.

Particle
Technology Laboratory
Manual
Submitted By:
Fatima Saleem (2020-CH-202)
Submitted By: Khan (2020-CH-203)
Abeeha Asif
Ahmad Hassan
Laaiba Khan Qureshi
Khurrum (2020-CH-219)
(2020-
Muhammad
CH-205) Hassan Bashir (2020-CH-243)
Muhammad Junaid
Kashaf Imran (2020-CH-249)
(2020-CH-209)
Submitted To:
Mam Azqa Khalid
Contents
Experiment No. 1:..............................................................................................................5
Objective:.......................................................................................................................5
Apparatus:.....................................................................................................................5
Theory:........................................................................................................................... 5
Procedure:...................................................................................................................... 6
Observations and Calculations:...................................................................................6
Discussion:.....................................................................................................................6
Conclusion:....................................................................................................................6
Experiment #2:..................................................................................................................7
Objective:.......................................................................................................................7
Apparatus and material required:...............................................................................7
Theory:........................................................................................................................... 7
Procedure:...................................................................................................................... 7
Observation & Calculations:........................................................................................8
Discussion:.....................................................................................................................8
Conclusion:....................................................................................................................8
Experiment # 3:.................................................................................................................9
Objective:.......................................................................................................................9
Apparatus and Required Material:.............................................................................9
Theory:........................................................................................................................... 9
Procedure:....................................................................................................................12
Observations & Calculations:.....................................................................................12
Graphs:........................................................................................................................13
Discussion:...................................................................................................................14
Conclusion:..................................................................................................................14
Experiment # 4:...............................................................................................................14
Objective:.....................................................................................................................14
Apparatus and material required:.............................................................................14
Theory:......................................................................................................................... 14
Procedure:....................................................................................................................15
 Observation & Calculation:........................................................................................15
Graphs:........................................................................................................................16
Discussion:...................................................................................................................17
Conclusion:..................................................................................................................17
Experiment # 05............................................................................................................... 17
Objective:.....................................................................................................................17
Apparatus and material required:.............................................................................17
Procedure:....................................................................................................................17
Theory:......................................................................................................................... 17
Observation & Calculation:........................................................................................18
Graph:.......................................................................................................................... 19
Discussion:...................................................................................................................19
Conclusion:..................................................................................................................19
Experiment #06................................................................................................................20
Objective:.....................................................................................................................20
Apparatus and material required:.............................................................................20
Theory:......................................................................................................................... 20
Features:....................................................................................................................... 21
Procedure:....................................................................................................................21
Observation and calculation:......................................................................................21
Graphs:........................................................................................................................22
Discussion:...................................................................................................................22
Conclusion:..................................................................................................................23
Experiment # 07............................................................................................................... 23
Objective:.....................................................................................................................23
Apparatus and material required:.............................................................................23
Theory:......................................................................................................................... 23
Procedure:....................................................................................................................23
Observation and calculation:......................................................................................24
Graphs:........................................................................................................................24
Discussion:...................................................................................................................25
 Conclusion:..................................................................................................................25
Experiment #08:..............................................................................................................26
Mixing of different solid particles..............................................................................26
Objective:.....................................................................................................................26
Equipment and material required:............................................................................26
Theory:......................................................................................................................... 26
Application:.................................................................................................................28
Procedure:....................................................................................................................28
Observation and Calculation:.....................................................................................28
Result and discussion:.................................................................................................28
Suggestions:.................................................................................................................28
Experiment # 09............................................................................................................... 29
Objective:.....................................................................................................................29
Equipment and material required:............................................................................29
Theory:......................................................................................................................... 29
Procedure:....................................................................................................................30
Observation and calculations:....................................................................................30
Discussion:...................................................................................................................30
Conclusion:..................................................................................................................30
Experiment # 10:.............................................................................................................31
Objective:.....................................................................................................................31
Equipment and material required:............................................................................31
Theory:......................................................................................................................... 31
Working:......................................................................................................................31
Application:.................................................................................................................32
Procedure:....................................................................................................................33
Observation and calculations:....................................................................................33
Result and discussion:.................................................................................................33
Conclusions:................................................................................................................. 33
Figure 1 Angle of Repose....................................................................................................5
Figure 2 Apparatus for Sieve Analysis................................................................................9
Figure 3 Sieve Apparatus..................................................................................................10
Figure 4 Horizontal Analysis Sieve...................................................................................10
Figure 5 Vertical sieve Analysis........................................................................................11
Figure 6 Motion in Sieve Analysis....................................................................................11
Figure 7 Differential Analysis Graph................................................................................13
Figure 8 Jaw Crusher.........................................................................................................15
Figure 9 Differential analysis of Jaw Crusher...................................................................16
Figure 10 Cumulative analysis of Jaw Crusher.................................................................16
Figure 11 Ball Mill............................................................................................................18
Figure 12 Graph of Ball Mill.............................................................................................19
Figure 13 Double Roller Crushers.....................................................................................20
Figure 14 Differential Analysis.........................................................................................22
Figure 15 Cumulative Analysis.........................................................................................22
Figure 16 Differential Analysis.........................................................................................24
Figure 17 Cumulative Analysis.........................................................................................25
Figure 18 V Blender..........................................................................................................26
Figure 19 Solid Mixing Through V Blender.....................................................................27
Figure 20 Flow Pattern......................................................................................................29
Figure 21 Cyclone Separate...............................................................................................31
Figure 22 Working Principle.............................................................................................32
 Experiment No. 1:

To determine Angle of Repose of solid Panicles.

Objective:

The purpose of angle of repose is to find the maximum steepest angle up to

which the materials can be piled up without slumping.

Apparatus:

1. Rotatory cylinder
2. Rice grains
Theory:

The angle of repose, or critical angle of repose of a granular material is the

steepest angle of descent or dip relative to the horizontal plane to which a material can be piled
without slumping. At this angle, the material on the slope face is on the verge of sliding. The
angle of repose can range from 0° to 90°.
Factors affecting:
The morphology of the material affects the angle of repose; smooth, rounded sand
grains cannot be piled as steeply as can rough, interlocking sands. When bulk granular
materials are poured onto a horizontal surface, a conical pile will form. The internal angle
between the surface of the pile and the horizontal surface is known as the angle of repose and is
related to the density, surface area and shapes of the particles, and the coefficient of friction of
the material. Material with a low angle of repose forms flatter piles than material with a high
angle of repose.
 Range:
Angle of repose ranges between 00 and90 0. [ CITATION PAe \l 1033 ]

  Figure 1 Angle of Repose

Angle of repose (°) Flow ability
25–30 Very free flowing
30–38 Free flowing
38–45 Fair flowing
45–55 Cohesive
>55 Very cohesive

Procedure:

l. Take the sample of rice grains in the rotary cylinder until it is half filled and
make the sample parallel to the horizontal.
2. Then rotate the cylinder in the clockwise direction and note the angle the
sample makes with that scale on the cylinder.
3. Repeat the experiment in the anti-clockwise direction.
4. Calculate the angle of repose f rice grains by taking the mean of both the
angles.[ CITATION DMu21 \l 1033 ]

Observations and Calculations:

Angle measured∈clockwise direction( A)=52°

Angle measured∈anti−clockwise direction(B)=80°
A+B 80° 132°
(
Angle of repose of rice grains C=
2 )
=52 °+
2
=
2
=66 °
Discussion:

Angle of repose experiments are a common means to characterize the

granular behavior of a material and investigate particles and material properties.

Conclusion:

From the experiment, the angle of repose for different materials is

measured to determine the flow of each material. Smaller angle indicates a good flow
property compare to large angle. Smaller particles have a large angle of repose due to the
cohesiveness. This cohesively causes a poor flow.

Experiment #2:
To calculate Actual an Apparent Density of solid materials

Objective:

1. Calculate the apparent density of the given solid.

2. Calculate the actual density of the given sample solid.
3. Then checking if there is any difference between the two densities due to space.

Apparatus and material required:

 Sand sample
 Water
 1000ml graduated cylinder
 Weighting balance

Theory:

 Actual Density:
“It is the fraction of mass per unit volume of the sample and it does not considers the volume
of pores in the material.”
 Apparent Density:
“It tells the relationship between the mass and volume of the material and it includes the
volume of the pores and water.”
Methods of determining the densities of material:
(A) Water soluble materials:
If the object is, it dissolves in water and place a measuring cylinder
containing the object on the vibrating filter of the filter material.
(B) Water insoluble materials:
If the substance does not dissolve in water than a measuring cylinder
containing an object full of water that binds it, then we measure the volume of the object in
the cylinder.
Procedure:

1. First weight the given sample of the solid.

2. After that place the sample in the measuring cylinder and determine the volume of the
sample, which it occupied without compacting.
3. Then calculate the apparent density of the material by using formula. mass of particles.
Mass of particle
Apparent density =  = Volume of particle without compacting

4. To calculate the real density of material, determine the nature of compound whether it is
water soluble or not
5. If the material is, water-soluble put the measuring cylinder containing material over the
vibratory sieve shaker the material.
6. Again, note the volume of material and determine the real density by using formula. Mass
of particles.
Mass of particle
Real density =  = Volume of particle without compacting

7. If the substance is not water soluble then the placed the material in the measuring cylinder
and pour water in it, water compacted the material and then again note the volume of
material in the cylinder and calculate the real density by using above formula.
8. In the end calculate the crushing ratio of material by given formula:
Apparent density
Crushing ratio = 
Real density
Observation & Calculations:

Mass of given sample=m=300 g

Volume of given sample of material before compacting=V 1=220ml
Volume of given sample of material before compacting=V 2=210 ml
m g
Apparent density of material=ρ A = =1.36
v1 ml
m g
Real density of material=ρ R= =1.43
v2 ml
 ρA
Crushing ratio=∅= =0.95
ρR
Discussion:

To test for differences in actual and apparent sanding, we used a water

method and a measuring cylinder as the sand did not dissolve in the water so that the water
could easily fill in the gaps between the fine sand particles. The sand absorbs water quickly
without flowing as water seeps into the sand quickly.
Conclusion:

This test was performed to assess the difference between the two densities
due to the apparent density of the sand to be approximately 1.36g / ml whereas the actual
density is from 1.43 g / ml. The addition of water filled the gaps in the sand particles by
increasing the density of the sand. For sand, the crushing rate of visible and actual density is
0.95.

Experiment # 3:
Sieve Analysis for a sample of solid Panicles

Objective:

 To study particle size distribution and analysis

 To separate particles of different sizes and calculating weight of different size particles
in the whole sample.

Apparatus and Required Material:

 Vibratory Sieve
 A set of 7 sieves
 Weighing Balance
 Brick particles as solid particles sample
Theory:

Sieve analysis is an analytical method in which distribution of particles occur due to

their difference in sizes with the help of granulated sieves that continuously move by
mechanical force either vertical or horizontal until the process completes.

Figure 2 Apparatus for Sieve Analysis

Methods of Sieve Analysis:

(1). Vibratory Sieve Analysis:

Vibratory method is a traditional method of sieve analysis. The
force of gravity acting on them distributes particles. The continuous back and forth vibration
of sieves cause spreading of particles uniformly and the particles move vertically downward.
This method is mostly used for particles having spherical shape.

Figure 3 Sieve Apparatus

(2). Horizontal Sieve Analysis:
In this method instead of moving vertically sieves move
horizontally in a plane to aid particles distribution. Horizontal sieve analysis is mostly used
for particles having needle like shape , flat , long or fibrous form.

Figure 4 Horizontal Analysis Sieve

(3). Tap Sieve Analysis:

In tap sieve analysis circular and horizontal motion is normally less than
vertical motion that is produced due to tapping motion of sieves. Their efficiency is less than
vibratory sieve analysis as it requires more time for particles distribution.

Figure 5 Vertical sieve Analysis

 (4). Air Jet Sieving:
It is a single sieve containing method in which sieve itself does not
move. A rotating jet of air move the sieve , a vacuum is present to aid air to move towards
sieve for sieving process. Fine particles are transported through mesh opening to vacuum
cleaner.

Figure 6 Motion in Sieve Analysis

Factors Affecting Sieving:

Process of sieving depends upon:
 The type of particles
 The number of particles
 The size of particles
Advantages of Sieving:
 It is easily operatable, as it does not require much skill.
 It is a very cheap method, as we do not need the installation of
expensive equipment.
 It requires less time as compared to traditional methods.

Disadvantages of Sieving:
 Its working is dependent on particles size and type so it cannot be used to
separate a mixture of particles of same sizes such as flour and chalk powder.
 It is impossible to use it for sieving emulsions and cohesive materials such as
clay.
 Procedure:

 Measure 1kg of feed sample i.e. coarsed particles of bricks with the help of
weight balance.
 Arrange all the 7 sieves according to their mesh sizes in order of sieve of larger
mesh number to sieve of smaller mesh number.
 Now put all the feed in first sieve and then lock the sieves so that no feed is
wasted during vibration.
 Start the vibratory shaker by providing electricity to it and set the time to
4minutes.
 After 4 minutes take out all sieves and weight the amount of feed in different
sieves having different mesh sizes.

