Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

classification

Submitted By:
Syed Ahmed Ali
Ahah
2021 – CH – 47
Submitted to:
Dr. M, Shazad
University of Engineering and Technology, Page | 1
Chemical Engineering
Lahore 09/12/202
Department 3
Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

Table of Contents

1 Abstract...................................................................................................................................................3
2 Related theory.........................................................................................................................................4
2.1 Introduction:....................................................................................................................................4
2.2 Types:...............................................................................................................................................4
2.2.1 Vertical current classifier:..........................................................................................................4
2.2.2 Horizontal classifier:.................................................................................................................5
2.2.3 Hydro cyclone:..........................................................................................................................6
2.3 Construction:....................................................................................................................................6
2.4 Working:..........................................................................................................................................7
2.5 Related terminologies:.....................................................................................................................7
2.6 Performance indicator:.....................................................................................................................7
2.6.1 Capacity:...................................................................................................................................7
2.6.2 Energy consumption:................................................................................................................7
2.7 Design parameters:...........................................................................................................................8
2.7.1 Cylinder diameter:.....................................................................................................................8
2.7.2 Inlet diameter:...........................................................................................................................8
2.7.3 Vortex finder diameter:..............................................................................................................8
2.7.4 Apex diameter:..........................................................................................................................8
2.7.5 Length of cone or angle:...........................................................................................................8
2.8 Operating parameters:......................................................................................................................8
2.8.1 Feed pressure:...........................................................................................................................8
2.8.2 Feed percentage solids:.............................................................................................................8
2.9 Feed characteristics..........................................................................................................................9
2.9.1 Feed particle size:......................................................................................................................9
2.9.2 Feed rate....................................................................................................................................9
2.10 Applications...................................................................................................................................9
2.11 Limitations:....................................................................................................................................9
2.12 Specifications:.................................................................................................................................9

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

3 Procedure:.............................................................................................................................................10
3.1 Machine study:...............................................................................................................................10
3.2 Performance:.................................................................................................................................11
3.3 Hints on calculation formulae:.......................................................................................................11
4 Observations, calculations and results:.................................................................................................11
5 Discussion:............................................................................................................................................14
5.1 Discussion on performance indicators:..........................................................................................14
5.2 Discussion on graph:......................................................................................................................14
5.3 Discussion on experiment:.............................................................................................................15
6 Conclusion:...........................................................................................................................................15
7 References:............................................................................................................................................16

List of figures:

Classifier ……………….……………………………………………………………...………….1

Hydraulic classifier ………………………………….……………………………………………5

Mechanical classifier …………...……………………………………………………………….. 6

Hydro cyclone ……………….…………………………………………………………………...7

Classifier construction …………….……………………………………………………………...8

Lists of tables:

Table # 01 ……………………………………………………………………………………….12

Table # 02 …………………………………………………………………………………..….. 12

Table # 03 ……………………………………………………………………………………… 14
List of graph:

Particle size distribution curve ……………………………………………………………….....14

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

EXPERIMENT # CLASSIFICATION

Figure#1: Classifier

1 Abstract
Classification is a method in which mixtures of minerals are separated based on the rate at which
a substance passes through a liquid medium. It takes less time to separate the powder compared
to the screening classifier. Its efficiency is therefore higher than that of the screen. The main
objective of this experiment is to study the different parts of the laboratory hydro-classifier, to
perform a screening test on the given material and to calculate the performance of the classifier.
The method used in classification in mineral processes is based on the separation of lighter
particles from heavier particles depending on their terminal velocities. It basically consists of two
product streams. One consists of light particles and one contains heavy particles. In the case of a
hydro-cyclone, a high speed is given, this creates a centrifugal effect and the heavy particles
move towards the screen wall and are collected at the top. On the other hand, lighter particles can
be collected in the vortex finder. Therefore, the separation is done in the classifier. The main
results we calculated from our experiment are operational cut size d50 = 2.3, design cut size
equal to 3.4, operational efficiency 1.1, cutting sharpness 22.22. However, by doing this
experiment, we will gain knowledge about the different parts of the classifier and how they work.
After carrying out this experiment, a table is drawn and calculations are made before the
distribution coefficient, particle size is plotted and various values are calculated from this.

And then we discuss the graph, the experiment and the conclusions drawn from it.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

2 Related theory
2.1 Introduction:
Classification is a useful technique for distinguishing between coarse and fine. Classifiers can be
wet and dry process. The wet process is often used to separate materials that cannot be separated
through sieves during ore processing. In a classifier, the feed size is usually less than 1 mm becau
se particles smaller than 1 mm cannot be separated by the sieve.

2.2 Types:
Classifier are divided into following main types:

 Vertical current classifiers

 Horizontal current classifiers
 Hydro-cyclone

2.2.1 Vertical current classifier:

Vertical flow classifier is also known as hydraulic classifier. This type of water classifiers are als
o used to extract pulp as they are called hydraulic classifiers. In the hydraulic classifier, water is
directed in the opposite direction to the settled particles [1]. It has a system in which water rises v
ertically. They disrupt the problem-solving process.
They can be used for rapid separation. Its schematic diagram is shown in figure# 02.

Figure#02: hydraulic classifier

2.2.2 Horizontal classifier:

Mechanical classifiers are an example of a horizontal classifier. They have a free settling
mechanism. They are used in grinding operations with a closed circuit and for the separation of
ore washing products. They act as sizing devices and have the ability to return small dense
particles to the mill. They are further divided into following types:

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 Settling cones:

They can be defines as a conical tank that is mainly used for the settling of coarse particles from
circulating water.

 Mechanical classifier:

It consists of a settling tank with parallel sides. It has a sloping bottom. In this screener, particles
larger than the desired size are settled in the settling tank and an overflow product is obtained
with minimal excess particles. They are further divided into raking sorters and spiral sorters. The
sorter does not consist of spirals and consists of rakes and parallel plates. Its maintenance is very
high. On the other hand, the spiral sorter consists of an inclined chute. Spirals spin around the
trough. In this sorter, smaller particles exit with an overflow current.

Figure#03: Mechanical Classifier

2.2.3 Hydro cyclone:
It is used in closed circuit grinding. It is simpler than a mechanical sorter and has a high capacity.
It consists of a conical shaped container that is connected to a cylindrical part. Its feed inlet is
tangential. An axially mounted tube passes through the top of the cylindrical section, which is
extended to the body of the cyclone, known as the vortex finder, as shown in Figure #04. Its
basic purpose is to prevent feed from shorting directly into the overflow.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

Figure#04: Hydro Cyclone

2.3 Construction:
Above all, the types of separators most commonly used today are hydro-cyclones, because they
have no moving parts and their efficiency is very high. In principle, the feed parts into which the
feed is fed have a cylindrical shape. It has an opening at the bottom for downstream particles
called the apex. For overflow particles, a tube called a vortex finder is extended from above. One
of the advantages of using a hydro-cyclone is that it has no moving parts and therefore has low
maintenance costs.

Figure#05: Classifier Construction

2.4 Working:
The classifier has a tower where the fluid rises at a uniform flow rate. When the feed enters the cl
assifier, the food items increase or decrease according to their width. Particles with tip velocities
less than the water velocity move in the flow. Similarly, objects with a terminal velocity greater t
han the speed of water move downward. This is the working principle of the product in mineral p
reparation.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

2.5 Related terminologies:

Free settling:

In a free solution, particles do not collide with each other. Sporadic events occur when free soluti
ons are available. If the solids content in water is less than 15%, a free solution is formed.

Hindered settling:

It is is known as Barrier Sedimentation occurs when the separation is based on density and the
solids in the water are more than 15%.
2.6 Performance indicator:
The performance of machine is indicated by following parameters:

2.6.1 Capacity:
Capacity is the measure of feed (mass or weight) per unit time. Capacity of classifier, especially
in case of hydro cyclone is 15 to 20 ton/hr. it can be increased up to 200 to 250 ton/hr if they are
parallel arranged. Its capacity can be calculated as

Capacity: Q= Pm/E ……………………………………….. (1)

2.6.2 Energy consumption:

Energy consumption is basically defined as the amount of energy required to perform any action.
It can be termed as power required for performing any action. Its power can be calculated as:

Energy consumption = PQ/ 360 ………………………… (2)

2.7 Design parameters:

2.7.1 Cylinder diameter:

When the diameter of the classifier cylinder increases (keeping all other parameters constant), the
area also increases and, as a result, a decrease in pressure occurs. Therefore, shedding and shear s
ize are reduced.

2.7.2 Inlet diameter:

As the cyclone inlet diameter increases, the maximum tangential velocity in the cyclone decrease
s. This means that the inlet size is inversely proportional to the maximum tangential speed of the
feed.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

2.7.3 Vortex finder diameter:

When the vortex tube diameter of the cyclone increases, the cutting size also increases with the in
crease in flow rate.

2.7.4 Apex diameter:

Appendix diameter also has a direct relationship with the area, overflow quantity and cut size.
When apex diameter is increased then area, overflow quantity and cut size also increases.

2.7.5 Length of cone or angle:

As the length of the cone increases, the cut becomes larger. Likewise, the length of the cone is in
versely proportional to the angle of the cone. When cone up and cone down.

2.8 Operating parameters:

2.8.1 Feed pressure:

When the pressure is high, large particles will mix into the sand and solid. When the feed pressur
e is low, a large amount of coarse particles will be mixed into the water flow. Therefore it is nece
ssary to control the pressure.
2.8.2 Percentage of feed waste:
As the feed waste increases, the collision of the product will increase, thus the cutting size will b
e affected. Therefore, the food percentage needs to be adjusted carefully, otherwise the performa
nce of the calculation will decrease.

2.9 Feed characteristics

2.9.1 Feed particle size:

Feed particle size can be defined as the average diameter of a food particle. The feed particle size
of the classifier is less than 1 mm. They cannot be separated by sieving, so we use separators to s
eparate particles smaller than 1 mm.
2.9.2. Feed rate
Initial speed is defined as the amount the machine feeds at one time. Studies have shown that effi
ciency can be increased by increasing the feed rate to the hydrocyclone. However, when the feed
price increases, its size decreases.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

2.10 Applications
Classifiers have a wide range of applications. Some of them are given below:

• They are used in the mining industry.

• They are used to control the length.
• They are used to increase product quality.
• They are used for dewatering, leaching and cleaning purposes in the chemical industry.
• They are used in chemical industries for dewatering, leaching and washing purpose.
2.11 Limitations:
• In a hydrocyclone, separation will be very difficult if the density of the mixture is almost
the same.

• It does not come into contact with very sticky liquids.

• It is not possible to create completely dry rivers.

• High speed in hydro-cyclones can cause wear of the machine.

2.12 Specifications:
Specifications of laboratory classifier are following:

Table #01: Specifications of laboratory hydro classifier

Name of Machine Centrifugal Hydro classier
Motor Power 0.25 HP
Motor RPM 500-2500
Size of Classifier 9 inch

Industrial specifications:

Table # 02 : Industrial specifications of hydro classifier

Name of machine Hydro classifier
Inlet height 0.720 m
Diameter 0.20 m
Length of vortex finder 0.220 m
Cone angle 30 degrees
Inlet out let diameter 0.0508 m

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

3 Procedure:
3.1 Machine study:
Hydro classifier consists of following component:

a. Cylindrical chamber:

It consists of a cylindrical chamber. That is directly connected with the conical body of the
classifier.

b. Apex of cone:

It is basically the bottom outlet of the cone. It can be termed as underflow discharge. c.

