Principles of Extractive Metallurgy

Lecture 04:
a. Particle Size Estimation and Industrial Screens

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Concepts:

• Methods for particle size estimation

• Equivalent size diameter for irregular particles
• Sieve analysis and average certain% passing size determination
• Industrial Screening techniques and their classification
• Static and Dynamic screens

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Keywords:
• Sieve-analysis
• Mesh number
• Elutriator
• Martin’s and Ferret’s diameter
• Cumulative %passing - size distribution
• Trommel Screen
• Gyratory Screen
• Roller Screen
• Grizzly Screen
• Banana Screen

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Methods of Size Estimation
• 1. Sieve Analysis: The particle size
can be characterized by determining Elutriator
the size of sieve hole or aperture the
particle will just pass through (oldest
& most common method).
• 2. Sedimentation Method: The time
the particle takes to settle in a fluid
(water) and express the particle size
as the size of a sphere that has the
same settling rate (Stokes diameter).
• 3. Microscopic Methods: Visual
examination under the optical
microscope or electron microscope
or the diffraction of a laser beam to vt = d2g(s - f)/18 Stokes’ Law
derive statistical dimensions of Ratio of the max to min diameter
particles. of the particles should be < 4
Stokes diameter x 0.94 = sieve size (approx)
Methods of Size Estimation

Mesh No.= the number

of openings in one inch
of screen

Sieve Size: Mesh

No. 4; 4.75 mm
Equivalent Size Diameter of Irregular Particles
Sieve Analysis
• A sample material successively pass through finer sieves and weighing the
amount collected on each sieve to determine %wt in each size fraction.
• The sieves are usually agitated to expose all the particles to the openings.
• Presence of ‘near-size’ particles can cause blinding/obstruction of the sieve
apertures, & reduce the effective area of the sieving medium.

subsequent sieve openings

are related by a factor of
1/√2 (Tyler's series)
Sieve Analysis
• The sieve size analysis of a mineral sample giving the mass fraction of mineral
retained between successive sieve sizes is usually recorded as in Table:
Size fraction, Mass Cum, Mass Cum. % Passing Sieve Cum. Mass
microns % % retained (100 –retained) (µm) % retained The average size of the
-3500+1750 27.6 27.6 100 3500 0.0 material is determined by
-1750+875 25.2 52.8 72.4 1750 27.6 using the arithmetic formula
-875+440 16.1 68.9 47.2 875 52.8 using mass % retained data
-440+220 9.5 78.4 31.1 440 68.9
21.6 220 78.4
-220+110 6.3 84.7
15.3 110 84.7
-110+55 2.9 87.6
12.4 55 87.6
-55 12.4 100
0 PAN 100
Total 100

To obtain the 80 % passing size, interpolation between the 3500 and 1750 micron screen size
is required. This is best done when a linear relation-ship exists between the size analysis data.
Sieve Analysis

Log-linear plot of cumulative % passing (undersize) vs. size, Log-log plot of cumulative % passing (undersize) vs. size,
Gaudin-Schuhmann
distribution
y=100

𝐥𝐨𝐠 𝒚 =𝐥𝐨𝐠 𝟏𝟎𝟎+𝒂 𝐥𝐨𝐠 𝒙 − 𝒂 𝐥𝐨𝐠 𝒌 𝐥𝐨𝐠 𝒚 =𝒂 𝐥𝐨𝐠 𝒙 +𝒄𝒐𝒏𝒔𝒕𝒂𝒏𝒕

The slope of the straight line = a, and k = x, when y = 100%.
The distribution parameter (a) give the range of different sizes in the
sample & the size parameter (k) is a measure of the top size.
Sieve Analysis
• Ex: From the sieve analysis data of a sample in Table, calculate (a) Average size of the sample
and (b) 80% passing size.

For determination of 80% passing size, cumulative weight percentages

passing are to be calculated by adding the weight percentages from the
bottom. All the values are shown in the next Table
Sieve Analysis

A horizontal line is drawn at 80% cumulative weight percent

passing. From the point of intersection of this horizontal line with
the curve, a vertical line is drawn on to the x-axis. The point at
which the vertical line meets x-axis is the 80% passing size. It is
580 microns.
Industrial Screening
• The screen is a surface having many apertures/holes,
usually with uniform dimensions.
• Particles presented to a screen surface either pass
through or are retained, according to whether the
particles are smaller or larger than the governing
dimensions of the apertures.
• Dry screening is generally limited to material above 5
mm (to 300mm) in size, while wet screening down to
ca. 250 μm is common. Sizing below 250 μm is more
commonly undertaken by classification.
• Screen efficiency (often called the effectiveness of a
screen) is a measure of the success of a screen in closely
separating oversize and undersize materials.
• Particle Size, Feed Rate, Screen Angle, Particle Shape,
Open Area, Vibration, Moisture affect effectiveness
Classification of screen according to their mode of work
The probability (p) of passage
for a spherical particle of size d
through a square aperture of a
size x made by a wire of
diameter w in a single event is:

The probability of passage for

n impingements
 Dynamic Screens

Transport oversize across the

Operate at 35-45% critical speed, lower capacities series of rolls while fines fall
than vibrating screens as a part of the screen through the gaps; high capacity,
surface is used at a time, more prone to blinding. low noise, less impact on materials

A nest of sieves up to around 2.7 m dia.

Break coal (75-100 mm) and separate harder circular tipping & horizontal gyratory
rock, and wood contaminants into the motion produce multiple size fractions;
oversize. operate at 60-70% critical speed ultrasonic devices to reduce blinding
Vibrating & Static Screens
Variable Multi-slope,
Inclined ~20o, circular
throw mechanism. > ~40-30o at the feed end
5000 t/h capacity; use to ~0-15o at discharge
for sizing the feed to end; a linear-stroke
primary & secondary vibration, higher
crushers capacity and more
efficient screening of
the near-size material
Designed for fine separations, direct rapping
of the screen mesh rather than vibration of
Widely used. the entire unit
Contraflow slows
the material &
permits more
efficient
separation, in-
flow permits a
greater
throughput.
Screening Efficiency
• If f, c, and u are expressed in terms of the fractions of undersize material in feed, overflow and underflow
respectively then

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Ex 2: A quartz mixture is screened
through a 1.5 mm screen to obtain
+1.5 mm fraction. The size analysis of
feed, overflow and underflow is shown
in Table. Calculate the effectiveness of the
screen.

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References
1. Mineral Processing Technology, 8th Ed., Barry A. Wills and James
A. Finch, 2016, Elsevier Ltd.
2. Mineral Processing, Jan Drzymala, 2007, Wroclaw University of
Technology.
3.Chemical Metallurgy: Principles and Practice. Chiranjib Kumar
Gupta, 2003, WILEY-VCH

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