HO CHI MINH CITY UNIVERSITY OF TECHNOLOGY

OFFICE FOR INTERNATIONAL STUDY PROGRAMS

MILLING – SIFTING - MIXING

Department: Processes and Equipment

Class: CC06

Huỳnh Xuân Mai 2053205

Nguyễn Minh Tú 2052304
Quách Hoàng Như Thảo 2052713

Group 1A
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OUTLINE
1. PURPOSE:...................................................................................................................................................... 2
2. THEORY ........................................................................................................................................................ 2
2.1. Capacity and performance of the mill ------------------------------------------------------------------------------- 2
2.2. Size distribution --------------------------------------------------------------------------------------------------------- 3
2.3. Sieve Performance ------------------------------------------------------------------------------------------------------ 3
2.4. Mix Equation ------------------------------------------------------------------------------------------------------------ 4
3. EXPERIMENTAL METHOD: ..................................................................................................................... 5
3.1. Mill .............................................................................................................................................................. 5
3.2. Sieve............................................................................................................................................................. 5
3.3. Mix .............................................................................................................................................................. 5
4. EXPERIMENTAL RESULT......................................................................................................................... 5
4.1. Results -------------------------------------------------------------------------------------------------------------------- 5
4.1.1. Mill ................................................................................................................................................... 5
4.1.2. Sieve ................................................................................................................................................. 6
4.1.3. Mixing............................................................................................................................................... 7
4.2. Graphs ------------------------------------------------------------------------------------------------------------------ 10
4.2.1. Milling ............................................................................................................................................ 10
4.2.2. Sifting: ............................................................................................................................................ 11
4.2.3. Mixing: ------------------------------------------------------------------------------------------------------------------ 12
4.3. Discussion -------------------------------------------------------------------------------------------------------------- 12
1) Discussing about the adaptation of Bond’s Law in predicting the milling efficiency, especially focus on
the other theories: .......................................................................................................................................... 12
2) Give the comments on the efficiency of sifting and milling. Compare with the result in book. Explain. ... 13
3) Discus about the reliability of the result and the most effective factors: .................................................. 13
4) Comment on the way taking the samples in the mixing experiment: ...................................................... 14
5) Comment of the reliability of the result and the elements that affect the most to the mixing experiment: . 14
5. APPENDIX: ................................................................................................................................................. 15
5.1. Milling calculation:--------------------------------------------------------------------------------------------------- 15
5.2. Sifting experiment calculation:-------------------------------------------------------------------------------------- 17
5.3. Mixing experiment calculation: ------------------------------------------------------------------------------------ 17
6. REFERENCES: ........................................................................................................................................... 17
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1. PURPOSE:
- Crushing a material, based on the sieve results, determines the size distribution of the material
after grinding, the power consumption and the productivity of the mill.
- Sieve the material after crushing, determine the sieve efficiency, build the cumulative
distribution schema of the material after grinding, and then determine the material size after
grinding.
- Mix the two materials to determine the mixing index at several time, build the mixing index
graph over time to determine the appropriate mixing time

2. THEORY
2.1. Capacity and performance of the mill
- The efficiency and efficiency calculations of the turbines have dimensions Dp1 (ft) and 80%
product after weighing has dimensions Dpj (ft).
- P is capacity for milling material which is very large in size to Dp (calculated for the unit
- volume / time), i = ∞.
1
𝑃 = 𝐾𝑏 √
𝐷𝑝
- According to the definition, the Wi is necessary energy to mill from a very large size up to 100µm
(KWh/ton), we have:
- Reliable between Wi and Kb (the Bond coefficient depends on the type of material and milling
machine).
1
60𝑊𝑖 = 𝐾𝑏 √
100 × 10−3
60𝑊𝑖
→ 𝐾𝑏 = ≈ 19𝑊𝑖
√10
1
→ 𝑃 = 19𝑊𝑖
√𝐷𝑝
1 1
𝑤ℎ𝑒𝑟𝑒 𝑃1 = 19𝑊𝑖 𝑎𝑛𝑑 𝑃2 = 19𝑊𝑖
√𝐷 𝑝1 √𝐷𝑝2

- Milling capacity of 1 ton - material over 1 minute from D p1 to Dp2 :

1 1
𝑃 = 𝑃2 − 𝑃1 = 19𝑊𝑖 ( − )
√𝐷𝑃2 √𝐷𝑃1

- T is productivity (ton/min). Capacity for milling T tons/min from D p1 to D p2 :

1 1
𝑃 = 𝑃2 − 𝑃1 = 19𝑊𝑖 ( − ) 𝑇, (𝐾𝑊)
√𝐷𝑃2 √𝐷𝑃1
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where Dp1, Dp2 is the size of material and product, nm.