Observations & Calculations:

Total feed input=0.998kg

Time of sieving=4 min
Mass retained after sieving=0.964kg
Sieve Screen Mass % mass Average Mass Cumulative Cumulative
No opening retained retained particle fraction Wt. % Wt. %
diameter in screen Size retained undersize Oversize
(mm) (mm)
Do M M% DAVG MAVG WUND WOVR
3 0.2 0.374 38.79 0.03879 0.0846 61.21 38.79
4 0.187 0.078 8.09 0.0809 0.0362 53.12 46.88
7 0.111 0.116 12.03 0.1203 0.0564 41.09 58.71
8 0.0937 0.078 8.09 0.0809 0.1008 33 67
10 0.0787 0.064 6.64 0.0664 0.1653 26.36 73.44
14 0.0555 0.016 1.66 0.0166 0.0524 24.7 75.3
Pan 0 0.238 24.7 0.247 0.5040 0 100
Total 0.964

Graphs:

Differential analysis
Davg ∧M avg
 Cumulative graph

Combined graph between

D0 and Wund
D0 and Wovr

Discussion:

Sieve analysis of coarsed bricks particles was done using a vibratory sieve
analyzer as 7 sieves of different mesh sizes was used so 7 different sized feeds are obtained.
Vibratory back and forth motion of analyzer caused the particles to move vertically
downward due to force of gravity.
Conclusion:

Separation of different sizes of bricks coarsed feed is done through sieving and
graph is plotted to see percentages of each sizes. The mass that retained after sieving id
0.964kg. We may apply it in the field of engineering most especially in construction of
structures like buildings, roads and bridges.

Experiment # 4:
To reduce the size of primary feed using Jaw Crusher.

Objective:

For increment in surface area of feed material by crushing coarser

feed into intermediate and fine particles.
Apparatus and material required:

1. Jaw Crusher
2. Weighing balance
3. Bricks
4. Hammer
5. Trays
6. Stack of sieves

Theory:

Jaw crusher:
“A jaw crusher  is a machine designed to reduce large rocks  into smaller rocks, gravel, and
sand or rock dust.”
Design of Jaw crusher:
Jaw crushers are designed with an intricate mechanical network of moving
hardened high carbon steel overlaid on a heavy block and fastened with bolts. Many types of
Jaw crushers exist in the current market differing largely by component assembly, area of
application (size), and model of design (operation). The principal operation of the device
hinges around compression breakage exerted by a movable Jaw plate against a stationary Jaw
plate.[ CITATION 1s2 \l 1033 ]
 Figure 8 Jaw Crusher

Efficiency of operation:
It is with clarity that the efficiency of operation during comminution activity thus
depends on energy dissipation at each stage. However, study have suggested that only 10%
of input power is utilized to diminish the particles to size of interest while a great percentage
is dispersed as heat and noise and for ineffective deformation of the material being processed
together with elastic strains absorbed by the device[ CITATION DLe14 \l 1033 ].
Procedure:

1. Firstly, take 6kg of bricks for crushing as feed

2. Then reduce the size of bricks to some extent by hammering.
3. After it switch ON the crusher and then note the time before putting the bricks into
the crusher.
4. Then, add the feed sample simultaneously.
5. After crushing process, we noted the time again required for crushing.
6. The crushed material containing the different sizes are collected in a tray.
7. After it take the product for sieve analysis and we will get the different size particles
separated. [ CITATION MJo17 \l 1033 \m MJo17]

Observation & Calculation:

Total feed input=1.028 kg

Coarser Particles=3.6 kg
Before Screen Analysis=1.6 kg
Sieve Screen Mass % mass Average Mass Cumulative Cumulative
No opening retained retained particle fraction Wt. % Wt. %
diameter in screen Size retained undersize Oversize
(mm) (mm)
5 4000 412 50 0 0.5 50 50
7 2839 72 8.2 3419.5 0.082 58.2 41.8
10 2000 66 8 2419.5 0.080 66.2 33
14 1410 56 6.7 1705 0.067 72.9 26.33
18 1000 44 1205 0.053 78.1 21
25 710 16 1.9 855 0.019 79.0 19.1
Pan 0 16 19.1 355 0.191 98.1 0
Total 824 100 1

Graphs:

Differential analysis
Davg ∧M avg

Figure 9 Differential analysis of Jaw Crusher

Cumulative graph between

 Combined graph between
o Do ∧W und
o Do ∧W ovr

Discussion:

The particles are very coarser but most of the particles were crushed
Figure 10 Cumulative analysis of Jaw Crusher before
sieve
analysis. The intersection point gave the value of about 50% product passing from sieve.
Conclusion:

The experiment was done to reduce the size of given material and after that sieve analysis
phenomenon was done. The product is actually due to jaws fixed in the crusher. The ratio of
size reduction is 0.934.
Experiment # 05
Size reduction of material using Ball Mill
Objective:

To reduce the size of solid material to fine and ultrafine (dust particles).
Apparatus and material required:


Ball mill

Balls

Vibratory
shaker and a
set of sieves

Collecting
tray
  Solid for a study

Procedure:

 Measure the inside

diameter of the ball
mill.
 Measure the size of
the ball with the help
of Vernier caliper.
 Fill the ball mill to half of its volume with balls.
 Before turn on the mill, set speed regulators to maximum.
 Measure the speed of rotation of the ball mill in the revolutions per minute.
 Analyze the product with the help of screen and note the particle diameter.
 Calculate the revolution per minute.

Theory:

Definition:
“Ball milling is a grinding method that grinds nanotubes into extremely fine powders”.
[ CITATION PIG20 \l 1033 ]

Figure 11 Ball Mill

Factors affecting grinding media:

Grinding media size, density, hardness, and texture.
 Size: The smaller the media particles, the smaller the particle size of the final product. The
particles of the grinding media should be much larger than the larger pieces of material to
be processed.
 Overcrowding: The media should be crowded rather than crushed. It becomes a problem
when the digestion media floats over the things that need to be considered.
 Sturdy: Milling sources need to be strong enough to grind material, but, where possible,
not too hard to age.
  Composition: Various grinding applications have special requirements. Some of these
requirements are based on some of the grinding media in the finished
product[ CITATION Xie15 \l 1033 ]
Benefits of ball mill:
 Cost of installation and grinding medium is low.
 Suitable for each batch and continuous operation.
 Ready to grind open and electric circuit.
 Applies to items of all levels of difficulty.

Observation & Calculation:

Diameter of ball mill=30.05 cm

Weight of feed=0.900 kg
Revolution∈1 minute=46
Revolution∈10 minutes=460
Weight of underize=1.94 kg
Sr. # Sieve No Mass Mesh Diameter % mass
Number mm Retained

1 5 0.214 0.157 4 11.0.3

2 7 0.084 0.111 2.839 4.33
3 10 0.110 0.0878 2 5.67
4 14 0.96 0.0555 1.410 49.48
5 18 0.088 0.0394 1 4.54
6 25 0.484 0.028 0.71 24.94
Graph:

Figure 12 Graph of Ball Mill

Discussion:

In Ball mill, the rate of particle size reduction depends on the mass fraction. If the
mass fraction increases then the rate of particle size reduction decreases, it only increase by
increasing the number of rotation or time.
Conclusion:

The experiment was done to reduce the size of given material and after that
sieve analysis was also done. The product is actually due to the ball present in ball mill which
reduce the size ratio of material. The ratio of size reduction is 3.46.
 Experiment #06
Objective:

Size reduction analysis using double roll crusher

Apparatus and material required:

 Double roll crusher

 Sample feed
 Sieves
 Weighing balance

Theory:

Definition:
"Double-Roll- Crushers are a
solid medium- sized crushing
machine as well as adhesive and
soft materials." [ CITATION
SWa21 \l 1033 ]

Figure 13 Double Roller Crushers

Working Principle:
The motor drives double roll crusher through the pulley or gear shaft opposite two rollers
rotate, or were driven by two motors rotate two rollers. Double roll crusher with material by
weight and the friction between the roll surface into the crusher and discharge within the
broken. Through changes in two double roll crusher roller bearing pads between the number, or
the use of worm gear to adjust the mechanical adjustment between the two rollers the force
generated to maintain the discharge opening gap, so that double-roll crusher even granularity.
Double roll crusher spring is the insurance unit. When a hard material or transport of bulk
materials fall into the crushing chamber cannot be crushed, the Roll of the force increases. The
movable bearing compression spring can leave the movable Roll, increasing the gap, two roll
to discharge a hard object, and then by the spring restoring force to the movable roll back to
the original position. Double roll crusher movable Roll can be used to replace the broken
boards. [ CITATION PHi09 \l 1033 ].

