CHAPTER THREE

SIZE SEPARATION OF SOLIDS

INTRODUCTION
• Solids may be separated from solids in the dry state by methods such as screening
(size separation-separation according to size), magnetic separation and electrostatic
separation. In this chapter, we will deal with screening.
• In chemical industry, the problem of separating solid particles that is encountered is
that of separation of a single solid material into a number of size fractions or to
obtain an uniform material for incorporation in a system wherein a certain chemical
reaction is occurring.
CONCEPT AND IMPORTANCE OF SCREENING OPERATION
Screening :
(i) A method of separating solid particles according to size alone is called screening.
(ii) Screening is an operation for separating solids on the basis of size alone.
(iii) It refers to the separation of solid materials on the basis of size using screens of
known openings.
(iv) Screening is the separation of a mixture of solid particles of various sizes into two or
more fractions by means of a screening surface.
• In screening, a mixture of solid particles of various sizes is dropped on a screening
surface/screen (a surface provided with suitable openings) which acts as a multiple
go and no-go gage. The material that passes through a given screen/screening surface
is called the undersize or minus (–) material while the material that remains on the
screen/screening surface is called the oversize or plus (+) material.
• A single screen can make a single separation of the material charged into two
fractions. These are called unsized fractions as only the upper or lower limit of the
particle sizes they contain is known and the other limit is not known. The material
can be separated into sized fractions i.e. the fractions in which both the maximum
and minimum particle sizes are known, by passing it through a series of screens of
different sizes. Screening is much more commonly adopted for dry particulate solids
and occasionally for wet particulate solids. In this topic, we will limit our discussion
to screening of dry particulate solids.
Materials for Screens :
Industrial screens are made from metal bars, woven wire cloth, silk bolting cloth,
perforated or slotted metal plates. Many varieties and types of screens are available for
different purposes but we will discuss few representative types.
(3.1)
Unit Operations-I 3.2 Size Separation of Solids

Necessity of or reasons for carrying out screening operation/importance of screening

operation :
The screening operation is industrially carried out in order to
(i) remove the fines from a feed material before a reduction equipment such as jaw
crusher, ball mill or rod mill,
(ii) prevent an incompletely crushed material (oversize) from entering into other unit
operations,
(iii) produce a commercial or process-grade material to meet specific particle size limits,
(iv) remove the fines from a finished product prior to shipping.
CLASSIFICATION OF SCREENS ON THE BASIS OF PERFORMANCE
Comparison of Ideal and Actual screens
• The objective of a screen is to accept a mixture of various sizes of grains and separate
it into two fractions, namely an underflow and overflow. The underflow is the one
that is passed through the screen and the overflow is the one that is rejected by the
screen.
• An ideal screen is the one which sharply separates the feed mixture in such a way
that the smallest particle in the overflow is just larger than the largest particle in the
underflow. The ideal separation defines a cut diameter Dpc (a typical particle
dimension) which makes the point of separation between the undersize and oversize
fractions and is nearly equal to the mesh opening of the screen.
• Fig. 3.1 (a) shows the performance of an ideal screen in terms of the screen analysis
of the feed. The point 'C' in the curve is a cut point. The fraction A consists of all
particles larger than cut diameter (Dpc) while the fraction B consists of all particles
smaller than cut diameter.
1.0 1.0
Oversize
B =A
C
f f
Undersize
A =B
Dpc
Dpc
0 0
Dp Dp
c = cut point
(a) Ideal screening (b) Screen analysis of products from ideal screening
Overlap
1.0
XD
ize

f
rs
de

e d XF
Fe
Un

ize
ers XB
Ov Dpc
0
Dp
(c) Actual screening
Fig. 3.1 : Ideal versus actual screening
Unit Operations-I 3.3 Size Separation of Solids

• Material A is the overflow and material B is the underflow. Fig. 3.1 (b) shows the
screen analysis of the ideal fractions A and B. The first point on the curve for B and
the last point on the curve for A have the same abscissa, and there is no overlap of
these curves.
• Actual screens do not yield a sharp separation. With actual screens, the screen
analysis of the overflow and underflow are similar to those shown in Fig. 3.1 (c). The
overflow is found to contain the particles smaller than the cut diameter, and the
underflow is found to contain particles larger than the cut diameter. The curves for A
and B overlap.
• With standard testing screens, it is possible to get the closest separations in case of
spherical particles. In this case also there is some overlap. In case of needlelike,
fibrous particles or particles which have tendency to aggregate into clusters, the
overlap is of a higher magnitude. Commercial screens usually give poorer
performance than testing screens of the same mesh handling the same feed mixture.
Comparison of Ideal screen and Actual screen :
Ideal screen Actual screen
1. Yields sharp separation. 1. Does not yield sharp separation.
2. Efficiency of the screen is 100%. 2. Efficiency of the screen is less than
100%.
3. Such screens do not found in practice / 3. Such screens are available in practice.
reality.
4. The overflow will contain only particles 4. The overflow may also contain particles
large than the cut diameter. small than the cut diameter.
5. Underflow will contain only particles 5. Underflow may also contain particles
smaller than the cut diameter. larger than the cut diameter.
TYPES OF STANDARD SCREEN SERIES
• Most particulate systems which are of practical interest consist of particles of a wide
range of sizes. A number of methods of particle-size determination are available but
most particle-size determinations are made by the screen analysis when the particles
are within the size range that can be measured by screens.
• Usually, for carrying out the analysis, standard screens of either the Tyler standard
screen series, U.S. sieve series or Indian standard sieves are used. The testing sieves
with square openings are constructed of woven wire screens, the mesh and
dimensions of which are standardised. Every screen is identified in meshes per inch.
• In coarse screens, the term mesh refers to the distance between adjacent wires or
rods. While in fine screens, the mesh is the number of openings per linear inch
counting from the centre of any wire to a point exactly one inch distant (e.g., a 200-
mesh screen will have 200 openings per linear inch).
Unit Operations-I 3.4 Size Separation of Solids

• The minimum clear space between the edges of the opening in the screening surface
is termed as screen aperture or screen-size opening.
• The Tyler standard screen series is based on a 200-mesh screen with a wire
0.0053 mm (0.0021 in) in diameter, giving a clear opening of 0.074 mm
(1/200 – 0.0021 = 0.0029 in).
• The screens coarser than a 200-mesh screen have their mesh and wire diameter so
adjusted that the area of opening in any one screen is approximately twice the area of
the opening in the next finer screen. This means that the ratio of the linear size of the
openings in any screen to that in the next finer screen is 2 (1.41) . Therefore, a
150-mesh screen will have an opening of 0.104 mm ( 2 × 0.0029 = 0.0041 in) with a
wire of 0.064 mm (1/150 – 0.0041 = 0.0026 in) diameter.
• Testing sieves of the Tyler standard sieve series are used to determine the efficiencies
of screening equipments and work of crushing and grinding machinery.
• The Indian Standard test sieves satisfy requirements of IS : 460 (Part-I) for the wire
cloth test sieves and IS : 460 (Part-II) for the perforated plate test sieves with respect
to widths of aperture, wire diameter and screening areas. The sieves from 22 micron
to 5.6 mm size have woven wire cloth fixed in spun brass frames. The sieves of size
5.6 mm to 125 mm are of woven wire cloth or perforated sheet in GI frames.
Type of Screen Analysis
There are two methods of reporting screen analysis : (1) Differential analysis,
(2) Cumulative analysis.
• Differential Analysis : The screen analysis in which the weight fraction of the
material retained on each screen is reported in a tabular or a graphical form as a
function of the mesh size/screen opening is called differential analysis.
• Cumulative Analysis : The screen analysis in which the cumulative weight fraction
of the material retained (cumulative oversize) or passing through (cumulative
undersize) each screen is reported in a tabular or a graphical form as a function of
the screen opening is called cumulative analysis.
• The fine particles are generally specified according to their screen analysis. A screen
analysis of a material is carried out by using testing sieves. A set of standard screens
is arranged serially in a stack in such a way that the coarsest of the screens is at the
top and the finest of the screens is at the bottom.
Unit Operations-I 3.5 Size Separation of Solids

• An analysis is carried out by placing the sample on the top screen and shaking the
stack in a definite manner, either, manually or mechanically, for a definite length of
time. The material retained on each screen is removed and weighed.
• For reporting the screen analysis, the amount of material retained on each screen is
expressed as the weight fraction of the total sample.
• The screen analysis of a sample is reported either in a tabular form or as graphs. The
results of a screen analysis can be reported in a tabular form to show the weight
fraction of the material retained on each screen as a function of the mesh size. As the
particles retained on any one screen are passed through the screen immediately above
it, two numbers are needed to specify the size, one for the screen through which the
fraction passes and the other for the screen on which that fraction is retained. Hence,
the notation 10/14 means through 10 mesh and on 14 mesh (i.e., the material is such
that it passes through the screen of mesh number 10 and collects on the screen of
mesh number 14). An analysis reported in a tabular form in this manner is called a
differential analysis.
• The material that is retained on the screen is the oversize or plus (+) of that screen
and the material that passes it is the undersize or minus (–). Thus, a – 10 + 14
fraction means the fraction of the material that passes through a 10-mesh screen but
is retained on a 14-mesh screen.
Table 3.1 shows a typical differential screen analysis.
Table 3.1
Mesh Screen opening Avg. particle Weight fraction
microns size microns retained
6/8 2362 2845 0.017
8/10 1651 2006 0.235
10/14 1168 1410 0.298
14/20 833 1000 0.217
20/28 589 711 0.105
28/35 417 503 0.062
35/48 295 356 0.028
48/65 208 252 0.017
65/100 147 178 0.010
100/150 104 126 0.005
150/200 74 89 0.002
Pan 0.004
1.0
Unit Operations-I 3.6 Size Separation of Solids

• The average particle size of the material retained on any particular screen (cited in
Table 3.1) is calculated as the arithmetic mean of two screen openings used to obtain
the fraction.
• The second method of reporting screen analysis is a cumulative analysis. The
cumulative analysis is obtained from the differential analysis by adding cumulatively,
the individual weight fractions of material retained on each screen, starting with that
retained on the largest mesh, and tabulating or plotting the cumulative sums against
the screen opening of the retaining screen under consideration.
• If we define φ by the equation of the form :
NT
φ = ∆φ1 + ∆φ2 + …… + ∆φN = ∑ ∆φN … (3.1)
T
N=1
where ∆φ1, ∆φ2 …… are the weight fractions of material retained on screens 1, 2,
……… numbered serially from top of the deck.
• Then, the cumulative analysis is the relation between φ and screen opening. The
quantity φ is the weight fraction of the sample that consists of particles larger than the
screen opening. For the entire sample, the value of φ is unity. The cumulative
analysis corresponding to the differential analysis of Table 3.1 is shown in Table 3.2.
Table 3.2 : Cumulative screen analysis
Mesh Screen opening in Cumulative fraction retained
micron (φ
φ) (oversize)
6 3327 0.0
8 2362 0.017
10 1651 0.252
(0 + 0.017 + 0.235)
14 1168 0.55
(0 + 0.07 + 0.235 + 0.298)
20 833 0.767
28 589 0.872
35 417 0.934
48 295 0.962
65 208 0.979
100 147 0.989
150 104 0.994
200 74 0.996
Pan – 1.0
φ = cumulative fraction retained on the screen
∴ 1 – φ = cumulative fraction passing through the screen.
Unit Operations-I 3.7 Size Separation of Solids

• The cumulative analysis is also reported by incorporating a cumulative fraction

passing through the screen as shown below :
Mesh Screen Cumulative fraction Cumulative fraction
opening retained passing through screen
(oversize) (undersize)
6 3327 0.0 1.0
8 2367 0.017 0.983
: : : :
: : : :
Pan – 1.0 0.00
• A graphical presentation of the screen analysis can be done on ordinary graph papers
but more conveniently on semilogarithmic papers where the size is plotted on a
logarithmic scale. A semilogarithmic plot avoids the crowding of most of the data
into small section of the diagram. The results of screen analysis represented as
fractional or cumulative distribution curves are shown in Fig. 3.2 (a) and (b).
• The fractional distribution curve is a plot of the weight fraction of material retained
against the average particle size and the cumulative distribution curves shown in
Fig. 3.2 (c) are obtained by plotting the fraction of the total weight of particles having
a size greater than or less than a given screen opening against the screen opening.
0.3

0.25
Cumulative fraction passing through
Cumulative fraction retained
Weight fraction retained

1.0 1.0
0.2
0.7

0.10 0.5

0.4
0.1
0.2
0.1 0.1
0.05 0 0
100 1000 5000
0 Screen opening in microns
100 1000 5000
Average particle size in microns
Differential Analysis

(a) Fractional distribution curve (b) Cumulative distribution curve

Unit Operations-I 3.8 Size Separation of Solids

0.25

Weight fraction retained

0.20

0.15

0.10

0.05

0
0.01 0.02 0.03 0.04 0.05 0.06 0.07
Average particle diameter

(c) Fractional distribution plot on ordinary graph paper

Fractional distribution plot
on semilog graph paper
Weight fraction retained

0.25
0.20
0.15
0.10

0.05
0
0.001 0.002 0.004 0.01 0.02 0.04 0.10
Average particle diameter (Dp) in

(d) Fractional distribution plot on semilog graph paper

Fig. 3.2 : Fractional and cumulative distribution curves
CAPACITY AND EFFECTIVENESS OF SCREENS
• The capacity and effectiveness are measures of the performance in industrial
screening. The capacity of a screen is the mass of material that can be fed per unit
time to a unit area of the screen. Capacity and effectiveness in screening operations
are closely related. For obtaining maximum effectiveness the capacity must be small,
and the large capacity is attainable only by reduction in the effectiveness. As the
capacity and effectiveness are opposing factors, a reasonable balance must be done
between them in actual practice.
• One can control the capacity of a screen simply by varying the mass flow rate of feed
to the screening equipment. For a given capacity, the effectiveness that can be
achieved depends upon the nature of the screening operation. For a given undersize
particle, the overall chance of passage through the screen is a function of the number
of contacts between the particle and the screen surface, and the probability of its
passage in a single contact. When the screen is overloaded, the number of contacts is
Unit Operations-I 3.9 Size Separation of Solids

small and the probability of passage on contact is reduced due to the interference of
the other particles. The effectiveness is improved by reducing the capacity since then
there will be more contacts per particle and better chance for passage on each
contact.
• The factors which tend to reduce the capacity and lower the effectiveness are :
blinding, cohesion of particles to the screen surface, oblique direction of approach of
the particles to the screen surface and interference of bed particles with the motion of
any one.
• The moisture content of the feed adversely affects the screening operation as the
damp particles are prone to stick to the screen surface and to each other.
Blinding of screen :
• It refers to the phenomenon wherein elongated, sticky, etc. particles become wedged
into the openings during screening and thus prevent the other particles from passing
through it. Thus, the blinding of a screen means the plugging of the screen with solid
particles.
• Due to blinding an appreciable fraction of the screen becomes inactive. The blinding
tendency is more pronounced with fine screens than with coarse screens.
Definition and Derivation of the Effectiveness of a Screen
Material Balances over a Screen :
• Consider that the feed to a screen consists of materials A and B, where A is the
oversize and B is the undersize material. Out of the total materials fed to the screen,
some part of it is removed as overflow and remaining part of it is collected as
underflow.
Let F be the mass flow rate of feed, (kg/h)
D be the mass flow rate of overflow, (kg/h)
B be the mass flow rate of underflow, (kg/h)
xF be the mass fraction of material A in feed.
xD be the mass fraction of material A in overflow.
xB be the mass fraction of material A in underflow.
The mass fractions of material B in feed, overflow and underflow are 1 – xF, 1 – xD, and
1 – xB respectively.
Overall material balance over a screen is
F = D+B … (3.2)
Material balance of 'A' over a screen is
xF.F = xD.D + xB.B … (3.3)
From Equation (3.2), we have
F–B = D … (3.4)
Unit Operations-I 3.10 Size Separation of Solids

Substituting the value of D from Equation (3.4) into Equation (3.3), we get
xF.F = xD (F – B) + xB.B … (3.5)
xF.F = xD.F – xD.B + xB.B
(xD – xF) F = (xD – xB) B … (3.6)
B xD – xF
F = xD – xB … (3.7)
Similarly, elimination of B from Equations (3.2) and (3.3) gives
D xF – xB
F = xD – xB … (3.8)

• The effectiveness of a screen (screen efficiency) is a measure of the success of the

screen in closely separating undersize and oversize materials. In the case of a
perfectly functioned screen, all the oversize material 'A' would be in the overflow and
all the undersize material would be in the underflow.
• The screen effectiveness based on the oversize material is the ratio of the amount
of oversize material A that is actually in the overflow to the amount of oversize
material A in the feed.
Screen effectiveness D.xD Quantity of oversize in the overflow
based on material A = EA = F.xF = Quantity of oversize in the feed … (3.9)
Similarly, the screen effectiveness based on the undersize material is given by
B (1 – xB)
EB = F (1 – x ) … (3.10)
F

The overall effectiveness of a screen can be given by

E = EA . EB … (3.11)
where E is the overall effectiveness of a screen.
Substituting the values of EA and EB from Equations (3.9) and (3.10) into
Equation (3.11), we get
D.B. xD (1 – xB)
E = F2 x (1 – x ) … (3.12)
F F

Substituting the values of D/F and B/F from Equations (3.8) and (3.7) into
Equation (3.12), we get
(xF – xB) (xD – xF) . xD (1 – xB)
E = (x – x )2 (1 – x ) x … (3.13)
D B F F

FACTORS AFFECTING PERFORMANCE OF SCREENS

Variables in Screening Operations :
• There are many variables in a screening operation that can be very easily changed.
The best combination of these variables results into the excellent performance of a
screening equipment.
Unit Operations-I 3.11 Size Separation of Solids

1. Method of feeding :
In order to obtain the maximum capacity and efficiency, the screening equipment must
be fed properly. The material should be spread evenly over a full width of the screening
surface and should approach the screening surface in a direction parallel to the longitudinal
axis of the screen and must be fed at a low rate.
2. Screening surfaces :
Use of single-deck screens in series results into the most efficient operation as in case of
multiple-deck screens lower decks are not fed so that their entire area is not used and each
separation requires a different combination of angle, speed, and amplitude of vibration for
the best performance.
3. Screen slope :
As the screen slope increases, the rate at which the materials travels over the screening
surface increases and at the same time, it reduces the bed thickness. The increase of rate of
travel means an increase in the quantity passing over the screen per unit time. Reduction in
the bed thickness allows the fines to approach the screen surface and pass through it.
However, the slope cannot be increased beyond a certain value because beyond that value
(limit) the material will travel down the screen much faster without getting screened and the
screening efficiency reduces drastically.
4. Vibration amplitude and frequency :
One has to select the proper amplitude of vibration to prevent blinding of the screening
cloth and for long bearing life. The frequency of vibration affects the capacity of the
screening equipment by regulating the number of contacts between the material and the
screening surface.
5. Moisture in feed :
The moisture associated with the feed material adversely affects the screening operation
and should be removed.
TYPES OF SCREENING EQUIPMENTS
• Screening equipments can be classified on the basis of size of material as the screens
may be required to pass grains ranging from several mm in diameter down to
200-mesh.
1. Grizzlies (fixed inclined screens) are used for the coarse screening of large
lumps.
2. Trommels (revolving screens) are generally used for fairly large particles.
3. Shaking and vibrating screens are used in a coarse range and also for fine sizing.
• In the screening operation, coarse particles pass easily through the large openings in a
stationary surface but for fine particles the screen must be agitated by shaking,
gyrating or vibrating it mechanically or electrically. Fig. 3.3 shows typical screen
motions.
Unit Operations-I 3.12 Size Separation of Solids

Eccentric
(a) (b)

Eccentric
(d)
(c)

Vibrator

Eccentric vibrator
(e) (f)

Fig. 3.3 : Motions of screens

(a) Gyrations in horizontal plane; (b) Gyrations in vertical plane; (c) Gyrations at one
end and shaking at other; (d) Shaking; (e) Mechanically vibrated;
(f) Electrically vibrated
Grizzlies / Grizzly Screens
Construction :
• A grizzly is a grid of parallel metal bars set in an inclined stationary frame, with a
slope of 30 to 45o. The slope, and therefore the path of the material is parallel to the
length of the bars. The length of the bar may be upto 3 m and the spacing between
the bars is 50 to 200 mm. The material of construction of the bars is manganese steel
to reduce wear. Usually, the bar is shaped in such a way that its top is wider than the
Unit Operations-I 3.13 Size Separation of Solids

bottom, and hence the bars can be made fairly deep for strength without being
choked by material passing partway through them.
• A stationary grizzly is usually used for a dry free flowing material and is not
satisfactory for a moist and sticky material.
Feed

C
Section at C-C
C

Undersize
Oversize

Fig. 3.4 : Grizzly

Working :
• A coarse feed (say from a primary crusher) is fed at the upper end of the grizzly.
Large chunks roll and slide to the lower end (the tail discharge), whereas small lumps
having size less than the opening in the bars fall through the grid into a separate
collector.
• If the angle of inclination to the horizontal is greater, greater is the output
(throughput) but the lower is the screen efficiency. Stationary inclined woven-metal
screens operate in the same way that separate particles 12 to 100 mm in size.
• A grizzly finds its greatest application in the separation of the undersize (fines) from
the feed to a primary crusher. A stationary grizzly is the simplest of all separating
devices. It requires no power and is the least expensive to install and maintain. As the
openings in the grizzly have a tendency to get blocked by wedge shaped particles, the
labour requirement for operating the grizzly is high and it is difficult to change the
openings in the bars.
• Grizzlies are used for only the coarest and roughest separations.
Trommel and Trommel Arrangements
Construction :
• A trommel is a revolving screen consisting of a cylindrical frame surrounded by wire
cloth or perforated plate (which acts as a screening surface). It is open at one or both
ends and inclined at a slight angle to the horizontal so that the material is advanced
by the rotation of the cylinder. These units revolve at relatively low speeds of 15 to
20 rpm.
Unit Operations-I 3.14 Size Separation of Solids

• A trommel is a mechanically operated screen consisting of a slowly rotating

perforated cylinder (or cylindrical frame) surrounded by wire cloth (or perforated
plate) with its axis at a slight angle to the horizontal.
• The perforations in the screening surface may be of the same size throughout (i.e.,
over the whole length of the cylinder) or may be of different size in which case the
small size perforation section is near the feed end. It is driven at the feed end through
a gear mechanism. It has a feed point at the upper end, an undersize product
discharge below the screening surface and a oversize discharge at the opposite end
(lower end). Fig. 3.5 shows a schematic diagram of trommel having sections of
different size perforations.
Large size Small size
openings openings

Tails

Discharge

Fig. 3.5 : Trommel (with screens of different openings)

Working :
• The material to be screened is fed at the upper end and gradually moves down the
screening surface towards the lower end. In doing so, the material passes over the
apertures of gradually increasing size (as the single cylinder is provided with
perforations ranging from the finest desired at the feed end to the coarsest at the
discharge end).
• If the single cylinder is provided with the screen having three different size
perforations then we get four fractions. The finest material is collected as the
underflow in the compartment near the feed end and the oversize material (coarsest)
is withdrawn from the discharge end. Such type of arrangement is usually used for
smaller capacities. With this type of trommel, there is a tendency of blockage of the
apertures by the large material and the screen with the finest opening being the
weakest it is subjected to the largest wear.
• The operating speed of a trommel is 30 to 50% of the critical speed (the critical speed
is the one at which the material is carried completely round in contact with the
screening surface).
Unit Operations-I 3.15 Size Separation of Solids

Various trommel arrangements

• For separation of a given material into several size fractions, several trommels are
operated in series. The first trommel of a series may have the coarsest perforations so
that it produces the coarsest finished product which is delivered to the next trommel
and so on. In such a case, it is most convenient to place the trommels one above the
other as shown in Fig. 3.6 (a).
• When the first trommel of the series has the smallest perforations, the oversize
material passes to the next trommel and so on. In such a case, it is most convenient to
put the screens in line, end to end as shown in Fig. 3.6 (b).

(a) (b) (c)

(d) (e)
Fig. 3.6 : Trommel arrangements
(a) One-size screen to each trommel, coarsest trommel first; (b) One-size screen to each
trommel, finest trommel-first; (c) Single trommel with different perforations;
(d) Concentric trommels with coarsest trommel inside; (e) Trommel with single-size
perforations.
Unit Operations-I 3.16 Size Separation of Solids

• If the screening equipment of this type is put into service for finer separations then
the cylinder may be covered with a fine wire or silk cloth instead of a perforated plate
or coarse wire screen. Such an equipment is usually called a reel.
• Fig. 3.6 (d) shows several concentric cylinders. The innermost is the longest and has
coarsest perforations. The outer ones are successively shorter and have finer
perforations.
In this arrangement, maximum load is given to the strongest screen but the
construction is complicated and expensive.
• Trommels are well suited for relatively coarse materials (1/2 in or over).
Comparison of Grizzlies and Trommels :
Grizzlies Trommels
1. These are stationary inclined screens. 1. These are revolving screens.
2. Usually, screen is a grid of metal bar. 2. Usually, screen is a perforated cylin-
drical member.
3. Openings in screen are large. 3. Openings in screen are small.
4. They handle large size feed. 4. They handle small size feed.
5. Capacity is large. 5. Capacity is relatively small.
6. Labour requirement is large. 6. Labour requirement is low.
7. Cheap construction. 7. Relatively expensive construction.
Trommels are well suited for relatively coarse material (12 mm and over).
Gyratory Screens
• Gyratory screens which are gyrated vertically contain several decks of screens
arranged one above the other and held in a box or casing. The screens are arranged
such that the coarsest screen is at the top and the finest at the bottom. Discharge
ducts are provided for the screens to permit removal of the several fractions. The
casing is inclined at an angle ranging from 16 and 30° with the horizontal. The
gyrations are in a vertical plane about a horizontal axis and are produced by an
eccentric shaft fixed in the floor of the casing halfway between the feed location and
discharge. The screens are rectangular and fairly long. The speed of gyration, the
amplitude of throw and the angle of tilt can be adjusted as per requirements.
• The mixture of particles is fed on the top screen. The whole assembly of screens and
casing is gyrated to screen the particles through the screen openings.
Shaking and Vibrating Screen
Vibrating screens :
• In some situations, the screen is rapidly vibrated with small amplitude to keep the
material moving and prevent blinding as far as possible. Vibrating screens are
commonly used in industry where large capacity and high efficiency are desired. The
vibrations may be produced mechanically or electrically, accordingly we have
mechanically vibrated screens and electrically vibrated screens.
Unit Operations-I 3.17 Size Separation of Solids

Motor
• The vibrations may be produced either
mechanically or electrically with Uneven load
Feed
frequency of 1800 to 3600 or even
more per minute. Mechanical Oversize
vibrations are generally passed on
from high speed eccentrics to the
casing and from there to inclined Screen
screens so that the whole assembly is
vibrated. Electrical vibrations are
generally passed on from heavy duty
solenoids directly to the screens so Undersize
Spring
that only screens are vibrated.
Vibrating screens may be mounted in
a multideck fashion (not more than
three decks) with the coarsest screen
at the top, either horizontally or
inclined upto 45o.
Fig. 3.7 : Vibrating screen (Lab. Model)
• Fig. 3.7 shows a directly vibrated (electrically) screen. Electrically vibrated screens
are widely used in the chemical industry. The vibrating screens have accuracy of
sizing, increased capacity per square meter and low maintenance cost per ton of
material.
Operation of the vibrating screen :
• In case of a single screen, the vibrations are given to the screen to effect the
separation of solid particles into two size fractions.
• In case of vibrating screen (generally consists of three decks), the material
to be separated is fed to the top screen and simultaneously the screens are vibrated
either electrically or mechanically at a frequency of 1000 to 3500 per minute
(1000-3500 vibrations per minute). Due to vibrations the particles on the screen are
kept moving and due to inclination given to the screens, the oversize material travels
along the screen and is collected separately. The undersize material passes through
the screen and is collected. Four fractions are obtained with a three deck screen.
SOLVED EXAMPLES
Example 3.1 : A quartz mixture having a certain screen analysis is screened through a
standard 10 mesh screen. Calculate : (a) the mass ratio of overflow and underflow to feed
and (b) the effectiveness of the screen.
Due to blinding an appreciable fraction of the screen surface becomes inactive. The
blinding tendency is more pronounced with fine screens than with coarse screens.
Data : Dp = Dpc = 1.651 mm, xF = 0.47, xD = 0.85 and
xB = 0.195 (cumulative mass fractions)
Unit Operations-I 3.18 Size Separation of Solids

Solution : xF = Mass fraction of material A in feed = 0.47

xD = Mass fraction of material A in overflow = 0.85

xB = Mass fraction of material A in underflow = 0.195

The mass ratio of overflow to feed is

D xF – xB
F = xD – xB

0.47 – 0.195
= 0.85 – 0.195 = 0.4198 ≈ 0.42 … Ans. (a)

The mass ratio of underflow to feed is

B xD – xF
F = xD – xB

0.85 – 0.47
= 0.85 – 0.195 = 0.58 … Ans. (a)

