MIP PRELIM 3. Ideal Contact - how much the material 2.
Mechanical Separation - those employing a
Unit Operations being processed is in contact for any length of selective barrier such as screen or a
A unit operation is a basic step in a time under specified conditions, such as filter media,
process that involves physical change or conditions of temperature, pressure, and etc. - those depending on the difference
chemical transformation during the process. 4. Rates of an Operation - Equilibrium must be on phase density alone,
Manufacturing may be defined as the attained for further change can take place - those depending on the fluid and
sequential application of technical unit and the process stops, however the process particle mechanics, and
operations to increase or convert raw material, tends to keep going. Resistance ( heat transfer, - those depending on the surface,
or materials, to a high-value added electrical resistance, etc.) provides the major electrical, or magnetic properties of particles
component or device. difficulty in tackling the rates of an operation.
Screening/ Sieving - a mechanical operation
Types of Unit Operations: (Swain, 2011) Solid-to-Solid Separation: Properties of Solids that is generally used in separating large
1. Mechanical Operations 1. Density - mass per unit volume - and Bulk particles into specific size fractions.
- Transportation Density (Apparent Density) - density of the - this is done by passing the mixture of
- Screening bulk solids or material material in a feed moving through uniformly
- Size Reduction Nonporous materials have a density spaced opening of the desired size as the
- Filtration equal to its true density. base
- Clarification Porous materials have lesser mass
- Mixing compared to its nonporous counterpart. APPLICATIONS OF SCREENING
2.Fluid-flow operations 2. Porosity - It is the amount of available • to remove the coarse particles for further
3.Heat-transfer operations; and spaces known as void spaces of a raw size reduction
4.Mass-transfer operations material in which water or air (or other • to remove the fine particles from crusher
materials) can fill up with. feeds to save power by preventing over-
Mechanical Operations Equipments Soil in reality, contains moisture (20% grinding
- Sieve shaker water). • to grade the crushed products into
- Test sieves Depending on soil compaction, commercial sizes, and
- Fluidization apparatues contains air on void spaces. • to perform a step for a subsequent process.
- Plate filter press Moisture is an important factor when
- High temperature - high pressure filter press dealing with materials such as Bagasse. TERMINOLOGIES
- Solids handling study bench 3. Specific Gravity - The ratio of the density of 1. Particle - a single piece of raw material
- Sigma mixer the material to the density of a reference being fed into the screen
- Roll crasher substance Dimension of a particle:
- Basket centrifuge 4. Hardness - resistance of material to - Martin’s Diameter - the mean
- Froth flotation unit indentation or scratching distance between two parallel tangents to
- Ball mill 5. Brittleness/ Friability - a property of a the projected particle diameter
- Belt conveyor material to be easily broken by impact - Feret’S Diameter - the mean chord
- Bucket conveyor 6. Toughness - resistance to impact, inverse of length of the projected particle perimeter
friability - Projected Area Diameter
Fundamental Concepts 7. Friction - resistance of material moving 2. Screen Aperture - clear size between the
1. Material Balance - mass balance against another material individual wires of the screen
2. Energy Balance - energy balance is done to 3. Mesh - number of screen apertures per unit
be able to determine the amount of energy Solid-to-Solid Separation: Screening length, larger the mesh number = finer the
required to carry out on operation. Methods of Separating Materials screen
1. Chemical Separation
4. Screen Interval - relationship between the how frequent oversize particles 5. Banana Screen - has different angles per
successive sizes of the screen openings in a retain in the screen. stage, 1st stage = 24 - 25 degrees, 2nd stage = 8
series - 24 degrees, 3rd stage = 0 - 8 degrees
- Common screen intervals are 2 for IDEAL PARTICLE SIZE FOR SCREENS
large apertures. 1. Particle is greater than 1.5W of the aperture. SCREEN ANALYSIS
√2=1.4141: for smaller apertures 2. Particle is less than 1.5W of the aperture. - testing of screen operations using testing
√(4&2) =1.892: for careful work and sieves
research FACTORS AFFECTING SCREENING OPERATIONS - evaluated by determining the percentages
5. Undersize Particles - particles that pass 1. Screening Surface - types of screen bed of materials passing or materials retained on
through apertures of the screen, commonly a) Parallel Bars/Rods - ideal for primary specified testing sieves.
