experiment.

3.2 Utilities:
● Measuring cylinder with Calibrated chart/scale.
● Limestone (250 g).
● Electronic weighing balance (2kg least count 0.1 gm.).
 3.3 Experimental Observations and calculations:

Weight of limestone taken: 180g

Volume of water added: 2L

1. Thickener area calculation:

Plot height of interface (hi) w.r.t. time (ti). Determine the intercept and the slope of the curve
atleast at 10 points of the curve (covering the whole range of time). The slope is the settling
velocity (v) corresponding to the points selected in step above and the intercept is for that
particular time. Obtain the concentration of solid using the following equation:
 where, concentration of solids in slurry initially
initial height of the interface
concentration of solids in slurry corresponding to interface .

2. Plot settling velocity (v) versus solids concentration (C). Calculate LC for different settling
velocity (v) using following equation.
Settling velocity(cm/s) Intercept(Zi) (cm) Concentration (Ci) (g/mL) (Li*Ci/S) (kg/m2*s)

4.55 45.5 0.09 3.855

0.3125 19.5 0.21 1.7586

0.375 15 0.293 1.215

0.2892 13.5 0.303 1.079

0.2 11.5 0.352 0.9585

0.099 9 0.455 0.7246

0.082 7.5 0.546 0.8728

0.078 7 0.575 0.915

0.076 6.75 0.607 1.044

0.074 6.5 0.63 1.126

CHARACTERISTICS OF
FLUIDIZED BED
Flow Height of
Rate h1 h2 Delta h Bed
4 20.8 18.8 2 16
6 21.4 18.1 3.3 16.5
8 22 17.5 4.5 16.9
10 22.5 17.1 5.4 18.2
12 22.9 16.6 6.3 19
14 23.5 16 7.5 21
12 22.7 16.9 5.8 18.8
10 21.8 17.2 5.1 17.9
8 21.8 17.7 4.1 16
6 21.3 18.3 3 16
4 20.9 18.6 2.3 16
Result and Discussion:

u (m/s)
Δ (Pth) ε log (u) log (ε) Δ (Pexp)

1440.8928 0.03395470442 0.32 -1.469100046 -0.4948500217 2459.1708

1440.8928 0.05093205664 0.3406060606 -1.293008787 -0.4677476286 4057.63182

1440.8928 0.06790940885 0.3562130178 -1.16807005 -0.4482902134 5533.1343

1440.8928 0.08488676106 0.4021978022 -1.071160037 -0.3955603069 6639.76116

1440.8928 0.1018641133 0.4273684211 -0.991978791 -0.3691975717 7746.38802

1440.8928 0.1188414655 0.4819047619 -0.9250320014 -0.3170387822 9221.8905

1440.8928 0.1018641133 0.4212765957 -0.991978791 -0.3754326677 7131.59532

1440.8928 0.08488676106 0.3921787709 -1.071160037 -0.4065159189 5656.09284

1440.8928 0.06790940885 0.32 -1.16807005 -0.4948500217 5041.30014

1440.8928 0.05093205664 0.32 -1.293008787 -0.4948500217 3688.7562

1440.8928 0.03395470442 0.32 -1.469100046 -0.4948500217 2828.04642

Precautions: