EHMOP1A – Mechanical Operations

Assignment 1
22 May 2023 Full Marks: 70
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Young Modulus Stress (GPa) 291

Tensile strength (MPa) 10.5
Hardness (Mohs scale) 6 – 6.5
Density (g/cm3) 4.9
Melting Point 1070°C

In a Pyrite Benefication Process the pyrite ore is crushed in the secondary jaw crusher of a and
classified using a circulator vibrating screen.
The crushed ore is classified using a 6mm The sieve analysis of a sample of the crushed product is given in
vibrating screen to separate the oversized the table below:
material so that it can be returned to the crusher. Sieve Mass fraction retained on the sieve
opening Crusher Feed to the screen Oversize Undersize
mm Feed (Crusher Product) from the from the
screen screen
-120 +100 0.15 -
-100 +80 0.49 -
-80 +60 0.23 -
-60 +40 0.13 -
-15 +12 - 0.45 0.60 0.04
-12 +10 - 0.21 0.18 0.10
-10 +7 - 0.18 0.09 0.11
-7 +5 - 0.07 0.05 0.17
-5 +1 - 0.09 0.08 0.58
A constant volume shape factor of 0.98 may be assumed for the
crushed particles fed to the classifying screen.

Question 1 (11 marks)

1. The crushed pyrite particles have a regular cuboid shape with average side lengths of 1.2mm. Looking at a single
particle, answer the following questions:
1.1. Calculate the equivalent surface-volume diameter of the pyrite particle.
(4)
1.2. Calculate the specific surface ratio for this pyrite particle. Compare this calculated value with the value obtained
from Figure 1.1 in the formula sheet.
(5)
1.3. Calculate the sphericity of the pyrite particle.
(2)
Question 2 (13 marks)
2. Considering only the feed to the screen, answer the following questions:

Sieve opening Mass fraction retained • A constant volume shape factor of 0.98 may be assumed for the crushed particles fed to the
mm on the sieve classifying screen.
Feed to the screen
(Crusher Product)
-15 +12 0.45 • Density 4.9 g/cm3
-12 +10 0.21
-10 +7 0.18
-7 +5 0.07
-5 +1 0.09

2.1. Is the mass fraction of the feed to the screen given as a frequency of a cumulative mass distribution?
(1)
2.2. Calculate the number of particles per kg of pyrite.
(5)
2.3. Calculate the cube root mean diameter of the particles fed to the screen.
(3)
2.4. Calculate the specific surface area of the particles fed to the screen and the sauter diameter.
(You can assume that the screen diameter  volumetric diameter, then s = 1/s = n. Use n = 1.75.)
(4)

Question 3 (16 marks)

Sieve opening Mass fraction retained on the sieve

mm Feed to the screen Oversize Undersize
(Crusher Product) from the from the
screen screen
-15 +12 0.45 0.60 0.04
-12 +10 0.21 0.18 0.10
-10 +7 0.18 0.09 0.11
-7 +5 0.07 0.05 0.17
-5 +1 0.09 0.08 0.58

3. Consider the vibrating screen used in the plant and the sieve analysis provided, answer the following questions:
3.1. What happens when near-mesh particles are fed to a screen?
(2)
3.2. What are the advantages of a vibrating screen when compared to a trommel screen?
(3)
3.3. Calculate the overall screen effectiveness if a product size of 6mm or less is desired.
(11)

EHMOP1A Assignment 1 Page | 2

Question 4 (15 marks)

Sieve opening Mass fraction retained on the sieve • Density 4.9 g/cm3
mm Crusher Feed to the screen
Feed (Crusher Product)
-120 +100 0.15 -
-100 +80 0.49 -
-80 +60 0.23 -
-60 +40 0.13 -
-15 +12 - 0.45
-12 +10 - 0.21
-10 +7 - 0.18
-7 +5 - 0.07
-5 +1 - 0.09

4. The pyrite is fed at a rate of 13 000 kg/hour to the secondary jaw crusher. The crusher is operated in a closed
cycle, with a recycle of 27 000 kg/hour.
4.1. Using Bond’s third law calculate the total energy consumption in kWh/tonne if the energy efficiency of the crusher
is 78%.
(10)
4.2. Shortly explain how a jaw crusher works and the stressing mechanism used for size reduction.
(5)

