Question Bank

Subject: Mechanical Operations (4330501)

Unit-3 Solid - Solid Separation

Define screening.
1. Screening is defined as unit operation in which solids are separated from R
solids on the basis of the size alone.

Write true or false.

i) A single screen separates a mixture of particle into two
fractions. TRUE
ii) Material that passes through the screen is called undersize or
2. minus (-) material. TRUE U
iii) Material that remains on the screen is called oversize or plus (+)
material. TRUE
iv) The Tyler standard screen series is based on a 200-mesh screen.
TRUE

Discuss the importance of screening operation.

The screening operation is industrially carried out in order to
 remove the fines from a feed material before a reduction
equipment such as jaw crusher, ball mill or rod mill,
3. U
 prevent an incompletely crushed material (oversize) from entering
into other unit operations,
 produce a commercial or process-grade material to meet specific
particle size limits,
 remove the fines from a finished product prior to shipping.
Classify screen on the basis of their performance.
On the basis of their performance, screen is classified as Ideal Screen and
Actual Screen.
An ideal screen is a type of screen which sharply separate the feed mixture
in such a way that the smallest particle in oversize would be just larger than
4. the largest particle in the underflow. U
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.
An actual screen does not provide a precise separation as obtained in ideal
screen. Reason it is not possible to achieve such sharp separation.

5. Differentiate between U

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Ideal Screen Actual Screen

Yields sharp separation. Does not yield sharp separation.
100% efficiency. Efficiency is never 100% and is
lesser.
Does not exist in reality. Exist in reality.
Overflow or head contains Overflow or head may contain
particles with size greater than Cut particles with size smaller than Cut
Diameter. Diameter.
Underflow or fines contains Underflow or fines may contain
particles with size smaller than Cut particles with size greater than
Diameter. Cut Diameter.

Grizzly Trommel
Stationary Inclined Screen Revolving Screen
Screen is grid of metal bar. Screen is a perforated cylindrical
chamber.
Opening in screen are large. Opening in screen are small.
Can handle large feed size. Can handle small feed size.
High capacity. Less capacity.
Large labor requirement. Less labor requirement.
Cheap in construction. Costly in construction.
Define
Cut diameter
Cut diameter Dpc is defined as a point which clearly makes the point of
separation between undersize and oversize particles and is nearly equal to
mesh opening of screen.

Mesh number
6. R
Number of openings per linear inch in a screen is called its Mesh Number.

Screen aperture or screen size opening

The minimum clear space between the edges of the opening in the
screening surface Screen Aperture or Screen size opening.

Differential Screen Analysis

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

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 Screen 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.

Capacity of screen
The capacity of a screen is the mass of material that can be fed per unit
time to a unit area of the screen.

Effectiveness of screen
The effectiveness of a screen (screen efficiency) is a measure of the success
of the screen in closely separating undersize and oversize materials.

Classification
Classification is a method of separating solid particles into fractions based
upon/according to their terminal falling/settling velocities.

Classifier
A device that separates the solids particles into two fractions (based
upon/according to their terminal falling/settling velocities) is called a
classifier.

Jigging
Jigging is a process of gravity concentration where solids are separated
based upon the differences in the behaviour of particles through a moving
fluid which in turn, depends upon densities/specific gravities.

Floatation
Flotation refers to an operation in which one solid is separated from
another by floating one of them at or on the liquid surface.
Discuss Blinding of screen

7. It refers to the phenomenon wherein elongated, sticky, etc. particles U

become wedged into the openings during screening and thus prevent the
other particles from passing through it. Due to blinding an appreciable

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

fraction of the screen becomes inactive. The blinding tendency is more

pronounced with fine screens than with coarse screens.
Derive equation for overall effectiveness of 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.
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.

1-xF be the mass fraction of material B in feed.

1-xD be the mass fraction of material B in overflow.
1-xB be the mass fraction of material B in underflow.

