Unit 1 - Screening

Lola Domnina B. Pestaño

ChE 512
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Lecture Objectives

At the end of this topic you are expected to:

• distinguish the different principles of solids-solids

separation as found in Chap 21/Perry’s Handbook;
• identify a suitable solids-solids separation
technology based on the characteristic of the
solids to be separated;

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Lecture Objectives Separation

At the end of this topic you are expected to: • 2 Classes of separation
– Diffusional operation
• identify solid sizes based on the differential and • Involves transfer between phases
cumulative screen analyses; and
– Mechanical separations - Important in
• compute for the effectiveness and capacity of a chemical manufacture
single screening process and multiple screening
processes.

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 Diffusional Separation Process Extraction

Separation of liquids by density and solubility.

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Chromatography Filtration

Separation by inner molecular attractions separation of solids from fluids (liquids or

gases) by interposing a medium through
which only the fluid can pass.

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Distillation Mechanical Separation

• Techniques used for the separation of

heterogeneous mixtures
• Based on the physical differences
between the particles such as the size,
shape or density.
• Can be applied for separating solids
from solids, solids from liquids and
solids from gases.

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 Mechanical Separation Mechanical Separation - Screening

Separation by particle size

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What is Screening? Applications

• mining and mineral processing

• Separation of mixture of particles of
• agriculture
various sizes into two or more fractions
• pharmaceutical
by a screening surface.
• food
• Screening is a method of separating
• plastics
particles according to size alone.
• recycling
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Screening Surface

• Interwoven Wire Mesh (carbon or

stainless steel, phosphor bronze)

• Cloth (silk, plastic, nylon, fiberglass)

• Perforated Plates

• Bars
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 Particle Size Particle Size

Dp – equivalent diameter of the Non-Equidimensional particles –particles

particle. that are longer in one direction than in
others, are often characterised by the
For Equidimensional particles: second longest major dimension
• In general "diameter“, Dp • Dp is the second
may be specified from geometry longest major dimension
• Dp is the diameter of a
sphere whose volume is
equal to that of the particle

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What is Dp Particle Size

Units of Dp depend on the size of particles

• Coarse particles: inches or millimeters

(c)
(a) (b) • Fine particles: screen size

• Very fine particles: micrometers or

nanometers
(e)
(d) • Ultra fine particles: surface area per unit
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Modern Particle Size Measurement

• using mechanical, aerodynamic, or hydrodynamic properties to identify
shape factor
• Laser Diffraction method
o the particle is allowed to settle in a viscous fluid, – Laser diffraction is currently the fastest method for particle sizing at
o then the calculated diameter of a sphere of the same substance that would have the
highest reproducibility. In combination with dry dispersion it can handle
same falling speed in the same fluid (i.e., the Stokes diameter) is taken as the large amounts of sample, which makes this method well suited for process
appropriate size parameter of the particle. applications.
o Since the Stokes diameter for the rod-shaped particle will obviously differ from the rod – It is now ranging from below 0.1 µm to about 1 cm.
diameter, this difference represents added information concerning particle shape.
o The ratio of the diameters measured by two different techniques is called the shape
factor.
• today methods based on the interaction of the particles with
electromagnetic waves (mainly light), ultrasound, or electric fields
dominate.

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 Image Analysis Methods • SEM for clay
• Scanning Electron Microscopy

• The extreme progress in image capturing and exceptional increase of the

computational power within the last few years have revolutionized microscopic
methods and made image analysis methods very popular for the characterization
of particles, especially since, in addition to size, relevant shape information
becomes available by the method. Currently, mainly instruments creating a 2D
image of the 3D particles are used. Two methods have to be distinguished.

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Separation Theory
• Nanoparticles
nm Feed
• Using dynamic
image analysis Oversize(Tails)

Undersize(Fines)
Screen

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Terminologies Terminologies
• Unsized function
• Undersize
A single screen can make a single separation into
Fines, passes through the screen openings. two fractions i.e. undersize and oversize. Such
• Oversize type of function is known as unsized function.
Tails, do not pass. • Sized function
When the material is passed through the series of
screens then it is divided into many fractions.
Such type of function is known as sized function.

