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Experiment no. 7: Hydroclassifier
Table of Contents
Abstract: ........................................................................................................................................................ 0
Apparatus: ..................................................................................................................................................... 2
Related Theory:............................................................................................................................................. 2
Introduction:.............................................................................................................................................. 2
Principle of Classification: ........................................................................................................................ 2
Types of classifiers: .................................................................................................................................. 3
Construction of Hydrocyclone: ................................................................................................................. 7
Working: ................................................................................................................................................... 7
Performance indicators of Hydroclassifier: .............................................................................................. 8
Factors affecting performance indicators:............................................................................................ 8
Applications .................................................................................................................................................. 9
Limitations .................................................................................................................................................. 10
Specifications of laboratory Hydroclassifier: ............................................................................................. 10
Specifications of Industrial Hydroclassifier ................................................................................................ 10
Procedure .................................................................................................................................................... 10
Observations and Calculations:................................................................................................................... 11
Product size analysis: .............................................................................................................................. 11
Graphs ......................................................................................................................................................... 12
Discussions: ................................................................................................................................................. 12
Graph Discussion: ....................................................................................................................................... 13
Conclusion .................................................................................................................................................. 13
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Abstract:
This experiment was performed to study the various parts of laboratory hydroclassifier with
special emphasis on their function. Further a screening test was performed on the given sample
of feed. Eventually, performance of classifier was calculated by determining cut size and
sharpness of separation.
Apparatus:
Laboratory hydro classifier
Feed sample
Torsion / Electrical balance
Sieve Shaker
Set of Sieves
Related Theory:
Introduction:
Classification involves separating solid particles present in a mixture into fractions of product
depending upon their terminal velocities in air or water. It is a method of sizing which is
performed to achieve uniform particle size as the product from grinding operation is highly
invariable. For smaller feed sizes, classification technique is used instead of screening. This is
because as the feed size becomes smaller, screening becomes inefficient for less time; and if we
provide greater time that will increase the cost and decrease the capacity of machine. The
product obtained from classifiers is less than 1 mm in size. The wet classification results with
light particles rising to the surface while heavy particles sinking to the bottom.
Principle of Classification:
Principle of Classification is based on the sedimentation velocity of solid particles suspended in
water or air. As the density of particles may influence the settling, the process should be
designed in such a way that decreases the effect of density and increases the effect of size, for
example addition of impurities. Impurities will change the composition of particles that in turn,
change the density. As a result, size effect will increase. In classification, small particles are
removed as overflow and large particles tend to be in the underflow. The upward velocity of
water is set such that it is in between the terminal velocities of particles slightly larger and
slightly smaller than the desired cut size.
Free settling:
Free settling takes place when the individual particles fall freely in a still fluid medium without
any interaction with fellow particles. If percentage of particles in water is less than 15%, then
they will experience free settling. The industry follows a 12-15% limit.
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Hindered settling:
Hindered settling takes place when the individual particle experiences interactions with
neighboring particles (water molecules, group settling) while falling down. Due to this
hindrance, the settling speed reduces.
Types of classifiers:
Classifiers
Horizontal
Vertical Current
Current Hydrocyclone
Classifier
Classifier
Mechanical
Settling cones
Classifier
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Types:
1. Settling cones:
Working Principle:
Settling cones or a cone classifier consists of a conical chamber in which slurry-feed is
added through a centrally located inlet pipe. Initially the bottom discharge opening i.e.
spigot is closed. As the slurry reaches a certain height, the spigot is opened and the settled
particle are allowed to escape. The fine particles tend to move towards the periphery of
the chamber along with water and overflow into a filter.
Applications:
They can be used for the classification of medium and fine-grain materials which are later
separated by gravimetric means. They can also be used as dewatering equipment in
small-scale operations. Mining and aggregate industries often use them to de-slime coarse
sands outputs.
Main Disadvantages:
o Loss of fines
o Large walls inclination approx. >50 degrees
o Increased wall resistance
2. Mechanical classifiers
Mechanical classifiers consist of a settling tank and a mechanism to carry away the
settled particles from the bottom of the tank. A discharge system is installed to convey
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
the settled solids and the overflow falls into a launder and extracted. Classifiers can be
rectangular or circular shaped with bottom inclined at some certain angle. Commonly,
most of the classifiers are of circular shape. They have countless applications.
Sometimes, these are used in closed circuit grinding, for washing and dewatering
purposes. They are also used for the gravity concentration of metallic ores.
