CLASSIFIERS

UNIT V
FLUID SOLID OPERATION
CLASSIFIERS
• Classifiers are essential for separating particles based on size, shape, or density in
mineral processing, chemical engineering, and other industrial applications. They
function by exploiting differences in sedimentation velocity among particles in a fluid,
effectively dividing them into finer and coarser fractions.
• The primary principle behind classifiers is based on differential settling velocity.
When particles are suspended in a fluid, their settling velocity depends on their size,
shape, and density. Larger or denser particles settle more quickly than smaller or
lighter particles.
• Classifiers can be broadly classified into two main types based on the force applied
for separation:
• Mechanical Classifiers
• Spiral Classifiers
• Rake Classifiers
• Cone Classifiers
• Hydraulic and Pneumatic (Air) Classifiers
• Hydraulic Classifiers (Settling Tanks)
• Pneumatic (Air)
• Classifiers Cyclone Classifiers
SPIRAL CLASSIFIERS
Construction:
• Consists of a sloped tank, with a helical screw or spiral
rotating along its axis.
• The screw is usually inclined, and the water flows in the
opposite direction to the screw.
Working:
1.Feed slurry enters the inclined tank.
2.The spiral rotates, stirring the slurry and carrying coarser
particles up the incline.
3.Finer particles remain in suspension and overflow at the
top.
Applications:
• Commonly used in closed-circuit grinding operations to
classify coarse and fine materials before further
processing.
Advantages:
• Simple and robust design.
• Handles large particle sizes effectively.
Disadvantages:
• Not efficient for very fine particles.
• Higher energy consumption.
RAKE CLASSIFIERS
Construction:
• Consists of an inclined tank with a set of rakes that
move through the slurry, lifting coarse particles
while allowing finer particles to flow over the weir.
Working:
• The rakes move in a reciprocating motion.
• They lift the coarse material, which travels up the
incline, while finer particles overflow.
Applications:
• Often used in coal processing and mineral
concentration.
Advantages:
• Simple mechanism.
• Suitable for medium and coarse particle
classification.
Disadvantages:
• Limited capacity for finer particles.
• Requires frequent maintenance due to wear.
CONE CLASSIFIERS
Construction:
• Consists of a cone-shaped tank with an outlet at the
bottom.
Working:
• Feed is introduced at the top.
• Larger particles settle towards the bottom, while lighter
particles are carried upward by a rising flow of fluid.
Applications:
• Often used in smaller-scale operations or as pre-classifiers
before further separation.
Advantages:
• Simple design, minimal maintenance.
• Effective for coarser particles.
Disadvantages:
• Limited throughput and less effective for fine
classification.
• Low efficiency for particles with similar densities.
HYDRAULIC CLASSIFIERS
Construction:
• A series of settling tanks arranged with partitions to facilitate
the flow of water and material.
Working:
• Water and slurry enter the settling chambers.
• Particles settle according to size and density, with coarser
particles settling first.
Applications:
• Used in mineral processing to classify ore by size.
Advantages:
• Effective for fine particles.
• Continuous operation possible.
Disadvantages:
• Requires large space.
• Limited precision for particles of similar densities.
AIR CLASSIFIERS
Construction:
• Consists of a vertical chamber with a rotating element and air
inlets.
Working:
• Air flows upwards, carrying finer particles, while larger particles fall
due to gravity.
• The rotating element enhances separation by controlling particle
flow.
Applications:
• Used in industries like cement, where fine powder is separated from
coarse particles.
Advantages:
• Suitable for dry processes.
• High precision for separating fine particles.
Disadvantages:
• Limited to relatively small particle sizes.
• High energy consumption for air flow.
CYCLONE CLASSIFIERS
Construction:
• Conical-shaped body with tangential inlet and outlets at the top and
bottom.
Working:
• Feed slurry or air enters tangentially, creating a vortex.
• Centrifugal force moves coarser particles to the outer wall, where they
settle and exit through the bottom.
• Finer particles move upward through the vortex finder and exit from
the top.
Applications:
• Used in mining and mineral processing to classify fine particles.
Advantages:
• Compact, high-capacity operation.
• Effective for both wet and dry classification.
Disadvantages:
• Requires high pressure for efficiency.