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 Particle Size: Mesh Particle Size: Mesh
• Mesh • Examples:
Hole of the screen is called the Mesh. Mesh 4 Mesh 50
• Mesh Number
1” 1”
It is defined as the number of holes per linear
inch.
1” 1”

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Particle Size: Mesh

• Aperture of screen
maximum clear space between the edges of
the screen opening. It is usually given in in. or
mm.
• A 3-mesh screen has
3 openings per inch and the
aperture is 1/3” minus the
diameter of the wire.
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Sieve Scale
• A sieve scale is a series of testing sieves
having openings in a fixed succession
(Largest opening to smallest)
• 3 Types:
– Tyler Standard Sieve Series (App. 5 MSH)
– US Sieve Series (Table 19-6/HB)
– International Test Sieve Series

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 Tyler Std Screen Scale (App. 5 MSH)
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Arrangement of Mesh Screens Unsized Function

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Methods of Indicating Particle Size for Methods of Indicating Particle Size for
mixtures of particles mixtures of particles

 Unsized Particles
 Oversize 4 Mesh, +4, +4.76 mm
 Undersize 4 Mesh, -4, -4.76 mm

 Sized Particles
 Through 4 on 6
 -4+6
 4/6
 -4.76 mm + 3.36 mm
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 Methods of Indicating Particle Size for Methods of Indicating Particle Size for
mixtures of particles mixtures of particles

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Screening Equipment Particle Size Distribution(PSD)

• Differential Screen Analysis: Data consist of

• Grizzly Screens Mesh No., n vs Wt frac or % retained on the
• Rotating Screens screen (n)
• Shaking Screens • Cumulative Screen Analysis (larger than
• Vibrating Screens Dp): Data consist of n vs Cumulative
• Oscillating Screens fraction larger than n (n)
• Cumulative Screen Analysis (smaller than
Dp): Data consist of n vs Cumulative
fraction smaller than n (1-n)
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Screen Analysis Screen Analysis

Differential Screen Analysis Cumulative PSD
50 kg 50 kg Larger than Dp
n n n n
5 kg 5 kg
Mesh 6 6 Mesh 6 6
20 kg 8 20 kg 8
Mesh 8 Mesh 8
10 10
Mesh 10
12 kg Mesh 10
12 kg
14 14
Mesh 14
6 kg Mesh 14
6 kg
20 20
3 kg 4 kg pan 3 kg 4 kg
Mesh 20 Mesh 20 pan

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 Screen Analysis
Cumulative PSD
50 kg Smaller than Dp

5 kg n 1- n
Mesh 6 6
20 kg 8
Mesh 8

12 kg 10
Mesh 10
14
Mesh 14
6 kg
20
3 kg Mesh 20
4 kg pan

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Material Balance Material Balance

Let F, R and P be the • Overall Material Balance
Feed mass flow rates of the Feed
R, xR F, xF Feed, Overflow and F, xF
Underflow resp.; and
F=P+R R, xR
Oversize Oversize
xF, xR and xP be the
mass fraction of the • Material Balance
oversize material in the
Undersize Undersize
3 streams. FxF = PxP+ RxR Screen
P, xP P, xP
Screen 1-xF, 1-xR and 1-xP are
the mass fractions of xP , xF , xR = fraction of the oversize material in the 3 streams.
the undersize material Note: All PxP , FxF and RxR did not pass through the mesh due
in the 3 streams. to BLINDED MESH. UST Chemical Engineering
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Blinded Screen Low Efficency of Screens

Actual screens do not give perfect separations.
1. Closest separations are obtained with spherical
particles on standard testing screens.
2. Needle-like or fibrous or where the particle tend to
aggregate into clusters that act as large particles that
act as large particles.
3. Long, thin particles may strike the screen surface
endwise and pass through easily.
4. Other particles of the same size and shape may strike
the screen sideways and be retained.
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 Blinded Screen Blinded Screen
Particle Shapes Particle Shapes

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Screen Effectiveness(E)/Screen
Cont. . .
Efficiency
• Overflow to Feed Ratio
R xP  xF A measure of success of the
 completeness of the separation is
F xP  xR
the screen effectiveness.
• Underflow to Feed Ratio

P xF  xR

F xP  xR

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Screen Effectiveness(E) Example No.1

