ASSIGNMENT 1: UNIT OPERATIONS

Particle Size

Average particle
Screen Opening Mass Fraction

Mesh diameter
Dpi (mm) Retained, xi mm

4 4.699 0.0000 - 0 0
6 3.327 0.0251 4.013
0.0063 0.0004
8 2.369 0.1250 2.845
0.0439 0.0054
10 1.651 0.3207 2.007
0.1598 0.0397
14 1.168 0.2570 1.409
< 1.5mm 0.1824 0.0919
20 0.833 0.1590 1.001
0.1588 0.1585
28 0.589 0.0538 0.711
0.0757 0.1497
35 0.417 0.0210 0.503
0.0418 0.1650
48 0.295 0.0102 0.356
0.0287 0.2261
65 0.208 0.0077 0.252
0.0306 0.4812
100 0.147 0.0058 0.178
0.0326 1.0284
150 0.104 0.0041 0.126
0.0325 2.0496
200 0.074 0.0031 0.089
0.0348 4.3974
Pan - 0.0075 0.037
0.2027 148.0663
1.0305 156.8595
Sample calculations of average particle diameter

( ) =

.+.
= .

1. The size of 35 kg crushed rocks has been analyzed using sieving method. The results of
the sieving process are tabulated in the Table 1. The density of the particle is 1550 kg/m3
and the shape factor are a =0.8 and = 0.69

Calculate:

(a) The specific area of particles ( Aw) (mm2/g) for the material between 4-mesh and pan.

6
=


6
= (1.0305) = . 2 /
0.69(0.001550)

(b) Number of particles in mixture (Nw) (particles/g) for the material between 4-mesh and
pan

1
=
3

1
= (156.8595) = . 2 /
0.8(0.001550)
 (c) Volume surface mean diameter (Ds) (mm)

1 1
=
= = 0.97
1.0305

(d) If 70% of the crushed glass must have size less than 1.5mm, please state whether or not
the particles need to be crushed again?

The particle need to be crushed again because, only 52.92% of the

average particle size is less than 1.5mm

Refer to the table particle with

> 1.5mm = (xi =0.0251+0.1250+0.3207=

< 1.5mm = (1-0.4708=

0.4708x100= 47.08%) whereas particle with
0.5292x100=52.92%).Thus it need to be crushed again to achieve 70%.

Size Reduction

2. State four 4 types of equipments employed in particles size reduction. Elaborate the
principles of those equipments.

Crusher
- Do the heavy work of breaking large pieces of solid material into small pieces
- A slow speed machines for coarse reduction of large quantities of solids
- Primary crusher can break the solids into 150-250mm size
- Secondary crusher could reduced the particle from primary crusher to 6mm in size
- Crusher reduces the solid size by compression

Grinder

Reduce crushed feed to powder

Product from a crusher is often fed to a grinder for further reduction.
The product from an intermediate grinder might pass a 40-mesh screen.
Most products from a fine grinder would pass a 200- mesh screen with 74 m opening.
Reduce the solid size by impact and attrition, sometimes combine with compression

Ultrafine grinder

Reduce solids to fine particles

Accepts feed particles not larger than 6 mm.
The product size is typically 1 to 50 m.
Reduce the solid size by attrition

Cutting machine

Give particles of definite size and shape 2-10mm in length

Reduce the size by cutting, dicing and slitting
 3. 110 tons/h of trap rock is crushed in a gyratory crusher. The feed is nearly uniform 2-in
spheres and produced the product of 0.08 in.size. Using the Bond method, estimate the
work necessary for the crushing process.

= 110 /

= 2 25.4 = 50.8 = 0.08 25.4 = 2.032

( ) = 19.32

Thus by using Bonds Law

= 0.3162

1 1
= 0.3162 ( )

1 1
= 0.3162 (19.32) ( )
110 2.032 50.8

= .