Diploma Engineering

Laboratory Manual

MECHANICAL OPERATION
4330501

CHEMICAL SEMESTER - 3

Enrollment No
Name
Branch
Academic Term
Institute

Directorate Of Technical Education

Gandhinagar - Gujarat

DTE’s Vision:

Institute’s Vision:
Institute’s Mission:

Department’s Vision:

Department’s Mission:
 Shri K. J. Polytechnic, Bharuch

Certificate

This is to certify that Mr. /Ms……………………………………………Enrollment

No. ………….………….. of 3rd Semester of Diploma in of Shri K. J. Polytechnic,
Bharuch (GTU Code: 0645) has completed the term work satisfactorily in Subject
Mechanical Operation (4330501) for the academic year: 2024 - 25 Term: 241 as
prescribed in the curriculum.

Place: ……………
Date: ……………

Subject Faculty Head of the Department

 Mechanical Operation (4330501)

Preface
The primary aim of any laboratory/Practical/field work is enhancement of required skills as well as
creative ability amongst students to solve real time problems by developing relevant competencies in
psychomotor domain. Keeping in view, GTU has designed competency focused outcome-based curriculum -
2021 (COGC-2021) for Diploma engineering programmes. In this more time is allotted to practical work than
theory. It shows importance of enhancement of skills amongst students and it pays attention to utilize every
second of time allotted for practical amongst Students, Instructors and Lecturers to achieve relevant outcomes
by performing rather than writing practice in study type. It is essential for effective implementation of
competency focused outcome- based Green curriculum-2021. Every practical has been keenly designed to serve
as a tool to develop & enhance relevant industry needed competency in each and every student. These
psychomotor skills are very difficult to develop through traditional chalk and board content delivery method in
the classroom. Accordingly, this lab manual has been designed to focus on the industry defined relevant
outcomes, rather than old practice of conducting practical to prove concept and theory.

By using this lab manual, students can read procedure one day in advance to actual performance day of
practical experiment which generates interest and also, they can have idea of judgment of magnitude prior to
performance. This in turn enhances predetermined outcomes amongst students. Each and every Experiment
/Practical in this manual begins by competency, industry relevant skills, course outcomes as well as practical
outcomes which serve as a key role for doing the practical. The students will also have a clear idea of safety and
necessary precautions to be taken while performing experiment.

This manual also provides guidelines to lecturers to facilitate student-centered lab activities for each
practical/experiment by arranging and managing necessary resources in order that the students follow the
procedures with required safety and necessary precautions to achieve outcomes. It also gives an idea that how
students will be assessed by providing Rubrics.

Diploma Chemical engineers work in various types of industries like Petroleum, Petrochemical,
Pharmaceuticals, Fertilizer, Food, Dyes Etc. Various Chemical manufacturing process involves solid particles
as raw material, catalyst, by-product, Product Etc. By learning this subject students will be familiar with
different mechanical operation like Size Reduction, Solid-solid separation, Solid-Fluid separation, Agitation,
Mixing, Filtration, conveying etc. involved in chemical industries.

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 Mechanical Operation (4330501)

Programme Outcomes (POs) to be achieved through Practical of this Course

Following programme outcomes are expected to be achieved through the practical of

the course:

1. Basic and Discipline specific knowledge: Apply knowledge of basic mathematics,

science and engineering fundamentals and engineering specialization to solve the
Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical engineering

problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical engineering

well-defined technical problems and assist with the design of systems components or
processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern Chemical

engineering tools and appropriate technique to conduct standard tests and
measurements.

5. Engineering practices for society, sustainability and environment: Apply

appropriate technology in context of society, sustainability, environment and ethical
practices.

6. Project Management: Use engineering management principles individually, as a

team member or a leader to manage projects and effectively communicate about well-
defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in updating in

the context of technological changes in field of Chemical engineering

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 Mechanical Operation (4330501)

Practical Outcome - Course Outcome matrix

Course Outcomes (COs):
a) CO1: Use fundamentals of mechanical operation.
b) CO2: Apply concept of size reduction, separation, agitation-mixing, Storage and
Conveying of Solid & Fluid.
c) CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
d) CO4: Calculate properties of solid particles, power consumption, and resistance, crushing
law constants, efficiency and material balance.

CO1 CO2 CO3 CO4

S. No. Practical Outcome

1. Measure volume surface mean diameter, mass √ √

mean diameter, number of particles using a sieve
2. shaker.
Perform differential and cumulative screen √ √
analysis.
3. Test Kicks law for crushing in Jaw crusher. √ √

4. Test Bond's law for crushing in a Roll crusher. √ √

Test Rittinger's law for grinding in a Ball mill and √

5. √
measure critical speed.
6. Determine rate of settling by Sedimentation. √
√
7. Measure rate of filtration, filter medium & cake √
√
resistance in Gravity filtration.
Measure efficiency of separation in froth flotation √
8. √
cell.
Measure efficiency of separation in Magnetic √
9. √
separator.
Measure power consumption in baffled and √
10. √
unbaffled Agitation vessel.

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 Mechanical Operation (4330501)

Index
(Progressive Assessment Sheet)

Date
Date Marks Dated
Sr Experiment/ Page Perform Submission (10) Sign
Sign
Practical Outcome
Measure volume surface mean diameter, mass
1 mean diameter, number of particles using a 7 - 13
sieve shaker.
Perform differential and cumulative screen
2
analysis. 14 - 22

3 Test Kicks law for crushing in Jaw crusher. 23 – 28

4 Test Bond's law for crushing in a Roll crusher. 29 – 35

Test Rittinger's law for grinding in a Ball mill

5
and measure critical speed. 36 – 43

6 Determine rate of settling by Sedimentation. 44 – 51

7
Measure rate of filtration, filter medium &
cake resistance in Gravity filtration. 52 – 60
Measure efficiency of separation in froth
8
flotation cell. 61 – 67
Measure efficiency of separation in Magnetic
9
separator. 68 – 72
Measure power consumption in baffled and
10
unbaffled Agitation vessel. 73 – 80

Total

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 Mechanical Operation (4330501)
Date: ……………
Practical No.1: Measure volume surface mean diameter, mass mean diameter,
number of particles using sieve shaker.
Objective:
Proper size of the particle required for processing in Chemical
industry. Required size of the particle will not be obtained from crushing
operations. Screening is operation in which different micron size particle
obtained, necessary for given operation. By performing this experiment
students will able to perform screening operation, also calculate different
solid properties.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design
of systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct
standard tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering

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 Mechanical Operation (4330501)

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the industry
identified competency 'Use of screening equipment in chemical process
industry':
1. Interprete screens based on its MESH Size.
2. Separate solid particles based on its size a per consumer requirement.
3. Calculate solid properties.

C. Expected Course Outcomes(Cos)

CO1: Use fundamentals of mechanical operation.
CO4: Calculate properties of solid particles, power consumption, and resistance,
crushing law constants, efficiency and material balance.

D. Practical Outcome(PRo)
Measure volume surface mean diameter, mass mean diameter, number of
particles using sieve shaker.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & equipments
• Practice good housekeeping

F. Prerequisite Theory:
Sieves are used industrially on large scale for the separation of particles
according to their size, for the small scale production of closely ground
material and for carrying out size analysis. Generally woven wire cloth is
used for the size analysis of very small particles. Solid particles which
passes through given screening surface are called undersize particles (-)
and particles remain on the screen are called oversize particles (+)
Below shown are some important terms.
1. Sphericity :It is expressed in terms of Φs = 6Vp /Dp Sp
2. Shape factor : It is expressed as a and defined as surface constant/ volume constant
3. Specific surface area :It is defined as surfaced area of particle per unit mass.
4. Mesh no.: It is the number of opening per linear inch.

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 Mechanical Operation (4330501)

G. Experimental set up

H. Resources/Equipment Required
Sr.No Instrument/Equipment
Specification Quanti
. /Components/Trainer kit ty
1. Different size screens In the range of 4 MESH to 200 MESH 5-10
size based on solid Feed mixture size
by visual inspection

2. Weighing Balance 2 kg capacity with +/- 0.001 accuracy 1

I. Safety and necessary Precautions followed

1. Feed should be evenly distributed to all over the screening surface so that
screen’s pore will not get blocked or choked.
2. Select proper amplitude and vibrations to prevent binding on screening surface.