EA = Recovery of desired material in the product It is desired to remove small particles from a
Px (x  x R )x P crushed stone mixture by screening through a 10-
 P  F
Fx F (x P  x R )x F mesh screen. The screen analysis of feed, overflow
EB = Recovery of undesired material in the reject and underflow are given in the table.
R (1  x R ) ( x  x F )(1  x R ) a) Calculate the mass ratios of the overflow and
  P underflow to feed.
F(1  x F ) ( x P  x R )(1  x F )
b) Plot Dp vs Screen analysis for the feed,
E=EAEB  Px P R (1  x R ) overflow and underflow
Fx F F(1  x F )
c) Find the effectiveness of the screen
( x  x F )(1  x R ) ( x F  x R ) x P
E P
( x P  x R )(1  x F ) ( x P  x R ) x F
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 Screen Analysis
Screen Analysis xF=.47 xP=.85 xR=.195
Mesh Dp Feed Overflow Underflow
Mesh Dp (mm) Feed Overflow Underflow
4 4.699 0 0
4 4.699 0 0
6 3.327 0.025 0.071 6 3.327 0.025 0.071
8 2.362 0.125 0.43 1 8 2.362 0.125 0.43 1
10 1.651 0.32 0.85 0.805
10 1.651 0.32 0.85 0.805
14 1.168 0.26 0.97 0.42
20 0.833 0.155 0.99 0.17 14 1.168 0.26 0.97 0.42
28 0.589 0.055 1.0 0.09 20 0.833 0.155 0.99 0.17
35 0.417 0.02 0.06 28 0.589 0.055 1 0.09
65 0.208 0.02 0.025
Pan 0.02 0
35 0.417 0.02 0.06
65 0.208 0.02 0.025
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Pan 0.02 0 62
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Solution Collaborative Work

Same problem, but use a 20 Mesh Screen
From the table, xF=0.47, xP=0.85, xR=0.195 instead.
P xF  xR What is the Effectiveness of the 20 Mesh Screen.
 = 0.42
F xP  xR Why is the 20 Mesh Screen an Effective/not
R xP  xF P
Effective Screen?
  1 = 0.58
F x P  xR F
( x P  x F )(1  x R ) ( x F  x R ) x P
E E = 0.669
( x P  x R )(1  x F ) ( x P  x R ) x F

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Example 2
It is desired to separate 1000 kg of a mixture of
crushed solids into three fractions, a coarse
fraction retained on a 20 mesh screen; a middle
fraction passing through a 20 mesh screen and
retained on a 65 mesh screen; and a fine fraction
passing through a 65 mesh screen. Two Tyler
Standard Screens are used to remove particles
20/65. Screen analysis of the feed, coarse, medium
and fine fractions are given. What are the
Effectiveness of the 20 and 65 screens, given the
following screen analysis.
Example 2
It is desired to separate 1000 kg of a mixture of
crushed solids into three fractions, a coarse
fraction retained on a 20 mesh screen; a middle
fraction passing through a 20 mesh screen and
retained on a 65 mesh screen; and a fine fraction
passing through a 65 mesh screen. Two Tyler
Standard Screens are used to remove particles
20/65. Screen analysis of the feed, coarse, medium
and fine fractions are given. What are the
Effectiveness of the 20 and 65 screens, given the
following screen analysis.

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 Screen Analysis (Ex2) Solution (Ex2)
Mesh F %Feed P %P R %M Q %Fine F=1000 kg
-4+6 2.51 3.26 0.50 0.00
-6+8 12.5 13.59 11.27 0.00
-8+10 32.07 38.04 18.03 1.66 P
-10+14 25.7 27.17 22.53 16.63
-14+20 15.9 16.30 13.52 21.38
-20+28 5.38 1.36 18.03 9.03
-28+35 2.1 0.27 8.11 2.38
-35+48 1.02 0.00 4.51 0.48 Undesired 20
-48+65 0.77 0.00 3.42 0.24
-65+100 0.58 0.00 0.09 13.30
-100+150 0.41 0.00 0.00 9.74
R
-150+200 0.31 0.00 0.00 7.36
pan 0.75 0.00 0.00 17.81
100 100 100.00 100.00 65
Q
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Screen Analysis (Ex2) Solution (Ex2)