• Efficiency drops with very fine particles.
 APPLICATION:
•Mineral Processing: Separates valuable minerals from waste based on particle size.
•Cement Industry: Controls particle size in cement production.
•Chemical Industry: Separates fine powders in chemical processes.
•Food Processing: Sorts materials like flour and starch by particle size.
•Pharmaceutical Industry: Ensures correct particle size in drug formulations.
•Wastewater Treatment: Separates solids from liquid in clarifiers

Advantages Disadvantages
Efficient separation for particles based on size Ineffective for ultra-fine particles, especially in
and density. gravity-based systems.
Versatile operation suitable for various Higher operating costs for pneumatic classifiers
industries. due to air requirement.
Continuous operation with minimal downtime. Space requirements for hydraulic classifiers.
Simple design and low maintenance in Prone to wear and clogging with abrasive
mechanical types. materials
Effective for both coarse and fine particles (with Limited precision for particles with similar
appropriate choice of classifier). densities and sizes.
SCREENING
Principle:
• Screening is a mechanical process used for the separation of particles based on their
size using a screen or mesh. The principle involves passing a mixture through a mesh
that allows only smaller particles to pass through, while larger particles are retained.
Parts & Construction:
• Screen Mesh: The core part made from steel or wire, with apertures sized to allow
certain particles to pass through.
• Frame: Provides structure to hold the screen mesh in place.
• Vibrating Mechanism: In some screens, mechanical vibrations (via motors) are
applied to assist in separating the particles.
• Feed Hopper: The container from which the material to be screened is fed.
Types of Screening:
• Static Screening: Material flows under gravity through the screen mesh.
• Vibrating Screening: The screen vibrates to prevent clogging and improve efficiency.
• Rotary Screening: Involves rotating drum screens.
Working:
• The feed material is loaded onto the screen surface, and the material moves under
gravity or vibration.
• Large particles are retained, while smaller particles pass through the mesh openings.
SCREENING
Applications:
• Mining (ore separation).
• Agriculture (grain cleaning).
• Wastewater treatment.
Advantages:
• Simple Design: Easy to design and operate.
• Low Maintenance: Fewer moving parts reduce maintenance requirements.
• Versatility: Can be used for a wide range of particle sizes.
• Low Operating Costs: Low energy consumption.
• Effective Separation: Good for separating large particles from fine
particles.
Disadvantages:
• Limited to Size Separation: Cannot separate particles with similar sizes.
• Clogging: Small particles may clog the mesh.
• Low Efficiency: Not effective for very fine particles.
• Requires Manual Intervention: In some systems, manual cleaning is
needed.
• Space Intensive: Large-scale screening can require significant space.
 GRAVITY SEPARATION
eparation utilizes the difference in density between particles to separate them under the influence of gra
SEDIMENTATION CLASSIFIERS THICKENING EL
Sedimentation: Classifiers:
Principle:
• Sedimentation is based on the difference in Principle:
the density of the solid particles and the • Classifiers separate particles based on
fluid. Heavier particles settle at the bottom, their size and density, using water or air
while lighter ones remain suspended. as a separating medium.
• Stokes' Law governs the settling velocity
of particles in a fluid. Types:
• For small spherical particles:
• v=2r2(ρp−ρf)g9μv = \frac{2 r^2 (\rho_p - \ • Hydraulic Classifiers: Use water to
rho_f) g}{9 \mu}v=9μ2r2(ρp​−ρf​)g​where: separate particles based on their size.
• v = Settling velocity • Mechanical Classifiers: Use a rotating
• r = Particle radius
screw to assist in separating particles.
• ρp​= Particle density
• ρf​= Fluid density Applications:
• g = Acceleration due to gravity
• Used in mining, agriculture, and
• μ = Dynamic viscosity of the fluid
chemical industries for particle
Applications: separation.
• Used in water treatment, mineral
processing, and wastewater treatment.
GRAVITY SEPARATION
Thickening: Elutriation:
Principle: Principle:
• Thickening increases the concentration of • Elutriation separates particles based on
solid particles in a slurry by allowing solid size and density using an upward flow of
particles to settle in a sedimentation tank. water or air. Lighter particles are carried
The settled material (sludge) is then
upward, while heavier particles fall.
removed, and the supernatant (liquid) is
drained. Working:
Working: • A fluid (typically water) is passed upward
• A slurry is fed into a thickening tank. through a column.
