Lecture: Mechanical Process Engineering

Tutorial Laminar Cross Flow Separation

Excersise:Designofacircularclassifier

Task:

Aquartzsuspension(solidvolumefraction5%)shallbeclearedbyuseofaroundclassifier.
For this all particles with diameters of 15 m and larger shall be separated. Calculate the
minimalrequiredareaoftheclassifier.

Given:

t
m A 120
d

d T 15 m

kg

m
kg
s 2750

m
fl 1000

Wanted:

Dinm

Lehrstuhl fr Mechanische Verfahrenstechnik

Prof. Dr.-Ing. habil. Jrgen Tomas

s 0,05

fl 10 3 Pas

k ,st 0,65
nk 3

Comminution
Task 1: Calculation of the Bond working index

A wet-discharge chamber ball mill (grinding chamber diameter is D = 3100 mm,

length L = 3200 mm), which works in a circuit with a hydrocylone, mills siliceous
material with dA,95=20 mm, particle size distribution characterized with
0,9

d
Q3 (d) = 95
in %
d
A,95

(1)

It is milled to a fine material with a diameter of dF,95=0,2 mm with

1,1

d
Q3 (d) = 95
in %
d
F,95

(2)

= 70 t/h and the electric energy demand is P = 530

The value of the throughput is m
kW.
a) Calculate the work index of Band Wi,m for this process.
b) The capacity of the milling system should be increased by setting up another
mill, which works under the same technological conditions (same milling type,
same bulk, same relative numbers of revolutions and so on) and it even shows
the same L/D-relation.
Which measurement should the mill have and which electric drive power is
necessary?

Task2:Designofajawcrusher
1600

A quartzite bulk (

) should be cummunited by a jaw crusher of the type

swing jaw crusher. The coarse crusher has the following parameters:
Intake angle:

18

Jaw-width:

500

Verify the intake angle!

Calculate stroke (h), number of revolutions of the engine (n), gap width (s), crushing
chamber size, throughput ( ) and energy demand (P)!
Schematic of a swingjaw-crusher, Illustration of
the input conditions
between the jaws.
Jaw width: w
Jaw depths: b
Intake angle:
Gap at outlet: s
Swing gap at outlet: h
Stroke at crushing jaw: h1

Particle intake and intake angle

The contact force F in the gap with intake angle creates a directly upwards relating
force component F sin( / 2). It antagonizes with the friction force Fcos(/ 2), which
needs to be bigger than the vertical component, in case of in taking particles. Both
forces appear twice, on the left and the right side. The gravitation force of the
particles will be outlined:
2

cos

sin

tan

For an assumed friction coefficient of stone on steel of

results in:
2 arctan

0,3 the intake angle

___

To guarantee enough safety in case of bad friction conditions coarse crushers with
an intake angle between 16 and 22 are chosen. Choosing =___ is all right.

Swing stroke h at the outlet gap

0,06

0,06 0.5

Jaw width w and stroke h in m.

.

____

General values of h for coarse crushers are between 20 and 50 mm. In this example
____
was taken.
Number of revolutions n of the drive shaft
The number of revolutions of the drive shaft is equal to the number of strokes of the
swing. Moving upwards the material will be crushed, moving downwards the material
will slide down to the crushing chamber. The number of revolutions, for which directly
enough curved material is theoretically taken out of the crushing chamber, is named
border number of revolutions nGR. In real the number of revolutions which is going to
be taken for coarse crushers is 10% up to 15% smaller than nGR.
Time for moving backwards (t1) = Falling time of the material (t2)

______

tan

0.85 0.9
0.9

_____

For croarse crushers the number of strokes is between 180 min-1 und 250 min-1. In
this example:
_______
is taken.

Gapwidth s
For the given jaw width und the apparent crushing ratio ns=w/s=69 , which needs to
be taken to prevent plugging, the gap width s will be calcualted as shown:
,

____

_____

taken:

_____

therefore is

______

Jaw height H and jaw depth b

tan
_________
Chosen:

_________

1.3 .1.7
1.6

chosen :1.6

________

Considering the results, the size of

the jaw crusher is defined. It has the
generalized size of ____________ .

Throughput
Using the prism of crushed material, which is falling out of the crushing chamber
while the backmovingphase of the swing und the number of revolutions of the drive
shaft the thoughput can be calculated.The
lower crushing jaw opens a gap between s
and s+h .For calculation the volume of the
prism volume average is taken. The material
is only sliding down in the backmovingphase
(while T/2),becuase of this case a loosening
up factor for the crushed material is
introduced.It is between 0.3 and 0.5.
Chosen: =0.5

tan

__________

________

_______

Instead of s+h/2 , the upper particlediameter of the treated material dF can be used
aswell.
Energy demand P
Because of many factors influencing the need of power of the engine the energy
demand needs to be calculated emperically.
Average values for the
specific need of Work
depending on the gap
width s..

in

1. Jaw crusher for hard

material at ns=5.
2. steep cone crusher for
hard and middlehard
material at ns=6.
3.flat cone crusher for hard
material at ns=3.
________

(Slope 1)

und

are mainly known from

experiments and practical use. If not, you need to

refer on specialised literature.

______

Tutorial: Adhesion Forces

Revision

a) What kinds of bonds between solid particles may arise?

b) How can be modeled the bulk strength due to adhesion?

Exercise 1:
A spherical particle of CaCO3 (s = 2,6 g/cm) adhere due to VAN-DER-WAALS-Forces
underside a horizontal slab. Which is the maximum diameter for the particle, so that it doesnt
fall down due to the gravitation?
The HAMAKER-constant is C H 1,6 10 19 J ,and the contact distance is a0 0,4 nm.

Exercise 2:
For a CaCO3-Powder with an average size d 50 2.5m , an average roughness d r 0.1m
and a bulk density b,0 300kg/m 3 calculate:
a)

the tensile strength 0 without a deformation, while a a 0 0.4nm

b)

the increase of the adhesive force with the plastic deformation at the particle
contacts, with p f 500 MPa

Exercise 3:

Calculate the resulting adhesive force and tensile strength between 2 spheres with existence
of a liquid bridge based on the wetting behaviour (=0 and 60) of the solid.
Note: derivation of the main curvature radii R1 and R2 by means of angular correlations at the
three phase contact
given: d = 100 m

20 ,

0 0.5
lg 72 10 3 J / m 2

Agglomeration

Porosity:

= VH

10

Vges

For monodisperse spheres (with no adhesion forces):

Coordination number

Porosity

(number of the nearest neighbours)

Closest packing

k = 12

= 0,26

k=6

= 0,48

(cubic face-centred)
Loosest packing
(simple cubic)
Random packing

= 0,42

Another pore characteristic:

Pore number e,
Conversion e :

e = VH

VS ,

e
;
1+ e

could be > 1 !!
e=

P =

Single particle:

Vparticle

P = (1 P ) S

A =

Agglomerate:

Vpore

VH,A

VA

P = (1 P ) (1 A ) S = (1 ges ) S
ges =

Vpore + VH,A

VA

Bulk of agglomerates:
b =

VH,b

Vb

b = (1 P ) (1 A ) (1 b ) S = (1 ges ) S
ges =

Vpore + VH,A + VH,b

Vb

P, A, b: for dry bulk materials

Porosity of Agglomerates
single particle

p =

VPore

VS

VPore
VP

agglomerate
VH,A
VA
A =

VH ,A
VA

bulk of agglomerates
Vb
VH,b

b =

VH ,b
Vb

total porosity: ges =

VPore + VH ,A + VH ,b
= 1 (1 P )(1 A )(1 b )
Vb

Tutorial: Agglomeration
Exercise 1: Bulk density and porosity of agglomerates

A fine filter dust with the solid density s = 2400 kg /m and a bulk density b = 800 kg /m is
dry. It should changed into spherical agglomerates to downsize the storage volume. What is
the maximum agglomerate porosity that is allowed so that the bulk density will be downsized
(with the porosity of the agglomerate bulk b = 0,4)? Calculate without any humidity and with
non-porous particles (p = 0)!
Exercise 2: Liquid requirement at the wet agglomeration

How much humidity Xl is required, so that wet agglomerates with a porosity A should have a
saturation level S? (s = 2700 kg / m3, A = 40 %, S = 0.8)

Exercise 3: Design of a roller press

A roller press is to be designed with a mass flow rate of 600 kg/h. A flake should be produced
with a thickness of 3 mm and a density of b,A = 1100 kg /m. Pressure tests are carried out at
which the agglomerate density b,A was examined depending on the pressure. For the flake
density an advantageous pressure pm = 54 MPa and a compressibility coefficient K = 4.8 were
determined. From shear tests the following characteristics are known:

effective angle of internal friction

e = 61,5

wall friction angle

W = 21,5

Assumptions are:

loss mass ratio

f = 0.1

roller rotation number

n = 16 min-1

pressure at the material feed p0 = 0,686 105 Pa

S1 = s2 = s = 3 mm

Exercise 1: Bulk density and porosity of agglomerates

A fine filter dust with the solid density s = 2400 kg /m and a bulk density b = 800 kg /m is
dry. It should changed into spherical agglomerates to downsize the storage volume. What is
the maximum agglomerate porosity that is allowed so that the bulk density will be downsized
(with the porosity of the agglomerate bulk b = 0.4)? Calculate without any humidity and with
non-porous particles (p = 0)!

b = s (1 A )(1 b )
1 b
A = 1
1 b s
A = 1

1
800
= 0.444
1 0.4 2400

Exercise 2: Liquid requirement at the wet agglomeration

How much humidity Xl is required, so that wet agglomerates with a porosity A should have a
saturation level S? (s = 2700 kg / m3, A = 40 %, S = 0.8)

Solution:
S=

Vl
V
= l
VH , A AV A

Xl =

with

ml
V
= l l
m s sV s
Vs

V ges

Xl =

= 1 A

l
A
S
s (1 A )

and

VH

V ges

=A

Exercise 3: Design of a roller press

A roller press is to be designed with a mass flow rate of 600 kg/h. A flake should be produced
with a thickness of 3 mm and a density of b,A = 1100 kg /m. Pressure tests are carried out at
which the agglomerate density b,A was examined depending on the pressure. For the flake
density an advantageous pressure pm = 54 MPa and a compressibility coefficient K = 4.8 were
determined. From shear tests the following characteristics are known:

effective angle of internal friction

e = 61,5

wall friction angle

W = 21,5

Assumptions are:

loss mass ratio

f = 0.1

roller rotation number

n = 16 min-1

pressure at the material feed p0 = 0,686 105 Pa

S1 = s2 = s = 3 mm

Solution:
flake production: j = 0, s = 3 mm

gripping angle 1 = f (K, e , W) from Fig. 1

for e1 = 50 and 1,1 = 16

for e2 = 70 and 1,2 = 20
(for K = 4.8 and for W = 21,5)

linear interpolation

1 = 1,1 +

1, 2 1,1
20 16
( e e ,1 ) = 16 +
(61.5 50) 18 o
e , 2 e ,1
70 50

normal stress ratio R = (2) / (1)

ratio of the average normal stresses in the material at 2 resp. 1

tentative assumption: s / D = 0.01
from Fig. 2: log R = 0,6 R = 100,6 = 4

calculation of the roller diameter acc. to JOHANSEN:

jd B + (1 j)s p m 1 + sin e

jd B (1 j)s cos 2
1 f
R p 0 1 sin e
D=
(1 cos 2 )cos 2
roughness coefficient for plain rollers j = 0
n

p
1 + sin e
m
s cos 2
1 f R p 0 1 sin e
D=
(1 cos 2 )cos 2

note:
The coefficient n is the so called compressibility. For the compressibility there are a
lot of approximate solutions with limited validity. According to JOHANSON the curve
b,A = f (p) is a straight line with the slope n = 1/K in a double logarithmic diagram and
can be described as a simple power function.

b ,A p
= *
*b
p

n = 0 incompressible
b* reference density of the agglomerate at a reference pressure p*
n

3mm 5.4 10 7
1 + sin 61.5
3mm cos18

5
0.9 4 0.686 10 1 sin 61.5
D=
= 319.7mm
(1 cos18) cos18
Verification of s / D:
s / D = 3 /319.7 = 0.0094
Difference of 6% to the selected value is inside the range of the error of reading the diagram;
no correction
Determination of the roller width :

B=

m&
600kg / 60 min
=
= 0.2095m
b, A (1 f ) D s n 1100kg / m 0.9 0.3197m 0.003m 16 min 1

Determination of the roller force:

roller force coefficient from Fig. 3

0.2093 0.3197m 2
BD
N
FW =
pm =
5.4 10 7 2 0.067 = 1.21 10 5 N
2
2
m
calculation of the power

torque coefficient T from Fig. 4

power per roller
PW =

D 2 B pm n T =

03197 2 m 2 0.2093m 5.4 10 7

N 16

0.005 = 1.21kW
m 2 60 s

The net power consumption of both rollers are Pges = 2.42 kW.

Tutorial: Mixing

Revision

1. How mixing processes can be divided regarding the process intention?

The following are the mixing processes divided based on the process intention:
a) The generation of stochastically homogenous material systems like mixtures of granular
materials, suspensions and emulsions.
b) Mixing of completely soluble liquids and gases. The coarse mixing is the rate-determining
step, so that also these mixing processes pertain to the mechanical process engineering.
c) The generation of a polyphase system inside the process space as a prerequisite to start of
superposed micro processes, e.g. at
* Flotation,
* Flocculation and
* Mass transfer between the disperse and the continuous phase.
2. How is the procedure to calculate the variance of a random mixture with the
mathematical model of STANGE?

The mathematical model of STANGE starts with a constant sample mass and together with a
constant number of particles inside the sample. The particle size distributions of the
components in the form of the number distributions Fo(msi) of the particle masses (with the
averaged particle masses m resp. m ) and the variances 2 resp. 2 of the particle mass
1
2
1
2
distributions are considered in the mathematical model.
For the variance of a random mixture obtain (from STANGE):

2 = 1 2 m (1 + v 2 ) + m (1 + v 2 )
1 2
Z
2
2 1
1
m
p
with
mp
sample mass
v 1 = 1 / m1 resp. v 2 = 2 / m2

(8.10)

variation coefficients of the particle mass distributions.

Here is a workable equation to calculate the variance of the sample composite. The effects of
the mixture fractions, the fineness and the regularity of the particle size distributions on the
variance 2Z are visible.
Now the equation should be checked for special cases:
a) The components have tight particle size distributions, that means v12 0 und v22 0:
(m m )

1 2
2 1 2 ( m + m ) = 1 2
(8.11)
1
2
2
1
Z
m
m
m
s
p
p
/ m + / m = 1 / m obtain, when m is the average particle mass of the sample.
1 1
2 2
s
s
m1 = m2 = ms brings, because mp/ms = N is the number of particles in the sample

2 = 1 2

(8.12)
N
b) The particle mass distributions of the components are approximately equal, that means:
m m und v 2 v 2 :
1
2
1
2

2 1 2 m (1 + v 2 )
(8.13)
s
Z
m
p
c) The fraction of one component is greater than the fraction of the other(1 0,9) and
z

m1 and m2 resp. v12 and v22 are on the same level:

2
2
(8.14)
1 2 m (1 + v 2 )
Z
2
2
m
p
2 is obtained by the fineness and the variation coefficient of the component which has
Z
the smaller fraction.
d) The mass fraction of both components are the same (1 2), but one component is
clearly finer than the other (m >> m ):
1
2

2 1 2 m (1 + v 2 )
1
1
Z
m
p

(8.15)

In this case 2 is obtained mainly by the particle size distribution of the coarse
Z
component.
This mathematical model is also applied in poly-component systems because the number of
components can be reduced to a binary system by combining all components to one
component which are similar and the remaining component is our interest.