Types:
Spiral classifiers
Spiral classifiers are rectangular in shape. The feed is entered through an opening
about halfway along the height of the settling tank. The tank walls slope is in
between 14 and 18 degrees. The slope is adjusted in a way that the top end is
above the overflow barrier. The feed size for spiral classifiers is in the range of
150 µm and coarser. There are S and H type spiral classifiers depending upon the
height of the sides of the classifier. In case of higher sides, it is called H-type and
the lower sides classifier is called S-type.
Rake classifiers
In rake classifiers, spirals are replaced by rakes. These are not as much common
as the spiral classifiers. The construction of rakes includes single or multiple
parallel lines of steel plates, hanging from a central shaft or shafts. These plates
are fixed on these shafts and have a repetitive back-and-forth and up-and-down
movement. The plates stir the settling solids and draw the settled particles to the
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
top of the tank. At the end of each stir, the plates move upwards abruptly and then
sink back into the tank after an eccentric movement, returning to its initial
position. As this operation goes on repetitively, the settled solids are conveyed to
the top of tank and eventually discharged to the sands launder. The overflow
crosses a weir at the bottom of the tank and is sent for further processing.
3. Hydrocyclone
The hydrocyclone classifier makes use of centrifugal forces along with gravitational force
to achieve rapid settling and classification. It has no moving part and is the most easy-to-
operate classifier. A typical hydro-cyclone consists of a conically shaped vessel, open at
its apex, or underflow, joined to a cylindrical section, which has a tangential feed inlet.
The top of the cylindrical section is closed with a plate through which passes an axially
mounted overflow pipe. The pipe is extended into the body of the cyclone by a short,
removable section known as the vortex finder, which prevents short-circuiting of feed
directly into the overflow. It is mostly used for 5-200 µm size range.
Figure 6: Hydrocyclone
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Construction of Hydrocyclone:
A hydrocyclone consists of:
Feed entry pipe
Feed cylinder
Vortex finder
Cyclone cone
Apex or spigot
The feed cylinder, spigot, and the cyclone cone is lined from inside with rubber or other
synthetic linings to resist the wear from highly abrasive slurry feeds. Different lining materials
can be used. The most commonly used materials are hard rubber, neoprene, and urethane. In
some cases, the protective lining is sprayed inside forming a hard monolithic bond with the base
metal. The apex is sometimes fitted with a concentric, hardwearing synthetic rubber inner sleeve,
which can be squeezed hydraulically or pneumatically to alter the diameter of the opening.
Working:
The working principle of hydrocyclone is based on the use of centrifugal force and a cyclonic
flow pattern which promotes separation of solids from the slurry. The solid particles must have
large density difference with the medium in order to achieve separation. Under a particular
pressure, the feed is entered radially into a cylindrical chamber of hydrocyclone, forming a
vortex. The bottom of the cylindrical chamber is axial and does not let the whole liquid escape
through it. Thus some of the liquid is forced to reverse its path which then flows anti-parallel
towards the overflow outlet. This reverse flow goes on to circle and an air core is formed at the
axis of rotation due to pressure drop. This centrifugal motion pushes heavier particles outward
and downward along the conical chamber wall. As the diameter of cone becomes smaller down
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
the way, the speed of water increases and so the separation. At last, the denser and large particles
which are concentrated are discharged through the spigot.
sharpness of separation/separation efficiency will not reduce significantly when the inlet size will
increase.
Similarly, cut size increases with increase in vortex finder diameter. Vortex finder diameter is
always lesser than apex diameter.
The increase in apex diameter increases the capacity but it will reduce the cut size. At the same
time, separation efficiency will increase. Usually, the apex diameter is variable in hydrocyclones.
Generally, the inlet diameter is 0.15-0.25 times of the cylinder diameter.
The vortex finder diameter is 0.30-0.45 times of the cylinder diameter.
The apex diameter is 0.25-0.35 times of the cylinder diameter.
Length or angle of cone
The angle of cone varies from 10.5 to 20 degrees depending upon the type of separation. The
lesser the angle, longer the cone and finer the particles. This means that cut size decreases on
increasing the angle, and separation efficiency increase. Increase in cone angle increases the air
core diameter and resultantly decreases the volume of underflow for a fixed apex diameter.
Operating Parameters:
Solids percentage:
Keeping all other operating parameters constant, a higher feed concentration will result in a
larger cut size, lower sharpness of separation, and a higher drop in pressure. High feed solids
concentration causes hindered setting, higher concentration of solids in the underflow and
enhances the capacity.
