Rajiv Gandhi University of Knowledge Technologies

Department of Chemical Engineering

Mechanical Unit Operations Lab
(CH2802)
Course Objectives:
 To enable the students to develop a sound working knowledge on different
types of crushing equipments and separation characteristics of different
mechanical operation separators

List of Experiments:
S.No Name of the experiment
1. Ball mill
2. Cyclone separator
3. Froth floatation
4. Gyratory sieve shaker
5. Jaw crusher
6. Plate and frame filter press
7. Sedimentation studies apparatus

Course Outcomes:
By the end of this course, the student should be able to:
 Design a mixed tank, calculate its power requirements and scale-up the
design.
 Understand and apply the basic methods of characterization of particles and
bulk solids, e.g. Average particle size, settling velocity.
 Describe the operation of filter processes and types of filters used to perform
solid-liquid separations, and calculate their power requirements.
BALL MILL (MO-104)

(VARIABLE SPEED)
 Foreword
Welcome to the fast growing family of K.C. product owners. We appreciate your interest in us
and thank you for buying our product.

You have chosen the finest quality product in the market which is produced using latest techniques
and has underwent strict quality control tests. It is a product that we are proud to build and you
are proud to own it.

Our products are easy to understand and operate. They are excellent for students who are trying to
gain practical knowledge through experiments.

However your comfort and safety are important to us, so we want you have an understanding of
proper procedure to use the equipment. For the purpose, we urge you to read and follow the step-
by-step operating instructions and safety precautions in this manual. It will ensure that your
favourite product delivers reliable, superior performance year after year.

This manual includes information for all options available on this model. Therefore, you may find
some information that does not apply to your equipment.

All information, specifications and illustrations in this manual are those in effect at the time of
printing. We reserve the right to change specifications or design at any time without notice.

Customer satisfaction is our primary concern. Feel Free to contact us for any assistance. So what
are you waiting for, roll up your sleeves and let us get down to work!

K.C. Engineers Pvt. Ltd.

 Important Information About This Manual

Reminder for Safety

Modification on Equipment:

This equipment should not be modified. Modification could affect its performance, safety or
disturbance. In addition damage or performance problems resulting from modification may not be
covered under warranties.

Precautions and Maintenance:

This is used to indicate the presence of a hazard that could cause minor or moderate personal injury
or damage to your equipment. To avoid or reduce the risk, the procedures must be followed
carefully.
 Contents
1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 2

6. Utilities Required …………………………………… 3

7. Experimental Procedure …………………………………… 3

8. Observation & Calculation …………………………………… 4

9. Nomenclature …………………………………… 5

10. Precautions & Maintenance Instructions …………………………………… 6

11. Troubleshooting …………………………………… 6

12. References …………………………………… 6

13. Block Diagram …………………………………… 7

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

(Rev. 1)
 BALL MILL
(VARIABLE SPEEDS)
1. OBJECTIVE:
To study the operation of a ball mill.

2. AIM:
2.1 To calculate the efficiency of a ball mill for grinding a material of known work
index (W i).

2.2 To study the effect of RPM on the power consumption of ball mill.

2.3 To calculate the critical speed (nc) of ball mill.

3. INTRODUCTION:
Generally the ball mills are known as the secondary size reduction equipment. The ball
mill is made in a great many types and sizes and can be used on a greater variety of soft
materials than any other type of machine. The feed must be non-abrasive with a
hardness of 1.5 or less. A ball mill consists of a cylindrical shell slowly turning about a
horizontal axis and filled to about 1/4th of its volume with solid grinding medium (i.e.
metallic balls etc.). When the ball mill is rotated, the grinding elements (balls) are carried
to the side of the shell nearly to the top, from where; they fall on the particles under
gravity. In a ball mill most of the size reduction is done by impact. The energy expanded
in lifting the grinding units are utilizes in reducing the size of the particles. Ball mill can
accept a feed size of 12mm or less and deliver a product size in the range of 50m. The
speed of ball mill varies between 60 to 70 RPM. As the product size become fines, the
capacity of a mill reduces the energy requirement increases.

4. THEORY:
A ball mill consists of a cylindrical shell slowly turning about a horizontal axis and filled
with solid grinding medium (metallic balls, wooden balls or rubber balls). In ball mill most
of the size reduction is done by impact.

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 1 of 7 (Rev. 1)
 CRITICAL SPEED OF A BALL MILL (nc):

1 g
nc   ------------- (1)
2 Rr
Where nc is critical rotational speed, R is radius of the ball mill and r is radius of the
ball.

For effective operation of the mill, the mill should be operate at 65 to 80 % of critical
speed. As the product size becomes finer, the capacity of a mill reduces and the energy
requirement increases. As the speed of the mill exceeds nc (i.e. mill is centrifuging the
size reduction capacity decreases.)

BOND CRUSHING LAW AND WORK INDEX:

A more realistic method of estimating the power required for crushing and grinding is

P K
 b ------------- (2)
m Dp

Where Kb is a constant which depends on the type of machine and on the material being
crushed, Dp is in millimeters, P in kilowatts and m in tons per hour.

Wi is defined as the gross energy requirements in kilo watt hours per ton of feed

needed to reduce a very large feed. This definition leads to a relation between K b and W i.

K b  0.3162  Wi ------------- (3)

If 80 percent of the feed passes a mesh size of Dpa mm and 80 percent of the product a
mesh of Dpb mm, it follows from eq (1) & (2).

P  1 1 
 0.3162  W i   
m  D DPa 
 Pb 

 1 1 
P  m  0.3162  W i    -------------- (4)
 D DPa 
 Pb 

5. DESCRIPTION:
The present laboratory ball mill consist a shell is fabricated from thick steel. It contain
balls. A revolution counter is provided to find the number of turns. A guard is provided on
gear for safety purposes. An opening and tightening arrangement is provided in the
centre of the shell to feed and to take off the material. Power is given by HP motor

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 2 of 7 (Rev. 1)
 coupled with horizontal gearbox. Drive is provided to vary the RPM. A RPM indicator
with proximity switch is provided in the set-up.

6. UTILITIES REQUIRED:
6.1 Electricity Supply: Single phase, 220 V AC, 50 Hz, 5-15 Amp combined socket
with earth connection.

6.2 Floor Area Required 1.5 m x 1 m.

6.3 Raw material for feed (size 5-8 mm).

6.4 Set of sieves with sieve shaker for analysis.

7. EXPERIMENTAL PROCEDURE:

7.1 STARTING PROCEDURE:

7.1.1 Prepare a uniform sized material for feed using sieve shaker (5mm to
8mm approx).

7.1.2 Fill the shell with the balls provided.

7.1.3 Ensure that all switches given on the panel are at OFF position.

7.1.4 Now switch ON the main power supply.

7.1.5 Set the revolution counter to zero position.

7.1.6 Switch ON the MCB and then starter to run the machine.

7.1.7 Run the machine at no load condition by determining the time for 10 or 20
pulses on the energy meter.

7.1.8 Switch OFF the starter and then MCB.

7.1.9 Fill the Feed in the ball mill.

7.1.10 Switch ON the MCB and then starter to run the machine.

7.1.11 Run the machine at loaded condition by determining the time for 10 or 20
pulses on the energy meter.

7.1.12 Repeat the experiment for different RPM.

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 3 of 7 (Rev. 1)
 7.2 CLOSING PROCEDURE:

7.2.1 When experiment is over switch OFF the power supply.

8. OBSERVATION & CALCULATION:

8.1 DATA:
Radius of the ball r = 0.011 m
Radius of the ball mill R = 0.1375 m
Acceleration due to gravity g = 9.81 m/sec2
Energy meter constant EMC = 3200 Pulses/kWh

Work Indexes Of Some Common Minerals

Material Work Index (Wi)

Bauxite (sp.gr =2.20) 8.78
Cement climker (sp.gr =3.15) 13.45
Coal (sp.gr =1.40) 13.00
Coke (sp.gr =1.31) 15.13
Gravel (sp.gr =2.66) 16.06
Gypsum rock (sp.gr =2.69) 6.73
Lime stone (sp.gr =2.66) 12.74
Quartz (sp.gr =2.65) 13.57

OBSERVATIONS:

Wf = _____ kg

tc = _____ sec

Dpa = _____ mm

Dpb = _____ mm

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 4 of 7 (Rev. 1)
 8.2 OBSERVATION TABLE:

P1 tp1 (sec) P2 tp2 (sec)

8.3 CALCULATIONS:

P 13600
P NL  (kW)
t p1EMC

P2  3600
P L (kW)
t p 2 EMC

P act P L P NL (kW)

W f 3600
m  (tons/h)
tc 1000

K b  0.3162 W i (kWh/tons)

 1 1 
P cal  m K b    (kW)
 D Pb D Pa 

P act
  100 (%)
P cal

1 g
nc    60 (RPM)
2 Rr

9. NOMENCLATURE:

Nom Column Heading Units Type

Dpa Average feed size mm Measured
Dpb Average product size mm Measured
EMC Energy meter constant Pulses/kWh Given
g Acceleration due to gravity m/sec2 Given
Kb Bond’s constant kWh/tons Calculated

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 5 of 7 (Rev. 1)
 m Feed rate tons/h Calculated
nc Critical speed of ball mill RPM Calculated
P1 Number of pulses counted at no load condition * Measured
P2 Number of pulses counted at loaded condition * Measured
Pact Actual power required for crushing kW Calculated
Pcal Calculated power required for crushing kW Calculated
PL Power consume by machine at loaded condition kW Calculated
PNL Power consume by machine at no load condition kW Calculated
R Radius of the ball mill m Given
r Radius of the ball m Given
tc Time for crushing sec Measured
tp1 Time for P1 pulses sec Measured
tp2 Time for P2 pulses sec Measured
Wf Weight of feed taken kg Measured
Wi Work index of material kWh/tons Given
 Crushing efficiency % Calculated

* Symbols are unit less.

10. PRECAUTION & MAINTENANCE INSTRUCTIONS:

10.1 Never run the apparatus if power supply is less than 180 volts and more than
230 volts.

10.2 Revolution counter should be zero before start.

10.3 Coupling fixing pin should be fixed after attached the ball mill coupling.

10.4 Don’t attach or detach the coupling during the experiment.

11. TROUBLESHOOTING:
11.1 If the motor is not working check the electric connection.

12. REFERENCES:
12.1 McCabe, Warren L. Smith, Julian C. Harriott, Peter (2005). Unit Operations of
Chemical Engineering. 7th Ed. NY: McGraw-Hill. pp 985-986, 992-993.

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 6 of 7 (Rev. 1)
13. BLOCK DIAGRAM:

K.C. Engineers Pvt. Limited, Ambala BALL MILL (Variable Speed)

Page No. 7 of 7 (Rev. 1)
FROTH FLOATATION CELL

(MO-124)
 Foreword
Welcome to the fast growing family of K.C. product owners. We appreciate your interest in us
and thank you for buying our product.

You have chosen the finest quality product in the market which is produced using latest techniques
and has underwent strict quality control tests. It is a product that we are proud to build and you
are proud to own it.

Our products are easy to understand and operate. They are excellent for students who are trying to
gain practical knowledge through experiments.

However your comfort and safety are important to us, so we want you have an understanding of
proper procedure to use the equipment. For the purpose, we urge you to read and follow the step-
by-step operating instructions and safety precautions in this manual. It will ensure that your
favourite product delivers reliable, superior performance year after year.

This manual includes information for all options available on this model. Therefore, you may find
some information that does not apply to your equipment.

All information, specifications and illustrations in this manual are those in effect at the time of
printing. We reserve the right to change specifications or design at any time without notice.

Customer satisfaction is our primary concern. Feel Free to contact us for any assistance. So what
are you waiting for, roll up your sleeves and let us get down to work!

K.C. Engineers Pvt. Ltd.

 Important Information About This Manual

Reminder for Safety

Modification on Equipment:

This equipment should not be modified. Modification could affect its performance, safety or
disturbance. In addition damage or performance problems resulting from modification may not be
covered under warranties.

Precautions and Maintenance:

This is used to indicate the presence of a hazard that could cause minor or moderate personal injury
or damage to your equipment. To avoid or reduce the risk, the procedures must be followed
carefully.
 Contents
1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 1

6. Utilities Required …………………………………… 2

7. Experimental Procedure …………………………………… 2

8. Observation & Calculation …………………………………… 3

9. Nomenclature …………………………………… 4

10. Precautions & Maintenance Instructions …………………………………… 4

11. Troubleshooting …………………………………… 4

12. References …………………………………… 4

13. Block Diagram …………………………………… 5

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

(Rev. 1)
 FROTH FLOTATION CELL
1. OBJECTIVE:
To study the working principle of froth flotation cell.

2. AIM:
To calculate the percentage recovery of coal in froth flotation cell from coal-sand
mixture.

3. INTRODUCTION:
Froth flotation cells are used for the separation of lighter density particles from higher
density particle, by depending upon their surface tension properties. i.e. cohesion &
adhesion properties. A flotation cell is the equipment in which the material is actually
separated or floated from the residual tailings. It consist a vessel or tank provided with a
feed at one end, an overflow for froth removal, and a discharge for tailings at the
opposite end, with a provision for introducing air for froth formation and agitation.

4. THEORY:
Flotation is an operation in which the separation of one of the constituents is carried out
by using a method which depends on the differences in surface tension properties of
materials involved. This method consists of suspending of mixture of finely divided solids
in water which is aerated so that air bubbles tend to adhere preferentially to one of the
constituents - the one which is difficult to wet and its effective apparent density is
reduced to such an extent that it rises to the surface in the form of a froth, and the one
which more readily absorbs, water phase becomes surrounded by water and sinks. If a
suitable frothing agent is added to liquid, the particles will be held in the surface by
means of a stable froth until they can be discharged. Froth flotation is widely used in the
metallurgical industries where, generally, the ore is difficult to wet and the residual earth
is readily wetted.

5. DESCRIPTION:
Froth flotation cell consists of an agitated vessel open at the top. In the chamber, an
impeller coupled to a shaft is fixed in a stationary diffuser. Agitator is provided with air
passage. Motor is given for drive the apparatus. The collector coated mineral particles

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

Page No. 1 of 5 (Rev. 1)
 adhere to the rising bubbles and are carried to the top of the cell to be removed in the
froth product tank. Valve is provided for draining purpose.

6. UTILITIES REQUIRED:
6.1 Electricity Supply: Single Phase, 220 V AC, 50 Hz, 5-15 Amp combined socket
with earth connection

6.2 Compressed Air Supply: @ 1 CMH at 2 kg/cm 2.

6.3 Water Supply (Initial fill).

6.4 Floor Drain Required.

6.5 Floor Area Required: 1.5 m x 1 m.

6.6 Electronics Weighing Balance :capacity 2 kg, least count 1 gm.

6.7 Oven for drying of product.

6.8 Chemicals:-

Coal : 100 gm

Sand : 900 gm

Pine oil : 10 ml

Kerosene : 10 ml

7. EXPERIMENTAL PROCEDURE:

7.1 STARTING PROCEDURE:

7.1.1 Take known weight of coal (100 gm) and sand (900 gm) and note down
the weight of coal

7.1.2 Prepare feed mixture of above material.

7.1.3 Prepare mixture of pine oil and kerosene in desired ratio.

7.1.4 Close the valve V1.

7.1.5 Put the feed mixture in flotation cell and pour water till it does not come
out of the flotation cell.

7.1.6 Connect the compressed air supply.

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

Page No. 2 of 5 (Rev. 1)
 7.1.7 Switch ON the stirrer.

7.1.8 Switch ON the power supply.

7.1.9 Add mixture of pine oil and kerosene in the flotation cell.

7.1.10 Wait till coal obtained on the surface of solution.

7.1.11 Collect the coal with the help of metallic strip.

7.1.12 Filter it using filter cloth.

7.1.13 Dry it and weigh.

7.1.14 Note down the weight of coal.

7.1.15 Repeat the experiment for different mixture ratio of pine oil and kerosene.

7.2 CLOSING PROCEDURE:

7.2.1 When experiment is over stop the stirrer.

7.2.2 Switch OFF the power supply.

7.2.3 Stop the compressed air supply.

7.2.4 Drain the water from vessel by open the valve V1.

8. OBSERVATION & CALCULATION:

8.1 OBSERVATION TABLE:

S.No. P (ml) K (ml) WF (gm) WP (gm)

8.2 CALCULATIONS:

WP
R  100 (%)
WF

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

Page No. 3 of 5 (Rev. 1)
 S.No. R (%)

9. NOMENCLATURE:

Nom Column Heading Units Type

K Volume of kerosene ml Measured
P Volume of pine oil ml Measured
R Percentage recovery of coal % Calculated
WF Weight of coal in feed gm Measured
WP Weight of coal obtained after froth flotation gm Measured

10. PRECAUTION & MAINTENANCE INSTRUCTIONS:

10.1 Never run the apparatus if power supply is less than 180 volts and more than 230
volts.

10.2 Close the drain valve properly.

10.3 Collect the product regularly in the collector.

10.4 Speed of the stirrer should not be high.

11. TROUBLESHOOTING:
11.1 If the pump gets jam open the back cover of pump and rotate the shaft manually.

12. REFERENCES:
12.1 Coulson, J M & Richardson, J F (1991). Chemical Engineering Vol-2. 4th Ed. ND:
Asian Books Pvt. Ltd. pp 47-51.