Exercise

Calculate the quality of mixing of 2-material-mixture (concrete mortar) consisting of cement

and sand with the equation of STANGE.
given.:

3t concrete mortar
mass fraction:

solid density:

There are 5 samples with a mass of 2 kg.

sand
cement

1=80 %
2=20 %

sand
cement

1=2.65 g/cm3
2=3.15 g/cm3

mP=2 kg

Result of analysis:

Sample-Nr.

Mass fraction of sand

i
1
2
3
4
5

1,i [-]
0.75
0.79
0.82
0.76
0.81

Sieving analysis of the materials before mixing:

Table 2: sieving analysis of cement

Table 1: sieving analysis of sand
i
1
2
3
4

di
[mm]
0.1.....0.5
0.5.....1.0
1.0......3.0
3.0......7.0

3,i
0.01
0.15
0.40
0.44

[-]

i
1
2
3
4
5

[mm]
di
0.0.....0.01
0.01.....0.025
0.025.....0.04
0.04.......0.09
0.09........0.1

3,i
0.01
0.10
0.29
0.55
0.05

[-]

Solution
For using the STANGE-equation, eq. (8.10) the following values are needed:
1

(given)

mass fraction sand

(given)

mass fraction cement

mp

(given)

mass of a sample

m1 , m 2

average particle mass

v1 = 1 / m1 resp. v 2 = 2 / m2

variation coefficients of the particle size distributions

Calculate the average particle mass

a) from the particle size volume distribution:

m=

s
6

1
k

3
m ,i

(8.7a)

3, i

i =1

m1 =

g 1
2.65 3

mm 3
3
6
0
.
78
10 mm

3
m ,i

3,i from table 3

i =1

m1 = 1.779 10 3 g
m2 = 1.51 10 8 g

b) from the particle size number distribution:

m=

s d 3m,i 0,i
6
i =1

m1 = 1.777 10 3 g

(8.7)
k

3
m ,i

0,i from table 3

i =1

m2 = 1.52 10 8 g
difference between a) und b): rounding errors!
Calculate the variation coefficients of the particle mass distribution
v1 = 1 / m1 = 1.61 10 3 g /1.777 10 3 g

v1 = 0.91

v 2 = 2 / m2 = 1.44 10 8 g /1.517 10 8 g

v2 = 0.95

see table 3,

m1 , m2
N

= m1,i m1 0,i , = m2 ,i m2 0,i

2
1

i =1

2
2

i =1

see table 3

Calculate the variance of a random mixture 2Z with the equation of STANGE:

2 = 1 2 m (1 + v 2 ) + m (1 + v 2 )
(8.10)
1 2
Z
2
2 1
1
m
p
0 .8 0 .2
Z2 =
0.8 1.517 10 9 (1 + 0.95 2 ) + 0.2 1.777 10 3 (1 + 0.912 )
3
2 10

Z = 2.3 10 4
special case d) m >> m :
1
2
2 is calculated from the particle size distribution of the coarse component
Z

2 1 2 m (1 + v 2 )
(8.15)
Z
1
1
m
p

2
Z

0 .8 0 .2
1.777 10 3 1 + 0.912
3
2 10

Z 5.1 10 4

Variance of the expectation values ~s :

k
~s 2 = 1 (
1 ) 2
k i = 1 1, i

~
s = 1 / 5 0.0047

~
s = 0.0307

(8.6a)

see table 4 (next page)!

Table 4: Calculation of the variance of expectation values

2
1,i
i

1,i

0.75

0.025

0.79

0.0001

0.82

0.0004

0.76

0.0016

0.81

0.0001

0.0047

Calculate the quality of mixing

a) MG = / ~s
1
Z

MG min MG 1 1

(8.16a)

MG1 = 0.0075 , Z with eq. (8.10) / MG1 = 0.0166 , Z with eq. (8.15)

2max = 1 2

MG min = Z max ;

(8.17)

MGmin = 2.3 10 4 0.4

MG min = 5.85 10 4 , Z with eq. (8.10) / MGmin = 1.28 10 3 , Z with eq. (8.15)

MG1 lies in the expected level, but difficult to interpret better to use : MG2
b) MG = 1 ~s /
2
max

0 MG 1 MG max

(8.16b)

MG =10.0307 / 0.4
2
MG =0.92
2

(without Z!)

MG max = 1 Z max

Z with eq. (8.10)

MG max = 1 2.3 10 4 0,4

MGmax = 0.9994 1

Z with eq. (8.15)

MG max = 1 5.1 10 4 0.4

MGmax = 0.9987 1

Table 3: Calculating the average particle masses and the variation coefficients
i

1
2
3
4

1
2
3
4
5

(m

in mm-3

Q0(d)

0,i

mi
in g

( m i m) 2

0.3704
0.3556
0.050
0.00352
0.78

0.3704
0.726
0.776
0.7795

0.4752
0.9314
0.9955
1.0

0.4752
0.4562
0.0641
0.0045

0.017810-3
0.26710-3
0.711510-3
0.780510-3
1.77710-3

3.09510-6
2.28110-6
1.13610-6
0.57710-6

1.470610-6
1.04010-6
0.072810-6
0.004510-6
2.58810-6

80000
18659
8448
2003
58
109168

80000
98658
107107
109110
109168

0.7328
0.9037
0.981
0.9995
1.0

0.7328
0.1709
0.0773
0.0185
0.00053

0.15110-9
1.5110-9
4.3810-9
8.3810-9
0.7510-9
1.51710-8

2.25610-16
1.86710-16
1.16410-16
0.45910-16
2.07510-16

165.310-18
31.910-18
9.010-18
0.8510-18
0.1110-18
207.210-18

di
in mm

3,i

dm,i
in mm

3,i / d3m,i
in mm-

Sand
0.1...0.5
0.5...1
1...3
3...7

0.01
0.15
0.40
0.44

0.3
0.75
2
5

Cement
< 0.01
0.01...0.025
0.025...0.04
0.04...0.09
0.09...0.1

0.01
0.1
0.29
0.55
0.05

0.005
0.0175
0.0325
0.065
0.095

3, i

/ d 3m,i

in g

in g

d m ,i =

d i + d i 1
2

Q 0 (d ) =

3, i

3, i

d 3m,i

i =1
N
i =1

0 , i = Q 0 ( d i ) Q 0 ( d i 1 )
d 3m,i

mi =

0 ,i

s d 3m,i 0,i
6

Tutorial: Powder Flow Properties

Revision:

a) What is the procedure to measure the flow properties of cohesive bulk materials?
The flow properties of cohesive bulk materials are characterized by the results of shear tests,
e.g. with the translation shear device developed by JENIKE.
A translation shear device consists of an upper linear moving ring, a lower closed base and a
layer. The interior volume is filled with a sample of the bulk material and compressed by a
normal stress = normal force FN / cross-section area A to a definite porosity . The bulk
material sample is pre sheared with the required shear stress = FS/A by linear moving the
ring against the base with a fixed pre shear stress An applied by the layer. Here the sample
must flow under constant volume ( = const.) and therefore is stationary, which means constant shear stress in time. By shearing with stepwise decreased normal stress
= FN/A you get pairs of variants (()) characterising the beginning flow (with loosening
respectively increase of porosity) on the yield locus. By changing the base against a sample of
wall material the measuring of wall friction is possible (wall yield locus).

b) What is the procedure to characterise the flow properties of cohesive bulk materials?
For the marking of the strength properties of a cohesive bulk material the uni-axial compressive strength c due to a maximum consolidation stress (greatest principal stress while consolidation) 1 is important. We can get the amount of c from the appropriate yield locus by
drawing a MOHR-circle which passes through the point of origin and tangent to the yield locus. The uni-axial compressive strength c is equivalent to the stress which leads to breaking
resp. flowing by uni-axial pressure in a bulk cylinder compressed with 1. Consequently at
lower c with available consolidation stress 1 a bulk material will flow easier.

The ratio of the greatest principal stress 1 and the uni-axial compressive strength c is particularly suitable for the characterisation of the flow ability of cohesive bulk materials. It is
called flow function ffc in terms of a dimensionless classification number:

ff 1
c
c
The following table shows the classification of bulk materials submitted by JENIKE advanced
by hardened material.

ffc:
10 ffc

marking:

examples:

free-flowing

dry sand

ffc

< 10

easily flowing

humid sand

ffc

<4

cohesive

dry cement

ffc

<2

greatly cohesive,
not flowing

humid powders

ffct

<1

hardened
with solid properties

aged cement

There is no compressive strength in adhesionless material (c = 0, yield locus goes through the
point of origin), so the flow function value draws to infinite. In the marking hardened the
uni-axial compressive strength ct due to solid bridges and describing with the so called
time yield locus is greater than the consolidation stress 1.

Exercise:
The flow classification numbers of a CaCO3-powder with d50 = 3 m, XW = 0,3 % and
s = 2600 kg/m have to collected. Table 1 and 2 show the experimental results measuring by
a JENIKE-shear-device. The following flow classification numbers are to find: (), R (M),
st, 0, ffc, W (W), W, C (1), e (1), i (1) und b (1).
Table 1: measured values of the current flow behaviour
yl-Nr.

An in kPa

An in kPa

Ab in kPa

Ab in kPa

b in kg/m

1.5

1.49

0.51

0.95

359

1.53

0.60

0.99

356

1.55

0.90

1.20

356

1.42

1.20

1.40

350

2.88

0.75

1.44

378

3.00

1.20

1.80

385

2.90

1.80

2.10

384

3.10

2.40

2.70

387

5.76

1.50

2.50

405

5.90

2.40

3.20

407

5.70

3.60

4.14

406

5.85

4.80

5.10

409

10.30

3.00

4.50

434

10.20

4.90

5.80

432

10.40

7.10

7.60

425

10.30

9.80

9.80

421

3.0

6.0

12.0

Table 2: measured values of the wall friction

W in kPa

15.10

12.30

9.50

5.40

2.60

1.40

W in kPa

7.12

5.89

4.47

2.59

1.25

0.66

7.11

5.89

4.46

2.61

1.27

0.65

Shear test analysis

Individual yield loci:

tan i c tan i Z

Uni-axial compressive strength:

c 2 c

1 sini

cosi

Major principal stress 1:

An c cos i

An sin i c cos i 2 2An cos 2 i

1 sin i

Effective friction angle:

e arcsin

Minor principal stress 2:

Stationary yield locus:

1 sin i c cos i
1 c cos i

1 sin e
1
1 sin e

Center stress

M,st 1 2

Radius stress

R,st 1 2

Stationary yield locus

Stationary friction angle:

R,st tan M,st 0

st arcsin tan
n

Bulk density:

Wall friction angle:

b b,0 1 M,st

ln b ln b,0 n 1 M,st

W arctan

W
W

A Possible Solution:

1)

draw ()-diagram
pre shear point
shear points
collect c und i
draw MOHR-circle (through the point of origin and tangent to the yield locus)
collect c

2)

calculate the major principal stress 1:

An c cos i

3)

1 sin i

calculate the effective friction angle e:

e arcsin

4)

1 sin i c cos i
1 c cos i

calculate the minor principal stress 2:

2

5)

An sin i c cos i 2 2An cos 2 i

1 sine
1
1 sine

calculate the flow-function ffc:

ff c

1
c

6)

draw the diagram w(w) and collect w

7)

b(1): for all yield loci collect b and 1

flow characteristics of bulk materials

time yield locus t > 0
it

ct

ct

shear stress

effective
yield locus

stationary yield locus

yield locus t = 0
c

i
st e

W
2

wall yield locus

normal stress

JENIKE - Shear test

normal force FN
layer
shear ring

shear force FS

compressed bulk material

shear base

FS
in
N
shear

shear displacement s in mm

shear stress in kPa

shear force FS in N

pre shear (stationary flow)

A

i
n
kP
A

in kPa stress in kPa

normal

Tutorial: Powder Flow Properties

Revision:

a) What is the procedure to measure the flow properties of cohesive bulk materials?

b) What is the procedure to characterise the flow properties of cohesive bulk materials?

Exercise:
The flow classification numbers of a CaCO3-powder with d50 = 3 m, XW = 0.3 % and
s = 2600 kg/m have to collected. Table 1 and table 2 show the experimental results measuring by a JENIKE-shear-device. The following flow classification numbers are to find: (), R
(M), st, 0, ffc, W (W), W, C (1), e (1), i (1) und b (1).
Table 1: measured values of the current flow behaviour
yl-Nr.

An in kPa

An in kPa

Ab in kPa

Ab in kPa

b in kg/m

1.5

1.49

0.51

0.95

359

1.53

0.60

0.99

356

1.55

0.90

1.20

356

1.42

1.20

1.40

350

2.88

0.75

1.44

378

3.00

1.20

1.80

385

2.90

1.80

2.10

384

3.10

2.40

2.70

387

5.76

1.50

2.50

405

5.90

2.40

3.20

407

5.70

3.60

4.14

406

5.85

4.80

5.10

409

10.30

3.00

4.50

434

10.20

4.90

5.80

432

10.40

7.10

7.60

425

10.30

9.80

9.80

421

3.0

6.0

12.0

Table 2: measured values of the wall friction

W in kPa

15.10

12.30

9.50

5.40

2.60

1.40

W in kPa

7.12

5.89

4.47

2.59

1.25

0.66

7.11

5.89

4.46

2.61

1.27

0.65

Shear test analysis

Individual yield loci:

tan i c tan i Z

Uni-axial compressive strength:

c 2 c

1 sini

cosi

Major principal stress 1:

An c cos i

An sin i c cos i 2 2An cos 2 i

1 sin i

Effective friction angle:

e arcsin

Minor principal stress 2:

Stationary yield locus:

1 sin i c cos i
1 c cos i

1 sin e
1
1 sin e

Center stress

M,st 1 2

Radius stress

R,st 1 2

Stationary yield locus

Stationary friction angle:

R,st tan M,st 0

st arcsin tan
n

Bulk density:

Wall friction angle:

b b,0 1 M,st

ln b ln b,0 n 1 M,st
0

W arctan

W
W

Tutorial: Silo design

Revision

a) What are the problems on storage of bulk materials?

b) What is the difference between funnel and mass flow? What are the advantages and the
disadvantages?

Exercise:
For a CaCO3-Powder with d50 = 3 m, XW = 0.3 % and s= 2600 kg/m dimension
a mass flow silo with a conic outlet hopper,
a mass flow silo with a cuneiform outlet hopper,
a funnel flow silo
with the method of JENIKE (, bmin). The flow characteristics of this powder are acquired in
the last tutorial powder flow properties due to the results of shear tests and they are shown
in table 1.

Table 1: Flow characteristics of CaCO3-Powder

yl

ffc

kPa

kPa

kPa

grd

grd

kg / m3

3.4

0.3

2.2

1.5

55

34

355

7.4

1.0

3.5

2.1

49

36

384

15.0

2.3

5.4

2.8

48

38

407

25.2

4.0

8.5

3.0

47

38

428

The value of the wall friction angle is W = 25.

Boundaries between Mass and Core Flow

axisymmetric Flow
(conic hopper)

Boundaries between Mass and Core Flow

Plane Flow
(wedge-shaped hopper)

Ascertainment of Approximated Flow Factor

(wall friction angle W between 10 and 30)

Function G(i) to Design a Hopper for Core Flow

Tutorial: Silo design

Revision

a) What are the problems on storage of bulk materials?

b) What is the difference between funnel and mass flow? What are the advantages and the
disadvantages?

Exercise:
For a CaCO3-Powder with d50 = 3 m, XW = 0.3 % and s = 2600 kg/m dimension
a mass flow silo with a conic outlet hopper,
a mass flow silo with a cuneiform outlet hopper,
a funnel flow silo
with the method of JENIKE (, bmin). The flow characteristics of this powder are acquired in
the last tutorial powder flow properties due to the results of shear tests and they are shown
in table 1.

Table 1: Flow characteristics of CaCO3-Powder

yl

ffc

kPa

kPa

kPa

grd

grd

kg / m3

3.4

0.3

2.2

1.5

55

34

355

7.4

1.0

3.5

2.1

49

36

384

15.0

2.3

5.4

2.8

48

38

407

25.2

4.0

8.5

3.0

47

38

428

The value of the wall friction angle is W = 25.

Solution:
1. Draw the diagrams b(1). e(1). i(1). c(1).
(equation of the consolidation function: c = 0.28 1 + 1.29 kPa)

2. Design a mass flow silo with a conic outlet hopper

Approximation: at the outlet opening: 1 between 0 and 5 kPa
Presumption:

1 = 2.0 kPa e = 60

Measured:

w = 25.

From diagram:

= 19.

minus 2-3:

= 17. (safe distance)

from diagram:

ff = 1.26

1 = 1 /ff

draw 1 into c(1)- diagram.

point of intersection gives:
1 = 2.52 kPa (calculation dont have to repeat)
c.krit = 2.00 kPa.
b = 340 kg / m3
calculate bmin:
bmin

m 1 c,krit sin 2 w
b g
2 2.00 103 Pa sin 2 25 17
340kg / m3 9.81m / s 2

bmin = 1.19 m

3. Design a mass flow hopper with a cuneiform outlet hopper

Presumption:

1 = 2.0 kPa e = 60.

Measured:

w = 25.

From diagram:

= 27.

without safe distance

from diagram:

ff = 1.16.

1 = 1 /ff

draw 1 into c(1)- diagram.

point of intersection gives:
1 = 2.22 kPa (calculation dont have to repeat)
c.krit = 1.91 kPa.
b = 340 kg / m3
calculate bmin:
b min

m 1 c,krit sin 2 w
bg

1 1.91 103 Pa sin 2 25 27

340kg / m3 9.81m / s 2

bmin = 0.56 m
lmin = 3 b min
lmin = 1.68 m

4. Design a funnel flow hopper

characteristics for high pressures (high value of 1)

i = 38 ; e = 47

Ascertainment of
w < (90 - ) e + 15
25 < (90 - ) 47 + 15 = 62
28 < 65
chosen: = 30

ffp = 2

1 = 1 /ffp

1 sine
G i ;ff p 1.7
ff p
4 sine

draw 1 into c(1)- diagram.

point of intersection brings:
c.krit = 2.96 kPa.
1 = 5.92 kPa
b = 375 kg / m3
from diagram: G(i) = 3.4
calculate bmin:
b min

c ,krit G i
b g

2.96 103 Pa 3.4

375kg / m3 9.81m / s 2

bmin = 2.74 m

Boundaries between Mass and Core Flow

axisymmetric Flow
(conic hopper)

Boundaries between Mass and Core Flow

Plane Flow
(wedge-shaped hopper)

Ascertainment of Approximated Flow Factor

(wall friction angle W between 10 and 30)

Function G(i) to Design a Hopper for Core Flow

Lecture: Mechanical Process Engineering

Tutorial: Particle Movement in a Fluid
Exercise1:
Task:

Calculatethestationarysettingvelocityoftwolimestoneparticles(1mand40minsize)
a)forgravitationalaccelerationandb)forcentrifugalaccelerationz=200g.

Given:

d1=1m

g=9,81m/s

vs(d1,g)

vs(d1,z)

d2=40m

z=200g

vs(d2,g)

vs(d2,z)

s=2,65g/cm

Wanted:

f=0,998g/cm

f=1mPas

Exercise2:

Task:

Calculate the stationary setting velocity of the d50 particle size of a quartz product with a
RRSBparticlesizedistribution.(d63=0,35mm,n=1,55).

Given:

RRSBdistribution:
n=1,55

d63=0,35mm

Wanted:

vs(d50)

s=3,15g/cm
f=0,998g/cm

f=0,9mPas

LEHRSTUHL FR MECHANISCHE VERFAHRENSTECHNIK

Prof. Dr.-Ing. habil. Jrgen Tomas

1
Exercise 1:

The particle size distribution of a particulate material should be determined by analysing a test
sieving. The masses being on the single sieves (see picture) were determined by balancing [in
g]. The initial weight was 190 g.

sieve mesh [mm]

2.5

mass fraction [g]

1.33

1.0

15.34

0.63

13.44

0.4

36.56

0.25

40.34

0.1

64.02

0.063

10.79

0.04

5.31
2.27

1. Calculate the cumulative particle size distribution Q3(d) and the particle size frequency
distribution q3(d),
2. Show Q3(d) and q3(d) in a normal diagram, q3(d) in a log - normal diagram,
3. Determine the median particle size d50 from the graphical picture of Q3(d) and the modal
particle size dh from the graphical picture of q3(d),
4. Calculate mean particle size dm,3,
5. Show Q3(d) in a logarithmical probability diagram and in a RRSB - diagram,
6. Calculate the specific surface area, related to mass, As,m and the Sauter - diameter dST,
7. Calculate the cumulative particle size distribution Q0(d) and the particle size frequency
distribution q0(d), related to quantity number, show Q0(d) and q0(d) in a normal diagram
and in a logarithmical probability diagram.