Overall material balance over a screen is

F=D+B (Eqn-1)
Material balance of 'A' over a screen is
xF.F = xD.D + xB.B (Eqn-2)
8. U
From Equation (2), we have
F–B=D (Eqn-3)

Substituting the value of D from Equation (3) into Equation (2), we get

xF.F = xD (F – B) + xB.B …
xF.F = xD.F – xD.B + xB.B
(xD – xF) F = (xD – xB) B
𝐵 𝑥 −𝑥
= 𝑥𝐷−𝑥𝐹 (Eqn-4)
𝐹 𝐷 𝐵

Similarly, elimination of B from Equations (1) and (2) gives

𝐷 𝑥 −𝑥
= 𝑥 𝐹 −𝑥𝐵 (Eqn-5)
𝐹 𝐷 𝐵

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.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Screen Effectiveness based on the Undersize Material is the ratio of the

amount of Undersize Material B that is actually in oversize to the amount
of undersize material in feed.

Substituting values of D/F and B/F in overall effectiveness equation gives

E=EAEB

Discuss the principle, construction, working advantages and

disadvantages of a grizzly.

Principle: Screening
Construction:
A grizzly is a grid of parallel metal bars set in an inclined stationary frame,
with a slope of 30 to 45°.
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
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
9. satisfactory for a moist and sticky material. A

Working:
A coarse feed is fed at the upper end of the grizzly. Large chunks roll and
slide to the lower end, 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
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.

Advantages
A stationary grizzly is the simplest of all separating devices. It requires no
power and is the least expensive to install and maintain.
Disadvantages

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

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.

Applications
A grizzly finds its greatest application in the separation of the undersize
(fines) from the feed to a primary crusher.
Grizzlies are used for only the coarest and roughest separations.
Discuss the principle, construction, working advantages and
disadvantages of a Trommel.

Principle: Screening (Revolving)

Construction:
A trommel is a revolving screen consisting of a cylindrical frame
surrounded by wire cloth or perforated plate. 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.
A trommel is a mechanically operated screen consisting of a slowly rotating
perforated cylinder surrounded by wire with its axis at a slight angle to the
horizontal.
The perforations in the screening surface may be of the same size
throughout or may be of different size in which case the small size
10. A
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 an oversize discharge at the opposite end.

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.
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

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

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.

Applications
Trommels are well suited for relatively coarse materials (1/2 in or over).
Discuss 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 Figure A.

11. 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 Figure
B.
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.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Figure 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.
Discuss the principle, construction and working of a Vibrating screen.

Principle: Screening (Electrically/Mechanically vibrated)

Construction:
Vibrating screen consists of stack of screens of different opening, stcaked
one above the other which are vibrated. The vibrations may be produced
either mechanically or electrically with frequency of 1800 to 3600 or even
more per minute. Mechanical vibrations are generally passed on from high
speed eccentrics to the casing and from there to inclined screens so that
the whole assembly is vibrated. Electrical vibrations are generally passed
on from heavy duty solenoids directly to the screens so 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
12. horizontally or inclined upto 45°. A

Working:
In case of vibrating screen, 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.
Applications:
Vibrating screens are commonly used in industry where large capacity and
high efficiency are desired.
Discuss the principle, construction and working of a Hydraulic Jig. A
Principle: It operates by providing very short periods for materials to settle
due to which the particles do not attain their terminal falling velocities and
13. initial velocities cause the separation.

Construction:
It consists of a rectangular section tank with a tappered bottom.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

The tank is divided into two compartments by a vertical baffle. In one

compartment, a plunger is incorporated which operates in a vertical
direction giving a pulsating motion to the liquid. In the other compartment,
a screen is incorporated in which the separation of material takes place. It
is provided with a connection for feeding liquid during the upstroke and
bottom discharge connection for the removal of small particles of heavy
material and gates at the side of jig for the removal of particles settled on
the screen and for overflow.

Working:
The material to be separated is fed over a screen and is subjected to a
pulsating action by oscillating liquid with the help of a reciprocating
plunger.
During the upward stroke of the plunger, input water is taken into the jig
and there is no net flow through the bed of solids. During the downward
stroke, water inlet is closed and particles on the screen are brought into
suspension and they segregate according to their size and density such that
the dense material is collected near the bottom of screen.
Very small particles of the dense material will pass through the screen and
are collected at the bottom of the jig. Small particles of the less dense
material carried by the liquid water are removed through an overflow. The
material retained on the screen is removed through gates provided at the
side.
Fractions obtained from Jigging
 Small and dense material passing through the screen collected at
the bottom of the tank.
 Small size less dense material in the liquid overflow.
 Large size dense material segregated near a screen removed
through a gate at the side.
 Large size less dense material segregated above the dense material
removed through a gate at the side.
Discuss the principle, construction and working of a Double Cone A
14. classifier.

