Experiment

AIM - To study the effect of froth flotation in the recovery of given sample from
the solution.

APPARATUS:-Froth flotation cell, collection beakers.

THEORY:-

Separation of a mixture of solids using froth flotation method depends on difference in surface
properties of materials involved. If the mixture is suspended in an aerated liquid, the gas bubbles
will allow to adhere the particles of the material which is not wetted by the liquid ( or difficult to
get wetted by the liquid ) and its effective density reduce to such an extent that it will be held at
the surface until they are discharged over the weir.

Froth flotation is widely used in metallurgical industries where generally the ore is generally
difficult to wet and the residual earth readily wetted. The main difficulty is to produce the forth
of sufficient stability to retain the particles of the desired constituent on the surface so that they
can be discharged over the overflow weir. Pine oil is used as frothing agent and produces stable
froth.

OBSERVATION:-

Weight of the sample (brick) taken = gm

MO Lab 22-23
PROCEDURE:- Weight about 10-15 gm of brick powder and feed it to the flotation cell. Add
sufficient quantity of water in cell and stir it well. Add a few drops of frothing agent (pine oil).
Stir this mixture for at least 10 minutes. Switch on the air compressor and allow compressed air
to pass through the mixture to generate the bubbles. Collect the forth produced in collection
beaker from the overflow air until no forth is coming out from the flotation cell. Switch off the
air compressor and stirrer. Allow the collected forth to get dried and weight it. Tabulate the
observations and calculate the percentage recovery. Repeat the experiment taking same amount
of sample nut different amount of frothing agent to study the effect on % recovery

CALCULATION:

MO Lab 22-23
 CYCLONE SEPERATOR
INTRODUCTION:-

Centrifugal separating devices consist of cyclone separators, rotational flow dust precipitators,
and mechanical centrifugal separators, the cyclones being most widely used. The smallest
particle size removable is about 5 µm, although smaller sizes as low as 0.1µm have been
separated in case where particle agglomeration takes place.

The cyclone separator is uniquely conceived so that the solid particles are separated from gases
under centrifugal flow path conditions to produce much greater separation forces than obtained
by gravitation methods. The flow path is patterned so that gases and solids are discharged
separately and with no appreciable entrainment.

Probably the most conspicuous property of centrifugal flow is the velocity distribution as
examines radially across the flow. If the wall boundary, where the velocity is zero is omitted, the
effect of viscous shear in the fluid will tend to give higher velocities near the inside of a
centrifugal path. In fluid mechanics this is called irrotational condition of flow and is a two
dimensional conditions. It may also be described as quasi representation of flow. This radial flow
distribution may be represented, as expression that states the tangential component of velocity
will vary in inverse as the radial distance. In a qualitative description, the cyclone may be said to
be produce favorable separation force, of its particle paths are of relatively short distance, and
the inner walls of the cylindrical and conical sections also provides impingement area. Here, as
when many small diameters baffles are used in preference to fewer larger units, the use of more
cyclones in parallel arrangement at the same pressure drop will give better efficiency of particle
removal for a given flow. This is reasonable, since an increase in the number of cyclones results
in separation at smaller radial distances in the centrifugal flows produces, and shorter particle
travel distances, before impingement on the inner walls of the cyclones. The entering gas at the
rectangular inlet first enters an annular space, tangentially to the wall of cylindrical section at the
top, and is also bounded inside the centrifugal path by the outside theoretical gas outlet pipe,
which is concentric with the cylinder. Although the inlet gas flow after entrance is only bounded
on the sides and top, and is free to pass downwards (which is does, following a spiral path on the

MO Lab 22-23
outer diameter similar to the upward directed center vortex), it is of some value to note possible
gross velocity changes of flow according to the approximate cross-section area represented. It
should be noted that inner and outer spiral paths of flow have the same sense of rotation and that
inner flow of the clean gas enters the outlet gas pipe below the lowest level of the rectangular
inlet. The rectangular inlet provides the lowest cross-section area of flow. In the downward
direction, the annular spaces is times the area, and the gas outlets, presumably even at some
lower static pressure, has only half the area for upward flow. The exact boundary condition
between the slow rotating outer vortex and fast rotating inner vortex, moving in their downward
and upward direction respectively, do not tend to contaminant the outgoing gases, since the inner
vortex rotation is reported to pass, to some extent, the residual small particles back into the outer
vortex, resulting in final entrainment of some very small solids.

DESCRIPTION:-

Proportional dimensions are shown in the figure.

MO Lab 22-23
The following statements summarize the essentials mechanical characteristics of cyclones;

conical
sections is possible. Slanted installations are also possible.

discharge
outlet in a typical case.

d concentric with top cylindrical section starting below the

rectangular inlet where dust-laden gas enters, partially separating the two vortexes flows of gas
downward and upward.

intermittently
removed.

Preventions are necessary in the prevention of air into the cyclone and leakage of dust and gas
out of the cyclone; either will reduce collection efficiency. For intermittent withdrawal of dust,
an airtight receiver is used; for continuous, a star valve or special types of locking gate valves are
used.

Fans are usually required with cyclones and may be placed to handle the dust-laden gas or the
cleaned gas from either upstream or downstream installations.

MO Lab 22-23
 SEDIMENTATION

AIM:- To study and carry out batch sedimentation tests to use the results to design a thickener.