Dr. Werner Hintz

2
Exercise sheet :

particle size

mass

mass fraction cumulative interval

fraction

fraction

width

frequency

mean

distribution

interval
diameter

di-1 - di

[mm]
1
2
3
4
5
6
7
8
9

Dr. Werner Hintz

mi

[g]

3,i

[%]

Q3,i

[%]

di

[mm]

q3,i

[% mm-1]

dm,i

[mm]

d m,i 3,i

3,i

100

d m,i 100

[mm]

[mm-1]

1 3 , i

d m3 ,i 100

[mm-3]

d
i =1

3, i
3
m ,i

Q0(d)

q0(d)

[-]

[mm-1]

100

[mm-3]

Task 2:
In many cases, at high temperatures exhaust fumes contain volatile heavy metals. These metals are adsorbed to flue dust particles, with the number of adsorbed heavy metal particles proportional to the surface of the flue dust particles.
We have a gas loaded with flue dust particles. There are approximately spherical flue dust particles with
a diameter d, whose particle size distribution Q3(d) is described by the following function (see illustration Fig. 1):

0
d d
min
Q3 (d ) =
d max d min

for

d < d min

for

d min d d max

for

d > d max

with

d min =

1 m

d max =

100 m

a)

Calculate the median particle diameter d50,3 and d50,2 out of the particle size distribution Q3(d) and
Q2(d). Hint: To calculate d50,2 you have to transform Q3(d) into Q2(d).

b)

Calculate the volume related specific surface area AS,V,K (in cm2/cm3) of the total particle population and of the partial particle population with d d50,3. Hint: You can start your calculation from
a generally valid computation formula in your script to calculate the volume related specific surface area AS,V,K.

c)

What percentage of heavy metal particles can be found in the particle fraction d d50,3, what in
the fraction d d50,3 ? Hint: Use the particle size distribution Q2(d) to calculate the surface area
related shares of the flue dust particle population.

Particle size distribution of dust particles

Particle size distribution Q3(d) in %

100

80

60

40

20

0
0

20

40

60

80

100

Particle diameter d in m

Figure 1: Particle size distribution Q3(d) of flue dust particles

120

Task 3:
Titania forms nano-scaled particles during a redispersion reaction in nitric acid, at a concentration of 0.1 mol/L,
and at a temperature 50 C. A sample of the suspension after a reaction time of 24 hours was taken out of the
vessel and analyzed by photon correlation spectroscopy (PCS). PCS gives a number based particle size distribution. Measurement data are given below, 0,i are the particle number fractions for each particle size fraction.
i particle size
[-]
fraction
[nm]

0,i

14.217.9

13.,4

17.922.5

36.2

22.528.4

34.3

28.435.7

13.7

35.745.0

2.3

45.056.6

0.1

[%]

a)

Calculate the cumulative particle size distributions Q0(d) and Q3(d).

b)

Calculate the mean particle diameter dm,3 (mass weighted particle diameter), as well as, the Sauter diameter dST (surface weighted particle diameter d32).

c)

Calculate the volume related specific surface area AS,V,K (in cm2/cm3) and the mass related specific surface area AS,m,K (in m2/kg) of the particle population. The solid particle density S is 3,600 kg/m3.

d)

Check graphically, if you can describe the particle size distribution Q0(d) and Q3(d) by a logarithmic normal Gauss distribution (LNVT). Determine from the graphic plot the median particle sizes ln,0 and ln,3.
Calculate the standard deviations ln,0 and ln,3, additionally .

Lecture: Mechanical Process Engineering

Seminar Separation Function
Exercise1:separationinascreeningmachine
Task:
Ascreeningmachinewithasievemeshof3millimeterswillbeimpingedby140tonsofallingravel
perhour.Themassflowrateofthecoarsefractionis84tonsperhour.Theparticlesizedistribution
has been identified by a sieve analysis. Table 1 shows the results of the analysis. On base of this
results,computetheseparationfunctionandtheseparationsharpness(selectivity).
Given:

Massflowrateofthefeed

mA

Massflowrateofthecoarseproduct

mG

140t/h

84t/h

Table1:resultsofthesieveanalysisofthecoarseandfineproducts

particlesizedin

massfraction(coarse)

massfraction(fine)

mm

G,iin%

F,iin%

<1

0,1

19,3

12

0,9

24,3

23

5,5

39,5

34

37,1

15,0

45

29,1

1,6

56

12,2

0,2

>6

15,1

0,1

(diameter)

Mechanical Process Engineering

Prof. Dr.-Ing. habil. Jrgen Tomas

Exercise 2: Separation in a hydro cyclone

Task:
A fine-grained quartz product has been separated in a hydro cyclone. (Rm,F =0,35). The particle size
distributions of the feed and the fine product have been determined by sieving analysis (see table 3).
Find the separation function.
Given:
Mass recovery of the fine product

R m,F

0,35

Table 3: Results of particle size distribution analysis

d
in m
< 20
20 - 40
40 - 63
63 - 80
80 - 100
100 - 125
125 - 150
> 150

A,i
in %
17,8
9,7
8,7
6,8
8,5
6,2
8,1
34,2

Wanted:
Separation function

Mechanical Process Engineering

Prof. Dr.-Ing. habil. Jrgen Tomas

Ti (di)

F,i
in %
35,8
21,5
20,8
12,8
7,8
0,9
0,4
0