12.2 Brown, George Granger (1995). Unit Operations. 1st Ed. ND: CBS Publishers &
Distributors. pp 99-103.

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

Page No. 4 of 5 (Rev. 1)
13. BLOCK DIAGRAM:

K.C. Engineers Pvt. Limited, Ambala FROTH FLOTATION CELL

Page No. 5 of 5 (Rev. 1)
JAW CRUSHER

(MO-101)
 Foreword
Welcome to the fast growing family of K.C. product owners. We appreciate your interest in us
and thank you for buying our product.

You have chosen the finest quality product in the market which is produced using latest techniques
and has underwent strict quality control tests. It is a product that we are proud to build and you
are proud to own it.

Our products are easy to understand and operate. They are excellent for students who are trying to
gain practical knowledge through experiments.

However your comfort and safety are important to us, so we want you have an understanding of
proper procedure to use the equipment. For the purpose, we urge you to read and follow the step-
by-step operating instructions and safety precautions in this manual. It will ensure that your
favourite product delivers reliable, superior performance year after year.

This manual includes information for all options available on this model. Therefore, you may find
some information that does not apply to your equipment.

All information, specifications and illustrations in this manual are those in effect at the time of
printing. We reserve the right to change specifications or design at any time without notice.

Customer satisfaction is our primary concern. Feel Free to contact us for any assistance. So what
are you waiting for, roll up your sleeves and let us get down to work!

K.C. Engineers Pvt. Ltd.

 Important Information About This Manual

Reminder for Safety

Modification on Equipment:

This equipment should not be modified. Modification could affect its performance, safety or
disturbance. In addition damage or performance problems resulting from modification may not be
covered under warranties.

Precautions and Maintenance:

This is used to indicate the presence of a hazard that could cause minor or moderate personal injury
or damage to your equipment. To avoid or reduce the risk, the procedures must be followed
carefully.
 Contents
1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 2

6. Utilities Required …………………………………… 2

7. Experimental Procedure …………………………………… 2

8. Observation & Calculation …………………………………… 3

9. Nomenclature …………………………………… 4

10. Precautions & Maintenance Instructions …………………………………… 5

11. Troubleshooting …………………………………… 5

12. References …………………………………… 5

13. Block Diagram …………………………………… 6

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

(Rev. 1)
 JAW CRUSHER
1. OBJECTIVE:
To study the operation of jaw crusher.

2. AIM:
To determine the efficiency of the crusher for crushing a material of known work index
(W i).

3. INTRODUCTION:
Jaw crushers do the heavy work of breaking large pieces of solid material into small
lumps. The jaw crusher is widely used in industry for coarse reduction of large quantities
of solids. They operate by compression and can break large lumps of very hard
materials, as in the primary and secondary reduction of rocks and ores. They are very
common in industry and have a wide application.

4. THEORY:
In a jaw crusher feed of known size distribution is admitted between the two jaws, set to
form a V open at the top. It is driven by an eccentric so that a great compressive force is
applied to lumps of solids caught between the jaws. Large lumps caught between the
upper parts of the jaw are broken, drop into narrower space below and are re-crushed
the next time the jaws close. The most common type of jaw crusher is the blake crusher.
In this machine an eccentric drives a pitman connected to two toggles, one of which is
pinned to the frame and the other to the swinging jaw. The pivot point is at the top of the
movable jaw or above the top of the jaws on the centerline of the jaw opening. The
greatest amount of motion is at the bottom of the V, which means that there is little
tendency for a crusher of this kind to choke.

BOND CRUSHING LAW AND WORK INDEX:

A more realistic method of estimating the power required for crushing and grinding is

P K
 b ---------------- (1)
m Dp

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 1 of 6 (Rev. 1)
 Where Kb is a constant which depends on the type of machine and on the material being
crushed, Dp is particle size in millimeters, P is power in kilowatts and m is mass flow rate
in tons per hour.

Wi is defined as the gross energy requirements in kilo watt hours per ton of feed

needed to reduce a very large feed. This definition leads to a relation between K b and
Wi.

K b  0.3162  Wi --------------- (2)

If 80 percent of the feed passes a mesh size of Dpa mm and 80 percent of the product a
mesh of Dpb mm, it follows from eq (1) & (2).

P  1 1 
 0.3162  W i   
m  
 DPb DPa 

 1 1 
P  m  0.3162  W i    --------------- (3)
 D DPa 
 Pb 

5. DESCRIPTION:
The set-up is a blake jaw crusher, contains two jaws of hard steel with one jaw stationary
and other is moving. A hopper is provided at the top for feeding material. The opening of
the jaw is adjustable. The motor is coupled to the machine through triple `V’ belt drive. A
handle is provided.

6. UTILITIES REQUIRED:
6.1 Electricity Supply: Single Phase, 220 V AC, 50 Hz, 5-15 Amp combined socket
with earth connection

6.2 Floor Area Required: 1m x 1m.

6.3 Raw material for feed (max size 50 mm)

6.4 Set of sieves with sieve shaker for analysis.

7. EXPERIMENTAL PROCEDURE:

7.1 STARTING PROCEDURE:

7.1.1 Prepare a suitable feedstock of a solid material.

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 2 of 6 (Rev. 1)
 7.1.2 Measure its size distribution.

