Fig. 3.

1
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering

3. Particle separation
3.1 Process principles of particle separation in particle technology
3.2 Evaluation of separation efficiency by separation probability (function)
3.3 Particle separation by sieving
3.3.1 Fundamentals and microprocesses of sieving
3.3.2 Model of screening dynamics
3.3.3 Sieving machines and screens

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.1
 Fig. 3.2
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Particle Separation Principles in Particle Technology
particle separation characteristic unit operation operation principle
A
float and sink cleaning F
L
H
A F
channel washing
H L
hydrotable separation
A
H F
density aerotable separation L

L F
jigging H
L A
counter current separation F
A
H
cross flow separation L
H
optical, colour, shape hand
sorting
P1 P2
radiation emission,
reflexion, diffraction, automatic
particle shape sorting
P1 P2
magnetic F
susceptibility magnetic separation

M NM
electric
conductivity electric separation + -

FP
wetting flotation
R
size, shape
molar mass semipermeable membrane separation A
C,R
F,P
10-5 10-4 10-3 0,01 0,1 1 10 100 103
fragment or particle size d in mm

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.2
 Fig. 3.3
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Separation (Grading) Efficiency Assessment

G
m
feed separation product G (coarse)
F
m
A
m product F (fines)

 total mass balance A =m

m  G +m
F (1)
 component balance  A ⋅ µ A ,i = m
m  G ⋅ µ G ,i + m
 F ⋅ µ F ,i (2)
G
m
 recovery coarse product G R m ,G = (3)
A
m
 G ,i m
m  µ G ,i
 recovery of valuable R m ,i = = G⋅ (4)
coarse fraction i m  A µ A ,i
 A ,i m
µ G ,i
 grading ratio Ai = >1 (5)
µ A ,i
m G ,i m
 µ G ,i
 separation function of a Ti (ξ) = = G ⋅ = R m ,G ⋅ A i (6)
m  A µ A ,i
 A ,i m
particle characteristic fraction ∆ξi
ξ 25
 separation sharpness κ= ≤1 (7)
ξ 75

Separation/Classification of particles according to size fractions ∆di:

1 coarse product G
perfect separation

m 
m q
κ=1 Ti (d ) ρ=const . = G ,i = G ⋅ G ,i = R m ,G ⋅ A i
 A ,i
m  A q A ,i
m
separation function Tj (d)

0.75
d 25 0,3 < κ < 0,6 sufficient
κ= ≤1
misplaced product d 75 0,6 < κ < 0,8 good
0,8 < κ < 0,9 very good
0.5
feed mass splitting

0.25

cut point dT = d50

0
d25 d50 d75 particle size d

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.3
 Fig. 3.4
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Separation Function (Grade Efficiency Curve)

Input mass flow rate m A

G
m
feed separation product G (coarse)
F
m
A
m product F (fines)

 F mass flow rate of fine particles

m
 G mass flow rate of coarse particles
m

Masse balance:
Total: A =m
m F +mG (1)
Component balance of each fraction i:
 A ⋅ µ A ,i = m
m  F ⋅ µ F ,i + m
 G ⋅ µ G ,i (2)
m m F,i m G ,i
with mass fractions µ A,i = A ,i , µ F,i = µ G ,i =
 A , tot
m  F, tot ,
m  G , tot
m

F
m
Mass recovery of fines F R m ,F =
A
m

m
Mass recovery of coarse G R m ,G = G
A
m

Total mass balance Eq.(1) can be rewritten as:

1 = R m ,F + R m ,G (1a)
and Eq.(2) as µ A ,i = R m , F ⋅ µ F ,i + R m ,G ⋅ µ G ,i (2a)

Separation function:

Separation function is defined as the ratio of mass of all particles

with size i in the separated coarse product to mass of particles with
the same size i in the feed:

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.4
 Fig. 3.5
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
 ⋅µ
 G ,i m
m µ
TG (d i ) = = G G ,i = R m,G ⋅ G ,i for coarse product
 A ⋅ µ A ,i
 A ,i m
m µ A ,i
µ F,i
TF (d i ) = R m , F ⋅ for fine product
µ A ,i
From Eq.(2a) TF (d i ) + TG (d i ) = 1

The coarse product is used T(di) = TG(di)

To find the separation function we can use Eq.(1a) and Eq.(2a)
It is necessary to know
a) case 1: one of R m ,f or Rm,c and two of three mass fractions
µ A ,i , µ F , i , µ G , i
b) case 2: three mass fractions µ A ,i , µ F,i , µ G ,i

1 coarse product G

d 25
separation function Tj (d)

0.75
κ= ≤1
d 75

0.3 < κ < 0.6 sufficient

0.5 0.6 < κ < 0.8 good

0.8 < κ < 0.9 very good

0.25

cut point dT = d50

0
d25 d50 d75 particle size d
⇒ Separation function characterizes the quality or grade of separation

Additionally one may use:

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.5
 Fig. 3.6
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
1 1 d 75 − d 25
ET = ⋅ (d 75 − d 25 ) or ξ= ⋅
2 2 d 50

Ideal or perfect separation:

T(d)
1

0
dT d

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.6
 Fig. 3.7
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
3.3 Screening

Screening (sieving) is the separation of a mixture of various grain

sizes into two or more products by a semipermeable membrane

Feed A L
Oversize
v overflow
G+F
coarse G

F
Vib.
Undersize
underflow
fine F

Semipermeable membrane (screening surface) with defined

opening size w acts as a multiple go-no-go gauge.