B F–D D
OR : F = F = 1 – F = 1 – 0.42 = 0.58 … Ans. (a)

The overall effectiveness of the screen is

(xF – xB) (xD – xF) xD (1 – xB)

E = (xD – xB)2 (1 – xF) xF

(0.47 – 0.195) (0.85 – 0.47) (1 – 0.195) (0.85)

= (0.85 – 0.195)2 (1 – 0.47) (0.47)

= 0.6691 ≈ 0.67 … Ans. (b)

DB xD (1 – xB)
OR : E = F2 x (1 – x )
F F

D B xD (1 – xB)
= F · F · x (1 – x )
F F

0.85 (1 – 0.195)
= 0.42 × 0.58 × 0.47 (1 – 0.47)

= 0.66914 ≈ 0.67 or 67% … Ans. (b)

Unit Operations-I 3.19 Size Separation of Solids

Example 3.2 : A dolamite mixture having the following screen analysis is screened
through a standard 100 mesh screen. Calculate the effectiveness of the screen and the mass
ratios of overflow and underflow to feed.
Screen analysis :
Mesh Feed Oversize Undersize (weight %)
35 7.07 13.67 0.00
48 16.60 32.09 0.00
65 14.02 27.12 0.00
100 11.82 20.70 2.32
150 9.07 4.35 14.32
200 7.62 2.07 13.34
– 200 33.80 0.00 70.02
100 100 100
Solution : From the screen analysis provided, the cumulative mass fractions for a
100-mesh screen are :
7.07 + 16.60 + 14.02 + 11.82
Feed : xF = 100 = 0.4951
= mass fraction of A in feed
13.67 + 32.09 + 27.12 + 20.70
Overflow : xD = 100 = 0.9358
= mass fraction of A in overflow
0.00 + 0.00 + 0.00 + 2.32
Underflow : xB = 100 = 0.0232
The mass ratio of overflow to feed is
D xF – xB
F = xD – xB
0.4951 – 0.0232
= 0.9358 – 0.0232
= 0.517 … Ans.
The mass ratio of underflow to feed is
B xD – xF
F = xD – xB
0.9358 – 0.4951
= 0.9358 – 0.0232

= 0.4829 ≈ 0.483 … Ans.

B F–D D
OR : F = F = 1 – F
= 1 – 0.517 = 0.483 … Ans.
Unit Operations-I 3.20 Size Separation of Solids

The overall effectiveness of the screen is

DB xD (1 – xB)
E = F2 x (1 – x )
F F

D B x D (1 – xB)
= F · F · x (1 – x )
F F

0.517 × (0.483) (0.9358) (1 – 0.0232)

= 0.4951 (1 – 0.4951)
= 0.9131 or 91.31% … Ans.
(xF – xB) (xD – xF) xD (1 – xB)
OR : E = (xD – xB)2 (1 – xF) xF
(0.4951 – 0.0232) (0.9358 – 0.4951) (0.9358) (1 – 0.0232)
= (0.9358 – 0.0232)2 (1 – 0.4951) (0.4951)
= 0.9131 or 91.31% … Ans.
Important Points
• A method of separating solid particles according to size alone is called screening.
• Grizzlies, trommels, vibrating screens and oscillating screens are the screening
equipments used in practice.
• The screen analysis in which the weight fraction of the material retained on each
screen is reported in a tabular or graphical form as a function of the mesh size/screen
opening is called differential analysis.
• The screen analysis in which the cumulative weight fraction of the material retained
or passing through each screen is reported in a tabular or graphical form as a function
of the screen opening is called cumulative analysis.
• The variables in screening operations are : method of feeding, screening surfaces,
screen slope, moisture in feed and vibration amplitude and frequency.
• The effectiveness of a screen is a measure of the success of the screen in closely
separating oversize and undersize materials.
• The capacity of a screen is the mass of material that can be fed per unit time to a unit
area of the screen.
Practice Questions
1. Define screening.
2. Define the terms : differential analysis and cumulative analysis.
3. Derive the equation for effectiveness of a screen.
4. Differentiate between actual screen and ideal screen.
5. Explain in brief the variables in screening operations.
6. Compare grizzlies with trommels.
7. Draw neat sketches of any two motions of screens.
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