7.1.3 Fix the opening of jaws.

7.1.4 Switch ON the power supply.

7.1.5 Start the machine with no load condition and record the time taken for 10-
20 pulses of energy meter.

7.1.6 Start feeding the solid material by hopper at a constant rate.

7.1.7 Again record the time taken for 10-20 pulses of energy meter.

7.1.8 Repeat the experiment for different opening of jaws.

7.2 CLOSING PROCEDURE:

7.2.1 When experiment is over switch OFF the power supply.

8. OBSERVATION & CALCULATION:

8.1 DATA:
Energy meter constant EMC = 3200 Pulses/kWh

Work Indexes Of Some Common Minerals

Material Work Index (Wi)

Bauxite (sp.gr =2.20) 8.78
Cement climker (sp.gr =3.15) 13.45
Coal (sp.gr =1.40) 13.00
Coke (sp.gr =1.31) 15.13
Gravel (sp.gr =2.66) 16.06
Gypsum rock (sp.gr =2.69) 6.73
Lime stone (sp.gr =2.66) 12.74
Quartz (sp.gr =2.65) 13.57

OBSERVATIONS:

Wf = _____ kg

tc = _____ sec

Dpa = _____ mm

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 3 of 6 (Rev. 1)
 Dpb = _____ mm

8.2 OBSERVATION TABLE:

P1 tp1 (sec) P2 tp2 (sec)

8.3 CALCULATIONS:

P 13600
P NL  (kW)
t p1EMC

P2  3600
P L (kW)
t p 2 EMC

P act P L P NL (kW)

W f 3600
m  (tons/h)
tc 1000

K b  0.3162 W i (kWh/tons)

 1 1 
P cal  m K b    (kW)
 D Pb D Pa 

P act
  100 (%)
P cal

9. NOMENCLATURE:

Nom Column Heading Units Type

Dpa Average feed size mm Measured
Dpb Average product size mm Measured
EMC Energy meter constant Pulses/kWh Given
Kb Bond’s constant kWh/tons Calculated
m Feed rate tons/ h Calculated
P1 Number of pulses counted at no load condition * Measured

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 4 of 6 (Rev. 1)
 P2 Number of pulses counted at loaded condition * Measured
Pact Actual power required for crushing kW Calculated
Pcal Calculated power required for crushing kW Calculated
PL Power consume by machine at loaded condition kW Calculated
PNL Power consume by machine at no load kW Calculated
condition
tc Time for crushing sec Measured
tp1 Time for P1 pulses sec Measured
tp2 Time for P2 pulses sec Measured
Wf Weight of feed taken kg Measured
Wi Work index of material kWh/tons Given
 Crushing efficiency % Calculated

* Symbols are unit less.

10. PRECAUTION & MAINTENANCE INSTRUCTIONS:

10.1 Never run the apparatus if power supply is less than 180 volts and more than 230
volts.

11. TROUBLESHOOTING:
11.1 If electric panel is not showing the input on the mains light, check the main
supply.

12. REFERENCES:
12.1 McCabe, Warren L. Smith, Julian C. Harriott, Peter (2005). Unit Operations of
Chemical Engineering. 7th Ed. NY: McGraw-Hill. pp 985-986, 988.

12.2 Brown, George Granger (1995). Unit Operations. 1st Ed. ND: CBS Publishers &
Distributors. pp 27-28.

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 5 of 6 (Rev. 1)
13. BLOCK DIAGRAM:

K.C. Engineers Pvt. Limited, Ambala JAW CRUSHER

Page No. 6 of 6 (Rev. 1)
PLATE & FRAME FILTER

PRESS (MO-131)
 Foreword
Welcome to the fast growing family of K.C. product owners. We appreciate your interest in us
and thank you for buying our product.

You have chosen the finest quality product in the market which is produced using latest techniques
and has underwent strict quality control tests. It is a product that we are proud to build and you
are proud to own it.

Our products are easy to understand and operate. They are excellent for students who are trying to
gain practical knowledge through experiments.

However your comfort and safety are important to us, so we want you have an understanding of
proper procedure to use the equipment. For the purpose, we urge you to read and follow the step-
by-step operating instructions and safety precautions in this manual. It will ensure that your
favourite product delivers reliable, superior performance year after year.

This manual includes information for all options available on this model. Therefore, you may find
some information that does not apply to your equipment.

All information, specifications and illustrations in this manual are those in effect at the time of
printing. We reserve the right to change specifications or design at any time without notice.

Customer satisfaction is our primary concern. Feel Free to contact us for any assistance. So what
are you waiting for, roll up your sleeves and let us get down to work!

K.C. Engineers Pvt. Ltd.

 Important Information About This Manual

Reminder for Safety

Modification on Equipment:

This equipment should not be modified. Modification could affect its performance, safety or
disturbance. In addition damage or performance problems resulting from modification may not be
covered under warranties.

Precautions and Maintenance:

This is used to indicate the presence of a hazard that could cause minor or moderate personal injury
or damage to your equipment. To avoid or reduce the risk, the procedures must be followed
carefully.
 Contents
1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 2

6. Utilities Required …………………………………… 3

7. Experimental Procedure …………………………………… 3

8. Observation & Calculation …………………………………… 4

9. Nomenclature …………………………………… 5

10. Precautions & Maintenance Instructions …………………………………… 6

11. Troubleshooting …………………………………… 6

12. References …………………………………… 6

13. Block Diagram …………………………………… 7

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
(Rev. 1)
 PLATE & FRAME FILTER PRESS
1. OBJECTIVE:
To study the operation of plate and frame filter press.

2. AIM:

2.1 To calculate the specific cake resistance ().

2.2 To calculate the medium resistance (R).

3. INTRODUCTION:
The separation of solids from a suspension in a liquid by means of porous medium or
screen which retains the solids and allow the liquid to pass is termed filtration. In general
the pores of the medium will be larger than the particles which are to be removed, and
the filter will work efficiently only after an initial deposit has been trapped in the medium.
Filtration is essentially a mechanical operation and is less demanding in energy than
evaporation or drying. The most suitable filter for any given operation is the one which
will fulfill the requirements at minimum overall cost. The most important factors in filter
selection are the specific resistance of filter cake, the quantity to be filtered and the solid
concentration.