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 Mechanical Operation (4330501)
J. Procedure to be followed:

1. Arrange the sieves in order of decreasing size. Keep pan at the bottom of
the stack. Place the top cover over the first screen.
2. Put the given 1000 gm weight sample in the top most sieves.
3. Cover the sieves and fit the sieves in a sieves shaker properly.
4. Run the shaker for a given time in such a way that sufficient screening
through any ofthe sieves takes place.
5. Take out the sieves carefully and weigh the samples of particle retained
on it one byone.
6. See that handling losses should be minimum.
7. Note down the size of screen (Mesh No.) in observation table.
8. Calculate the mass fraction of material retained on each screen.

K. Observations and Calculations:

Observation Table:
1. Weight of feed =.

2. Screening time =

3. Shape factor, a =

4. For rounded sand ɸs =

5. Particle density ρp =

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 Mechanical Operation (4330501)
Observation Table: 3
Sr. Mesh Screen Avg. Mass of Mass Xi*D Xpi /Dpi Xi/Dpi3
No. No. size Di Particle Particles fraction pi

(mm) Diameter retained Retained

Dpi m (gms) Xi
(Di-1+Di)/2
(mm)
1

TOTAL

Calculations:
1. Volume surface mean diameter
Ds = (1/∑ (Xi/Dpi))
=

2. Mass mean diameter

Dw = ∑ (Xi*Dpi)

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 Mechanical Operation (4330501)

3. Number of Particles
Nw= (1/ (a* ρp ))* ∑ (Xi/Dpi 3)

L. Interpretation of Results
1. Volume surface mean diameter = mm

2. Mass mean diameter = _ mm

3. Number of Particles =

M. Conclusion:

N. Practical related Quiz.

1. Define Screening.

2. Define Mesh Number.

3. What is Sphericity.

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 Mechanical Operation (4330501)
O. References / Suggestions
1. https://youtu.be/tM2NXWqAGB8
2. https://nptel.ac.in/courses/103107123
3. https://www.solnpharma.com/2021/11/sieve-shaker-principle-construction.html
4. https://www.youtube.com/watch?v=HpdTi9Okn-A
5. https://www.youtube.com/watch?v=oHUy7dIqN3o

P. Assessment-Rubrics
Criteria Marks Rubrics Marks
Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring

Performance
techniques.
Observation 2 Prepare Observation table & perform calculations properly
& Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission & 2 Preparation of final report and solved all the assignment
Quiz questions
Total marks Obtained
(out of 10)

Sign with Date

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 Mechanical Operation (4330501)
Date: ……………
Practical No.2: Perform differential and cumulative screen analysis.
Objective:
Proper size of the particle required for processing in Chemical industry.
Required size of the particle will not be obtained from crushing operations.
Screening is operation in which different micron size particle obtained,
necessary for given operation. By performing this experiment students will
able to carry out screening operation, also perform differential and
cumulative analysis.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design
of systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct
standard tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering

14 | Page
 Mechanical Operation (4330501)
B. Expected Skills to be developed based on competency:
This practical is expected to develop the following skills for the industry
identified competency 'Use of screening equipment in chemical process
industry ':
1. Interpret screens based on its MESH Size.
2. Separate solid particles based on its size a per consumer requirement.
3. Carry out Differential and Cumulative screen analysis based on mass
fraction.
C. Expected Course Outcomes(Cos)
CO1: Use fundamentals of mechanical operation.
CO2: Apply concept of size reduction, separation, agitation-mixing, Storage and
Conveying of Solid & Fluid.
.
D. Practical Outcome(PRo)
Perform Differential & Cumulative screen analysis.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & equipments
• Practice good housekeeping
F. Prerequisite Theory:
Differential and cumulative screen analysis is a method used in solid particles
analysis and understands the particle size distribution of solid particle samples.
This method involves passing solid samples through a series of screens with
progressively smaller mesh sizes, and measuring the weight or percentage of soil
retained on each screen.

The differential screen analysis method involves plotting the weight or

percentage of soil retained on each screen against the size of the particles,
resulting in a curve known as a particle size distribution curve. This curve allows
to determine the proportion of solid particles of different sizes, which is useful in
determining other physical properties.

The cumulative screen analysis method involves plotting the weight or

percentage of solid passing through each screen against the size of the particles.
This method allows to determine the cumulative proportion of solid particles of a
particular size or smaller.

Both methods can be used in conjunction to gain a more comprehensive

understanding of the particle size distribution of a solid particles sample. The
information obtained from these methods can be used in solid particle
classification and engineering applications.

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 Mechanical Operation (4330501)

G. Experimental set up

H. Resources/Equipment Required
Sr.No. Instrument/Equipment Specification Quanti
/Components/Trainer kit ty
1. Different size screens In the range of 4 MESH to 200 MESH 5-10
size based on solid Feed mixture size
by visual inpection

2. Weighing Balance 2 kg capacity with +/- 0.001 accuracy 1

I. Safety and necessary Precautions followed

1. Feed should be evenly distributed to all over the screening surface so that
screen’s pore will not get blocked or choked.
2. Handling losses should be minimum.
3. Weigh properly solid particles collected on each screen.

J. Procedure to be followed
1. Arrange the sieves in order of decreasing size as we go down. Keep pan
at the bottom of the stack. Place the top cover over the first screen.
2. Put the given 1000 gm weight sample in the top most sieves.
3. Cover the sieves and fit the sieves in a sieves shaker properly.

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 Mechanical Operation (4330501)
4. Run the shaker for a given time in such a way that sufficient screening
through any ofthe sieves takes place.
5. Take out the sieves carefully and weigh the samples of particle
retained on it one byone.
6. See that handling losses should be minimum.
7. Note down the size of screen (Mesh No.) in observation table.
8. Calculate the mass fraction of material retained on each screen.
9. Prepare Differential and Cumulative screen analysis graph.

K. Observations and Calculations

Observation:
Mass of feed = gm.

Screening time =

OBSERVATION TABLE:
Sr. Mesh No. Screen Avg. Mass of Diff. Cum. Mass
No. Size Di Particle Particles Mass Fraction
(mm) Diameter Dpi retained fraction lower than
(Dpi-1 + Dpi)/2 (gms.) Retained Dpi (Xi*)
(mm) (Xi)
1

10

TOTAL

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 Mechanical Operation (4330501)
GRAPHS:
1. Xi Vs. Dpi (Differential Screen analysis)
2. Xi* Vs. Dpi (Cumulative Screen analysis)
Calculations: Prepare screen analysis graph for Differential as well as cumulative
screen analysis
L. Interpretation of Results
1. Xi Vs. Dpi (Differential Screen analysis)
2. Xi* Vs. Dpi (Cumulative Screen analysis)

M. Conclusion

N. Practical related Quiz.

1. What is screen analysis?

2. Differentiate ideal and actual Screen.

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 Mechanical Operation (4330501)

O. References / Suggestions
1. https://nitsri.ac.in/Department/Chemical%20Engineering/MO3.pdf
2. http://ecoursesonline.iasri.res.in/mod/page/view.php?id=835
3. https://www.youtube.com/watch?v=6WwKN9wUqYM

P. Graph

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 Mechanical Operation (4330501)

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 Mechanical Operation (4330501)

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 Mechanical Operation (4330501)

Q: Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtaine
d
Practical 2 Handling of apparatus for precise measurement.
Setup

Performanc 2 Record Observations correctly & adapt safe measuring

e techniques.
Observatio 2 Prepare Observation table & perform calculations properly
n&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment
& Quiz questions
Total marks Obtained
(out of 10)

Sign with Date

22 | Page
 Mechanical Operation (4330501)

Date: ……………
Practical No.3: Test Kick’s law for crushing in Jaw crusher.
Objective:
Size of particle plays important role in reaction rate. In chemical engineering size
of particle is very important. Much Chemical industry requires reduced size of
particle as raw material. Jaw crusher is important equipment used in industry for
size reduction. By performing this practical, student will able to understand the
particle size determination as well as test kick’s constant based on power
requirement.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering specialization
to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical engineering

problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical engineering

well-defined technical problems and assist with the design of systems components
or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern Chemical

engineering tools and appropriate technique to conduct standard tests and
measurements.