• The larger and denser particles settle, and • The fluid velocity is controlled such that
the thickened slurry is removed from the only lighter particles are carried away by
bottom, while the clarified liquid is removed the flow.
from the top.
Applications:
Applications:
• Common in mineral processing for
• Used in mineral processing, wastewater separating fines.
treatment, and sludge management.
CENTRIFUGAL
SEPARATION
Continuous Centrifuges:
Principle:
• Continuous centrifuges separate liquids from solids
(or liquids from other liquids) by rotating at high
speeds, generating a centrifugal force.
Working:
• The mixture is fed into a rotating bowl, where
centrifugal force separates components based on
their density.
Applications:
• Used in dairy processing (milk cream separation),
mineral processing, and pharmaceuticals.
Expression:
• The centrifugal force on a particle is given by:
F=mω2rF = m \omega^2 rF=mω2r where:
• mmm = mass of the particle
• ω\omegaω = angular velocity
• rrr = radius of rotation
CENTRIFUGAL
SEPARATION
Cyclones and Hydrocyclones:
Principle:
• Cyclones use high-speed rotational motion to create centrifugal forces that
separate particles from gases or liquids.
Working:
• The feed is introduced tangentially to create a vortex.
• Heavier particles are forced to the outer wall and collected at the bottom (for
solids) or the side (for liquids).
• Lighter particles are carried upwards and exit through the top.
Applications:
• Used in mineral processing, dust collection, and oil recovery.
Advantages:
• High Separation Efficiency: Good for fine particles.
• Continuous Operation: Can handle continuous flow of materials.
• Compact Design: Smaller equipment for high capacity.
• Low Operating Costs: Requires less power and maintenance.
• Scalable: Can be scaled up for large operations.
Disadvantages:
• Energy-Intensive: Requires high energy input.
• Wear and Tear: Parts wear out due to the abrasive nature of the material.
• Limited to Specific Materials: Not effective for all particle types.
• Requires Pre-Treatment: Pre-sorting of the material may be needed.
• Maintenance: Periodic cleaning is required for continuous operation.
ELECTROSTATIC SEPARATION
Principle:
• Electrostatic separation uses an electric field to separate particles
based on their electrical conductivity or charge.
Working:
• Charged particles are separated by their affinity to electric fields.
Non-conductive materials are attracted to oppositely charged
surfaces, while conductive materials are repelled.
Applications:
• Used in recycling, mineral separation, and food industry.
Advantages:
• No Need for Chemicals: Effective without requiring any
chemicals.
• Good for Fine Materials: Can handle very fine particles.
• Low Operating Costs: Minimal power consumption.
• Non-Destructive: Preserves the integrity of materials.
• Environmental Benefits: Does not produce harmful byproducts.
Disadvantages:
• Limited Material Types: Only effective for conductive and non-
conductive materials.
• Sensitive to Environmental Factors: Humidity and moisture
affect performance.
• Complexity: Requires precise control over the electric field.
• Not Effective for Wet Materials: Only works for dry materials.
• Initial Setup Cost: High initial cost for equipment.
MAGNETIC SEPARATION
Principle:
• Magnetic separation relies on the magnetic properties of
materials. Magnetic particles are attracted to magnets, separating
them from non-magnetic particles.
Working:
• A magnetic field is applied to attract ferromagnetic materials, which
are then removed from the mixture.
Applications:
• Used in mineral processing, recycling, and food industries.
• Advantages:
• Simple Process: Easy to operate and maintain.
• High Throughput: Can process large amounts of material quickly.
• Cost-Effective: Low operating and maintenance costs.
• Continuous Process: Suitable for continuous operations.
• Non-Damaging: Does not harm materials during separation.
Disadvantages:
• Limited to Magnetic Materials: Only effective for magnetic or
ferromagnetic materials.
• Strength of Magnet: Requires strong magnets for efficiency.
• Potential Contamination: Risk of contamination if magnets are
not cleaned properly.
• Energy Consumption: Magnets can be energy-intensive.
• Equipment Wear: Parts of the magnetic separators may wear out
over time.