4. THEORY:
Filtration involves the separation of solids from liquids by passing a suspension through
a permeable medium, which retains the particles.

FOR INCOMPRESSIBLE CAKE:

The basic filtration equation is:

dt    cV 
   R --------- (1)
dV AP  A 

dt   cV R
 2  ----------(2)
dV A P AP

Integrate the above equation for t = 0 to t and V = 0 to V

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 1 of 8 (Rev. 1)
 t
 c V
R V

 dt 
0 A 2 P  VdV 
0
AP  dV
0
----------(3)

  c V 2 
R
t   V  ----------(4)
A P  2  AP
2

 c R
Let a1  ,t 
A P
2
AP

Put these value in equation (2)

a1V 2
t  b1V
2

a 
t  V  1  b1  ----------(5)
2 

a1
Put  a , b1  b
2

Put these value in equation (5)

t
 aV  b
V

Plot a graph of t/V vs V and find slope “a” and intercept “b”.

 and R can be calculated as :

A 2 Pa

C

APb
R


5. DESCRIPTION:
The set up consists of 7 plates and 6 frames. Frames are covered with filter cloth. Feed
is fed by gear pump at the top in slurry tank, and filtrate collected from the outlet valve.
After removing cake washing and cleaning can be done by water provided by water tank.
Inlet and outlet pressures are measured by pressure gauges. Rate of filtrate removals is
measured by measuring tank provided.

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 2 of 8 (Rev. 1)
6. UTILITIES REQUIRED:
6.1 Electricity Supply: Single Phase, 220 V AC, 50 Hz, 5-15 Amp combined socket
with earth connection.

6.2 Water Supply (Initial fill).

6.3 Floor Drain Required.

6.4 CaCO3: 10 kg.

7. EXPERIMENTAL PROCEDURE:

7.1 STARTING PROCEDURE:

7.1.1 Prepare feed solution by mixing 4 kg of calcium carbonate in 40 liter of

water.

7.1.2 Note down the weight of feed and volume of water.

7.1.3 Close all the valves V1-V6.

7.1.4 Ensure that switches given on the panel are at OFF position.

7.1.5 Fix the plate and frames on the press.

7.1.6 Fill water in the water tank.

7.1.7 Filter the prepared solution and fed it in the feed tank.

7.1.8 Switch ON the power supply.

7.1.9 Switch ON the agitator of the feed tank.

7.1.10 Connect the outlet of the filter press to the filtrate tank.

7.1.11 Open the valve V1.

7.1.12 Start the pump and allow feed to enter the press by open the valve V2 and
by pass valve V3 and keep close the valve V4.

7.1.13 Note down the inlet slurry pressure and outlet slurry pressure and keep it
constant.

7.1.14 Collect filtrate in the receiver by open the valve V4 and record the weight
of filtrate collected and time.

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 3 of 8 (Rev. 1)
 7.1.15 Run the filtration till there is appreciable fall in rate of filtrate collection.

7.1.16 Repeat the experiment for different pressure drop.

7.2 CLOSING PROCEDURE:

7.2.1 When experiment is over switch OFF the agitator.

7.2.2 Switch OFF the pump.

7.2.3 Stop the supply of slurry by closing the valve V1.

7.2.4 Drain the slurry tank by open the valve V6.

7.2.5 Open the valve V4 and V5 for circulation of water (Washing is necessary).

7.2.6 Switch OFF the power supply.

8. OBSERVATION & CALCULATION:

8.1 DATA:
Number of frame NF =6
Area of filtrate tank Ac = 0.0398 m2
Area of one frame AF1 = 0.04 m2
Viscosity of the filtrate  = 9.03*10-5 N-sec/m2

OBSERVATIONS:
Pi = ______ kg/cm2

Po = ______ kg/cm2

M = ______ kg

V1 = ______ Lit

8.2 OBSERVATION TABLE:

S.No t (sec) h (cm)

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 4 of 8 (Rev. 1)
 8.3 CALCULATIONS:

Ac  h
V  (m3)
100

CALCULATIONS TABLE:

S.No. t (sec) V (m3) t/V (sec/m3)

Plot the graph of t/v vs v and find slope “a” and intercept “b”.

a  ______ (sec/m6)

b  ______ (sec/m3)

A  2  NF  AF 1 (m2)

P  (Pi  Po )  98066.5 (N/m2)

m
C  1000 (kg/m3)
V1

A 2  P  a
 (m/kg)
 c

A  P  b
R (m-1)


9. NOMENCLATURE:

Nom Column Heading Units Type

A Total filtration area m2 Calculated
2
Ac Area of filtrate tank m Given
2
AF1 Area of one frame m Given
a Slope of the graph t/V vs V sec/m6 Calculated
b Intercept of the graph t/V vs V sec/m3 Calculated
C Concentration of the slurry kg/m3 Calculated

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 5 of 8 (Rev. 1)
 h Height of filtrate collected in time t cm Measured
m Mass of CaCO3 in feed kg Measured
Nf Number of frame * Given
P Pressure drop kg/cm2 Calculated
Pi Inlet pressure kg/cm2 Measured
Po Outlet pressure kg/cm2 Measured
R Medium resistance m-1 Calculated
t Time to collect filtrate sec Measured
V Volume of filtrate collected in time t m3 Calculated
V1 Volume of liquid in feed Lit Measured
 Specific cake resistance m/kg Calculated
 Viscosity of the filtrate N-sec/m² Given

* Symbols represent unitless quantity.