The final portions consist of grains of more uniform size than

those of the original mixture.

Oversize, overflow, plus or coarse product is that remains on the

screen.

Undersize, underflow, minus or fine product is passing through

the openings of screen

If screen consist of more then one screening surfaces:

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.7
 Fig. 3.8
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
One (n) screening or intermediate product is passing through 1th
or nth surface and retained on a subsequent surface.
The screening surface may consist of
• woven-wire d
• silk
• plastic cloth
• perforated or punched plate
w
w+s

• grizzly bars and wedge wire sections

Aperture or screen-size opening is the minimum free space bet-

ween the edges of the opening in the screening surface.

Open Area of a screen is the ratio of actual openings versus total

screen area Aopen/Atot
Aperture

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.8
 Fig. 3.9
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Sieve Scale in SI-units (mm or µm):
A sieve scale is a series of testing sieves having openings in a
fixed succession; for example:
the widths of the successive openings have a constant ratio of, e.g.
q = 2 or 1.414, while the areas of the openings have a constant ra-
tio of 2.
Generally it is:
d n = d n −1 q = d 0 q n
e.g. for n = 10
q = n 10 = 10 10 = 1.25
Or for the Tyler scale q = 4 2 or 1.189.
The Tyler sieve series adopted by the National Bureau of Standards (USA)

The sieve opening is specified in millimeters, which is understood

to be the free opening or space between the wires.

Acc. to US-standard wire cloth can be specified by the old non-

metric mesh, which is the number of openings per linear inch
counting from the center of any wire to a point exactly 25.4 mm (=
1 inch) distance.
1 2 3 n=mesh

1 inch or 25.4 mm

- In this non-metric US system mesh is used for cloth w < 12.7

mm (2 mesh)
- But free openings are used for coarser cloth w > 12.7 mm

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.9
 Fig. 3.10
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Testing Sieves are generally used for characterization of parti-
cle size distribution.

Fundamentals

Probability screening principle uses the fact that particles mov-

ing almost at right angles to a screening surface have a low proba-
bility to pass through when the particle size is larger than about
half of the opening.

Classification of screening operations:

a) Scalping - Strictly, the removing of a small amount of oversize
from a feed which is predominantly fines. Typically, the re-
moval of oversize from a feed with approximately a maximum
of 5% oversize
Type of screen: grizzly
b) Separation (coarse) - separation at w ≥ 6 mm (4 mesh) and
larger.
Type of Screens: Vibrating screen, horizontal or inclined with
small angle.
Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.10
 Fig. 3.11
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Separation (fine) - separation smaller than w < 6 mm (4 mesh)
and larger than w ≥ 0.6 mm (48 mesh) …. 1 mm
Type of Screens: Vibrating screen, horizontal or inclined;
high-frequency and low-amplitude vibrating screens.

Separation (very fine) - separation smaller than 0.6 …. 1 mm.

Type of Screens: High-frequency low-amplitude electrically
vibrating screens;
⇒ separation in a fluid flow (hydrocyclones, centrifugal
wheel separators, wind shifters.
°
c) Dewatering - Removal of free water from a solids-water mix-
ture:
Moisture influence on screening efficiency
Efficiency

Dry moist Wet

Moisture content

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.11
 Fig. 3.12
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Screening number (Froude number)
k = a/g

Throw number

kv = aS,max/(g.cosβ)
with aS,max maximum particle acceleration perpendicular to screen surface
β inclination angle of screen surface
g gravitational acceleration

kv Particle move- Characterisation of screening behav-

ment iour
≤1 no throw, plan- very low screening efficiency, ob-
ing struction in short time
1 .. 1,5 no throw of par- slow screening, obstruction
ticle layer
1,6 .. 1,8 very low throw very resting screening, easy screen
able particle
2,1 .. 2,3 between low and resting screening, difficult
steep throw screen able particles
3,0 .. 3,5 steeper throw Sharp screening, difficult screen able
fine particles
3,3 .. 4,0 very steep throw very sharp and scarified screening
.. 8,0

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.12
 Fig. 3.13
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Transport of bulk along the sieve
Feed A
L
coarse G
hA G+F
v