5. Engineering practices for society, sustainability and environment: Apply

appropriate technology in context of society, sustainability, environment and ethical
practices.

6. Project Management: Use engineering management principles individually, as a

team member or a leader to manage projects and effectively communicate about
well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in updating in

the context of technological changes in field of Chemical engineering

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the industry identified
competency 'Use size reduction equipment in chemical process industry ':
1. Identify different size reduction equipments.
2. Interpret Jaw crusher.

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 Mechanical Operation (4330501)

C. Expected Course Outcomes(Cos)

CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance, crushing
law constants, efficiency and material balance.
.
D. Practical Outcome(PRo)
Test Kick’s law for crushing in Jaw crusher.

E. Expected Affective domain Outcome(ADos)

1. Follow safe practices.
2. Maintain tools & equipments
3. Practice good housekeeping

F. Prerequisite Theory:

A jaw crusher uses compressive force for breaking of particle. This mechanical pressure is
achieved by the two jaws of the crusher of which one is fixed while the other reciprocates. A
jaw or toggle crusher consists of a set of vertical jaws, one jaw is kept stationary and is called
a fixed jaw while the other jaw called a swing jaw, moves back and forth relative to it,
by a cam or pitman mechanism, acting like a class II lever or a nutcracker. The volume or
cavity between the two jaws is called the crushing chamber. The movement of the swing jaw
can be quite small, since complete crushing is not performed in one stroke. The inertia
required to crush the material is provided by a flywheel that moves a shaft creating an
eccentric motion that causes the closing of the gap.

Jaw crushers are heavy duty machines and hence need to be robustly constructed. The outer
frame is generally made of cast iron or steel. The jaws themselves are usually constructed
from cast steel. They are fitted with replaceable liners which are made of manganese steel, or
Ni-hard (a Ni-Cr alloyed cast iron). Jaw crushers are usually constructed in sections to ease
the process transportation if they are to be taken underground for carrying out the operations.
𝑃 Dsa
= K K . 𝑙𝑛
𝑚 Dsb
Where: P: Power Consumed (kW)
Dsa: Diameter of feed (m)
Dsb: Diameter of Product (m)
Kk: Kick’s law Constant (kWh/ton)
𝑚: :Mass flow rate of feed (ton/hr)
Dsa/Dsb = Size reduction ratio

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 Mechanical Operation (4330501)

G. Experimental set up

H. Resources/Equipment Required
Sr.No Instrument/Equipment
Specification Quanti
. /Components/Trainer kit ty
1. Jaw Crusher 10-15 kg/hr capacity, suitable for 1
operation on 415 V, 50 Hz, 3 phase Ac
supply with energy meter

2. Set of standard screens Different MESH size 5-10

3. Weighing Balance 2 kg capacity with +/- 0.001 accuracy 1

I. Safety and necessary Precautions followed

1. Feed rate is adjusted so that crusher will not get blocked or choked.
2. Don't put hand or finger in to the hopper. Feed material can be
dropped by using suitable container.

J. Procedure to be followed
1. Run the jaw crusher with no load.
2. Determine the time required to complete onerevolution of energy meter disc (or
the time required to consume 1 unit of electrical energy), for energy calculation.
3. Feed 2 kg of sample slowly into the crusher (sample of size may be +4 to -2 mesh) &
note down the power consumption under crushing condition of jaw crusher, by
noting the time required for one revolution of energy meter disc, withthe help of stop
watch.
4. Also note down the total time of crushing.
5. Perform sieve analysis of the crushed material.

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 Mechanical Operation (4330501)

K. Observations and Calculations:

Observations:
1. Power Consumed ( P)= kWh
2. Mass of feed m = kg= ton
3. Total crushing time T = min
4. Average Feed size of material Dsa = mm

OBSERVATION TABLE:
Sr. Mesh Screen Avg. Mass of particle Mass fraction of Xi / Dpi
No. No. Size Di Particle (gms) particle
(mm) Diameter, Dpi (Xi)
(Dpi-1+Dpi)/2,
(mm)
1

10

TOTAL

Calculations:
1. Average size of feed (Find it by visual inspection) Dsa= mm

2. Average size of the crushed product Dsb : mm

a. Volume surface mean diameter is given by

1
Dsa = 𝑥𝑖 where i= 1 to n
𝛴
𝐷𝑝𝑖

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 Mechanical Operation (4330501)

3. Feed rate = Mass of feed/ Time of crushing

𝑃 Dsa
4. Kick’s law: 𝑚 = KK . 𝑙𝑛 Dsb

L. Interpretation of Results
Kick’s law constant Kk =

M. Conclusion

N. Practical related Quiz.

1. What is working principle of Jaw crusher?

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 Mechanical Operation (4330501)

2. List out industrial application of jaw crusher.

O. References / Suggestions
1. https://oreflow.com.au/what-is-a-jaw-crusher-and-how-does-it-work/
2. https://www.nitsri.ac.in/Department/Chemical%20Engineering/MO2.pdf
3. https://www.youtube.com/watch?v=_Pi6LAFRJ9c
4. https://www.youtube.com/watch?v=yTIePG1E-kY
5. https://www.youtube.com/watch?v=KbFt1aG2jnM
6. https://www.youtube.com/watch?v=mCGZFB6tWlo
7. https://www.youtube.com/watch?v=lvgttJutnRk

P. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtaine
d
Practical 2 Handling of apparatus for precise measurement.
Setup

Performanc 2 Record Observations correctly & adapt safe measuring

e techniques.
Observatio 2 Prepare Observation table & perform calculations properly
n&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment
& Quiz questions
Total marks Obtained
(out of 10)

Sign with Date

28 | Page
 Mechanical Operation (4330501)

Date: ……………
Practical No.4: Test Bond's law for crushing in roll crusher.
Objective:
Size of particle plays important role in reaction rate. In chemical engineering size of
particle is very important. Much Chemical industry requires reduced size of particle as
raw material. Roll crusher is important equipment used in industry for size reduction.
By performing this practical, student will be able to understand the particle size
determination as well as test Bond’s constant based on power requirement.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic mathematics,

science and engineering fundamentals and engineering specialization to solve the
Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical engineering

problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical engineering

well-defined technical problems and assist with the design of systems components
or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern Chemical

engineering tools and appropriate technique to conduct standard tests and
measurements.

5. Engineering practices for society, sustainability and environment: Apply

appropriate technology in context of society, sustainability, environment and ethical
practices.

6. Project Management: Use engineering management principles individually, as a

team member or a leader to manage projects and effectively communicate about
well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in updating in

the context of technological changes in field of Chemical engineering

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the industry identified
competency 'Use size reduction equipment in chemical process industry ':
1. Identify different size reduction equipments.
2. Interpret Roll Crusher
C. Expected Course Outcomes(Cos)
CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance, crushing
law constants, efficiency and material balance.

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 Mechanical Operation (4330501)
.
D. Practical Outcome(PRo)
Test Bond’s law for crushing in Roll crusher.
E. Expected Affective domain Outcome(ADos)
• Follow safe practices.
• Maintain tools & equipments
• Practice good housekeeping

F. Prerequisite Theory:
The Roll crushers are low speed machines for coarse reduction of large quantities of
solids. In roll crusher, size reduction of samples can be achieved by compression action.
Material is to be crushed and fed from top. As the roll rotates the material gets
caught between them and gets caught between them and gets reduced in size by action
of compression and then it discharge from the bottom. Selection of crushing roll is
based on required product size.
This equation gives the relationship between the size of feed, the radius of rolls, the gap
between the rolls and angle of nip.
With this equation, the roll diameter can be determine by knowing the value of size of
feed, size of product and angle of nip.