Factors affecting double roll crusher:

Following are the factors that affect the double roll crushers:
 Material to be crushed
 Feed size
 Product size
 Reduction rate
 Capacity
 Compressive strength
 Moisture content [ CITATION VBu08 \l 1033 ]

Features:

• Compact structure
• low noise and efficient;
• Easy to install and only need simple foundation;
• Can adjust the pressure and size easily.
• Self-protection, the parts cannot be damaged when hard materials such as the metals
goes into the crushing cavity.
• Low cost maintenance and easy to maintain.
Procedure:

 Take 1 kg of feed sample i.e. coarse particles of bricks and feed it into the crusher.
 Note the time of crushing and the feed is continuously fed into the double roll crusher.
 When all the feed is crush then stop the stopwatch and measure the time. Then collet all
the fine and ultra-fine particles.
 Then passes the fine particles and ultra-fine particles to the sieve analysis procedure and
note the readings.
 Observation and calculation:

Total feed input=0.998 kg

Time ¿ crush=27 sec
Mass after crushing=0.972kg
Sieve Screen Mass % mass Average Mass Cumulative Cumulative
No opening retained retained particle fraction Wt. % Wt. %
diameter in screen Size retained undersize Oversize
(mm) (mm)
Do M M% DAVG MAVG WUND WOVR
3 0.2 0.374 38.79 0.03879 0.0846 61.21 38.79
4 0.187 0.078 8.09 0.0809 0.0362 53.12 46.88
7 0.111 0.116 12.03 0.1203 0.0564 41.09 58.71
8 0.0937 0.078 8.09 0.0809 0.1008 33 67
10 0.0787 0.064 6.64 0.0664 0.1653 26.36 73.44
14 0.0555 0.016 1.66 0.0166 0.0524 24.7 75.3
Pan 0 0.238 24.7 0.247 0.5040 0 100
Total 0.964
Graphs:

Differential analysis
Davg ∧M avg

Figure 14 Differential Analysis

Cumulative graph between

Combined graph between
o Do ∧W und
o Do ∧W ovr
 Discussion:

Maintenance particles are enormous in size after passing through the crusher roll,
converted into very small particles. Reducing the particle size is related to the strength of the
crusher roll. When the particles have a round shape holding on to them becomes very
difficult. Feed size should between 13mm to 9mm and crushed particles in ¼ size.
Conclusion:

This test was performed to reduce the size of the sample provided by the crushing
using a Double Roll Crusher and then sieve analysis. The feed is actually a jaw crusher
product, which is the main crusher. Reduction rate is approximately 27 seconds.
Figure 15 Cumulative Analysis

Experiment # 07
Size reduction analysis using pebble mill
Objective:

It is used for the reduction of size particles from intermediate to fine particles.
Apparatus and material required:

 Pebble mill
 Stack of sieves
 Coal as a feed
 Weighting
balance

Theory:

Definition:
“A rotating cylinder in
which usually
hard rounded
stones or flint
pebbles grind
ceramic materials
to extreme fineness”.

[ CITATION Lov19 \l 1033 ]

Difference between Ball Mill and Pebble mill:
Pebble mills and stone mills can be considered ball mills, the basic
difference being that the average length and width are large. The shell length is usually
 between 2 and 5 inches. These mills are used to grind various materials into 100 mesh and to
refine them. The Tube Mill uses steel or steel balls as a grinding method, as well as various
metal lines and alloys.[ CITATION MGi17 \l 1033 ]
Factors affecting grinding:
The grinding in the pebble mill is influenced by:

 Residence time

 Size, density and number of balls

 Quality of balls

Procedure:

 Take 1 kg of coal sample and fed into pebble mill.

 Fill the 1/4th volume of mill with feed and note the time before turning on the mill.
 Then we set timer for half hour for milling process.
 After half an hour, machine should be turned off and the material is taken out.
 After taken out the material from mill, do sieve analysis.

Observation and calculation:

Total feed input=200 g

Weight after milling=196 g
Sieve No Screen Mass % mass Mass Cumulative Cumulative
opening retained in retained fraction Wt. % Wt. %
diameter screen retained undersize Oversize
(mm)
Do M M% MAVG WUND WOVR
5 0.157 0.096 49.79 0.497 52.32 49.74
7 0.111 0.004 2.07 0.0207 50.25 51.81
10 0.0787 0.004 2.07 0.0207 48.18 53.88
14 0.0555 0.004 2.07 0.0207 46.11 55.95
18 0.0394 0.004 1.036 0.01036 45.074 56.986
25 0.028 0.002 1.554 0.0155 43.52 58.54
Pan 0 0.003 43.52 0.435 0 102.06
Total 0.193
Graphs:

Differential analysis
Davg ∧M avg

Figure 16 Differential Analysis

Cumulative graph between

Combined graph between
o Do ∧W und
o Do ∧W ovr

Figure 17 Cumulative Analysis

 Discussion:

The particles were of intermediate size so the longer residence time of low energy
pebble produce fine particle. The intersection point gave the value of about 50% product
passing from sieve.
Conclusion:

This experiment was done to reduce the size of coarse particles into fine one and
after that sieve analysis phenomenon was also done. The product obtained is due to the balls
present in pebble mill whose size reduction ratio is 4.0.