Feed Pressure:
If the feed pressure is below the aimed pressure, a coarser cut size than desired will be obtained.
On the other hand, if the pressure is higher than desired, more fines will become a part of
underflow. That means cut size will decrease. Therefore, it is important to keep the pressure
constant in order to keep d50 constant.
Applications
Wastewater treatment
Starch Industry: To refine starch
Potato Processing Industry: to separate starch from cutting water in French fries and
chips
For separation of gypsol from cottonseed protein in cottonseed oil processing
To separate oil from water
Sand separation and classification
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Limitations
Process only very small sized particles
Efficiency reduces when the flow is below capacity
It's difficult to separate compounds with comparable densities.
Cannot deal with a viscous flow.
Abrasive wear is caused at extremely high velocities.
Cannot produce entirely dry underflow.
In reverse flow cyclones, clogging of the dust outflow is typical.
Procedure
Identify each part of the machine and find out its function.
Take a feed sample and perform sieve analysis by using the sieve set.
After measuring the weights retained on each sieve, mix the sample properly.
Close the spigot valve at the bottom of the hydroclassifier and the fill the tank with water
by opening the valve of water supply connected to the hydroclassifier.
When the tank is filled, open the spigot valve and adjust it to maintain a uniform flowrate
at overflow and underflow ends.
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Put collection lauders beneath the overflow and underflow tanks for collection of test
products.
Pour the mixed sample at an appropriate uniform feed rate from the feed end at the center
position of the classifier.
Collect the underflow and overflow products into the launders and kept them there until
all the solid particles settle down at the bottom.
Decant the clear water from each launder very slowly so that no solid particle may go
away from the launder.
Collect dewatered overflow and underflow products in separate trays and dry them in
oven at 110° C.
Use sieves of same aperture size as that of screens for feed and perform sieve analysis on
each product separately.
Lastly, plot a graph between distribution coefficient and aperture size and determine the
cut size and performance of classifier.
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Graphs
Plot between Distribution coefficient % and aperture size:
120
100
distribution coefficient %
80
60 real
corrected
40
20
0
0 0.2 0.4 0.6 0.8 1 1.2
aperture size (mm)
Discussions:
The experiment helped us understand the functioning of a hydrocyclone. We grasped its
operational conditions and later experimented to find its performance.
In mineral industry, the classification operation by hydrocyclones are carried out under wet
conditions. Dry classification is seldom performed. On entering feed chamber, the slurry feed
gets divided inside the feed cylinder and the conical section as a result of the inlet feed pressure
and the swirling action. The denser particles start settling quickly under the action of gravity and
centrifugal forces. The less denser and light particles remain at the center of axis of cyclone and
escape through overflow. However, some of the heavier and light particles do get trapped in the
opposite streams and escape.
The hydroclassifier has no moving part. Its operation depends upon.
1. Feed stream characteristics
2. Cyclone geometry
The feed stream characteristics include:
1. Size and size distribution of solids in the feed slurry
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Particle Technology Lab Report
University of Engineering and Technology, Lahore
Experiment no. 7: Hydroclassifier
Graph Discussion:
The graph plotted between aperture size and distribution coefficient is known as the performance
curve. The blue curve shows the actual values. The curve demonstrates that the cyclone cut size
is 0.26 mm. A similar curve for the overflow can also be drawn that will look exactly like this
curve. It is noted that this curve does not pass through the origin. This means that a fraction of
slurry bypassed the cyclone without classification. Thus the cut size for this curve needed
correction. The red curve shows the corrected values. The actual cut size was 0.26 mm. After
correction, it became 0.4 mm. This graph can help us find out a lot of other properties like
imperfection, partition error and sharpness index. Sharpness index has already been calculated
above and it turned out to be 0.36.
To calculate imperfection (corrected),
d75 – d25/2d50 = 0.66-0.24/ 2(0.4) = 0.52
To calculate 75% partition error (corrected),
d75/d50 = 0.66/0.4 = 1.65
Conclusion
Hydrocyclone is quite efficient machine for the classification of fine particles. It is beneficial for the
wastewater treatment, dewatering and desliming purposes. Our laboratory hydrocyclone has a cut size
of 0.4mm and its sharpness of separation is 0.36.
References
[1] D. Y. Ashok Gupta, Mineral Processing Design and Operations, Elsevier.
[2] J. A. F. Barry A. Wills, Will's Mineral Processing: An introduction to the Practical Aspects of Ore
Treatment and Mineral Recovery, Elsevier.
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Particle Technology Lab Report
University of Engineering and Technology, Lahore