Vortex finder:

It consists of a pipe that is extended from the top of overflow particles that is called vortex finder.

d. Electric motor:

It is used to drive machine.

e. Angle of cone:

In case of hydro classifier the angle is 30 degrees.

3.2 Performance:
• Learn about the technology first. Then remove any food that needs to be separated.
• Analyze samples and measure their weight.
• Close the nose from the top or bottom and enter the feed.
• Then fill the water tank with water from the outlet.
• After the water tank is full, open the upper part and adjust the flow rate evenly.
• A disk is then placed below the stream and it flows to collect the material.
• After the product is changed, it is sometimes collected with the help of a pot and the pro
duct is waited for it to thicken.
• Then carefully pour out the water in the pot, leaving nothing broken.
• Collect dewatering overflows and overflows and dry them in the oven.
• The product is then sieved using a sieve.
• Then draw the table and do the calculations.

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

3.3 Hints on calculation formulae:

Following formulae are very useful in order to calculate different parameters as following:

• Operational efficiency = design cut size – operational cut size

• Efficiency of separation = (d75 – d25) / 2d50
• Sharpness of separation = slope of curve = (y2 – y1) / (x2 –x1)
• Energy consumption = PQ/ 360
• Capacity: Q= Pm/E

4 Observations, calculations and results:

Calculations, observations and results for classifier are following:

Table #03: Observation

Unbalanced Data Balanced Data

Mesh Feed Distribution Distribution
Under Under
Number# (g) Overflow(g) Coefficient Overflow(g) Coefficient
flow(g) flow(g)
(%) (%)
60.0 6.0 5.0 0.3 5.0 5.0 1.0 16.7
80.0 8.0 5.0 0.6 8.0 5.0 2.0 25.0
100.0 8.0 7.0 1.3 16.0 7.0 1.0 12.5
150.0 9.0 6.0 3.5 39.0 6.0 3.0 33.3
200.0 11.0 3.0 8.6 78.0 4.0 7.0 63.6
270.0 12.0 2.0 10.8 90.0 2.0 10.0 83.3
Pan 14.0 2.0 13.7 98.0 1.0 13.0 92.9

Graph#01:

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Particle Technology Lab Classification Ayesha Naeem 2021- CH- 01

110
100
90
80
efficient
%
70 Ideal curve
60
Non-ideal
-co 50
Distribution
40
30
20
10
0
0.01 0.1 1 10 100
Seperation limit particle size

Graph#1: Particle Size Distribution Graph

Calculations:

Cut size calculations:

Operational cut size (actual cut size): d50 = 2.3

Design cut size: d50 = 3.4

Operational efficiency = 3.4 -2.3 = 1.1

Sharpness of separation:

Slope = (70 – 50) / (3.2 – 2.3) = 22.22

Efficiency of separation:

Efficiency of separation= (d75- d25)/2d50 = 0.56

Free settling ratio:

From Stokes law: da/db = [(Db –Df)/ (Da – Df)]1/2=[( 7.5 -1)/(2.65 -1)]1/2 = 1.99

From Newton’s law: da/db = (Db –Df)/ (Da –Df) = ( 7.5 -1)/(2.65 -1) =3.94

Hindered settling ratio: da/db= (Db -Dp)/(Da -Dp) = (7.5 -1.5) / (2.65 -1.5)

= 5.22

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Calculations of performance indicators:

 Energy consumption (power):

It can be calculated as:

E=PQ/3600 ……………….. (3)

P= Pressure drop

Q= Flow Rate

Power= 7hp

As hydro classifier does not have moving parts so its power is low.

 Capacity:

Capacity of machine can be calculated by given formula:

Q=Pm/E ……………………………….………… (4)

Q=Capacity of machine

E=Energy required

Pm=Shaft Power Q=Capacity=17

tons/ hr

5 Discussion:
5.1 Discussion on performance indicators:
• Energy consumption can be called as machine output. As the size of the classifier
increases, it also increases. Similarly, it depends on various factors. We calculated the
power of the classifier, which is 7 hp.

• The capacity of the classifier can be increased if the units are arranged in parallel. It is
mostly 15 to 20 tons/hour. We calculated the value of the capacity, which is 17 tons/hour.
It's alright. When the units are arranged in parallel, the output ranges are 200 – 250 t/h.

• Classifier efficiency is higher than sieve efficiency. In our experiment, the operating
efficiency of the hydro-classifier is 1.1, and its separation efficiency is 0.56, i.e. 56%.
That is very low. This may be due to various errors such as inefficiency of the machine or

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errors in conducting the experiment or it may be due to contamination of the machine. At

an industrial level, an efficiency of 80 to 85% is acceptable

5.2 Discussion on graph:

Graph#01: Particle size distribution graph:

Charts play an important role in calculating various parameters like cut size etc. The chart
discussed in the above section gives the cut size value, it is d50 = 2.3. Some values are not
exactly the same as ideal machine values, it may be due to machine inefficiency, human error,
etc. Similarly, we calculate the operating efficiency of the valve from the graph, which is 1.1,
because it is the difference between the operation and the design size of the cut, and its value is
not very large, so we can say that our process is optimized. The ideal curve of the plot tells us
that the distribution coefficient is almost the same for different values of particle size up to a
certain limit before suddenly there is an abrupt change and the separation limit for particle size
becomes constant. Then again, at a certain value, the distribution coefficient remains the same.
But it didn't actually happen, in real case it doesn't give sharp curves. At the beginning, the
distribution coefficient remains slightly constant, but suddenly gives a sharp steepness. This
actually deviates from the ideal curve. It may be due to some kinds of errors like the experiment
may not be done correctly or there may be an error in the calculation or our machine may be
malfunctioning. From this we can conclude that the practical classifier has less efficiency than
the ideal classifier. From the graphs we can calculate the cut size value as described above and
the separation sharpness and so on.

5.3 Discussion on experiment:

All experiments must be performed with caution, otherwise our calculated results will be incorre
ct. Similarly, for a distribution system, we must consider all factors that may affect its performan
ce. In our laboratory we use hydraulic classifiers for wet cleaning. Wet process will reduce dust f
ormation and allow the machine to pass, but it may cause our machine to tear. Some of the result
s in the above calculations and figures may differ from the actual results, which may be due to th
e machine being inadequate or the machine malfunctioning. It may not be working properly or du
e to human error or contamination of the machine etc. It may be due. We must do the experiment
carefully, otherwise we will not get any benefit. We can also eliminate or reduce errors by consid
ering these situations and testing carefully..

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6 Conclusion:
We learn classifiers for particle separation. Particles can be classified by their density differences
or by their width relative to the liquid, which is usually water. The feed enters the hydraulic class
ifier through an opening called the crown. Pay attention to the feed pressure and feed percentage.
Once the machine is activated, the flow material and container are passed through the apex and v
ortexer. Then, after a while, the granules come to life, the products are stored in compartments an
d dry in the oven, I measure their weight, write the data in tabular form and then draw a picture.
The figure is plotted between partition coefficient and particle size. The actual curve is then com
pared to the ideal curve. We will talk about the errors in the experiment. Classifiers are useful for
separating objects and perform better than scanning. It is widely used in many areas such as mini
ng and particle size control, and is also used in the chemical industry for different processes such
as leaching and dehydration.

7 References:
 Mineral processing technology (an introduction to practical aspects of ore treatment and
mineral) by Barry A. Wills, Tim Napier – Munn, 7th edition
 Mineral processing design and operation
 Construction, working and maintenance of crushers for crushing bulk materials by K.P
Shah.

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