Experiment #08:
Mixing of different solid particles

Objective:

1. To check if different solid particles on mixing form a homogenous solution or not.

2. To check the rate of blending of solid particles with respect to time.
Equipment and material required:

 V- Blender
 Solid Particles ( 100 g sand )
 Brick powder ( 100 g )
Theory:

In industrial process engineering, mixing is a unit operation that involves

manipulation of a heterogeneous physical system with the intent to make it more
homogeneous. Familiar examples include pumping of the water in a swimming pool to
homogenize the water temperature, and the stirring of pancake batter to eliminate lumps (DE
agglomeration).
 Mixing is performed to allow heat and/or mass transfer to occur between one or
more streams, components or phases. Modern industrial processing almost always involves
some form of mixing. Some classes of chemical reactors are also mixers.
With the right equipment, it is possible to mix a solid, liquid or gas into another solid, liquid or
gas.

Figure 18 V Blender

Mixing Classification:
The type of operation and equipment used during mixing depends on the
state of materials being mixed (liquid, semi-solid, or solid) and the miscibility of the materials
being processed. In this context, the act of mixing may be synonymous with stirring-, or
kneading-processes.

Solid – Solid
mixing:
Blending
powders is
one of the
oldest unit-
operations
in the solids
handling
industries.
For many
decades
powder
blending
has been used just to homogenize bulk materials. Many different machines have been
designed to handle materials with various bulk solids properties. Based on the practical
experience gained with these different machines, engineering knowledge has been
 developed to construct reliable equipment and to predict scale-up and mixing behavior.
Nowadays the same mixing technologies are used for many more applications: to
improve product quality, to coat particles, to fuse materials, to wet, to disperse in liquid,
to agglomerate, to alter functional material properties, etc. This wide range of
applications of mixing equipment requires a high level of knowledge, long time
experience and extended test facilities to come to the optimal selection of equipment
and processes.

Figure 19 Solid Mixing Through V Blender

Solid-solid mixing can be

performed either in batch mixers,
which is the simpler form of
mixing, or in certain cases in
continuous dry- mix, more
complex but which provide
interesting advantages in
[3]
terms of segregation, capacity and validation. One example of a solid–solid mixing process is
mulling foundry molding sand, where sand, bentonite clay, fine coal dust and water are mixed
to a plastic, moldable and reusable mass, applied for molding and pouring molten metal to
obtain sand castings that are metallic parts for automobile, machine building, construction or
other industries. [ CITATION Mix21 \l 1033 ]

1. Liquid – liquid mixing

2. Gas – Gas mixing
3. Liquid – solid mixing
4. Gas – solid mixing

5. Liquid – Gas mixing

 Application:

Mixing is widely used in industry such as,

1. Feed.
2. Paint.
3. Metals.
4. Minerals.
5. Plastics.
6. Pharmaceutical.
7. Chemical.
8. Food

Procedure:

 First, take sample of brick powder, sand each 100 g, and put it into blender.
 Switch on the blender and mix it for 3 minutes
 Then take out the sample and check if the homogenous mixture is reached or not.
 Repeat the procedure for 5 and 7 minute for mixing.
Observation and Calculation:

• Weight of sand = 100 g

• Volume of sand = 70 ml
• Weight of brick powder = 100 g
• Volume of brick powder = 75 ml
• After mixing Volume = 137 ml
Discussion:

The difference between the given volume and mixed volume

is 8 ml.
Conclusions:

If we give the mixing more time the mixture would be more homogenous and
velocity of blender will also affect the extent of homogenous mixing.
 Experiment # 09
Objective:

To study the flow pattern of a given sample of solid particles through cylinders of
different diameters.
Equipment and material required:

1. Cylinder
2. Sand
3. Cylinder Stand

Theory:

Flow pattern :
“Flow pattern is basically the pattern of the solid particles from beginning point to the end
point , where it is converted to the final product.”

Figure 20 Flow Pattern

Flow rate:
The flow pattern of solids passing through different diameters depends upon the flow rate .
Relation between diameter and time of flow:
The relation of diameter and time of flow is inversely related. The more the diameter of the
cylinder the less it takes the time to flow and vice versa .
Characteristics of mass flow:
 Density of flow is constant
 No dead zones are formed
 Flow is uniform
 FIFO

Funnel flow:
 Occurs when some material in a bin moves while the rest remains stationary. The walls of the
hopper section are not steep enough or smooth enough to force the material to flow along them.
[ CITATION htt8 \l 1033 ]
Procedure:

 Take a sample of the sand, put it in first cylinder from the top, and lid it.
 Now fill the remaining cylinders with the same volume.
 Now from the first cylinder when the lid is removed then start the stopwatch.
 Now the material will start falling and then observe the flow pattern of the sand
particles.
 Repeat the experiment for other different cylinders and note the time of flow.
 Remember to fill all the cylinders with material equally.

