COMSATS UNIVERSITY ISLAMABAD, LAHORE CAMPUS

(DEPARTMENT OF CHEMICAL ENGINEERING)

LAB REPORT
PARTICULATE TECHNOLOGY (CHE-112)
“Kneader mixer Experiment”
Submitted to:
Sir Zufishan Shamair
Submitted by:
2nd Semester
Section: A
Group: E

Mehroz FA19-CHE-003
Sahar Khan FA19-CHE-009
Shafaq Imtiaz FA19-CHE-019
Maryam Fatima FA19-CHE-083
Objective:.................................................................2
Hypothesis:..............................................................2
Equipment Used:......................................................3
PPE:.........................................................................3
Procedure:................................................................3
Formula:...................................................................4
Observation and calculation:....................................4
Results:..................................................................12
Graph:....................................................................12
Logical explanation:...............................................12
Conclusion:............................................................12
Safety Precautions:.................................................13
Process and Application of Kneader Mixer:...........13
Group Member Contribution:...................................9

Page: 1
Kneader Mixer Lab Report:
Objective:
To find out the energy required to mix (blend) sand and sodium carbonate (Na2CO3) in the ratio
10:1 using laboratory kneader mixer used for flowing solids (dry Solids). To find out the total
energy required for the case mentioned above.

Hypothesis:
 Kneader mixer is ideal for mixing, kneading, of highly viscous, sticky, and dough like
product.
 Kneader mixer blades are attached to easily pull, shear, compress, knead and fold the mass of
material.
 Kneader mixer used to mix homogeneously up to 99%.
 Kneader mixer due to compressibility, kneading, folding function widely used in chemical,
food, fertilizer, sealing compound and paint industries.

Figure 1

Figure 1 shows us a basic kneader mixer and its important parts

Page: 2
Equipment Used:
 Kneader mixer
 Blades
 Gear box
 Motor
 Flask
 Stirrer
 Pipette
 Burette

PPE:
 Lab coat
 Wear mask
 Safety gloves
 Safety goggles
 Safety shoes

Procedure:
 Take 3000 g of dry sand of the size -30 mesh.
 Take 300 g of sodium carbonate of the size -30 mesh.
 Note down the time (t1) required for 2 revolutions (n1) of the energy meter disc under un-
loaded conditions. Also note down the energy meter factor (N).
 Charge the cleaned and dried mixer with 3000 g sand.
 Place 300 g of sodium carbonate gently over the sand.
 Place a covering (paper or some cardboard) on the mixer to avoid dust losses.
 Note down the initial meter reading (R 1) and turn on the mixer. Start the stopwatch
simultaneously to measure the total time (T) required for mixing.
 After 2 minutes of total time, turn off the machine and take 2 g sample from the mixer.
 Try to dissolve the sample taken in 50 ml of distilled water present in titration flask. Sand
will settle down and sodium carbonate be dissolved in the water.

Page: 3
 Using methyl orange as indicator and N/10 HCL as titrant, titrate the solution with constant
shaking of the flask.
 Note down the volume used of the HCl when light pink (to red) end point appears.
 Repeat the above experiment i.e. take samples from the mixer after every two minutes and
titrate them against N/10 HCl. Also note down the meter reading (R 2) after each two minutes
of machine’s working.
 During the practical try to note down twice the time (t1) required for 2 revolutions (n2) under
loaded conditions. Take the average value of the two t2s.
 Take the average of these two values.
 When three consecutive readings of volume used of HCL are same, stop the mixer for further
analysis.
 Empty the mixer and note down the time (t 1) required for two revolutions (n 1) of the energy
meter disc under unloaded conditions. Take the average value of two t1s.

Formula:

 E= ( nt ₂₂ − nt ₁₁ ) × TN×100
×W
kWh /ton

n ₂ T ×100
 E ¿( ) ×
t kWh /ton
t₂ N ×W
M ₁V ₁ M ₂V ₂
 =
n₁ n₂

Observation and calculation:

Total weight of the sand taken = W1 = 3000 g = 3 kg

Total weight of sodium carbonate taken = W2 = 300 g = 0.30 kg

Total weight of both the sand and sodium carbonate taken = W = W1 + W2 = 3.3 kg

No. of revolutions of energy meter for un-loaded conditions = n1 = 2

Time elapsed for n1 revolutions = t1 = 315 s

No. of revolutions of energy meter for loaded conditions = n2 = 2

Time elapsed for n2 revolutions = t2 = 250 s

Page: 4
Energy meter factor = N = 60 rev/kWh

Total time of mixing = T = 2080 s

Calculation:

E= ( 2502 − 3152 )× 2080 ×100

60 ×3.3
kWh /ton

E=¿ 1.734 ≈ 2.0 kWh/ton

E t= ( 2502 )× 2080 ×100

60 ×3.3
kWh/ton

E t=¿ 8.40 ≈ 8.0 kWh /ton

Table 1.1

No. of Mixing Time Volume of Acid Ratio

Observation (min) used
s (mL)

1 2 3.7 101.02:1
2 4 7.55 48.9:1
3 6 9.43 39.02:1
4 8 11.3 32.54:1
5 10 13.2 27.61:1
6 12 15.09 24.03:1
7 14 16.98 21.24:1
8 16 18.86 19.01:1
9 18 20.75 17.19:1
10 20 33.96 10:1

Using Balanced Chemical Equation

Page: 5
2HCl + Na2CO3 H2O + 2NaCl + CO2

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 3.7 M ₂ ×50

=
2 1

M2 = 3.7 × 10-3 g/mol

As we know that

No. of moles
Molarity = g/L
Volume∈litres

Molarity ×Volume
n= (To convert ml to liters)
1000

( 3.7 ×10−3 ) (50)

n=
1000

n = 1.85 × 10-4 moles

mass∈ grams
No. of moles =
Molecular mass

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (1.85 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0196 gm

Mass of sand = 2gm- 0.0196 gm

Mass of sand = 0.3767 gm

1.98
Ratio of sand to Na2CO3 =
0.0196

Ratio = 101.02 = 101:1

Calculation 2:

M ₁V ₁ M ₂V ₂
=
n₁ n₂
Page: 6
0.1× 7.55 M ₂ ×50
=
2 1

M2 = 7.55 × 10-3 g/mol

( 7.55× 10−3 )(50)

n= = 3.775 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (3.775 × 10-4) (105.9888)

Mass of Na2CO3 = 0.04001 gm

Mass of sand = 2gm- 0.04001 gm

Mass of sand = 1.959 gm

1.959
Ratio of sand to Na2CO3 =
0.04001

Ratio = 48.9:1

Calculation:3

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 9.43 M ₂ ×50

=
2 1

M2 = 9.43 × 10-3 g/mol

( 9.43 ×10−3 ) (50)

n= = 4.715 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (4.715 × 10-4) (105.9888)

Mass of Na2CO3 = 0.049973 gm

Mass of sand = 2gm- 0.049973 gm

Mass of sand = 1.95 gm

Page: 7
 1.959
Ratio of sand to Na2CO3 =
0.049973

Ratio = 39.02:1

Calculation: 4

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 11.3 M ₂ ×50

=
2 1

M2 = 0.113 g/mol

( 0.113 ) (50)
n= = 5.65 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (5.65 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0598 gm

Mass of sand = 2gm- 0.0598 gm

Mass of sand = 1.94 gm

1.94
Ratio of sand to Na2CO3 =
0.0598

Ratio = 32.54:1

Calculation: 5

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 13.2 M ₂ ×50

=
2 1

Page: 8
M2 = 0.0132 g/mol

( 0.0132 ) (50)
n= = 6.6× 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (6.6 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0699 gm

Mass of sand = 2gm- 0.0699 gm

Mass of sand = 1.93 gm

1.93
Ratio of sand to Na2CO3 =
0.0699

Ratio = 27.61:1

Calculation: 6

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 15.09 M ₂ ×50

=
2 1

M2 = 0.01509 g/mol

( 0.01509 ) (50)
n= = 7.545 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (7.545 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0799 gm

Mass of sand = 2gm- 0.0799 gm

Mass of sand = 1.92 gm

1.92
Ratio of sand to Na2CO3 =
0.0799

Page: 9
Ratio = 24.03:1

Calculation: 7

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 16.98 M ₂ ×50

=
2 1

M2 = 0.01698 g/mol

( 0.01698 ) (50)
n= = 8.49 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (8.49 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0899 gm

Mass of sand = 2gm- 0.0899 gm

Mass of sand = 1.91 gm

1.91
Ratio of sand to Na2CO3 =
0.0899

Ratio = 21.24:1

Calculation: 8

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 18.86 M ₂ ×50

=
2 1

M2 = 0.01886 g/mol

( 0.01886 ) (50)
n= = 9.43 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Page: 10
Mass of Na2CO3 = (9.43 × 10-4) (105.9888)