- If P multiply by 4/3
Consumption capacity of the motor:
𝑃 = 𝑈𝐼 cos 𝜑

Where U: voltage (V)

I: amperage (A)
cos 𝜑: factor of capacity
- Milling efficiency:
𝑃
𝐻= 100%
𝑃′

2.2. Size distribution

−𝑑∅
= 𝐾𝐷𝑝𝑏
𝑑𝐷𝑝

Where ø: cumulative mass on D p

Dp: particle size
K, b: coefficients describe particle distribution
- Differential from ø = ø1 to ø = ø2 corresponding with Dp = D1 and Dp = D2 , we have:
𝐾
∅2 − ∅1 = (𝐷 𝑏+1 − 𝐷𝑝2
𝑏+1 )
𝑏 + 1 𝑝1

- We consider between the n th sieve and the (n+1)th sieve, and assume use the standard sieve
which have Dpn - 1 / Dpn = r = const.
−𝐾 𝑏+1 )
∆∅𝑛 = ∅𝑛 − ∅𝑛−1 = (𝐷 𝑏+1 + 𝐷𝑝𝑛−1
𝑏 + 1 𝑝𝑛

and replace Dpn – 1 = r.Dpn , we get:

𝐾. (𝑟 𝑏+1 − 1) 𝑏+1
∆∅′𝑛 = 𝑏+1
𝐷𝑝𝑛 = 𝐾′𝐷𝑝𝑛
𝑏+1

𝐾.(𝑟 𝑏+1−1)
with 𝐾′ =
𝑏+1
or log ∆∅𝑛 = (𝑏 + 1) log 𝐷𝑝𝑛 + log 𝐾′
- K’ and b are determined by drawing ∆øn and Dpn based on the logarithmic graph then infer angular
coefficient K+1 and angular ordane K’ ➔ K and b

2.3. Sieve Performance

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𝐽
𝐸= × 100
𝐹𝑎

F: Initial material mass input the sieve, (g)

J: Material mass under the sieve, (g)
a: Particle ratio can pass through the sieve, (%)
- F.a is determined in the laboratory:
+ Sift F can find out J1 . Take the remain material on the F – J1 sieve and sift again can infer J2,
continue to take the rest material on the F – (J1 + J 2) and again sift it.
+ The total J1 + J2 + J3 + … will asymptote F.a
+ Sieve performance is 100% if J 1 = F.a.

2.4. Mix Equation

- When mix the amount a of A with the amount b of B, will create a homogeneous mixture.
Component A and B in ideal mixture:
𝑎
• With A: 𝐶𝐴 =
𝑎+𝑏
𝑏
• With B: 𝐶𝐵 =
𝑎+𝑏
- These components will be the same in any volume of the mixture. However, this ideal mixture
just can be reached when mix time increase until infinite and don’t have any factor against mix
process.
- In reality, time can’t advance infinite so component A and B will be different in part of different
volume.
- To evaluate the homogeneous of the mixture, we consider mean squared different.
- If in V1, the volume composition of A and B is C 1A , C1B respectively, then the mean squared
different of ideal mixture is:
∑𝑁
𝑖=1(𝐶𝐴 − 𝐶𝑖𝐴 )
2
𝑠𝐴 = √
𝑁−1