Observation and calculations:

• Length of cylinder (filling material): 14 cm

No.of Diameter Flow Comment
observation of opening rate
s
01. 5cm 4s,5ms Largest
diameter
02. 4cm 4s,50ms Large
diameter
03. 3cm 6s,85ms Small
diameter
04. 2cm 18s,5ms Smallest
diameter

Discussion:

The flow of solids in a cylinder is linear and when the lid is open, the solid flow
through different diameters and we obtain our product in the bucket. There may be a product
loss if the material is sticky of flow out of the bucket. Therefore, to reduce the product loss
take the solid in powder form but granular so that there is no contamination.
Conclusion:

As a result, the material flowing through larger diameter of cylinder consumes less
time and vice versa.
 Experiment # 10:

Objective:

To study the operation cyclone separator.

Equipment and material required:

• Electricity supply:1 phase 220V AC,1kW

• Floor area 2m*1m
• Material for feed(coal)
• Weighing balance
Theory:

Cyclone separators or simply Cyclones are

separation devices (dry scrubbers) that use the
principle of inertia to remove particulate matter
from flue gases. Cyclone separators is one of
many air pollution control devices known as
pre-cleaners since they generally remove larger
pieces of particulate matter.

Figure 21 Cyclone Separate

 Working:

Cyclone separators work much like a centrifuge, but with a continuous feed of dirty air. In a
cyclone separator, dirty flue gas is fed into a chamber. The inside of the chamber creates a spiral
vortex, similar to a tornado. This spiral formation and the separation. The lighter components of this
gas have less inertia, so it is easier for them to be influenced by the vortex and travel up it.
Contrarily, larger components of particulate matter have more inertia and are not as easily
influenced by the vortex.

Components of cyclone separator:

Cyclones are centrifugal separators, consists of an upper cylindrical part referred to as
the barrel and a lower conical part referred to as cone. They simply transform the inertia force of
gas particle flows to a centrifugal force by means of a vortex generated in the cyclone body.
Effectiveness:
Cyclone separators are generally able to remove somewhere between 50-99% of all
particulate matter in flue gas. How well the 22
Figure cyclone
Working separators
Principle are actually able to remove this
matter depends largely on particle size. If there is a large amount of lighter particulate matter,
less of these par0ticles can be separated out. Because of this, cyclone separators work best on
flue gases that contain large amounts of big particulate matter.
There are several advantages and disadvantages in using cyclone separators. First, cyclone
separators are beneficial because they are not expensive to install or maintain, and they have no
moving parts. This keeps maintenance and operating costs low. Second, the removed
particulate matter is collected when dry, which makes it easier to dispose of. Finally, these
units take up very little space. Although effective, there are also disadvantages in using cyclone
separators. Mainly because the standard models are not able to collect particulate matter that is
smaller than 10 micrometers effectively and the machines are unable to handle sticky or tacky
materials well.[ CITATION htt9 \l 1033 ]
Application:

Applications vary depending on the fluid from which particles are removed. For
example,
• A hydro cyclone is used for liquid
• A gas cyclone for gas
• A dust or air cyclone separator is used for air fluid streams.

Procedure:

 Prepare feedstock of coal with constant average particle size .Size 50,40,20,10,8,6,4, and
2micro meter .Prepare about 200gms each.
 Run the cyclone with pure air at fixed speed by adjusting the blower value.
 Now feed the dust particle of one particle size (say 50 micrometer) 200gms at a constant
rate.
 Collect the solid at the solid outlet of the cyclone.
 Measure the weight of the particle collected at the bottom of the cyclone.
 Calculate the collection efficiency.
 Repeat steps 4 to 7 for all sizes of solid particles.
Change the air inlet velocity and repeat step 3 to 7 for a particulate solid.

Observation and calculations:

Weight of coal=98g
After separating the weight of the coal = 78g
So,
78
Efficiency= × 100
93
Efficiency=83.8%
 Discussion:

The efficiency of the cyclone separator is 83.8%.

Conclusions:

Due to dust environment of lab/industry is harmed or the pollution is occurred so if

we put a pipeline on the top of the separator to outside of the lab/industry we can controlled the
environment of the lab and industry.

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