Mesh F %Feed P %P R %M Q %Fine F=1000 kg
-4+6 2.51 3.26 0.50 0.00 Let Subscript F1 =
-6+8 12.5 13.59 11.27 0.00
1 : +20 P1 =
-8+10 F1 32.07 P1 38.04 R 1 18.03 Q 1 1.66
F2 = P P2 =
-10+14 25.7 27.17 22.53 16.63 2: -20+65 F3 =
-14+20 15.9 16.30 13.52 21.38
3: -65 P3 =
-20+28 5.38 1.36 18.03 9.03
-28+35 2.1 0.27 8.11 2.38
-35+48 F2 1.02 P2 0.00 R 2 4.51 Q 2 0.48 20
-48+65 0.77 0.00 3.42 0.24
-65+100 0.58 0.00 0.09 13.30
R R1 =
-100+150
F3
0.41
P3
0.00
R
0.00
Q
9.74
Q1 = R2 =
-150+200 0.31 0.00 3 0.00 3 7.36
pan 0.75 0.00 0.00 17.81 Q2 = R3 =
100 100 100.00 100.00 65
Q3 =
Q
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Effectiveness (E20) Effectiveness (E20)

F1 =886.8 F1 =886.8
F2 =92.7 P1 = 724 F2 =92.7 P1 = 724
F3 =20.5 P2 = 12 F3 =20.5 P2 = 12
S1 = 162.8 P3 = 0 S1 = 162.8 P3 = 0
S2 = 80.7 S2 = 80.7
S3 = 20.5 20 S3 = 20.5 20
R1 = 146.1 +20 Desired (Subscript 1)
R2 = 75.6
Q1 =16.7 -20+65 Undesired (Subscript 2&3)
R3 = 0.2
Q2 = 5.1 65
Q3 = 20.3

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 Effectiveness Effectiveness (E65)
F1 =886.8
F2 =92.7 P1 = 724
F3 =20.5 P2 = 12
S1 = 162.8 P3 = 0
S2 = 80.7
S3 = 20.5 20
R1 = 146.1
R2 = 75.6
Q1 =16.7 R3 = 0.2
Q2 = 5.1 65
Q3 = 20.3

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Effectiveness (E65) Effectiveness

-20+65 Undesired (Subscript 1&2) 65

S1 = 162.8 -65 Desired (Subscript 3)

S2 = 80.7
S3 = 20.5
R1 = 146.1
R2 = 75.6
Q1 =16.7 R3 = 0.2
Q2 = 5.1 65
Q3 = 20.3

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Seatwork Find:
Dpmean
Mesh %Feed %P %M %Fine a) Effectiveness Rotary Trommel Screen
-4+6 4.013 2.51 3.26 0.50 0.00 of Mesh 35 and
-6+8 2.8445 12.5 13.59 11.27 0.00 100 if the
-8+10 2.0065 32.07 38.04 18.03 1.66 product
-10+14 1.4095 25.7 27.17 22.53 16.63 desired is the A trommel screen, also known as a rotary screen, is
-14+20 1.0005 15.9 16.30 13.52 21.38 middle fraction a mechanical screening machine used to separate
-20+28 0.711 5.38 1.36 18.03 9.03 b) Analysis of materials, mainly in the mineral and solid-waste
-28+35 0.503 2.1 0.27 8.11 2.38 particles in the processing industries. It consists of a perforated
-35+48 0.356 1.02 0.00 4.51 0.48 pan cylindrical drum that is normally elevated at an angle at
-48+65 0.2515 0.77 0.00 3.42 0.24 c) Volume mean the feed end. Physical size separation is achieved as the
-65+100 0.1775 0.58 0.00 0.09 13.30 diameter of feed material spirals down the rotating drum, where the
-100+150 0.1255 0.41 0.00 0.00 9.74 feed undersized material smaller than the screen apertures
-150+200 0.089 0.31 0.00 0.00 7.36 d) Specific passes through the screen, while the oversized
pan 0.75 0.00 0.00 17.81 surface area of material exits at the other end of the drum.
100.0 the feed
100 100 0 100.00
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Rotary Trommel Screen Rotary Trommel Screen

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End.

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