Mechanical Separations I

Introduction
The separating action depends on the character of the particle being separated and the forces on the
particle which cause the separation. The important characteristics of the particles are size, shape
and density; and of the fluid are viscosity and density.
Mechanical separations can be divided into four groups based on differences of density and
size/shape of the particle being separated.
 sedimentation
 centrifugal separation
 filtration and
 Sieving

The Velocity of particles moving in a fluid

Under a constant force, particles in a liquid accelerate for a time and thereafter move at a uniform
velocity. This maximum velocity which they reach is called their terminal velocity.
• When a particle moves steadily through a fluid, there are two principal forces acting upon it, the
external force (applied force less the reaction force exerted on the particle by the surrounding
fluid) causing the motion and the drag force resisting motion which arises from frictional action
of the fluid.

• Fs= V a (ρp - ρf)

• ρp – density of particle
• ρP – density of fluid
• where Fs is the net external accelerating force on the particle, V is the volume of the particle, a is
the acceleration which results from the external force, ρp is the density of the particle and ρf is the
density of the fluid.
 Forces acting on a particle settling through a fluid
Depend on the velocity of the particles.
when V is increasing, drag force also
FB = Volume × density of liquid × g increasing
FB = V× ρ × g
Forces acting on a particle
FB = m × g
settling

FG > FB
FG = Volume × density of solid × g

FG = V× d ×g
FG = m × g

Net force acting on the particle = FG – FB- FD

FG- FB-FD = 0 (reach to Terminal velocity/ V max)
FG = FB +FD
The Velocity of particles moving in a fluid
The drag force on the particle (F d) is obtained by multiplying the velocity pressure of the
flowing fluid by the projected area of the particle

Fd = C ρf V2 A /2
where C is the coefficient known as the drag coefficient, ρ f is the density of the fluid, v is the
velocity of the particle and A the projected area of the particle at right angles to the direction of
the motion. It has been found, theoretically, that for the streamline motion of spheres, the
coefficient of drag is given by the relationship:

C = 24/(Re) = 24μ/D vm ρf
Where Re is Reynolds number, µ is viscosity of fluid, D is diameter of the particle. By equating
Fd and Fs and Substituting this value for C and rearranging, we arrive at the equation for the
terminal velocity magnitude
Vm = D2a (ρp -ρf)/18 μ
This is the fundamental equation for movement of particles in fluids.
 Sedimentation

Sedimentation uses gravitational forces to separate particulate material from fluid streams. The
particles are usually solid, but they can be small liquid droplets, and the fluid can be either a
liquid or a gas.
Sedimentation is very often used in the food industry for separating dirt and debris from
incoming raw material, crystals from their mother liquor and dust or product particles
from air streams.
In sedimentation, particles are falling from rest under the force of gravity. Therefor in
sedimentation, takes the familiar form of Stokes' Law:

Vm = D2g (ρp - ρf)/18 μ

Stoke's Law applies only in streamline flow and strictly only to spherical particles.

Sedimentation Equipment
For separation of solid particles from liquids by gravitational sedimentation is designed to
provide sufficient time for the sedimentation to occur and to permit the overflow and the
sediment to be removed without disturbing the separation. Continuous flow through the
equipment is generally desired, so the flow velocities have to be low enough to avoid
disturbing the sediment.
 Flotation (Revers of sedimentation)
In some cases, where it is not practicable to settle out fine particles, these can sometimes
be floated to the surface by the use of air bubbles.

This technique is known as flotation and it depends upon the relative tendency of air and
water to adhere to the particle surface. The water at the particle surface must be displaced
by air, after which the buoyancy of the air is sufficient to carry both the particle and the
air bubble up through the liquid.

Its action depends upon surface forces, and surface forces can be greatly changed by the
presence of even minute traces of surface active agents, flotation may be promoted
by the use of suitable additives.
 particle Air bubble(no weight technically)

Settling under Flotation

In some instances, the air bubbles remain round the solid particles and cause froths.
These are produced in vessels fitted with mechanical agitators, the agitators whip up the
air-liquid mixture and overflow the froth into collecting troughs.

