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Lect 4

Lecture 4 slides of principles of extractive metallurgy - IIT KHARAGPUR

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Priyadarshi Kumar
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11 views19 pages

Lect 4

Lecture 4 slides of principles of extractive metallurgy - IIT KHARAGPUR

Uploaded by

Priyadarshi Kumar
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Principles of Extractive Metallurgy

Lecture 04:
a. Particle Size Estimation and Industrial Screens

1
Concepts:

• Methods for particle size estimation


• Equivalent size diameter for irregular particles
• Sieve analysis and average certain% passing size determination
• Industrial Screening techniques and their classification
• Static and Dynamic screens

2
Keywords:
• Sieve-analysis
• Mesh number
• Elutriator
• Martin’s and Ferret’s diameter
• Cumulative %passing - size distribution
• Trommel Screen
• Gyratory Screen
• Roller Screen
• Grizzly Screen
• Banana Screen

3
Methods of Size Estimation
• 1. Sieve Analysis: The particle size
can be characterized by determining Elutriator
the size of sieve hole or aperture the
particle will just pass through
(oldest & most common method).
• 2. Sedimentation Method: The time
the particle takes to settle in a fluid
(water) and express the particle size
as the size of a sphere that has the
same settling rate (Stokes
diameter).
• 3. Microscopic Methods: Visual
examination under the optical
microscope or electron microscope
or the diffraction of a laser beam to v = d2g( -  )/18 Stokes’ Law
t s f
derive statistical dimensions of
particles. Ratio of the max to min diameter
of the particles should be < 4
Stokes diameter x 0.94 = sieve size (approx)
Methods of Size Estimation

Mesh No.= the number


of openings in one inch
of screen

Sieve Size: Mesh


No. 4; 4.75 mm
Equivalent Size Diameter of Irregular Particles
Sieve Analysis
• A sample material successively pass through finer sieves and weighing the
amount collected on each sieve to determine %wt in each size fraction.
• The sieves are usually agitated to expose all the particles to the openings.
• Presence of ‘near-size’ particles can cause blinding/obstruction of the sieve
apertures, & reduce the effective area of the sieving medium.

subsequent sieve openings


are related by a factor of
1/√2 (Tyler's series)
Sieve Analysis
• The sieve size analysis of a mineral sample giving the mass fraction of mineral
retained between successive sieve sizes is usually recorded as in Table:
Size fraction, Mass Cum, Mass Cum. % Passing Sieve Cum. Mass
microns % % retained (100 –retained) (µm) % retained The average size of the
-3500+1750 27.6 27.6 100 3500 0.0 material is determined by
-1750+875 25.2 52.8 72.4 1750 27.6 using the arithmetic formula
-875+440 16.1 68.9 47.2 875 52.8 using mass % retained data
-440+220 9.5 78.4 31.1 440 68.9
-220+110 6.3 84.7 21.6 220 78.4
-110+55 2.9 87.6 15.3 110 84.7
-55 12.4 100 12.4 55 87.6
Total 100 0 PAN 100
To obtain the 80 % passing size, interpolation between the 3500 and 1750 micron screen size
is required. This is best done when a linear relation-ship exists between the size analysis data.
Sieve Analysis

Log-linear plot of cumulative % passing (undersize) vs. size, Log-log plot of cumulative % passing (undersize) vs. size,
Gaudin-Schuhmann 𝑥 𝑎
distribution y=100
𝑘

𝐥𝐨𝐠 𝒚 = 𝐥𝐨𝐠 𝟏𝟎𝟎 + 𝒂 𝐥𝐨𝐠𝒙 − 𝒂𝐥𝐨𝐠𝒌 𝐥𝐨𝐠 𝒚 = 𝒂 𝐥𝐨𝐠𝒙 + 𝒄𝒐𝒏𝒔𝒕𝒂𝒏𝒕


The slope of the straight line = a, and k = x, when y = 100%.
The distribution parameter (a) give the range of different sizes in the
sample & the size parameter (k) is a measure of the top size.
Sieve Analysis
• Ex: From the sieve analysis data of a sample in Table, calculate (a) Average size of the sample
and (b) 80% passing size.

For determination of 80% passing size, cumulative weight percentages passing are to be
calculated by adding the weight percentages from the bottom. All the values are shown
in the next Table
Sieve Analysis

A horizontal line is drawn at 80% cumulative weight percent passing. From the point of
intersection of this horizontal line with the curve, a vertical line is drawn on to the x-axis.
The point at which the vertical line meets x-axis is the 80% passing size. It is 580 microns.
Industrial Screening
• The screen is a surface having many apertures/holes,
usually with uniform dimensions.
• Particles presented to a screen surface either pass
through or are retained, according to whether the
particles are smaller or larger than the governing
dimensions of the apertures.
• Dry screening is generally limited to material above 5
mm (to 300mm) in size, while wet screening down to
ca. 250 μm is common. Sizing below 250 μm is more
commonly undertaken by classification.
• Screen efficiency (often called the effectiveness of a
screen) is a measure of the success of a screen in
closely separating oversize and undersize materials.
• Particle Size, Feed Rate, Screen Angle, Particle Shape,
Open Area, Vibration, Moisture affect effectiveness
Classification of screen according to their mode of work
The probability (p) of passage
for a spherical particle of size d
through a square aperture of a
size x made by a wire of
diameter w in a single event is:

The probability of passage for


n impingements
Dynamic Screens

Transport oversize across the


Operate at 35-45% critical speed, lower capacities series of rolls while fines fall
than vibrating screens as a part of the screen through the gaps; high capacity,
surface is used at a time, more prone to blinding. low noise, less impact on materials

A nest of sieves up to around 2.7 m dia.


Break coal (75-100 mm) and separate harder circular tipping & horizontal gyratory
rock, and wood contaminants into the motion produce multiple size fractions;
oversize. operate at 60-70% critical speed ultrasonic devices to reduce blinding
Vibrating & Static Screens
Variable Multi-slope,
Inclined ~20o, circular
throw mechanism. > ~40-30o at the feed end
5000 t/h capacity; use to ~0-15o at discharge
for sizing the feed to end; a linear-stroke
primary & secondary vibration, higher
crushers capacity and more
efficient screening of
the near-size material
Designed for fine separations, direct rapping
of the screen mesh rather than vibration of
Widely used. the entire unit
Contraflow slows
the material &
permits more
efficient
separation, in-
flow permits a
greater
throughput.
Screening Efficiency
• If f, c, and u are expressed in terms of the fractions of undersize material in feed, overflow and underflow
respectively then

9/15/2024 16
Ex 2: A quartz mixture is screened through a 1.5 mm
screen to obtain +1.5 mm fraction. The size analysis of
feed, overflow and underflow is shown in Table.
Calculate the effectiveness of the screen.

9/15/2024 17
9/15/2024 18
References
1. Mineral Processing Technology, 8th Ed., Barry A. Wills and James
A. Finch, 2016, Elsevier Ltd.
2. Mineral Processing, Jan Drzymala, 2007, Wroclaw University of
Technology.
3.Chemical Metallurgy: Principles and Practice. Chiranjib Kumar
Gupta, 2003, WILEY-VCH

19

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