∑𝑁
𝑖=1(𝐶𝐵 − 𝐶𝑖𝐵 )
2
𝑠𝐵 = √
𝑁−1

With CA , CB is the composition of A, B in the mixture. We can see the more ideal the mixture is,
the smaller the sA, sB is. sA , sB depend on many factors but the most important is the time. The
relation between s and time is described by the graph (assume other factors are not change).
- In real, depend on the requirement of s, we can determine the suitable time. To evaluate the
homogeneous of the mixture, we can see another value is mix index:
𝜎𝑒
𝐼𝑠 =
𝑠

with σe: standard deviation

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𝐶𝐴 𝐶𝐵
𝜎𝑒 = √
𝑛

𝐶𝐴 𝐶𝐵 (𝑁 − 1)
→ 𝐼𝑠 = √
𝑛. ∑𝑁
𝑖=1(𝐶𝐴 − 𝐶𝑖𝐴 )
2

n: the number of particle in case of mix loose material.

3. EXPERIMENTAL METHOD:
3.1. Mill
- Turn on the machine without load to measure the no - load power
- Give 200g of rice to the mill
- Turn on the input screw, press the meter, measure the maximum load current intensity
- When the current is back to no – load value, press the meter to determine the grinding time
3.2. Sieve
- Determine sieve efficiency at 0.2 mm size: sieve 80g grinded rice 5 times, each time 5 minutes
and weigh the rice through the sieve each time.
- Determine the size distribution of the material after grinding: sieve 80g grinded rice through
various sieves of different size for 20 minutes and weigh accumulated rice in each sieve.
3.3. Mix
- Put 1.5kg of green beans and 3kg of soy beans into the machine
- Turn on the machine
- Stop the machine at 6 times (5s, 15s, 30s, 60s, 120s, 300s) and take 8 samples at each time
according to the chart. Count each particle in the sample.

4. EXPERIMENTAL RESULT
4.1. Results
4.1.1. Mill
Amperage (A)
Mass Time
No load Load

200g 56s 3.2 3

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Sieve sizes Mass percentage

Mass Mass distribution
(mm) distibution

0.315 50.1 50.1 0.63

0.25 5.76 55.86 0.70

0.15 12.9 68.76 0.86

0.10 4.87 73.63 0.92

log(𝜟p) log(𝜟𝜱) 𝜱

-0.50 1.70 0.63

-0.60 0.76 0.07

-0.82 1.11 0.16

-1.00 0.69 0.06

Power consumption for the motor of the loaded mill:

Pload = UIcosφ = 220 x 3 x 0.8 = 528 (W)

Power consumption for the motor of the no - load mill:

Pno - load = UIcosφ = 220 x 3.2 x 0.8 = 563.2 (W)

Power consumption for the material grinding engine:

P’ = Pload - Pno – load = 480 – 512 = -35.2 (W)

4.1.2. Sieve
- Determine sieve efficiency at 0.2 mm size
No. of times Time (min) Mass distribution Sum Ji

1 5 25.63 25.63

2 5 0.62 26.25

3 5 0.26 26.51
4 5 0.13 26.64

5 5 0.13 26.77

- Determine the size distribution of the material after grinding

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Sieve Size (mm) Mass (g)

0.315 50.1

0.25 5.76

0.15 12.9

0.10 4.87

4.1.3. Mixing

5s 15s 30s 60s 120s 300s CA CB

Sample
S G S G S G S G S G S G 0.67 0.33
1 68 25 100 39 51 33 53 89 70 54 48 46
2 59 116 42 68 49 41 33 29 67 42 37 30
3 58 39 40 52 45 63 31 71 48 37 32 36
4 82 40 60 37 59 32 42 20 70 35 28 8
5 89 124 59 62 50 35 40 38 44 23 47 25
6 49 14 57 34 99 59 53 53 51 52 41 16
7 97 194 40 51 67 76 43 36 68 53 60 27
8 124 68 38 40 43 40 39 49 40 74 38 49

TIME 5"

Sampl
S G CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is
e

1 68 25 0.73 0.06 0.004

2 59 116 0.34 -0.33 0.10

3 58 39 0.60 -0.06 0.005

4 82 40 0.67 0.005 0.00003

0.303 1246 0.013 0.06
5 89 124 0.41 -0.25 0.06

6 49 14 0.78 0.11 0.012

7 97 194 0.33 -0.33 0.11

8 124 68 0.65 -0.02 0.0004

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TIME 15"