If =160, cos = 0.961= (r+d) / (r+R)

It is used in crushing of oil seeds and in gun powder industry.
Surface energy created by crushing to the energy absorbed by solid.
BOND’S LAW:
Bond has suggested a law intermediate between Rittinger’s and kick’s law for
estimating the power required for crushing and grinding operations.
Bond suggested that the work required to form a particles of size DP form a very large
feed is proportional to the square root of the surface to volume ratio of the product
(Sp/Vp)= 6/ SDp Bond’s law:
P/m= Kb [1/ Dsb 1/ Dsa]
P/m= 0.3162 Wi [1/ Dsb 1/ Dsa]
Where, P = Power required for crushing in kW
m = Tons of feed in one hour of grinding time (Feed rate in tons/hour)
Dsa & Dsb= Diameters of sieves through which 80% of the feed & product pass
respectivelyin mm.
Wi = Work index in KWh/tones {or kW/(tons/hr)}
WORK INDEX (WI) : As the amount of gross energy in kilowatt-hr per ton of feed material
required to reduce a very large feed to such size that 80% of the product passes through a 100
µm screen

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 Mechanical Operation (4330501)

H. Experimental set up

I. Resources/Equipment Required
Sr.No Instrument/Equipment
Specification Quanti
.
/Components/Trainer kit ty
1. Roll Crusher 5-25 kg/hr capacity, suitable for 1
operation on 415 V, 50 Hz, 3 phase Ac
supply with energy meter

2. Set of standard screens Different MESH size 5-10

3. Weighing Balance 2 kg capacity with +/- 0.001 accuracy 1

J. Safety and necessary Precautions followed

a. Feed rate is adjusted so that crusher will not get blocked or choked.
b. Don't put hand or finger between two Rolls. Feed material can be dropped
by using suitable container.

K. Procedure to be followed
1. Measure required dimensions of roll crusher.
2. Prepare 1 kg brick sample of 1”- ¾” size.
3. Start the roll crusher and find power consumption from power meter.
4. Start feeding the material to the crusher and find out power required
under loadedcondition and time required to crush the material
5. Pass the crushed product from 3/8” sieve . measure the weight of
undersize obtained
6. Take 100gm representative sample from the undersize and do sieve
analysis of itusing sieve shaker.

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L. Observations and Calculations:

Observations:

1. Mass of feed = kg = ton

2. Crushing Time= sec = hrs

3. Power consumption = kw

4. Average Dia. Of feed particle = mm = m

5. Average Dia. Of product particle = mm = m

OBSERVATION TABLE: Feed Analysis

Sr. Mesh Screen Avg. Mass of particle Mass fraction of Xi / Dpi
No. No. Size D i Particle (gms) particle
(mm) Diameter, Dpi
(Xi)
(Dpi-1+Dpi)/2,
(mm)
1

TOTAL

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Product Analysis:

Sr. Mesh Screen Avg. Mass of particle Mass fraction of Xi / Dpi

No. No. Size Di Particle (gms) particle
(mm) Diameter, Dpi
(Xi)
(Dpi-1+Dpi)/2,
(mm)
1

TOTAL

Calculations:
1
1. Average size of feed Dsa= 𝑥𝑖 where i= 1 to n (mm)
𝛴
𝐷𝑝𝑖

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1
2. Average size of the crushed product Dsb= 𝑥𝑖 where i= 1 to n (mm)
𝛴
𝐷𝑝𝑖

3. Feed rate = Mass of feed/ Time of crushing

4. Bond’s law : p/m̊= Kb [ 1/ Dsb 1/ Dsa]

M. Interpretation of Results
Bond’s law constant Kb =

N. Conclusion

O. Practical related Quiz.

1. What is working principle of Roll crusher?

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 Mechanical Operation (4330501)
2. Explain angle of nip of roll crusher.

P. References / Suggestions
1. https://www.nitsri.ac.in/Department/Chemical%20Engineering/MO2.pdf
2. https://www.youtube.com/watch?v=KbFt1aG2jnM
3. https://www.youtube.com/watch?v=v6Qjne3LUkA
4. https://www.youtube.com/watch?v=kbe05JrXbJs
5. https://www.youtube.com/watch?v=BTRlj5WgVik

Q. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring techniques.

Performance
Observation 2 Prepare Observation table & perform calculations properly
&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment questions
& Quiz
Total marks Obtained (out
of 10)

Sign with Date

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 Mechanical Operation (4330501)

Date: ……………
Practical No.5: Test Rittinger's law for grinding in ball mill and measure critical speed.
Objective:
Size of particle plays important role in reaction rate. In chemical engineering size
of particle is very important. Much Chemical industry requires reduced size of
particle as raw material. Ball mill is important grinding equipment used in industry
for size reduction. By performing this practical, student will able to understand the
particle size determination, Critical speed of ball mill as well as test Rittinger’s
constant based on power requirement.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering specialization
to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical engineering

problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical engineering

well-defined technical problems and assist with the design of systems components
or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern Chemical

engineering tools and appropriate technique to conduct standard tests and
measurements.

5. Engineering practices for society, sustainability and environment: Apply

appropriate technology in context of society, sustainability, environment and ethical
practices.

6. Project Management: Use engineering management principles individually, as a

team member or a leader to manage projects and effectively communicate about
well-defined engineering activities.
7. Life-long learning: Ability to analyze individual needs and engage in updating in
the context of technological changes in field of Chemical engineering.

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the industry identified
competency 'Use size reduction equipment in chemical process industry ':
1. Identify different size reduction equipments.
2. Interpret Ball mill.

C. Expected Course Outcomes(Cos)

CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance, crushing
law constants, efficiency and material balance.
.
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 Mechanical Operation (4330501)

D. Practical Outcome(PRo)
Test Rittinger's law for grinding in ball mill and measure critical speed.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & equipments
• Practice good housekeeping

F. Prerequisite Theory:
The ball mill is a key piece of equipment for grinding crushed materials, and it is
widely used in production lines for powders such as cement, silicates, refractory
material, fertilizer, glass ceramics, etc. as well as for ore dressing of ferrous and non-
ferrous metals. The ball mill can grind ores and other materials either wet or dry.
In case of continuously operated ball mill, the material to be ground is fed from the left
through a 60° cone and the product is discharged through a 30° cone to the right. As the
shell rotates, the balls are lifted up on the rising side of the shell and then they cascade
down (or drop down on to the feed), from near the top of the shell. In doing so, the solid
particles in between the balls and ground are reduced in size by impact.
1. Rittinger’s law equation:
𝑃 1 1
=Kr(𝐷𝑠𝑏 − 𝐷𝑠𝑎)
𝑚

Where:
P: Power Consumed (kW)
m: Mass flow rate of feed (ton/hr)
Dsb: Volume surface mean diameter of Product(m)
Dsa: Volume surface mean diameter of feed (m)
Kr: Rittinger’s Constant (kWh.m/ton)
2. Critical Speed of Ball Mill:
1 𝑔
Nc=2𝜋 √𝑅−𝑟
Where:
Nc : Critical speed of ball mill (rps)
g: Gravitational acceleration (9.81 m/s2)
R: Radius of ball mill (m)
r: Radius of ball (m)

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 Mechanical Operation (4330501)

H. Experimental set up

I. Resources/Equipment Required
Sr.No Instrument/Equipment Specification Quanti
. /Components/Trainer kit ty
1. Ball mill 5 kg capacity, suitable for operation 1
on 415 V, 50 Hz, 3 phase Ac supply
with energy meter

2. Set of standard screens Different MESH size 5-10

3. Weighing Balance 2 kg capacity with +/- 0.001 accuracy 1

J. Safety and necessary Precautions followed

a. Feed material to be filled with 50 % capacity of ball mill.
b. Don't put hand or finger in to the hopper. Feed material can be dropped by using
suitable container.

K. Procedure to be followed
1. Measure all the dimensions of the mill i.e. dia., length, speed, ball dia. etc.
2. Take 1000 gm of uniformly mixed feed. Carry out screen analysis taking 100 gm
of feed.
3. Now feed 1000 gm of sample in the mill charged with ball.
4. Grind the sample for 15-20 minutes.
5. Take out the material & carry out the screen analysis with 100 gm of uniformly
mixedproduct.
6. Note the observation in the table.

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L. Observations and Calculations:

Observations:
1. No. of balls=
2. Speed of ball mill= rpm.
3. Ball Mill radius= mm = m
4. Radius of balls= mm. = m
5. Feed material= _____________
6. Mass of feed= gm = ton
7. Power Consumed (P) = kW
8. Time of grinding(t) = min. = hrs.

OBSERVATION TABLE:
Feed Sample Analysis:-

Sr. Mesh Screen Size Avg. Particle Mass Diff. mass fractions xi
No. No. Di (mm) Diameter Dpi retained (Xi) Dpi
(Dpi-1 + Dpi)/2 (gms)
(mm)
1

∑= ∑= ∑=

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 Mechanical Operation (4330501)

Product Analysis:-

Sr. Mesh Screen Size Avg. Particle Mass retained Diff. mass xi
No. No. Di (mm) Diameter (gms) fractions (Xi) Dpi
Dpi
(Dpi-1 + Dpi)/2
(mm)
1

∑= ∑= ∑=

Calculations:
1. Average size of feed Feed size (Dsa)

Volume Surface mean Diameter of feed

1
Dsa = 𝑥𝑖 where i= 1 to n
𝛴
𝐷𝑝𝑖

2. Average size of the crushed product Dsb :

Volume surface mean diameter is given by
1
Dsb = 𝑥𝑖 where i= 1 to n
𝛴
𝐷𝑝𝑖

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 Mechanical Operation (4330501)

3. Feed rate = Mass of feed/ Time of crushing

4. Rittinger’s Constant (Kr):

𝑃 1 1
=Kr(𝐷𝑠𝑏 − 𝐷𝑠𝑎)
𝑚

5. Critical speed (Nc) of ball mill:

1 𝑔
Nc=2𝜋 √𝑅−𝑟

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M. Interpretation of Results
1. Rittinger’s constant Kr = kWh /ton
2. The critical speed of ball mill= rpm

N. Conclusion

O. Practical related Quiz.

1. Classify size reduction Equipments.

2. Define critical speed of ball mill.

3. What is working principle of ball mill?

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P. References / Suggestions
1. https://www.nitsri.ac.in/Department/Chemical%20Engineering/MO2.pdf
2. https://www.youtube.com/watch?v=KbFt1aG2jnM
3. https://www.youtube.com/watch?v=TZyPJR4fYxo
4. https://www.youtube.com/watch?v=6w2pxQ3oDGo
5. https://www.youtube.com/watch?v=L7y0jPQpzfY
Q. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring techniques.

Performance
Observation 2 Prepare Observation table & perform calculations properly
&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment questions
& Quiz
Total marks Obtained (out
of 10)

Sign with Date

43 | Page
 Mechanical Operation (4330501)

Date: ……………
Practical No. 6: Determine rate of settling by sedimentation at ultimate height.
Objective:
Separation of solids from slurry has significant importance in chemical
process industries. Sedimentation is one of the most widely used
processes in the treatment of water. The simplest method of removing
suspended impurities is plain sedimentation. For finding the rate of solid
separation. Calculation of settling velocity gives information about the
sedimentation process. By performing this experiment, students will able
to calculate the terminal settling velocity, by performing the
sedimentation test.
A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design
of systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct
standard tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering

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 Mechanical Operation (4330501)

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the
industry identified competency 'Use basic principles of chemical
engineering in different applications':
1. Find out settling rate solid pollutantsby using sedimentation techniq.
2. Interpret sedimentation test.

C. Expected Course Outcomes(Cos)

CO2: Apply concept of size reduction, separation, agitation-mixing, Storage and
Conveying of Solid & Fluid.
CO4: Calculate properties of solid particles, power consumption, and resistance,
Crushing law constants, efficiency and material balance.

D. Practical Outcome(PRo)
Determine rate of settling by sedimentation.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & equipments.
• Practice good housekeeping.

F. Prerequisite Theory:

The time rate of decrease in height of visible interface between clear liquid &
slurry containing the particles is known as sedimentation or settling rate. The
observed height of interface when plotted as function of the time indicates the
progress of sedimentation.
In the slurry particles having different layer will settle at different rate. The line
of sedimentation is not sharp but it is observed between clear liquid & the slurry
as the settling goes on. The particles near the bottom of container build up
concentrated sludge. There may not be well defined interface.

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 Mechanical Operation (4330501)

INDUSTRIAL APPLICATIONS:-
1. To eliminate the contamination of liquid.
2. To recover solid particles from the slurry.
3. To purify the slurry.

H. Experimental set up

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I. Resources/Equipment Required

Sr.No Instrument/Equipment Specification Quanti

. /Components/Trainer kit ty
1. Measuring cylinder 1000 ml 1

2. Beaker 1000 ml 1

3. CaCO3 As per Concentration required to

prepare slurry

4. Stop Watch 1

J. Safety and necessary Precautions followed

1. Carefully stir the solid in liquid.
2. Take reading carefully, as particle settle quickly.

K. Procedure to be followed
1. Prepare the slurry of CaCO3 with concentration of 10% by weight in the
measuring cylinder.
2. The slurry must be prepared such that the CaCO3 is equally distributed
to the whole bulk.
3. Measure the height of the interface after different intervals of the time.
Similarly repeat the procedure for other slurries.
4. For preparing the slurry of 2% by wt., Mass of CaCO3 = 20 gm, Vol. of water =
980 ml.

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L. Observations and Calculations

OBSERVATION TABLE:

Sr. Slurry
No. Interface Height(cm) Time(min)

M. GRAPHS:

Plot the settling curve: Clear liquid interface height (Z cm) Vs Time (t
min). We can obtain ultimate height (Zu) of the slurry and ultimate
settling time (tu) from the observations and alsofrom the curve.
Calculations Plot the settling curve :
Rate of settling by sedimentation at ultimate pointX= dH/dt
Where, dH/dt is a slope of H (Interface height) Vs. Time (t) Graph.

From the graph ultimate time is mins &

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 Mechanical Operation (4330501)
The slope at that point is m/min

N. Interpretation of Results

Rate of settling at ultimate point = ______________m/min

O. Conclusion

P. Practical related Quiz.

1. Define free settling and hindered settling.

2. List out industrial application of batch sedimentation.

3. List out different zone of sedimentation process.

Q. References / Suggestions
1. https://old.amu.ac.in/emp/studym/3070.pdf
2. https://www.youtube.com/watch?v=nCXt0kAFoFA
3. https://www.youtube.com/watch?v=rK8vNQ0v6kg
4. https://www.youtube.com/watch?v=Y3Jbs4xoTcY

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R. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring

Performance
techniques.
Observation 2 Prepare Observation table & perform calculations properly
& Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission & 2 Preparation of final report and solved all the assignment
Quiz questions
Total marks Obtained
(out of 10)

Sign with Date

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 Mechanical Operation (4330501)

Date: ……………
Practical No. 7: Measure rate of filtration, filter medium & cake resistance in
Gravity filtration.
Objective:
Separation of liquid from solid has given lot of importance in
many process industries. Many processes required separation of liquid
from solid at the last step of operation. Liquid or sometime solid required
as a product. Many filtration equipments are used for such operations in
chemical process industry. Gravity filtration used during Research stage
through the laboratory experiment using glass wares. By performing this
experiment, students will able to understand filtration operation and
capable to find the filtration rate curve.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design of
systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct standard
tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering

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 Mechanical Operation (4330501)

B. Expected Skills to be developed based on competency:

This practical is expected to develop the following skills for the industry
identified competency 'Use various filtration equipment in chemical
process industry:
1. Identify different types filtration equipment's used in chemical industry.
2. Interpret gravity filtration technique.

C. Expected Course Outcomes(Cos)

CO2: Apply concept of size reduction, separation, agitation-mixing, Storage and
Conveying of Solid & Fluid.
CO4: Calculate properties of solid particles, power consumption, and resistance,
Crushing law constants, efficiency and material balance.
D. Practical Outcome(PRo)
Determine rate of filtration, filter medium & cake resistance in Gravity filtration.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & apparatus.
• Practice good housekeeping.

F. Prerequisite Theory:

Gravity filtration is a constant pressure filtration. During filtration the solids in

the slurry are retained on the filter medium as a bed of particles through which
filtrate must pass. The filtrate passes through two major kinds of resistances:
1. Resistance due to filter cake.
2. Resistance due to filter medium.

Now total pressure drop of filtration

= Pressure drop through filter medium + Pressure drop through cake
∆P = ∆Pm + ∆Pc
= (μu/gc) (mcα/A + Rm) ----------- (1)
mc= Mass of Solids in filter at time,t = VC
μ = Filtrate viscosity, kg/(m)(s)
ρ = Filtrate Density
Rm = Filter medium resistance, m-1
α = Filter cake resistance, m/kg
C= Concentration of Solid in Slurry, kg/m3
V=Volume of Filtrate,m3
𝑑𝑉/𝑑𝑡
Also velocity, u= 𝐴 ----------------(2)
∆P = (μu/gc)(mcα/A + Rm) -------------- (3)

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Using the values of u and mc from
above equations
(dt/dv) = (μ/Agc∆P)(mcα/A + Rm) ----------- (4)
(dt/dv) = (μ/Agc∆P)( V c α/A + Rm) -------- (5)

In gravity filtration ∆P is constant; it is the value of vacuum indicated by

vacuum gaugemounted over the vacuum pump. The only variables are V and t in
equation (5).
Also when t=0, V=0
From Equation (5)
(μRm/Agc∆P) =(dt/dV)o= 1/qo
The equation (5) can be written as
dt/dV =(1/q) = (μcα/A2 gc∆P)V+(1/qo)
dt/dV =(1/q) = Kc V+(1/qo)
Here Kc = (μcα/A2 gc∆P)---------- (6)
Integration of above equation between the limits (0,0) and (t,V) gives
t/V = (Kc/2) V+(1/qo)---------- (7)
Hence the plot of (t/V) Vs. V will be linear with a slope (Kc/2) and intercept of (1/qo)
From these two values we can find the values of α and Rm

G. Experimental set up

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 Mechanical Operation (4330501)
H. Resources/Equipment Required
Sr.No Instrument/Equipment Specification Quanti
. /Components/Trainer kit ty
1. Measuring cylinder 1000 ml 1

2. Beaker 1000 ml 1

3. Flask 1000 ml 1

4. Funnel 1

5. Filter cloth/filter paper

6. CaCO3 As per Concentration required to

prepare slurry
7. Stop Watch 1

I. Safety and necessary Precautions followed

1. Carefully stir the solid in liquid.
2. Take reading carefully.

J. Procedure to be followed
1. Prepare the slurry of known concentration of lime in water i.e. 100 gm
of lime in 1 liter of water in a beaker.
2. Place a funnel with suitable filter media over the measuring cylinder.
Pour the slurry(uniform) on the filter medium kept over the funnel.
3. Maintain a constant height of slurry in the funnel. Measure the volume
of the filtrate collected with respect to time & notes the reading in an
observation table.
4. Calculate the average specific cake resistance & filter medium resistance.

K. Observations and Calculations

Observations:
a. Concentration of Slurry, c= (kg/m3

b. Filtrate density = kg/m3

c. Filtrate viscosity = (N)(sec)/m2

d. Diameter of funnel, D = cm= m

e. Area of filter = m2

f. Height of liquid in the funnel, h = cm= m

g. Type of filter medium = laboratory filter paper/cotton cloth

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 Mechanical Operation (4330501)
h. Slurry Density = (Kg/m3)

i. Slope of the graph (Kc/2)=

j. Intercept of the graph (1/q0 )=

OBSERVATION TABLE:

Sr. Timet VolumeV VolumeV t/V

No. Sec. liter m3

L. GRAPHS:
Plot the settling curve: Clear liquid interface height (Z cm) Vs Time (t min).
We can obtain ultimate height (Zu) of the slurry and ultimate settling time (tu)
from the observations and alsofrom the curve.
Calculations
• Pressure head of slurry in the funnel
∆P = ρsgh

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Where,
ρs = Density of the slurry (kg/m3)
g = gravitational acceleration (m/s2)
h = Height of liquid in the funnel, h (m)
Value of Kc

Slope of graph=
Kc = Slope of graph t/V Vs. V * 2
Value of 1/q0
= Intercept of graph t/V Vs. V
• Specific cake resistance

• Filter media Resistance:

M. Interpretation of Results
1. Filter medium resistance Rm (m-1) =
2. Specific cake resistance α (m/kg) =

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N. Conclusion

O. Practical related Quiz.

1. What is effect of pressure drop in cake and filter media resistance for
compressiblecake?

2. Write formula of cake resistance for constant flow rate.

P. References / Suggestions
1. https://en.wikipedia.org/wiki/Gravity_filtration
2. http://www.nitttrc.edu.in/nptel/courses/video/103103155/lec26.pdf
3. https://scholar.cu.edu.eg/?q=magdi/files/chapter_8_filtration.pdf
4. https://www.youtube.com/watch?v=cRDBPtTnCGs
5. https://www.youtube.com/watch?v=wEuqAzLDQlw

Q. Graph
Plot a graph of (t/V) Vs. V will be linear with a slope (Kc/2) and
intercept of (1/qo), From these two values we can find the values of α
and Rm.

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R. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring techniques.

Performance
Observation 2 Prepare Observation table & perform calculations properly
&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment questions
& Quiz
Total marks Obtained (out
of 10)

Sign with Date

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 Mechanical Operation (4330501)

Date: ……………
Practical No. 8: Measure efficiency of separation in froth flotation cell.
Objective:
Froth flotation technique is used to separate hydrophobic material from
hydrophilic material in wastewater treatment industries or mineral
processing industries. By performing this student's will able understand
to find efficiency of Froth flotation cell.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design
of systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct
standard tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering.

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B. Expected Skills to be developed based on competency:
This practical is expected to develop the following skills for the
industry identified competency 'Use various solid-solid separation
equipment in chemical process industry:
1. Identify Froth flotation cell for separation of solid materials.
1. Interpret froth flotation cell.

C. Expected Course Outcomes(Cos)

CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance,
crushing law constants, efficiency and material balance.
D. Practical Outcome(PRo)
Measure efficiency of separation in froth flotation cell.
E. Expected Affective domain Outcome(ADos)
• Follow safe practices.
• Maintain tools & apparatus.
• Practice good housekeeping.

F. Prerequisite Theory:
Froth Flotation is a surface-chemistry process of separation of fine solids that takes
advantage of the differences of wettability at solids particle-surfaces. Solid surfaces are often
naturally wettable by water and termed hydrophilic. A surface that is non-wettable is water
repelling and termed hydrophobic. If a surface is hydrophobic, it is also typically air attracting
termed aerophilic, and is strongly attracted to an air interface, which readily displaces water at the
solid's surface. In froth Flotation, separation of a binary solids mixture may be accomplished by
the selective attachment of hydrophobic solid particles to gas bubbles (typically air). The other
hydrophobic solid particles remain in the liquid (typically water). The difference in the density
between the air bubbles and water provides buoyancy that preferentially lift the hydrophobic
solids particles to the surface where they remain entrained in a froth which can be drain off or
mechanically skimmed away, thus, effecting the separation. Froth Flotation if often used to
separate solids of similar densities and sizes, which prevent other types of separations based upon
gravity that might otherwise be employed. It is especially useful for particles below 100 µm,
which are typically too small for gravity separation using jigging and tabling. The lower size limit
for flotation separation is approximately 35 µm; although particles as small as 1 µm can be
separated. At these small particles sizes, it may be difficult take advantage of surface properties

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differences to induce selective hydrophobicity. On the other hand, particle, greater than 200 µm
tend to be readily sheared from the bubble surfaces by collision with other particles or vessel
walls. However, relativity low density materials, such as coal may be successfully separated up to
1600 µm in some systems.
Separation of a mixture of solids using froth floatation method depends on difference in
surface properties of the materials involved. If the mixture is suspended in an aerated liquid, the
gas bubbles will allow, the particles of the material which is not wetted by the liquid (or difficult
to get wetted by the liquid) to adhere and its effective density reduce to such an extent that it will
be taken to the surface. If a suitable frothing agent is added to the liquid, the particles will be held
at the surface until they are discharged over the weir.
Froth Floatation is widely used in metallurgical industries where generally the ore is
difficult to wet and the residual earth is readily wetted. The main difficulty is to produce the froth
of sufficient stability to retain the particles of the desired constituent on the surface so that they
can be discharged over the overflow weir. Pine oil is used as frothing agent and produces stable
froth.
This method is extensively employed in primary treatment of minerals specially sulphides.
The process is based on different characteristics of mineral with water and with oil. The crushed
ore along with water is taken in a floatation shell. Various additives are added depending on
nature of ore and a current of air is taken. The additives usually used are pine oils. They are of
three types.

1. Frothers : Frothers like pine oils from a stable with sizes at the top.
2. Collectors : They stick themselves to grain the mixture and they
become water repellent.
3. Floatating Agents : It will not appear in overflow.

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G. Experimental set up

H. Resources/Equipment Required

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 Mechanical Operation (4330501)
Sr.No Instrument/Equipment
Specification Quanti
. /Components/Trainer kit ty
1. Froth Floatation Cell Capacity approx 20 l 1

2. Air Compressor 220 V AC, 50 HZ, Single Phase, 0.5 1

HP motor
3. Agitator 0.5 HP motor, SS 304 1

4. Diffuser Stationary Copper Tube 1

I. Safety and necessary Precautions followed

1. Take precaution during handling chemicals used for flotation.
2. Collect and measure carefully solid collected in flotation.

J. Procedure to be followed
1. Add sufficient quantity of water in cell to half of its capacity.
2. Take known amount of graphite/Charcoal Powder/Brick Powder and feed it to the
floatation cell.
3. Add a few drops of frothing agent (Pine Oil/ kerosene).
4. Stir this mixture for at least 3-5 minutes.
5. Add few drops of soap solution/detergent powder to the tank.
6. Switch ON the air compressor and allow the compressed air to enter the cell using
the air regulator to generate the bubbles so that the water does not come out from
the cell.
7. Collect the froth produced in collection vessel from the overflow weir until no
froth is coming out of the cell.
8. Switch OFF the air compressor and stirrer.
9. Allow the collected froth to get dried and weigh it.
10. Tabulate the observations and calculate percentage recovery.

K. Observations and Calculations

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 Mechanical Operation (4330501)
Observations:
Weight of the sample (graphite/charcoal powder/Brick Powder) taken: ______________ gm

OBSERVATION TABLE:
Amount of Frothing Agent Wt. of Sample Recovery of
Sr.
Added taken Sample % Recovery
No.
(Drops) (gm) (gm)
1.
2.
3.
4.
5.

Calculations

% recovery = (Wt. of sample recovered / Wt. of sample initially taken) * 100

=
=
L. Interpretation of Results
1. % recovery =

M. Conclusion

N. Practical related Quiz.

1. What is the process of froth flotation?

2. What are applications of froth flotation process?

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O. References / Suggestions
1. https://www.youtube.com/watch?v=E2Ln8KgrhpA
2. https://www.911metallurgist.com/blog/explain-froth-flotation-process
3. https://www.sciencedirect.com/topics/earth-and-planetary-sciences/flotation-froth

P. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtaine
d
Practical 2 Handling of apparatus for precise measurement.
Setup

Performanc 2 Record Observations correctly & adapt safe measuring

e techniques.
Observation 2 Prepare Observation table & perform calculations properly
&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment
& Quiz questions
Total marks Obtained
(out of 10)

Sign with Date

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 Mechanical Operation (4330501)
Date: ……………
Practical No. 9: Measure efficiency of separation in Magnetic separator.
Objective:
Separation of solid from solid is important operation in chemical process
industry. Magnetic separation is the process for separation of solid from
solid. By performing this operation students will able to understand process
of separation and measure efficiency of magnetic separator.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic

mathematics, science and engineering fundamentals and engineering
specialization to solve the Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical

engineering problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical

engineering well-defined technical problems and assist with the design
of systems components or processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern

Chemical engineering tools and appropriate technique to conduct
standard tests and measurements.

5. Engineering practices for society, sustainability and environment:

Apply appropriate technology in context of society, sustainability,
environment and ethical practices.

6. Project Management: Use engineering management principles

individually, as a team member or a leader to manage projects and
effectively communicate about well-defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in

updating in the context of technological changes in field of Chemical
engineering.
B. Expected Skills to be developed based on competency:
This practical is expected to develop the following skills for the
industry identified competency 'Use various solid-solid separation
equipment in chemical process industry:
1. Identify given magnetic separation process for solid-solid separation.
2. Interpret magnetic drum separator.

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 Mechanical Operation (4330501)

C. Expected Course Outcomes(Cos)

CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance,
crushing law constants, efficiency and material balance.

D. Practical Outcome(PRo)
Measure efficiency of separation in Magnetic separator.

E. Expected Affective domain Outcome(ADos)

• Follow safe practices.
• Maintain tools & apparatus.
• Practice good housekeeping.

F. Prerequisite Theory:
Magnetic separation is one ways to separate heterogeneous solid mixture
this is done by use of bar magnet .a bar magnet attracts object made of iron
, the easiest way to separate magnetic substance from nonmagnetic
substance.
Magnetic impurities are removed from their ores by magnetic separation
, ex. Magnetite from quartz or magnetic contaminants or other valuable
minerals from nonmagnetic values All magnetic are affected in some
way when placed in magnetic field , although with most substances the
effect is too slight to be detected , materials can be classified in two
groups whether they are attracted or repelled diamagnetic along the
lines of magnetic force to a point where the field intensity is smaller ,
the forces involved here are small and diamagnetic substances cannot
be concentrated magnetically , paramagnetic are attracted along the
lines of magnetic force to points of greater field intensity.
As material reaches the drum, the magnetic field attracts and holds
ferrous particles to the drum shell. As the drum revolves, it carries the
material through the stationary magnetic field. The nonmagnetic
material falls freely from the shell, while the magnetic particles are held
firmly until they are carried out of the magnetic field.

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 Mechanical Operation (4330501)
G. Experimental set up

H. Resources/Equipment Required
Sr.No Instrument/Equipment Specification Quanti
. /Components/Trainer kit ty
1. Magnetic drum 1

2. Iron fillings

3. Saw dust

I. Safety and necessary Precautions followed

1. Keep safe distance from moving parts of magnetic drum separator.
2. Carefully handle raw materials used for given separation.

J. Procedure to be followed
1. Take 500 gm of saw dust and iron fillings each.
2. Mix it thoroughly so that proper mixing done.
3. Feed the mixture through the hopper/inlet.
4. Allow the mixture to fall on rotary drum.
5. Collect the fractions of magnetic (Iron filling) and non magnetic
(Saw Dust) in the respective bins.

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 Mechanical Operation (4330501)

K. Observations and Calculations

Observations:
(i) Weight of saw dust=______________ gm
(ii) Weight of iron fillings= ____________gm

Calculations
The efficiency of the magnetic separation

Efficiency (Ƞ) = [weight of the collected magnetic materials/weight of the

total feed materials]* 100
=
=

L. Interpretation of Results

% efficiency of magnetic separator =

M. Conclusion

N. Practical related Quiz.

1. What is the principle of magnetic separator?

2. Give industrial examples of magnetic separation.

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 Mechanical Operation (4330501)
O. References / Suggestions
1. https://www.youtube.com/watch?v=PMxjordJ73o
2. http://www.kanetec.co.jp/en/pdf/120_138.pdf
3. https://core.ac.uk/download/pdf/297714768.pdf

P. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtaine
d
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring

Performance
techniques.
Observation 2 Prepare Observation table & perform calculations properly
& Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission & 2 Preparation of final report and solved all the assignment
Quiz questions
Total marks Obtained (out
of 10)

Sign with Date

72 | Page
 Mechanical Operation (4330501)

Date: ……………
Practical No. 10: Measure power consumption in baffled and unbaffled Agitation vessel.
Objective:
Agitation vessel is used as reactor in chemical industry. Agitation improves
reaction rate. By performing this experiment, students will able to calculate
power consumption in baffled and unbaffled vessel.

A. Expected Program Outcomes (POs)

1. Basic and Discipline specific knowledge: Apply knowledge of basic mathematics,

science and engineering fundamentals and engineering specialization to solve the
Chemical engineering problems.

2. Problem analysis: Identify and analyze well-defined Chemical engineering

problems using codified standard methods.

3. Design/ development of solutions: Design solutions for Chemical engineering

well-defined technical problems and assist with the design of systems components or
processes to meet specified needs.

4. Engineering Tools, Experimentation and Testing: Apply modern Chemical

engineering tools and appropriate technique to conduct standard tests and
measurements.

5. Engineering practices for society, sustainability and environment: Apply

appropriate technology in context of society, sustainability, environment and ethical
practices.

6. Project Management: Use engineering management principles individually, as a

team member or a leader to manage projects and effectively communicate about well-
defined engineering activities.

7. Life-long learning: Ability to analyze individual needs and engage in updating in

the context of technological changes in field of Chemical engineering.

B. Expected Skills to be developed based on competency:

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 Mechanical Operation (4330501)
This practical is expected to develop the following skills for the industry
identified competency 'Use various agitation tanks in chemical process
industry:
1. Identify agitation vessel with different types of agitators.
2. Interpret baffled and unbaffled Agitation vessel.

C. Expected Course Outcomes(Cos)

CO3: Operate size reduction equipment, separators, agitators, mixers and conveyors.
CO4: Calculate properties of solid particles, power consumption, and resistance, crushing
law constants, efficiency and material balance.
D. Practical Outcome(PRo)
Measure power consumption in baffled and unbaffled Agitation vessel.
E. Expected Affective domain Outcome(ADos)
• Follow safe practices.
• Maintain tools & apparatus.
• Practice good housekeeping.
F. Prerequisite Theory:
Power required for agitation of a particular liquid in a baffled or unbaffled tank depends on
viscosity and density of the liquid, impeller diameter, Speed of agitation, along with other
geometrical factors like height of liquid in vessel, impeller pitch, impeller size, and impeller
type etc.
If liquid is assumed Newtonian the function of power required for agitation is given by
P= ψ(n, Da, gc, µ, g, ρ, S1, S2, …..Sn) …..(1)
(Pgc)/( ρn3Da5) = ψ{(ρnDa2/µ), (n2Da/g), S1, S2, …..Sn } …….(2)
Here (Pgc)/( ρn3Da5) is a dimensionless group called Power number, so above equation can
be written in termsof Dimensionless groups
Np = ψ(NRe, NFr, S1, S2, …..Sn) (3)
Where,
Np= power number = (Pgc)/( ρn3Da5) ….(4)
NRe = ρnDa2/µ
Ψ = Some function relating power number to other dimensionless group and shapeFactors
Ρ = Power required for agitation
ρ = Density of fluid
µ = Viscosity of fluid
n = Speed of agitator in RPM

Da = Diameter of impeller
The value of Np is found out from the graph of Np v/s NRe from standard literature
The group NRe is proportional to a Reynolds number calculated from the diameter and

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peripheral speed of the impeller. The power number Np is analogous to a friction factor or a
drag co-efficient acting on a unit area of the impeller and the inertial stress. The inertial
stress, in turn is related to the flow of momentum associated with bulk motion of the fluid.
The Froude number NFr is a measure of the ratio of the inertial stress to the gravitational
force per unit area acting on the fluid. It is important where there is significant wave motion
on a liquid surface as in ship design.
The various shape factors in above equation depends on various measurements. For a
turbine agitated vessel for example S1=Da/Dt, S2=E/Da, S3=L/Da, S4=W/Da, S5=J/Dt, S6=H/Dt
Dt =Diameter of tank, m
E= Height of impeller above vessel floor, m
H= Depth of liquid in vessel, m
J=Width of baffle, m
L = Length of impeller blade, m
W= Impeller width, m
If the tank is unbaffled, at low Reynold number below 300 the power number curve for
baffled and unbaffled tanks are identical. At higher Reynold number the curve diverges, in
unbaffled tank a vortex is formed and theFroude number has an effect,
(Np/NFr)= ψ(NRe, S1, S2, …..Sn) ……(5)
m = (a – log10 NRe)/b ……(6)
Here a and b are constants. The power number NP read from the ordinate must be
corrected by multiplyingNFr
Another method of calculating the power required for agitation is based on following
discussion:
P = (Np ρn3Da5/gc) ….(7)
At low Reynold number the lines of Np Vs NRe for baffled and unbaffled tank coincide
and slope of line on logarithmic scale is -1. The flow becomes laminar in this range and
density is no longer a factor
Here P=(KL µn2Da3/gc) ……(8)
Above equation can be used for NRe<10
In case of baffled tank at Reynold number larger than about 10,000, the power

number is independent of theReynold number and viscosity is not a factor. The flow is fully
turbulent and
P = KT(Np ρn3Da5/gc) ….(9)
Values of KL and KT for various impellers and tanks are obtained from literature.

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G. Experimental set up

H. Resources/Equipment Required
Sr.No Instrument/Equipment Specification Quanti
. /Components/Trainer kit ty
1. Agitated vessel tank Suitable operation on 220 V, power-1000 1
W
2. Propeller type agitator 1

3. Drive motor 1

4. Speed controller 1

I. Safety and necessary Precautions followed

1. Keep safe distance from equipment.

2. Use hand gloves during experiment.

J. Procedure to be followed
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1. Clean the vessel and agitator.
2. Make necessarily connection for agitator motor and energy meter.
3. Measure all the dimensions for vessels after keeping the agitator properly in the vessel
4. Fill the 60% height of the tank with water. Take 4 - 5 readings of power consumed
during agitation by setting different speed of agitator with the rotating of the knob of
speed controller. Follow this procedure for baffled and unbaffled tank both. Also note
down the speed at which vortex forms in unbaffled tank.
5. Repeat the above procedure by keeping the slurry of lime(5%, 10%)within the tank
upto 60% height ofthe tank. Note down the readings of power at different speed of
rotation.

K. Observations and Calculations

Observations:
Type of impeller :
Da= Impeller diameter =
Dt=Diameter of tank =
E= Height of impeller above vessel floor =
H= Depth of liquid in vessel =
No. of baffles attached=
J=Width of baffle =
L = Length of impeller blade =
W= Impeller width =

Observation Table:
(1) Unbaffled tank (water & Slurry)
Sr. Knob Speed of Voltmeter Ameter Power Calcula
No. Position Agitation Reading Reading W=VI ted
RPM & RPS (Volt) (Amp) (Watt) Power
(Watt)
Water
Water
Slurry

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 Mechanical Operation (4330501)
Slurry
(2) Baffled tank (water & Slurry)
Sr. Knob Speed of Voltmeter Ameter Power Calculat
No. Position Agitation Reading Reading W=VI ed
RPM & RPS (Volt) (Amp) (Watt) Power
(Watt)
water
water
Slurry
Slurry

Calculation:
Speed of Agitator n : _____________RPM

Calculation of Reynod’s Number :NRe = n Da2ρ /µ

Calculation of Froude Number: NFr = n2Da/g

Power consumption : Read the power number Np from the graph of Np Vs NRe
Now calculate the power
P = (Np ρn3Da5/gc) NP= KT ρn3Da5/gc

Power consumption
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 Mechanical Operation (4330501)
P=(KL µn2Da3/gc)

L. Interpretation of Results
Power required at different speed (i) calculated values and (ii) values read from the power meter
areas below:

M. Conclusion

N. Practical related Quiz.

1. What is the purpose of Agitation?

2. What is vortex formation in agitated vessel? How can it be prevented?

O. References / Suggestions
1. https://myengineeringtools.com/Piping/Power_Agitator_Calculation.html
2. https://www.youtube.com/watch?v=tFaaafemAx0
3. https://www.youtube.com/watch?v=2ASqplhOyEk
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4. https://www.diva-portal.org/smash/get/diva2:544860/FULLTEXT01.pdf

P. Assessment-Rubrics

Criteria Marks Rubrics Marks

Obtained
Practical 2 Handling of apparatus for precise measurement.
Setup

2 Record Observations correctly & adapt safe measuring techniques.

Performance
Observation 2 Prepare Observation table & perform calculations properly
&
Calculation
Result & 2 Interpretation of results & Conclusion written properly
Conclusion
Submission 2 Preparation of final report and solved all the assignment questions
& Quiz
Total marks Obtained (out
of 10)

Sign with Date

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