Question 5 (8 marks)
5.1. Differentiate between the terms Agglomeration and Granulation
(2)
5.2. How are the interparticle forces of liquid bridges and solid bridges related.
(2)
5.3. Recommend a suitable size enlargement process for the following products:
5.3.1. Enlarging sauce and soup powders granules with a porous structure and a large surface area
5.3.2. Enlarging fertiliser granules with a moderate density and very spherical particles in a continuous process
5.3.3. Enlarging pharmaceutical powders with a high granule density typically in batch processes
5.3.4. Enlarging ceramic granules with a low granule density to a product size of 1mm
(4)

Question 6 (8 marks)

6. The pyrite ore (13 000 kg/hour) from the primary jaw crusher is moved to the secondary jaw crusher using a screw
conveyor elevated to 5m over a distance of 15m. The conveyor has a screw cross-sectional area of 1.5 m2 and a
pitch of 1.212 m. (The pyrite ore is assumed to be a heavy abrasive material)
6.1. Estimate the power consumption (kW) required to move the crushed pyrite ore from the primary to the secondary
jaw crusher.
(3)
6.2. Calculate the speed of the screw in revolutions per minute.
(3)
6.3. Would a belt conveyor be a better choice for this application? Motivate your answer.
(3)

EHMOP1A Assignment 1 Page | 3

 EHMOP1A – Mechanical Operations
Formula and Data Sheet
LU 1, LU 2 and LU 3

Single Particle
Shape Figure Volume Surface Area
Cuboid 𝑙 × 𝑏 × ℎ 2𝑙𝑏 + 2𝑏ℎ + 2ℎ𝑙
Cylindrical 𝜋𝑟 2 ℎ 2𝜋𝑟ℎ + 2𝜋𝑟 2
Conical 1 2
𝜋𝑟 ℎ 𝜋𝑟𝑙 + 𝜋𝑟 2
3

Spherical 4 3
𝜋𝑟 4𝜋𝑟 2
3

𝑆 6𝑉 3
6 6
𝑑𝑠 = √ 𝑝⁄𝜋 ; 𝑑𝑣 = √ 𝑝⁄𝜋 ; 𝑑𝑣𝑠 = ; 𝑠𝑝 =
𝑆𝑝 𝜌𝑠 𝑑𝑣 𝜓𝑠
2 𝑑𝑎𝑣𝑔
𝜋𝑑𝑣 1
𝜓𝑠 =
𝑆𝑝
; 𝜆𝑠 =
𝜓𝑠
; 𝑛=(
𝑑𝑣
) 𝜆𝑠 ; 𝑉𝑝 = 𝜆𝑣 𝑑𝑎𝑣𝑔 3

Mixtures of Particles
6 𝑛𝑖 𝑥𝑖 𝑀 1 𝑥𝑖 𝑚𝑖
𝑠𝑚 = ∑𝑖 ; (𝑁) = 𝑁 = 𝜆 ∑𝑖 3 ; 𝑁𝑖 = 3
𝜌𝑠 𝑑𝑎𝑣𝑔𝑖 𝑣 𝜌𝑠 𝑑𝑎𝑣𝑔 𝜌𝑠 (𝜆𝑣𝑖 𝑑𝑎𝑣𝑔 𝑖)
𝑖

Statistical Mean Diameters

Σ𝑁𝑖 𝑑𝑖 Σ𝑁𝑖 𝑑𝑖2 Σ𝑁𝑖 𝑑𝑖3 Σ𝑁𝑖 𝑑𝑖4
𝐷𝐴 = 𝐷𝑁 = ; 𝐷𝐿 = ; 𝐷𝑆 = ; 𝐷𝑉 =
Σ𝑁𝑖 Σ𝑁𝑖 𝑑𝑖 Σ𝑁𝑖 𝑑𝑖2 Σ𝑁𝑖 𝑑𝑖3
1⁄2 1⁄3
Σ𝑁𝑖 𝑑𝑖2 Σ𝑁𝑖 𝑑𝑖3 Σ𝑁𝑖 1
𝐷𝑆𝑅 = [ ] ; 𝐷𝐶𝑅 = [ ] ; 𝐷𝐻 = ; 𝐷𝑉𝑆 = ∑(𝑛
Σ𝑁𝑖 Σ𝑁𝑖 Σ(𝑁𝑖 ⁄𝑑𝑖 ) 𝑖 𝑥𝑖 /𝑑𝑖 )