Sample S G CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is

1 100 39 0.72 0.05 0.002

2 42 68 0.38 -0.28 0.08

3 40 52 0.43 -0.23 0.05

4 60 37 0.62 -0.048 0.002

0.26 819 0.013 0.07
5 59 62 0.49 -0.18 0.032

6 57 34 0.63 -0.04 0.001

7 40 51 0.44 -0.23 0.05

8 38 40 0.49 -0.18 0.03

TIME 30"

Sample S G CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is

1 51 33 0.60 -0.06 0.003

2 49 41 0.54 -0.12 0.01

3 45 63 0.42 -0.25 0.06

4 59 32 0.65 -0.018 0.0003 0.15 842 0.013 0.09

5 50 35 0.59 -0.08 0.006

6 99 59 0.63 -0.04 0.001

7 67 76 0.47 -0.20 0.04

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8 43 40 0.52 -0.15 0.02

TIME 60"

Sample S G CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is

1 53 89 0.37 -0.29 0.086

2 33 29 0.53 -0.13 0.018

3 31 71 0.30 -0.36 0.131

4 42 20 0.68 0.01 0.0001

0.35 719 0.013 0.06
5 40 38 0.51 -0.15 0.024

6 53 53 0.50 -0.16 0.028

7 43 36 0.55 -0.12 0.015

8 39 49 0.44 -0.22 0.05

TIME 120"

Sampl
S G CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is
e

1 70 54 0.56 -0.10 0.00

2 67 42 0.61 -0.05 0.00

3 48 37 0.56 -0.10 0.0003 0.41 1148 0.013 0.05

4 70 35 0.16 -0.50 0.0004

5 44 23 0.66 -0.009 0.002

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6 51 52 0.50 -0.17 0.03

7 68 53 0.56 -0.10 0.01

8 40 74 0.35 -0.31 0.02

TIME 300"

Sample N X CiA CiA-CA (CiA-CA)2 Ʃ n 𝝈e Is

1 48 46 0.51 -0.15 0.02

2 37 30 0.55 -0.11 0.01

3 32 36 0.47 -0.20 0.03

4 28 8 0.78 0.11 0.01

0.14 568 0.013 0.09
5 47 25 0.65 -0.01 0.0001

6 41 16 0.72 0.05 0.003

7 60 27 0.69 0.02 0.0005

8 38 49 0.44 -0.22 0.05

4.2. Graphs
4.2.1. Milling

1
0.8
0.6
𝜟p(mm)
0.4
0.2
0
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35

Chart 1. Chart of ƩJi following time

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1.5

1
log(𝜟𝜱)

y = 1.3556x + 2.0568
R² = 0.431
0.5

0
-1.2 -1 -0.8 -0.6 -0.4 -0.2 0

-0.5
log (𝜟p)
Chart 2. Chart of Log∆∅𝑛 following LogDpn

4.2.2. Sifting:

27.00

26.80

26.60

26.40

Mass distribution
26.20
(g)

26.00

25.80

25.60

25.40
0 1 2 3 4 5 6
No. sifting times (n)

Chart 3. Chart of accumulated distribution of size distribution of the material on sieve

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4.2.3. Mixing:

Is-t
0.1
0.09
0.08
0.07
0.06
Is 0.05
0.04
0.03
0.02
0.01
0
0 50 100 150 200 250 300 350

t(s)

Chart 4. Chart of mixing index following time

4.3. Discussion
1) Discussing about the adaptation of Bond’s Law in predicting the milling efficiency, especially
focus on the other theories:

Based on the milling theories mentioned in 2.1.2, we can see that:

- The Surfacial Theory of P. R. Rittinger: It can only be precisely applicable under condition that
the energy provided to per weigh unit of solid is not too considerable, and can be used to
measure the real milling process with K r determined practically on the milling machine, which is
same as the real one. Because of the constraint energy condition and the complex K r
determination due to the must of determining the factor based on each identified material and
machine, so that, this theory does not have high practical in milling process prediction.
- The Volumetric Theory of Kick: On the basis of stress analzation theory of the elasticity in the
elastic limitation. This theory does not have high practical value due to the complicated K r
determination.
- Bond’s Law: This is the highes practical value theory in the milling efficiency prediction.
Because work factor Wi has included the inner friction inside the milling machine. At the same
time, it has small error when implementing the calculation the efficiency on the different milling
machines of the same type and with the dry and wet milling processes. Therefore, this theory is
very convenient for the calculation.
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2) Give the comments on the efficiency of sifting and milling. Compare with the result in book.
Explain.
❖ Milling efficiency is calculated based on: E = 16.06%
- The weight of material used for milling M (by scale).
- Milling time (by stopwatch).
- The current with maximum load measured by Ammeter. The efficiency can be concluded to be
pretty low.
- Objective reasons:
• The efficiency of the machine is not high.
- Subjective reasons:
• The error when weighting the materials.
• Time adjustment is not precise.
However, these reasons cause very small errors which do not affect the result.
• Due to the measurement after sifting: Because the material is very light-weighted and
small particles, so that it is easy to disperse into the surrounding environment (by wind).
Besides, an amount of material is still stick on the the surface of sieve due to its small
size.
This has the most effective on the error of the result.
❖ Sifting: E = 93.48%
Efficiency is calculated based on:
- The weight of material went through sieve after the first sifting J 1.
- The amount of material might go through sieve J.a, is measured by the chart 1.
Efficiency is pretty high, thanks to:
• The humidity in the material is low.
• The suitable thickness of the material on sieve, which can make the material go through
much faster and more easily.
• The flat surface of the sieves.

3) Discus about the reliability of the result and the most effective factors:
❖ Milling:
The reliability of milling result is low.
The most effective factors (are as said above in the question 2)
❖ Sifting:
The reliability of sifting is high.
The most effective factors affect the result:
- The low humidity of the material.
- The suitable thickness of the material on the sieves.
- The flat surface of sieves.
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- The leftovers of the material on sieve from the previous sifting.

- The simple calculation also helps to reduce the error in the calculation.
❖ Mixing:
- The beans size distribution: Because of the different size between the soya beans and green
beans that affects badly on the process.
- Time mixing: The time measurement implement is unprecise. But it is not considerable.
- Specific weight of material: Green beans and soya beans have appoximate specific weights,
which make the precess convenient.
- Breakability: These beans are not easily breakable, so that the process operating more easily.
- The samples are taken from different positions (as the diaphragm), which makes sure the unique
property of sample.
- The sample calculation helps to avoid the error.
4) Comment on the way taking the samples in the mixing experiment:
The samples in the experiment is taken at 6 different time: 5" , 15", 30", 60", 120" vaø 300". At
each time, we take 8 samples as the diagram:

1 2 3

4 5

6 7 8

We have to take the samples at those above positions to make sure the analysation of all
beans, which can make the samples unique so that, the results will give a higher accuracy.
Because during the mixing process, not all the position have the same bean distribution.
Therefore, we have to take s lot positions to calculate the average. The beans only have the
most uniform distribution at some time in the mixing process.
Besides, we have to take the samples at 6 different time to analyse the change of the mixing
index according to time. Since then, we can find the time that the beans reach the highest
mixing index. That is the time we shough implement the beans mixing to meet the highes
uniform level.
5) Comment of the reliability of the result and the elements that affect the most to the mixing
experiment:
The reliability of the mixing result is pretty high.
The elements affect significantly on the mixing result:
- The beans distribution: Due to the different sizes between green beans and soya beans, the mixing
process is affected badly.
- Mixing time: is determined by the stopwatching (manually), so there will be error. But it is
unconsiderable.
- The specific weight of the material: Because green beans and soya beans has approximate weight
so it can support the mixing process.
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- Breakability: Green beans and soya beans do not have the breakability, which makes the process
operate more easily.
- Samples are taken at positions (as the diagram), so that the unique property of the sample is
ensured, which makes the result have higher accuracy.
- The result calculation is simple so the error is too small to mention.