Settling Under Combined Forces

• It is sometimes convenient to combine more than one force to effect a mechanical separation.
In consequence of the low velocities, especially of very small particles, obtained when gravity is
the only external force acting on the system, it is well worthwhile to also employ centrifugal
forces.
• Probably the most common application of this is the cyclone separator. Combined forces are
also used in some powder classifiers such as the rotary mechanical classifier and in ring dryers.
 Cyclones
Cyclones are often used for the removal from air streams of particles of about 10 µm or more
diameter. They are also used for separating particles from liquids and for separating liquid
droplets from gases.
The cyclone is a settling chamber in the form of a vertical cylinder, so arranged that the particle-
laden air spirals round the cylinder to create centrifugal forces which throw the particles to the
outside walls. Added to the gravitational forces, the centrifugal action provides reasonably rapid
settlement rates. The spiral path, through the cyclone, provides sufficient separation time. A
cyclone is illustrated in following figure.

Cyclones…
Stokes' Law shows that the terminal velocity of the particles is related to the force acting. In a
centrifugal separator, such as a cyclone, for a particle, rotating round the periphery of the
cyclone:

Fc = (mv2)/r
where Fc is the centrifugal force acting on the particle, m is the mass of the particle, v is the
tangential velocity of the particle and r is the radius of the cyclone.
This equation shows that the force on the particle increases as the radius decreases, for a fixed
velocity. Thus, the most efficient cyclones for removing small particles are those of smallest
diameter. The limitations on the smallness of the diameter are the capital costs of small diameter
cyclones to provide sufficient output, and the pressure drops.
Cyclones
The optimum shape for a cyclone has been evolved mainly from experience and proportions
similar to those indicated in above figure (a) have been found effective. The efficient operation of
a cyclone depends very much on a smooth double helical flow being produced and anything which
creates a flow disturbance or tends to make the flow depart from this pattern will have considerable
and adverse effects upon efficiency. For example, it is important that the air enters tangentially at
the top.

The efficiency of collection of dust in a cyclone is illustrated in Figure (b). Because of the
complex flow, the size cut of particles is not sharp and it can be seen that the percentage of entering
particles which are retained in the cyclone falls off for particles below about 10 µm diameter.
Cyclones can be used for separating particles from liquids as well as from gases and also for
separating liquid droplets from gases.
 Centrifugal Separations
Sometimes the separation by sedimentation may be very slow because the specific gravities of the
components may not be very different, or because of forces holding the components in association.
Also, under circumstances when sedimentation does occur there may not be a clear demarcation
between the components but rather a merging of the layers.
Much greater forces can be obtained by introducing centrifugal action, in a centrifuge. Gravity still
acts and the net force is a combination of the centrifugal force with gravity as in the cyclone. Because
in most industrial centrifuges, the centrifugal forces imposed are so much greater than gravity, the
effects of gravity can usually be neglected in the analysis of the separation.

centrifugal force
The centrifugal force on a particle that is constrained to rotate in a circular path is given by

Fc = mrω2
where F c is the centrifugal force acting on the particle to maintain it in the circular path, r is the
radius of the path, m is the mass of the particle, and ω (omega) is the angular velocity of the particle.
Or, since ω = v/r, where v is the tangential velocity of the particle
Fc = (mv2)/r
Rotational speeds are normally expressed in revolutions per minute, so that above equation can also
be written, as

ω = 2ΠN/60 (as it has to be in s-1, divide by 60)

Fc = mr(2ΠN/60)2 = 0.011 mrN2
where N is the rotational speed in revolutions per minute.

Centrifugal force in a centrifuge

The centrifugal force depends upon the radius and speed of rotation and upon the mass of the particle.
If the radius and the speed of rotation are fixed, then the controlling factor is the weight of the particle
so that the heavier the particle the greater is the centrifugal force acting on it.

Rate of separation

• The steady-state velocity of particles moving in a streamline flow under the action of an
accelerating force is
• V m= D2a (ρp- ρf) /18μ
• If a streamline flow occurs in a centrifuge we can write as a

• is the tangential acceleration;

•F c = ma
• F c/m = a = r(2πN/60)2
so that

Vm = D2r(2πN/60)2(ρp - ρf) /18 μ

(V m = D2N2r (ρp- ρf) /1640 μ )