Screening Errors and Screen Effectiveness

𝑦𝑃 𝑃 (1 − 𝑦𝑃 ) 𝑃 𝑦𝑃 (𝑦𝐹 − 𝑦𝑅 ) (1 − 𝑦𝑃 ) (𝑦𝐹 − 𝑦𝑅 )
𝐸𝑐 = ( ) [1 − ( )] = ( ) [1 − ( )]
𝑦𝐹 𝐹 (1 − 𝑦𝐹 ) 𝐹 𝑦𝐹 (𝑦𝑃 − 𝑦𝑅 ) (1 − 𝑦𝐹 ) (𝑦𝑃 − 𝑦𝑅 )

Size Reduction Laws

𝐸 𝐷
= 𝐾𝐾 𝑙𝑛 ( 𝐹 )
𝑀 𝐷 𝑃
𝐸 6𝐾𝑅 1 1 1 1 6𝐾𝑅
= 𝐾𝑅 (𝑠𝑃 − 𝑠𝐹 )= [𝐷 − ] = 𝐾𝑅 ′ [𝐷 − ] ; 𝐾𝑅′ = , D(m)
𝑀 𝜌𝑠 𝑉𝑆,𝑃 𝐷𝑉𝑆,𝐹 𝑉𝑆,𝑃 𝐷𝑉𝑆,𝐹 𝜌𝑠

𝐸 1 1 1 1
𝑀
= 𝐾𝑏 [ − ] = 0.3162𝑊𝑖 [ − ], D(mm)
√𝐷𝑃𝑏 √𝐷𝐹𝑏 √𝐷𝑃𝑏 √𝐷𝐹𝑏

EHMOP1A Assignment 1 Page | 4

Typical values of sphericities for common materials:
Material Sphericity, (s) Material Sphericity, (s)
Sand (rounded) 0.83 Coal dust (up to 10mm) 0.65
Fused flue dust 0.89 Flint sand (jagged flakes) 0.43
Fused flue dust (aggregates) 0.55 Mica flakes 0.28
Tungsten powder 0.89 Berl saddles 0.3 (average)
Sand (angular) 0.73 Raschig rings 0.3 (average)
Pulverised coal 0.73
Table 1.1 from Narayan C.M & Bhattacharya B.C.; Mechanical Operations for Chemical Engineers; 3rd Edition; Khanna Publishers

Figure 1.1 Plots of Specific Surface Ratio (n) versus Average Particle Size for Different Materials (From G.G. Brownand Associates, Unit Operations, Wiley,
New Yark, 1950, by permission)
Figure 1.1 from Narayan C.M & Bhattacharya B.C.; Mechanical Operations for Chemical Engineers; 3rd Edition; Khanna Publishers

Table of Rittinger’s numbers

2
Material Rittinger’s Number (m /J)
Galena 0.0957
Sphalerite 0.0573
Pyrite 0.02303
Quartz 0.0179
Calcite 0.07745
Table 2.1 from Narayan C.M & Bhattacharya B.C.; Mechanical Operations for Chemical Engineers; 3rd Edition; Khanna Publishers

Table of typical Work Index values

Mineral Specific Gravity Work index, Wi Mineral Specific Gravity Work index, Wi
Bauxite 2.20 8.78 Hematite 3.53 12.84
Cement clinker 3.15 13.45 Limestone 2.66 12.74
Cement raw material 2.67 10.51 Phosphate rock 2.74 9.92
Clay 2.51 6.30 Pyrite ore 4.9 8.9
Coal 1.4 13.00 Quartz 2.65 13.57
Coke 1.31 15.13 Shale 2.63 15.87
Granite 2.66 15.13 Slate 2.57 14.30
Gravel 2.66 16.06 Trap Rock 2.87 19.32
Gypsum rock 2.69 6.73

EHMOP1A Assignment 1 Page | 5

Transportation of Solids

Screw Conveyor

Belt Conveyor

EHMOP1A Assignment 1 Page | 6