Mass of Na2CO3 = 0.0999 gm

Mass of sand = 2gm- 0.0999 gm

Mass of sand = 1.9 gm

1.9
Ratio of sand to Na2CO3 =
0.0999

Ratio = 19.01:1

Calculation: 9

M ₁V ₁ M ₂V ₂
=
n₁ n₂

0.1× 20.75 M ₂ ×50

=
2 1

M2 = 0.02075 g/mol

( 0.02075 ) (50)
n= = 1.0375 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (1.0375 × 10-4) (105.9888)

Mass of Na2CO3 = 0.1099 gm

Mass of sand = 2gm- 0.1099 gm

Mass of sand = 1.89 gm

1.89
Ratio of sand to Na2CO3 =
0.1099

Ratio = 17.19:1

Calculation:10

M ₁V ₁ M ₂V ₂
=
n₁ n₂

Page: 11
 0.1× 33.96 M ₂ ×50
=
2 1

M2 = 0.03396 g/mol

( 0.03396 ) (50)
n= = 1.698 × 10-4
1000

Mass in grams = (No. of moles) (Molecular mass)

Mass of Na2CO3 = (1.698 × 10-4) (105.9888)

Mass of Na2CO3 = 0.1799 gm

Mass of sand = 2gm- 0.1799 gm

Mass of sand = 1.82 gm

1.82
Ratio of sand to Na2CO3 =
0.1799

Ratio = 10:1

Energy used for crushing 1-ton material = E= 1.73 kWh/ton

Total used for crushing 1-ton material = E t = 8.4 kWh/ton

Table 1.1 shows all the end results of calculation

Results:
Energy required to mix one ton of material in the ratio 10:1 1.73------ kWh

Total energy required to mix one ton of material in the ratio 10:1 is 8.4-------- kWh.

Total mixing time 20---------- min

Page: 12
Graph:

Volume to Ratio Graph

120

100
101.02

80
Ratio

60
48.9
39.02
40 32.54
27.61
24.03
21.24
19.01
17.19
20 10

0
0 5 10 15 20 25 30 35 40
Volume

X axis represents volume used in milliliters, the independent variable

Y axis represents ratio between sand and Na2CO3
The graph illustration represents a ratio to volume graph

Logical explanation and conclusion:

As it is mentioned in the process we have to end up with the desired ratio of the mixture, in order
to check that if we have achieved our goal or not, we keep on taking a specific amount of
mixture out of the kneader mixers chamber, after regular intervals of time. We then titrate that
mixture and perform our calculations to find out the ratio. Once our ratio is equal to the desired
ratio we stop our machine and stop the process as our objective is achieved. From the graph
shown above we can see a relation between the ratio and volume as with an increase in volume
the ratio is decreasing nonuniformly and then it finally comes to the desired ratio 10:1 where the
process is stopped

Safety Precautions:
 Check and clean around the Kneader Mixer before use
 Cover material inside the mixer with lid to avoid dust during dry mixing.
 Ensure wires are protected.
 Keep the workshop air circulation.
 After end of workshop, switch off power supply, clean and oil the mixer.

Page: 13
Process and Application of Kneader Mixer:
 Plastic industry
 Pharmaceuticals
 Food & Confectionery: Processing of finely milled wheat flour, béchamel sauce, chocolate,
bubble gum, biscuit dough, and sugar paste.
 Paint & Solvents: Kneading of polyester putty, glass putty, adhesives, and sealants.
 Rubber, mixing of rubber solution and silicon rubber.
 FMCG , blending of liquid soaps, liquid detergents
 Crayon and pencil lead
 Explosives
 Fiberglass resin dough
 Gaskets and gland packing’s
 Grinding wheel preparations
 Hot-Melts
 Inks and pigment
products
 Marzipan
 Mastics
 Metal powders
 Molding
preparations
 Pencil erasers

Group Member Contribution:

Observation, calculation, formula by Mehroz, Shafaq, Maryam, Sahar
Graph, logical explanation and formatting by Mehroz
Hypothesis and procedure by Maryam Fatima
Safety precautions and applications by Shafaq
PPE, equipment and table construction by Sahar
SELF EVALUATION
MEHROZ 25% CONTRIBUTION
SAHAR KHAN 25% CONTRIBUTION

Page: 14
SHAFAQ IMTIAZ 25% CONTRIBUTION
MARYAM FATIMA 25% CONTRIBUTION

Page: 15