Principle: Classification using hydraulic water.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Construction:
It consists of a conical vessel incorporating a second hollow cone in it. The
inner cone is slightly larger in angle, arranged apex downwards and is
movable in a vertical direction. The bottom portion of the inner cone is cut
away and its height relative to the outer cone is regulated by a screw
adjustment.

Working:
The feed to be separated is fed in the form of a suspension to the center
of the inner cone. It flows downward through the inner cone and out at a
baffle at the bottom of the inner cone. Hydraulic water is fed near the
outlet for the coarse material.
The solids from the inner cone and a rising stream of water are mixed
below the inner cone. Then they flow through an annular space between
the two cones.
Classification occurs in the annular space, the fine particles are carried
away in the overflow, whereas the coarse particles settle against the
hydraulic water to the bottom and are removed periodically.
Discuss the principle, construction and working of an Electrostatic A
precipitator.

Principle: Electrostatic Separation depends on differences in the electrical

properties (conductivity) of the materials to be treated.
15.
Construction:
The electrostatic separator shown in figure consists of a grounded
rotor/rotating drum, a hopper for feeding the solids, an active electrode,
situated/placed at a small distance from the drum and collecting bins.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Working
The solids to be separated are fed on to a rotating drum, either charged or
grounded, from a hopper. The conductive particles in a very short time will
assume the potential of the rotating drum, which is opposite to that of an
active electrode and hence, they get attracted towards the active
electrode. The non-conductive material is repelled by the electrode and
attracted by the drum. The non-conductive material falls down straight
under the influence of gravity and is collected in a separate bin.
Discuss the principle, construction and working of a Magnetic separator. A
Principle: Separating solid particles by means of a magnetic field.

Construction:
16.

Working:

Discuss the principle, construction and working of a Froth flotation cell. A

Principle: Separation by froth flotation depends on differences in the
surface properties of the materials.

Construction:
The mechanically agitated flotation cell consists of a tank having square or
17.
circular cross-section. It is provided with an agitator which violently
agitates the pulp. A compressor / blower is used to introduce air into the
system through a downpipe surrounding the impeller shaft. The bottom of
the tank is conical and is provided with a discharge for tailings. An overflow
is provided at the top for mineralized froth removal.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Working:
Water and material are fed to the cell. The promotors and frothers are
added. Agitations are given and air is bubbled in the form of fine bubbles.
Air-avid particles due to reduction in their effective density, will rise to the
surface and be held in the froth before they are discharged from the
overflow. Hydrophilic particles will sink to the bottom and removed from
the discharge for tailings.
Classify screening equipment’s.
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.
18. A
Grizzlies are used for the coarse screening of large lumps.
Trommels (revolving screens) are generally used for fairly large particles.
Shaking and vibrating screens are used in a coarse range and also for fine
sizing.
19. Numerical on screening A

Draw a neat and labelled diagram of Froth flotation cell.

20. A

21. Draw a neat and labelled diagram of Hydraulic jig chamber. A

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

22. Discuss the factors affecting selection of equipment for solid separation A

Draw a neat and labelled diagram of a grizzly.

23.

Draw a neat and labelled diagram of a trommel.

24.

25. Draw a neat and labelled diagram of a vibrating screen.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

Draw a neat and labelled diagram of a various trommel arrangement.

26.

27. List applications of Jigging.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch
 Question Bank
Subject: Mechanical Operations (4330501)

 Jigging is used for concentrating heavy minerals from the light

minerals.
 It is commonly employed for coarse material having a size 20-mesh
and above and where there is a fairly large difference between the
effective specific gravity of the valuable and the waste material.
 They are used mostly to treat iron ores, few lead-zinc ores, etc.

Prepared by: Dhaval N. Yadav

Lecturer in Chemical Engineering Department,
SKJP, Bharuch