F
Vib.
fine F

Optimal length of sieve → L = v ⋅ τ

a) intensive horizontal mixing ( D hor → ∞ )
b) ideally displacement along sieve (Dax = 0)
Model is applicable only at h << L

hs
v = 2⋅g⋅h
and h ~ w
h
v = 2⋅g⋅w

- mass flow rate through w

one opening: s
 w = ρ⋅ w2 ⋅ v = ρ⋅ w2 ⋅ 2⋅g ⋅ w
m

- mass flow rate through surface that includes one opening and the wire
(c=0.5)
w −d 
2

m s = c ⋅ρ⋅  ⋅ 2 ⋅ g ⋅ (w − d )
w +d 

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.13
 Fig. 3.14
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Model of Screening Dynamics

Assumption: fast horizontal mixing

c G ( x, y, z, t ) = c G ( t ) → oversize
c F ( x , y, z, t ) = c F ( t ) → undersize
G+F
Vib.
The probability of passing undersized
particles through the sieve
w−d
2
Pk = 
d

 w+s
The amount of oversized and undersized particles
determines the random particle flow (diffusion)
through the particle bed on the screen w
dm F m
= − k Gr ⋅ Pk ⋅ A ⋅ F w+s
dt mG
A area of screening surface
k sieve constant for separation ( w / d ≥ 10)

assumption → k(n, p, w, d, Pd) = k(n, p)

 k ⋅P ⋅A⋅t  t
m F = m F 0 exp − Gr k  = m F0 exp − 
 mG   t0 
mG 1
t = =
with 0 k ⋅ P ⋅ A k
Gr k sieve

What time is necessary for sieving?

Residence time function F(t) is
m F0 − m F ( t )  t
F( t ) = = 1 − exp − 
m F0  t0 
mF0 input mass
mF the mass in the equipment at the time t
Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.14
 Fig. 3.15
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Residence time distribution is represented by f(t)
dF( t ) 1  t 
f (t) = = exp − 
dt t0  t0 
Mean residence time:
∞ ∞
1  t t  t mG
τ = ∫ f ( t ) tdt = ⋅ ( t 0 ) ∫ exp −  d  = t 0 =
2

0 t0 0  t0  t0  t0  k Gr ⋅ Pk ⋅ A

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.15
 Fig. 3.16
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Screening machines

Screening machines may be divided into five main classes: griz-

zlies, revolving screens, shaking screens, vibrating screens, and
oscillating screens.

Grizzlies are used primarily for scalping at 50 mm and coarser

Revolving screens and shaking screens are generally used for sepa-
rations above 13 mm

Vibrating screens cover this coarse range and also down into the
fine openings.

Oscillating screens are confined in general to the finer openings

below 6 mm.

Grizzly Screens consist of a set of parallel bars held apart by

spacers at some predetermined opening. Bars are frequently made
of manganese steel to reduce wear. A grizzly is widely used before
a primary crusher in rock- or ore-crushing plants to remove the
fines before the ore or rock enters the crusher. It can be a station-
ary set of bars or a vibrating screen.
• stationary grizzly
• flat grizzlies
• vibrating grizzlies.

Revolving screens or drum (trommel) screens, once widely used,

are being largely replaced by vibrating screens. They consist of a
cylindrical frame surrounded by wire cloth or perforated plate,
open at both ends, and inclined at a slight angle. The material to be

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.16
 Fig. 3.17
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
screened is delivered at the upper end, and the oversize is dischar-
ged at the lower end. Their capacity is not great, and efficiency is
relatively low.

Mechanical Shaking Screens consist of a rectangular frame

which holds wire cloth or perforated plate and is slightly inclined
and suspended by loose rods or cables or supported from a base
frame by flexible flat springs. The frame is driven with a recipro-
cating motion. Such devices have given way to vibrating screens.
The advantages of this type are low headroom and low power re-
quirement. The disadvantages are the high cost of maintenance of
the screen and the supporting structure owing to vibration and low
capacity compared with inclined high-speed vibrating screens.

Vibrating Screens are used as standard practice when large capac-

ity and high efficiency are desired. The capacity, especially in the
finer sizes, is so much greater than that of any of the other screens
that they have practically replaced all other types when efficiency
of the screen is an important factor. Advantages include accuracy
of sizing, increased capacity per unit area, low maintenance cost
per ton of material handled, and a saving in installation space and
weight.
There are a large number of vibrating screens on the market, but
basically they can be divided into two main classes:
• mechanically
vibrated
screens
• electrically vi-
brated screens

Mechanically Vi-
brated Screens
Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.17
 Fig. 3.18
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering

Electrically Vibrated Screens are particularly useful in the chem-

ical industry. They handle very successfully many light, fine, dry
materials and metal powders from approximately 4 mm (6 mesh)
to as fine as 0.078 mm. Most of these screens have an intense,
high-frequency (25 to 120 vibrations/s)
low-amplitude
vibration supplied
by means
of an electromagnet.

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.18
 Fig. 3.19
Prof. Dr. J. Tomas, chair of Mechanical Process Engineering
Range of separations that can be obtained with various kinds of
screens (to convert inches into millimeters, multiply by 25.4):
.

Fig_MPE_3 VO Mechanical Process Engineering - Particle Technology Particle Separation/Screening Dr. S. Aman/Prof. Dr. J. Tomas 07.05.2012 Figure 3.19