denoted as (-) sign screening (coarser particles)
6. Oversized Particles - the particles that retain b) Punched Plate - sheets punched by MASS FRACTION
in the screen, commonly denoted as (+) sign various patterns - The sample is taken to the sieve tester where
7. Blinding - when particles tend to block the c) Woven Wires - used in finer screenings it is shaken for a specific amount of time and
screen aprtures thus prevent screening - precrimped to avoid wearing the mass of each products retained on each
Reasons: - square is used for equal sizes sieve is measured with respect to the whole
1. Presence of near mesh particles that particles mass of the sample.
have sizes very close to the screen aperture - rectangular is used for needle like
size. shapes PURPOSE OF SCREEN ANALYSIS
2. Cohesion of particles to each other. • To determine the effectiveness of a specific
3. Moisture of the particles tend to stick Requirements for Material Selection for Screen screen size.
to the surface of the screen. Surfaces • Evaluating screens by obtaining samples
1. Strong enough to carry load fromproducts and know what sizes are to be
CATEGORIES OF SCREENING 2. Wear and abrasion resistant expected throughout the operation.
1. Dry Screening - contains a natural amount 3. Corrosion resistant • On the contrary, screen analysis of feed can
of moisture or the material has been dried 4. Economical also be used to select the appropriate screen
before screening size for a specific material feed.
2. Wet Screening - for screening fines and SCREENING EQUIPMENTS
moist materials whose screening is very dfficult 1. Grizzly Screens - used for primary screenings, CUMULATIVE PLOTS - Plots of mass fraction
without washing 20 to 300mm, stationary or moving at an retained on each sieveversus particular sieve
angle of 20 to 50 degrees aperture (PAN should be 1)
STRATIFICATION 2. Vibrating Screens - widely used for high
- the process of letting large particles to rise efficiency and high capacity operations, FRACTIONAL OR DIFFERENTIAL PLOTS - are the
and small particles to passed through the large opening (high amplitude) = slower plots of the mass fraction on each sieve versus
gaps speed, smaller opening (low amplitude) = the average sieve size (the sum of the feed
faster speed should equal to 1)
Factors affecting Stratification 3. Gyratory Screens - screens that are in a
1. Material Travel Flow form of series of decks, rotates because of the CAPACITY OF A SCREEN - measured by the
2. Stroke Characteristics centrifugal force, and has the highest mass of the material that can be fed per unit
3. Surface Particle Moisture efficiency among the equipments time to a unit area of the screen
4. Trommel Screens - frames that are
SEPARATION PROBABILITY cylindrical/ conical, can be in single, trommel FORMULAS:
- Pertains to how frequent undersize in series, or compound trommel forms Mass balance
particles pass through the screen and F=P+R
� � � (� −� )
Recovery = �� = ��(�� − �� )
�� � � �
Rejection = 1 - effectiveness of recovery
(1 − �� )� (1 − � )(� −� )
Rejection = 1 - (1 −�� )�
= 1 - (1 −� �)(� �− ��)
� � �
PRODUCT - FEED RATIO
� �� − ��
=
� �� − ��
REJECTED - FEED RATIO
� �� − ��
=
� �� − ��
Screen Effectiveness = Recovery x Rejection
� � (1 − �� )� � (� −� ) (1 − �� )(�� −�� )
E = � [1 −
�� �
]= � � � [1-
(1 −��)� �� (�� − �� )
] (1 −��)(�� − �� )
OVERALL EFFECTIVENESS
� (� −� )(� −� )(1 − �� )
�������� = � � � � 2 �
� (� − � ) (1 −� )
� � � �
Where:
• F = mass flow rate of the feed
• R = mass flow rate of reject.
• P = mass flow rate of product
• �� = mass fraction of desired material in feed
• �� = mass fraction of desired material in
reject
• �� = mass fraction of desired material in
product
SCREEN CAPACITY
Q = ACEDG
Where:
Q = capacity of the screen, tons per hour
A = area of screen, square feet
C = theoretical capacity of screen, tons/hr-��2
E = efficiency factor
D = deck factor
G = aggregate-size factor