10. PRECAUTION & MAINTENANCE INSTRUCTIONS:

10.1 Cleaning of plates and frames and its clothes is must.

10.2 For proper cleaning circulation of water is necessary (for this operation open the
valve V4 & V5).

10.3 Feed slurry is filtered before feeding it into the tank.

10.4 Plates & frames should be properly tightened.

11. TROUBLESHOOTING:
11.1 If the slurry is leakage more than enough detached the plate and frame, arrange
it properly and tight it again.

11.2 If the slurry is not coming properly, then check the holes of the cloths and frames
are matching or not, if not arrange it accordingly.

12. REFERENCES:
12.1 Brown, George Granger (1995). Unit Operations. 1st Ed. ND: CBS Publishers &
Distributors. pp 231-233.

12.2 McCabe, Warren L. Smith, Julian C. Harriott, Peter (2005). Unit Operations of
Chemical Engineering. 7th Ed. NY: McGraw-Hill. pp 1008-1010, 1019-1025.

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 6 of 8 (Rev. 1)
13. BLOCK DIAGRAM:

K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 7 of 8 (Rev. 1)
K.C. Engineers Pvt. Limited, Ambala PLATE & FRAME FILTER PRESS
Page No. 8 of 8 (Rev. 1)
SEDIMENTATION STUDIES

APPARATUS (EBE-106)
 Foreword
Welcome to the fast growing family of K.C. product owners. We appreciate your interest in us
and thank you for buying our product.

You have chosen the finest quality product in the market which is produced using latest techniques
and has underwent strict quality control tests. It is a product that we are proud to build and you
are proud to own it.

Our products are easy to understand and operate. They are excellent for students who are trying to
gain practical knowledge through experiments.

However your comfort and safety are important to us, so we want you have an understanding of
proper procedure to use the equipment. For the purpose, we urge you to read and follow the step-
by-step operating instructions and safety precautions in this manual. It will ensure that your
favourite product delivers reliable, superior performance year after year.

This manual includes information for all options available on this model. Therefore, you may find
some information that does not apply to your equipment.

All information, specifications and illustrations in this manual are those in effect at the time of
printing. We reserve the right to change specifications or design at any time without notice.

Customer satisfaction is our primary concern. Feel Free to contact us for any assistance. So what
are you waiting for, roll up your sleeves and let us get down to work!

K.C. Engineers Pvt. Ltd.

 Important Information About This Manual

Reminder for Safety

Modification on Equipment:

This equipment should not be modified. Modification could affect its performance, safety or
disturbance. In addition damage or performance problems resulting from modification may not be
covered under warranties.

Precautions and Maintenance:

This is used to indicate the presence of a hazard that could cause minor or moderate personal injury
or damage to your equipment. To avoid or reduce the risk, the procedures must be followed
carefully.
 Contents
1. Objective …………………………………… 1

2. Aim …………………………………… 1

3. Introduction …………………………………… 1

4. Theory …………………………………… 1

5. Description …………………………………… 2

6. Utilities Required …………………………………… 2

7. Experimental Procedure …………………………………… 2

8. Observation & Calculation …………………………………… 4

9. Nomenclature …………………………………… 6

10. Precautions & Maintenance Instructions …………………………………… 6

11. Troubleshooting …………………………………… 7

12. References …………………………………… 7

13. Block Diagram …………………………………… 8

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

(Rev. 1)
 SEDIMENTATION STUDIES APPARATUS
1. OBJECTIVE:
To study the batch sedimentation process.

2. AIM:
2.1 To determine the effect of initial concentration and initial suspension height on
the sedimentation rates.

2.2 To show the effect of flocculating agent.

2.3 To show the effect of particle size distribution.

3. INTRODUCTION:
Sedimentation is the process of letting suspended material settle by gravity. Suspended
material may be partials, such as clay or silts, originally present in the source water.
More commonly suspended material or floc is created from material in the water and the
chemical used in coagulation or in the other treatment process, such as lime softening.
Sedimentation is accomplished by decreasing the velocity of the water being treated to a
point below which the particle will no longer remain in suspension. When the velocity no
longer supports the transport of the particles, gravity will remove them from the flow.
Some of the more comman types of factors to consider are:

The size and type of particles to be removed have a significant effect on the operation of
the sedimentation tank. Because of their density, sand or silt can be removed very easly.
In contrast colloidal material, small particles that stay in suspension and make the water
seem cloudy, will not settle until the material is coagulated and flocculated by the
addition of a chemical, such as an iron salt or almunium sulphate.

The shape of the particle also affects its settling characteristics.

4. THEORY:
For any batch sedimentation experiment, on slurry of known concentration, the height of
a liquid-solid interface is obtained as a function of time. Slopes of this curve at any point
of time represent settling velocities of the suspension at that time and are characteristics
of specific solid concentration.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 1 of 8 (Rev. 1)
 At the beginning of a batch sedimentation process, the solid is uniformly distributed in
the liquid. The total depth of suspension is maximum but after a short while the solid
have settled to give a zone of clear liquid. After some times it is divided into three zone,
clear liquid zone, partial dense zone and dense zone. Earlier dense zone increases then
decreases.

In the present experimental set-up record the height with respect to time and plot the
graph between them to show the various effects.

5. DESCRIPTION:
The set up consists of five cylinder made of borosilicate glass. The cylinders are
mounted on vertical back-panel, which is illuminated from behind. Measuring scale are
provided for each of the cylinders.

6. UTILITIES REQUIRED:
6.1 Electricity Supply: Single Phase, 220 V AC, 50 Hz, 5-15 Amp combined socket
with earth connection.

6.2 Laboratory glass ware:-

Graduated cylinders (2 Lit) : 5 Nos.

Stop watch : 1 No.