5. APPENDIX:
5.1. Milling calculation:
a. The determination of the equilibrium diameter of the material particle:
- The equilibrium of the particle is a diameter of a sphere has the same ratio V/S.
V ( / 6)D 3tñ D tñ
- To the spherical particle: = =
S D 2tñ 6
- The average dimensions of the rice:
• Length: L = 6mm

• Diameter: D = 1.5mm

V (  / 4)D 2 L DL
- Consider the rice as a cylinder  = =
S DL + ( / 2)D 2
4L + 2D
D tñ DL 3DL 3  1. 5  6
So: =  D tñ = = = 2 (mm)
6 4L + 2D 2 L + D 2  6 + 1. 5

Therfore: Dp1 = Dtñ = 2 (mm)

b. Chart Logn following LogDpn:

Line equation: Logn = (b+1)LogDpn + logK’ (*)

According to chart 2, the diagram goes through 3 points

𝑏 + 1 = 1.3556 𝑏 = 0.3556
So: ′ ⇨ ′
log 𝐾 = 2.0568 𝐾 = 113.9725

K( r b +1 − 1)
But: K’=
b +1
𝐷𝑝𝑛−1 0.315 0.25 0.15
With: r = =( + + )/3 = 1.48
𝐷𝑝𝑛 0.25 0.15 0.10

𝐾′(𝑏+1) 113.9725×1.3556
Therefore: K = = = 220.2749
(𝑟 𝑏+1−1) (1.481.3556 −1)

Chart for distribution of the size distribution of the material on sieve:

− d
Differential equation: = KD bp
dD p

  d = − K  D
b
p dD p
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−𝐾 −220.2749
 = 𝐷𝑝𝑏+1 + 𝐶 = 𝐷𝑝𝑏+1 + 𝐶 = −162.4925𝐷𝑝1.3556 + C
𝑏+1 1.3556

 : Weight accumulated on sieve D p , g

Khi Dp = 0.425 thì  = 0.39  C = 51.33

1.3556 −51.33
 𝐷𝑝 = √( )
−162.4925

Bond’s law: Dp2 is the size of the material after the milling process as long as 80% of weight goes throuh
sieves  The accumulated weight  = 20% = 0.2.

 Dp2 = 0.43 mm

c. Milling efficiency calculation:

The efficiency to grind the material (dry process) from size D p1 to size D p2 :

4  1 1 
P=  19Wi  −  T (KW)
3  Dp 2 D 
 p1 

With:

• Wi – Work index. According to the theory, Wi = 13KW.h/ton.

• T – Milling capacity, ton/ min

M
With: T =
t

• M – Weight of milling material, ton

• t – Milling time, min

• Dp1, Dp2 – Dimension of the material particle and product particle, mm

4 1 1 200×10−6
So: P = × 19 × 13 × ( − )× =0.058 kW
3 √0.43 √2 56/60

d. Milling machine efficiency calculation:

Power consumped for the machine: P’ = U.I.cos

With:

• U – voltage, V

• I – current at maximum loading, A

• cos - power coefficiency

So: P’ = 220 x 3 x 0.8 = 528 (W) = 0.528 (kW)

Milling machine efficiency:

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𝑃 0.058
𝐻= × 100% = × 100% = 10.98%
𝑃′ 0.528

5.2. Sifting experiment calculation:

5.2.1. Chart Ji according to the number of sifting time:
Based on the chart 1 => The curve gets closer to the line Ji = 26.77

So: F.a = 18.4

5.2.2. Sifting efficiency:

𝐽𝑖 25.63
𝐸= × 100% = × 100% = 95.74%
𝐹. 𝑎 26.77

5.3. Mixing experiment calculation:

- The constituents of Soya beans and Green beans in an ideal mixture:
𝑎
• With Soya beans: 𝐶𝐴 =
𝑎+𝑏

𝑏
• With Green beans: 𝐶𝐵 =
𝑎+𝑏

- The composition of A and B in ideal mixture:

a 3.0
CA = = = 0.67
a + b 3.0 + 1.5

CB = 1 – CA = 0.33

C A C B (N − 1)
- Mixing indicator: I s = N
n. (C A − C iA ) 2
i =1

With:

• N –Number of the sample volume V i. In this experiment, N = 8.

• n – Number of beans in case of separating material mixing.

6. REFERENCES: