2021-CH-86 Ali Hasnain

Ch.E-203L Particle Technology Lab

Submitted to:

Dr. Muhammad Shahzad

Submitted by:

Ali Hasnain (2021-CH-86)

Department of Chemical Engineering

UET Lahore

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Centrifugal Hydro Classifier

ABSTRACT:
The main objectives of this experiment are to study the various parts of
Laboratory Hydro classifier with special emphasis on their functions and calculate
performance of hydro classifier by measuring sharpness of separation and cut size. We
performed a screening test on a given sample. The methodology of this classifier is
perform a screening test on a given sample by putting different size particles traveled
with different terminal velocity. Due to gravity and centrifugal force large particle moved
downward and small particles remain suspended. The conclusion is that

APPARATUS:
 Laboratory hydro classifier
 Feed
 Electrical balance
 Sieve Shaker
 Set of Sieves

REALTED THEORY:
Introduction:
Hydro-cyclones for Classification were briefly considered starting in 1891.
In hydro classifier pump installed which could create high velocity spiraling flows in
hydro-cyclones that provide the mechanism to separate the feed into coarse and fine
particles. Mostly Alumina used in the construction of hyro-cyclones.

The purpose of this classifier is cut solid particles in liquid according to their
size and density. The classifying rotor in hydro classifier can install vertically or
horizontal and different parts may be made of ceramic. In industries, its capacity and size
ranges will be different.

Types of Classifications:
Classifier can be divided into different categories based on different size
range and capacity:

 Vertical Current Classifiers

 Horizontal Current Classifiers

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1. Settling cones
2. Mechanical classifiers
a. Rake classifiers
b. Spiral classifiers

Vertical Current Classifier:

Hydraulic Classifier:
Vertical current classifier such as hydraulic classifiers are used hindered
settling types and so increase the effect of density on the separation. In this type of
classifier, solid particles suspended in liquid separate into two distinct size fractions. The
principle in this classifier is totally based on size of the particles by difference in terminal
velocity in a liquid.

Figure#01. Hydraulic classifier

Horizontal Current Classifier:

Settling Cones:
Classification of medium and fine particles for subsequent processing in hydro
mechanical gravimetric separation. Settling cones classification are more precise
separation processes than screen classification. It consist of several settling chambers in
the form of inverse pyramids. Larger particles flow towards outlet at the bottom.

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Figure#02 Settling Cones

Mechanical Classifier:
Horizontal current classifiers such as mechanical classifiers are used free-
settling type. The size term is highlighted in this type of classifier.

Figure#03 Mechanical Classifier

 Rake Classifier
It is a large tanks in which a slurry of feed particles is fed in liquid. The
main purpose of this type of classifier is to separate the solid from liquid. A series of
rakes drop into the flow of slurry and is pulled upwards. Some of the small particles will
flow up at the top of the rake. The rest will be move along with the large particle up the
incline.

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Figure#04 Rake Classifer

 Spiral Classifier
Spiral Classifier is a common classification equipment used in mineral
processing plants. It has the different features like simple structure, high capacity and
high efficiency. The principle of this type is that the size and specific gravity are
different, so the sedimentation speed in the liquid is different. It can use the spiral blade
to rotate the coarse material. The fines particles are discharged from the overflow pipe at
top.

Figure#05 Spiral Classifier

CONSTRUCTION:
Hydro Classifier consists of following parts:
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 Vortex finder
 Inlet head casting
 Feed chamber
 Cylindrical section
 Cone casting
 Liners
 Apex
 Apex valve
 Pneumatically operated apex orifice

Figure#05 Construction

Hydraulic Classifiers consist of cone vessels where pulp is introduced vertically from top
and water injected from bottom from series of column. Water moves upward which tend
the lighter particles to move upward towards vortex. Heavier particles due to gravity and
high weight particles settle down and leave through Apex.

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WORKING PRICIPLE:
The feed material is carried into the classifier which is filled with
water by inlet flow stream. Different particles travel with different terminal velocity. Two
phenomenon exists. One is free-settling in which particles don’t intersect and size is
considered. The particles settle down by action of gravity and weight. Internal rotors
apply drag force opposite to centrifugal force which tend the coarser particles towards
centre while allowing air to pass through them.

Figure# forces acting on orbital partciles

The other phenomenon is hindered-settling in which particles intersect to each other and
density is considered. So the coarser particles settle down through underflow and lighter
particles suspended then collected through overflow.

RELATED TERMINOLOGIES:
Particles extracted from Earth. Different sizes particles have different
compositions and densities. Direct relation is existing between velocity and density which
means that more density more velocity. Density enhances terminal velocity in downward
density. So first calculate the density and size distribution in feed.

 Free-Settling
In this phenomenon, we assume particles don’t collide with each other. They settle down
freely under the action of gravity and wight. Only force acting is direct force that is
resistance by fluid. To determine whether it is free or hindered settling, important
parameter is solid percentage.

If

Solid percentage is less than 15, it will be free settling

Free-settling under the action of gravity, stroke’s law will be applicable to less than 5µm.

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Where

g= Gravity of Earth

Ds= Density of solid particle

Df= Density of fluid

V= Terminal velocity

դ= Viscosity of fluid

d= diameter

We can get idea from this law is that terminal directly proportional to density and
diameter.

Assume two particles having different sizes and densities but have same terminal
velocity. Possible if larger particle has smaller density as compare to smaller one.

So

Reduced the equation (9.4) to this;

 Hindered-Settling

In this phenomenon, we assume particles intersect each other. In which Fluid act as
suspended. Density of particle increase. Effect of density is mostly considered. When
concentration of particles in fluid is large then particle size effect is less considered.
Particle separate on the basis of density basis not on size. It cannot applied at industrial
level.

if

Particle size is larger than 5mm then only Newton’s law is applicable.

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Here

g= Gravity of Earth

Ds= Density of solid particle

Df= Density of fluid

V= Terminal velocity

d= diameter

so reduced the equation (9.6) to this;

PERFORMANCE INDICATIONS:
Classifier Efficiency:
Ideal;

All particles smaller than 500µm should be reported in overflow and all particles greater
than 500µm should be reported in underflow.

Real;

In real, inefficiency is not a vertical line. Virial curve is percentage of different size
particles in underflow.

Here

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f = percentage of material in the classifier feed

o = percentage of material in the overflow

F = weight of classifier feed

O = weight of classifier overflow

Graph# Graph between Particle Size and Distribution Coefficient(%)

Sharpness of separation:
Slope of central portion curve is known as sharpness of separation. Higher value of
separation means products will more efficient.

Acceptable value is 2.5

So slope is calculated as;

Here

ΔY=(y2-y1)

ΔX=(x2-x1)

If

tan45 =1

θ is greater than 1 then efficiency will be high. Which means that steeper more vertical
then θ = 90

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tan90= ∞

θ is infinity which means that we get maximum efficiency.

Difference between measured and designed cut size:

Cut size is at which 50% reporting to underflow and overflow.

If more difference is present between measured and designed cut size is larger then we
get less efficiency of classifier.

If difference is less between measured and designed cut size then we get high efficiency
of classifier.

CAPACITY:
Capacity is one of the most prominent or important features in classifications.
Capacity is basically amount of weight per unit time. It can be varied with;

 Size

The capacity of the given mill can be found out by using the following formula;

Energy consumption:

PARAMETERS AFFECTING PERFORMANCE

Design Parameters
We have to maintain the only one term that is cut size.

Cylinder diameter
If diameter of cylinder is greater then the surface area increases and velocity decrease.
So, the cut size will also be decrease because larger particles also go to apex.

Inlet diameter
Inlet diameter has same effect as that of cylinder diameter. If inlet diameter is high then
larger particles tend to move towards apex. So, the cut size will be less.

Vortex finder diameter

Vortex diameter means increase of area of overflow pipe. When vortex find diameter
will be increase more amount of material go to overflow. Also, larger particle size goes
towards overflow. So, the cut size will increase.

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Apex diameter
Apex diameter means increase the diameter of underflow pipe. When apex diameter will
increase then smaller particles also settle down towards underflow pipe. So, the cut size
will decrease.

Length of cone or angle in cone

Length is inversely proportional to angle of cone. When length increase then angle will
decrease. So, the more amount of material goes towards apex and cut size decreases.

Operating Parameters
Feed pressure
Feed pressure has direct relation with cut size. When feed pressure is high then more
amount of material goes towards vortex. So, the cut size will increase. When feed
pressure is low then more amount of material go towards apex. So, the cut size decrease.

Feed percent solids

Feed percent solids have direct relation with cut size. When feed percentage is high then
more amount of material go towards vortex. So, the cut size will increase. When feed
percentage is low then more amount of material go towards apex. So, the cut size
decrease.
APPLICATIONS:
 It is used for washing and dewatering process feed control
 It is used as closed circuit grinding in secondary circuit
 It is used for recovery of fine sand, limestone and coal
 Hydro-classifier is used where clean rank sands are needed
 Centrifugal classifier used for fine separation in mining operations
 It is used for preparation of table feed Sizing of homogeneous materials

LIMITATIONS:

 Characteristics of separation are poor

 High load produce less sharpness
 It is too costly
 It is used for two product separations

SPECIFICATION OF INDUSTRIAL MODEL:

Table#01. Specifications of Common Indus. Models.

Parameters of models HTS70 HTS100

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Diameter of grinding disc (mm) 70 100

Classification motor power (kW) 2.2 3

Rotation speed of classifying 4500 3250

wheel (rpm）(max)
Air volume (m³/h)(max) 150 300
Product fineness (μm/D97） 5~100 3~100
Classification efficiency (η%) 60~80 60~80

SPECIFICATION OF BALL MILL:

Table#02. Specifications Of Ball Mill

Name of Machine Centrifugal Hydroclassifier

Motor Power 0.25 HP

Motor RPM 500 – 2500

Size of classifier 9 inch

PROCEDURE:
 Firstly, identify each part of the machine
 Study the functions of each part.
 Fill the tank with water by opening the valve of water supply.
 Take the sample after sieve analysis.
 Close the valve at the bottom of the hydro-classifier.
 When the tank is filled then open the valve and adjust it to maintain a flowrate at
uniform condition.
 Fed the sample in tank which is filled with water.
 Collect the underflow and overflow products into the separate buckets.
 Kept the product until all the solid particles settle down at the bottom.
 Dry the products of underflow and overflow in oven at 110° C.
 Again, perform sieve analysis on each product separately by using sieves.
 Determine the cumulative weights and draw graph between geometric mean of
passing and retained size of each fraction versus cumulative passing size.

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 Determine the cut size and performance of classifier.

OBSERVATIONS AND CALCULATIONS:

Cumulative mass Average
Aperture size( mm) individuals
% size

passing Retaining Average Measured %age Passing Retaining Avg x %

31.75 4.76 12.29 7 1.22 98.78 1.22 14.9938

4.76 3.35 3.99 18 3.152 95.628 4.372 12.57648

3.35 2 2.59 48 8.4 87.228 12.772 21.756

2 1 1.91 90 15.76 71.462 28.532 30.1016

1 0.0 0.707 95 16.63 54.838 45.162 11.75741

0.5 0.25 0.353 183 32.04 22.798 77.202 11.31012

Total :103.
Total :571
6334

Discussion:
It further decrease the size of the product of roll crusher. It converts the particles into
more fine form. It will reduce 1.5 m top size run-of-mine ore to 20 cm. Since they
depend on high velocities, wear is greater than for jaw or gyratory crushers. Hence
impact crushers should not be used on ores containing over 15% silica (Lewis et
al., 1976). However, they are a good choice for primary crushing when high
reduction ratios are required (the ratio can be as high as 40:1) and a high
percentage of fines, and the ore in- abrasive.

Conclusion:

References:
 Ashok Gupta, Dennis Yan, -Mineral Processing Design and Operations An
Introduction (2006)
 https://www.sciencedirect.com/topics/chemistry/ball-milling
 https://www.911metallurgist.com/ball-milling/

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