6.3 Chemicals:-

CaCO3 : 2 kg

Distilled water : 10 Lit

7. EXPERIMENTAL PROCEDURE:

7.1 STARTING PROCEDURE (FOR CASE-1):

7.1.1 Prepare five different slurry solutions.

7.1.2 Fill the solution in cylinders.

7.1.3 For first three cylinders, take (50,100,150) gm CaCO3 in 2 liter water and
note down the initial height, which is same.

7.1.4 For second two cylinders, take (100,100) gm CaCO3 in 2 liter water and
note down the initial height which is different.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 2 of 8 (Rev. 1)
 7.1.5 Connect the electric supply.

7.1.6 Switch ON the light.

7.1.7 Stir the solution of cylinder-1 until a uniform solution is achieved. Record
the initial time.

7.1.8 Start the stop watch and record the height of clear liquid interface at every
5 minute interval.

7.1.9 Also note down the time.

7.1.10 Repeat the above steps for all remaining cylinders.

7.1.11 Record the final height and time for each cylinder.

7.2 CLOSING PROCEDURE (FOR CASE-1):

7.2.1 When experiment is over switch OFF the light.

7.2.2 Switch OFF the power supply.

7.2.3 Clean all the cylinders.

7.3 STARTING PROCEDURE (FOR CASE-2):

7.3.1 Prepare five slurry solutions, take 100 gm CaCO3 in 2 liter water for each
cylinder with different amount of flocculants (5,10,15,20,25) ml and note
down the initial height, which is same.

7.3.2 Fill the solution in cylinders.

7.3.3 Connect the electric supply.

7.3.4 Switch ON the light.

7.3.5 Stir the solution of cylinder-1 until a uniform solution is achieved. Record
the initial time.

7.3.6 Start the stop watch and record the height of clear liquid interface at every
5 minute interval.

7.3.7 Also note down the time.

7.3.8 Repeat the above steps for all remaining cylinders.

7.3.9 Record the final height and time for each cylinder.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 3 of 8 (Rev. 1)
 7.4 CLOSING PROCEDURE (FOR CASE-2):

7.4.1 When experiment is over switch OFF the light.

7.4.2 Switch OFF the power supply.

7.4.3 Clean all the cylinders.

7.5 STARTING PROCEDURE (FOR CASE-3):

7.5.1 Take five different size of calcium carbonate and note down the size of it.

7.5.2 Prepare slurry solution by mixing known amount of sodium carbonate with
2 liter of water.

7.5.3 Fill the solution in cylinders.

7.5.4 Connect the electric supply.

7.5.5 Switch ON the light.

7.5.6 Stir the solution of cylinder-1 until a uniform solution is achieved. Record
the initial time.

7.5.7 Start the stop watch and record the height of clear liquid interface at every
5 minute interval.

7.5.8 Also note down the time.

7.5.9 Repeat the above steps for all remaining cylinders.

7.5.10 Record the final height and time for each cylinder.

7.6 CLOSING PROCEDURE (FOR CASE-3):

7.6.1 When experiment is over switch OFF the light.

7.6.2 Switch OFF the power supply.

7.6.3 Clean all the cylinders.

8. OBSERVATION & CALCULATION:

8.1 DATA:
Initial concentration of solution Co = __________ kg/m3

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 4 of 8 (Rev. 1)
 8.2.a OBSERVATION TABLE (FOR CASE-1):

S.No Cylinder-1 Cylinder-2 Cylinder-3 Cylinder-4 Cylinder-5

 Z  Z  Z  Z  Z
(sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm)

8.2.b OBSERVATION TABLE (FOR CASE-2):

S.No Cylinder-1 Cylinder-2 Cylinder-3 Cylinder-4 Cylinder-5

 Z  Z  Z  Z  Z
(sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm)

8.2.c OBSERVATION TABLE (FOR CASE-3):

Dp Cylinder-1 Cylinder-2 Cylinder-3 Cylinder-4 Cylinder-5

(mm)
 Z  Z  Z  Z  Z
(sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm) (sec) (cm)

8.3 CALCULATIONS:

(FOR CASE-1):

Plot the graph of Z vs  for cylinder- 1, 2 & 3.

Plot the graph of Z vs  for cylinder- 4 & 5.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 5 of 8 (Rev. 1)
 (FOR CASE-2):

Plot the graph of Z vs  for cylinder- 1, 2, 3, 4 & 5.

(FOR CASE-3):

ZO  _____ (cm) [Initial height of Z]

CO Z O
C (kg/m3)
Z

CALCULATION TABLE (FOR CASE-3):

Dp (mm) Cylinder-1 Cylinder-2 Cylinder-3 Cylinder-4 Cylinder-5

C (kg/m3) C (kg/m3) C (kg/m3) C (kg/m3) C (kg/m3)

Plot the graph of Dp vs C for cylinder- 1, 2, 3, 4 & 5.

9. NOMENCLATURE:

Nom Column Heading Units Type

C Concentration of sediment at any time  kg/m3 Calculated
Co Initial concentration of sediment kg/m3 Given
Dp Size of solid particles mm Measured
Z Height of suspension clear liquid interface cm Measured
Zo Initial height of suspension clear liquid interface cm Calculated
 Time of settling sec Measured

10. PRECAUTION & MAINTENANCE INSTRUCTIONS:

10.1 Keep apparatus free from dust.

10.2 Always drain the cylinders after use.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 6 of 8 (Rev. 1)
11. TROUBLESHOOTING:
11.1 If light is not showing ON then check the mains.

12. REFERENCES:
12.1 Coulson, J M & Richardson, J F (1991). Chemical Engineering Vol-2. 4th Ed. ND:
Asian Books Pvt. Ltd. pp 174-188.

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 7 of 8 (Rev. 1)
13. BLOCK DIAGRAM:

K.C. Engineers Pvt. Limited, Ambala SEDIMENTATION STUDIES APPARATUS

Page No. 8 of 8 (Rev. 1)