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SCREEN ANALYSIS
Purpose of Screen Analysis
Methods of Reporting Sieve/Screen Analysis
Ways to Visualize the Size Fractions of the
Compiled Data

SCREEN EFFECTIVENESS
Formulas for: Screen Effectiveness,
Recovery, and Rejection
Mass Fractions
Sample Problems

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MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
 • Testing of screen operations
using testing sieves

• Evaluated by determining the

percentages of materials
passing (undersize) or materials
retained (oversize) on specified
testing sieves.

Screen Analysis
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• To determine the effectiveness of a
specific screen size.
• Evaluating screens by obtaining samples
from products to know what sizes are to
be expected throughout the operation.
• On the contrary, screen analysis of feed
can also be used to select the
appropriate screen size for a specific
material feed.

Purpose of Screen Analysis

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
 - used for control &
analytical purpose

- for example,
determining the
efficiency of
screening devices
and the work of
crushing and
grinding
equipment Testing Sieves
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 1. Individual screens
2. Complete the set
3. Place the material
4. Shake
5. Measure

Method of Making
Screen Analysis
https://www.particletechlabs.com/analytical-testing/particle-size-distribution-
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analyses/sieve-analysis
 The sample is
taken to the sieve
tester where it is
shaken for a
specific amount of
time and the mass
of each products
retained on each
sieve is measured
with respect to the Mass
whole mass of the
sample.
Fraction
https://www.particletechlabs.com/analytical-testing/particle-size-distribution-
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analyses/sieve-analysis
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Steps for Screen Analysis
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Mesh System

If a material has passed through the

20-mesh sieve but is retained on the
24-mesh sieve, its designation can be
denoted by:
(20/24) or (-20 +24) fraction
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Tyler Screen Standard
Screen standard with screen intervals of 2

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 Recall: Screen Interval
SCREEN INTERVAL:

the relationship between the successive sizes of

screen openings in a series

10 inches

9 inches

8 inches

7 inches

6 inches

5 inches There is a large relative

difference between the 1-
in. and 2-in. sizes, but in
1 inch the 9-in. and 10-in. are
almost alike for practical
uses.
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 Recall: Screen Interval
SCREEN INTERVAL:

the relationship between the successive sizes of

screen openings in a series.

8 inches

4 inches

2 inches

1 inch

½ inch These sizes vary in

geometric progression,
¼ inch and the factor or screen
interval is 2.

..and so on

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

 Recall: Screen Interval
SCREEN INTERVAL:

the relationship between the successive sizes of

screen openings in a series.

If closer sizing is desired,

an additional screen is
inserted between each two
screens of this series and
the screen interval becomes
𝟐.

𝟒
screen interval = 𝟐
(𝒇𝒐𝒓 𝒄𝒂𝒓𝒆𝒇𝒖𝒍 𝒘𝒐𝒓𝒌 𝒂𝒏𝒅 𝒓𝒆𝒔𝒆𝒂𝒓𝒄𝒉)

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 Tyler Screen Standard
𝟐𝟎𝟎 − 𝒎𝒆𝒔𝒉 𝒔𝒄𝒓𝒆𝒆𝒏

screen interval = 𝟐
wire diameter = 𝟎. 𝟎𝟎𝟐𝟏 𝒊𝒏.
aperture = 𝟎. 𝟎𝟎𝟐𝟗 𝒊𝒏.

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1. Overloading of screens
2. Electrostatic forces
3. Small amount of moisture

Factors that could

affect the results:

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What can be done?
WET-AND-DRY SCREENING
1. Weighed sample is pulped with a
nonsolvent, frequently water
2. Then the sample will be decanted over the
finest screen in the series
3. More water is added
4. Stirring and decantation are repeated until
no fines are in suspension after stirring
5. Water from a wash bottle is placed on the
screen until the drip is clear
6. The water is decanted from the undersize
fraction
7. The material is dried.
8. The oversize is also dried
9. They are put over the entire series of screens
10.The new undersize fraction is weighed with
the fraction obtained by
MANUFACTURING ANDwet screening
INDUSTRIAL PROCESSES | B_ASA 2023
 Method of Reporting
Sieve/Screen Analysis

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

 by calculating the
by calculating the
cumulative percentage
mass percentage of
of size fractions
each size fraction
retained on each sieve

by calculating the
Methods of
cumulative percentage
Reporting
Sieve/Screen of size fractions
Analysis through each sieve

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

 1. Fractional or
Differential Plots
2. Cumulative Plots

Ways to Visualize the

Size Fractions of the
Compiled Data
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
1. Fractional or
Differential
Plots

- the plots of the mass fraction

on each sieve versus the average
sieve size

Advantage: The material feed is focused in this plot.

Disadvantage: You need to calculate the average sieve size.

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
1. Fractional or
Differential
Plots

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1. Fractional or Differential Plots

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2. Cumulative Plots

- plots of mass fraction retained

on each sieve versus particular
sieve aperture

Advantage: Easy to plot

Disadvantage: The particles are not considered in this plot

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
2. Cumulative Plots
Cumulative
Tyler Screen Screen Aperture Mass Fraction
Mesh (in.) through
Screens
𝟏
−𝟖 + 𝟏𝟎 𝐢𝐧. = 𝟎. 𝟏𝟐𝟓 𝐢𝐧. 𝟏
𝟏𝟎
𝟏
−𝟏𝟎 + 𝟏𝟒 𝐢𝐧. = 𝟎. 𝟎𝟕 𝐢𝐧. 𝟎. 𝟗𝟕
𝟏𝟒
−𝟏𝟒 + 𝟐𝟎 𝟎. 𝟎𝟓 𝐢𝐧. 𝟎. 𝟖𝟑
−𝟐𝟎 + 𝟐𝟖 𝟎. 𝟎𝟑𝟓𝟕 𝐢𝐧. 𝟎. 𝟓𝟖
−𝟐𝟖 + 𝟑𝟓 𝟎. 𝟎𝟐𝟖𝟔 𝐢𝐧. 𝟎. 𝟑𝟖
−𝟑𝟓 + 𝟒𝟖 𝟎. 𝟎𝟐𝟎𝟖 𝐢𝐧. 𝟎. 𝟐𝟒
−𝟒𝟖 + 𝟔𝟓 𝟎. 𝟎𝟏𝟓𝟒 𝐢𝐧. 𝟎. 𝟏𝟓
−𝟔𝟓 + 𝟏𝟎𝟎 𝟎. 𝟎𝟏 𝐢𝐧. 𝟎. 𝟎𝟗
−𝟏𝟎𝟎 + 𝟏𝟓𝟎 𝟎. 𝟎𝟎𝟔𝟕 𝐢𝐧. 𝟎. 𝟎𝟓
−𝟏𝟓𝟎 + 𝟐𝟎𝟎 𝟎. 𝟎𝟎𝟓 𝐢𝐧. 𝟎. 𝟎𝟐
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
2. Cumulative Plots
Cumulative
Tyler Screen Screen Aperture Mass Fraction
Mesh (in.) through
Screens
𝟏
−𝟖 + 𝟏𝟎 𝐢𝐧. = 𝟎. 𝟏𝟐𝟓 𝐢𝐧. 𝟏
𝟏𝟎
𝟏
−𝟏𝟎 + 𝟏𝟒 𝐢𝐧. = 𝟎. 𝟎𝟕 𝐢𝐧. 𝟎. 𝟗𝟕
𝟏𝟒
−𝟏𝟒 + 𝟐𝟎 𝟎. 𝟎𝟓 𝐢𝐧. 𝟎. 𝟖𝟑
−𝟐𝟎 + 𝟐𝟖 𝟎. 𝟎𝟑𝟓𝟕 𝐢𝐧. 𝟎. 𝟓𝟖
−𝟐𝟖 + 𝟑𝟓 𝟎. 𝟎𝟐𝟖𝟔 𝐢𝐧. 𝟎. 𝟑𝟖
−𝟑𝟓 + 𝟒𝟖 𝟎. 𝟎𝟐𝟎𝟖 𝐢𝐧. 𝟎. 𝟐𝟒
−𝟒𝟖 + 𝟔𝟓 𝟎. 𝟎𝟏𝟓𝟒 𝐢𝐧. 𝟎. 𝟏𝟓
−𝟔𝟓 + 𝟏𝟎𝟎 𝟎. 𝟎𝟏 𝐢𝐧. 𝟎. 𝟎𝟗
−𝟏𝟎𝟎 + 𝟏𝟓𝟎 𝟎. 𝟎𝟎𝟔𝟕 𝐢𝐧. 𝟎. 𝟎𝟓
−𝟏𝟓𝟎 + 𝟐𝟎𝟎 𝟎. 𝟎𝟎𝟓 𝐢𝐧. 𝟎.AND
MANUFACTURING 𝟎𝟐INDUSTRIAL PROCESSES | B_ASA 2023
2. Cumulative
Plots

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

2. Cumulative Plots

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
- a measure of the success of a screen in
separating undersize and oversize
materials in a mixed feed

Screen Effectiveness
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To determine the effectiveness of a screen
without using the overall mass flow rates of
the screen, samples from the feed and the
end products are taken and mass fractions
are used for the analyses.

Screen Effectiveness
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Initially…

𝐹 =𝑃+𝑅

F = mass flow rate of the feed

R = mass flow rate of reject
P = mass flow rate of product

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

𝐸 = (𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦)𝑥(𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛)

Screen Effectiveness
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
 𝑥𝑝 𝑃
𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 =
𝑥𝐹 𝐹

XF = mass fraction of desired material in feed

XR = mass fraction of desired material in reject
XP = mass fraction of desired material in product

Recovery
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛
= 1 − 𝑒𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑛𝑒𝑠𝑠 𝑜𝑓 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 𝑜𝑓 𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙

1 − 𝑥𝑝 𝑃
𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛 = 1 −
1 − 𝑥𝐹 𝐹

Rejection
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Therefore,

𝒙𝒑 𝑷 𝟏 − 𝒙𝒑 𝑷
𝑬𝒇𝒇𝒆𝒄𝒕𝒊𝒗𝒆𝒏𝒆𝒔𝒔 = 𝟏−
𝒙𝑭 𝑭 𝟏 − 𝒙𝑭 𝑭

Screen Effectiveness
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Applying material balance on the mass of feed flowing
through the screen:

𝐹 =𝑃+𝑅

Finding the Ratio P/F

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Applying material balance on the mass of feed flowing
through the screen:

𝐹 =𝑃+𝑅

Finding the Ratio R/F

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Thus, P/F is

𝑃 (𝑥𝐹 − 𝑥𝑅 )
=
𝐹 (𝑥𝑃 − 𝑥𝑅 )
also,
𝑅 (𝑥𝐹 − 𝑥𝑝 )
=
𝐹 (𝑥𝑅 − 𝑥𝑃 )

Finding the Ratio

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
Recovery Equation

𝑥𝑃 𝑥𝐹 − 𝑥𝑅
𝑅𝑒𝑐𝑜𝑣𝑒𝑟𝑦 =
𝑥𝐹 𝑥𝑃 − 𝑥𝑅

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 Rejection Equation

1 − 𝑋𝑃 𝑋𝐹 − 𝑋𝑅
𝑅𝑒𝑗𝑒𝑐𝑡𝑖𝑜𝑛 = 1 −
1 − 𝑋𝐹 𝑋𝑃 − 𝑋𝑅

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 Effectiveness Equation

𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑛𝑒𝑠𝑠
𝑋𝑃 𝑋𝐹 − 𝑋𝑅 1 − 𝑋𝑃 𝑋𝐹 − 𝑋𝑅
= 1−
𝑋𝐹 𝑋𝑃 − 𝑋𝑅 1 − 𝑋𝐹 𝑋𝑃 − 𝑋𝑅

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

 Overall Effectiveness:
- a function of undersize screening
effectiveness and oversize screening
effectiveness.

Brown’s equation using overflow mass

fraction as the desired product:

𝑥𝑜 (𝑥𝐹 − 𝑥𝑢 )(𝑥𝑜 − 𝑥𝐹 )(1 − 𝑥𝑢 )

𝐸𝑜𝑣𝑒𝑟𝑎𝑙𝑙 =
𝑥𝐹 (𝑥𝑜 − 𝑥𝑢 )2 (1 − 𝑥𝐹 )

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

Sample Problem: Cumulative Fraction
Smaller than 𝐷𝑃
1. A quartz mixture having the screen Mesh 𝐷𝑃, 𝑚𝑚
Overflow, Underflow,
analysis shown in the table is screen Feed, 𝑋𝐹
𝑋𝐷 𝑋𝐵
through a standard 10-mesh screen.
The cumulative screen analysis of the 4 4.699 0 0
overflow and the underflow are also 6 3.327 0.025 0.071
given in the table. 8 2.362 0.15 0.43 0
Calculate the mass ratios of the 10 1.651 0.47 0.85 0.195
(a) overflow to feed; 14 1.168 0.73 0.97 0.58
(b) underflow to feed; 20 0.833 0.885 0.99 0.83
(c) overall effectiveness of the screen. 28 0.589 0.94 1.00 0.91
(d) overall effectiveness of the screen 35 0.417 0.96 0.94
using Brown’s equation 65 0.208 0.98 0.975
Pan 1.00 1.00
Consider the underflow
as the product.
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
PS01:
A sand mixture was screened
through a standard 12-mesh
screen. The mass fraction of
the undersize material in
feed, overflow, and underflow
were found to be 0.4, 0.8,
and 0.2, respectively.
Calculate the screen
effectiveness based on the
undersize materials.

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

Solution:

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

Solution:

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

Solution:

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023

MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023
• Brown,G., Unit Operations (1950),
Unit Operations, CBS Publications.
• McCabe, W., Smith, J., Harriott,P.,
(1993), Unit Operations of Chemical
Engineering (5th Edition), McGraw-Hill
Inc.
• Peurifoy, R., Schexnayder,C., Shapira,
A. (2006), Construction, Planning,
Equipment, and Methods, Engineering
(7th Edition), McGraw-Hill Inc.
• Swain, A., Patra, H., Roy, G. (2011),
Hill Inc.
References
Mechanical Operations, Tata McGraw-
References
MANUFACTURING AND INDUSTRIAL PROCESSES | B_ASA 2023