PRINCIPLE:-

The separation of a suspension in to a supernatant clear liquid and a rather liquid containing a
logger concentration of solids is called sedimentation. Sedimentation is carried out as a
continuous process in thickener, which receives the sustentation at center or the vessel, permit
the overflow of the clear liquid, at the top and produce sludge at the bottom. The capacity of a
continuous thickener is determine by the fact that the solids initially present in the feed must be
able to settle through all zones of slurry concentration viz. The clarification zone, the settling
zone, the upper compression zone and the compression zone at the rate at which they are
introduced. If the area of cross-section of the thickener is not sufficient, the solids will build up
from the bottom, and be present in the overflow. The setting rate and the solids concentration in
the minimum capacity can be calculated on the basis of kynch theory. These can be determined
Type equation here.by the analysis of single batch setting test dates.

PROCEDURE:-

Prepare slurry of the desired initial concentration in a measuring jar.

Stir the whole mass well so that concentration is uniform throughout the jar.

Stop stirring and allow the solids to settle. Record the height of interface as a function of time.

Tabulate the data. Calculate the settling velocity (V) by drawing tangent to the curve obtained by
plotting height of the interface against time and measuring their topes.

MO Lab 22-23
Conclusion -

MO Lab 22-23
 JAW CRUSHER

AIM:- To study and determine the Rittinger’s Constant, Bond’s Constant, kick’s Constant and
Work Index.

APPARATUS:- Jaw Crusher, Sieve shaker, Sieves, Weighing Balance, Weighing balance.

THEORY:-

The crusher has a fixed jaw and a moving jaw pivoted at the top with the crushing faces
themselves formed of manganese steel. Science the maximum movement of the jaw is at the
bottom, there will be little tendency for the machine to clog, through uncrushed material may fall
through and have to be returned to the crusher. Further, the maximum pressure will be exerted on
the large material which is introduced at the top the machine is usually protected so that it is not
damaged if lumps of metal invariantly enter, by making one of the toggle plates in the driving
mechanism relatively weak so that, if any large stresses are set up, this is the first part of fail.
Easy renewal of the damaged part is then possible. Jaw crushers are made with jaw widths
varying from about 150 mm to 1.0 m and the running speed is about 240 rpm, the smaller
machines running at the higher speeds. The speed of operation should not so high that a large
quantity of fines is produced as a result of material being repeatedly crushed because it cannot
escape sufficiently quickly. The angle of nip, the angle between the jaws, is usually about
300.Because the action is intermittent, the loading on the machine is uneven and the crusher
therefore incorporates heavy flywheel. The power requirement of the crusher depends on the size
of the capacity.

Points to be Observed:-
1. Feed mass (F)
2. Crushing time (t)
3. Energy consumed during the crushing time (E)
4. Particle Density (ρP)
5. Shape Factor (λ)
6. Energy Consumption for Empty Run
7. Energy Consumption for Crushing period

MO Lab 22-23
8. Actual energy used for crushing of Material

Two tables to be studied

1. Before Crushing and After Crushing

Conclusion -

MO Lab 22-23
 BALL MILL
AIM:- To determine Critical index, Work Index, Bond’s Law, Rittinger’s Law and Kick’s Law
for Ball mill.
APPARATUS:- Ball mill, sieve, sieve shaker, weighing balance, and weight box.
THEORY:- In its simplest form, the Ball Mill consists of a rotating hollow cylinder, partially,
filled with its axis either horizontal or a small angel to be ground may be fed in through a hollow
trunion at one end the product leaves through a trunion at the other end for continuous type
operation. The outlet is normally covered with a coarse, screen to prevent the escape of the balls.
The inner surface of the cylinder is usually lined with an abrasion – resistant material such
manganese steel, stoneware or rubber. Less wear takes place in rubber – lined mills, and the
coefficient friction between the balls and the cylinder is greater than with steel or stoneware
lining. The balls are therefore carried further in contact with the cylinder and thus drop on the fed
from a greater height. In some cases, lifter bars are fitted to the inside of the cylinder. A new type
of ball mill is now being used to a increasing extent, where the mill is vibrated instead of being
rotated, and the rate of passage material is controlled by the slope of the mill. The ball mill is
used for the grinding of a wide range of materials, including coal, pigments, and feldspar for
pottery, and will take feed up to about 50mm in size. The efficiency of grinding increasing with
the hold – up in the mill, until the voids between the balls are filled. Further increase in the
quantity then lowers the efficiency again. The balls are usually made of flint steel and occupy
between 30 and 50 percent of the volume of the mill. The diameter of ball used will vary
between 13mm and 125mm and the optimum diameter is approximately proportional to the
square root of the size of feed, the proportionality constant being a function of the nature of the
material. During grinding, the balls themselves wear and are constantly replaced by new one so
that the mill contains ball of various ages, and hence of various sizes. This is advantageous since
the large balls deal effectively with the feed and the small ones are responsible for giving a fine
product. The maximum rate of wear of steel balls, using very abrasive materials, is about
0.3kg/mg of material for dry grinding and 1- 1.5 kg/mg for wet grinding. The normal change of
balls amounts to about 5 mg/m3. In small mills where very fine grinding is required, pebbles are
often used in place of balls. In the compound mill, the cylinder is divided into a number of
compartments by vertical perforated plates. The material flows axially along the mill and can
pass from one compartment to the next only when its size has been reduced to less than that of

MO Lab 22-23
the perforations in the plate. Each compartment is supplied with balls of a different size; the
large balls are at the entry and end, thus operate on the feed material, whilst the small balls come
into contact with the material immediately before it is discharged. This results in economical
operation and the formation of a uniform product. It also gives an improved residence time
distribution for the material, since a single ball mill approximates closely to a completely mixed
system.

PROCEDURE:-
Sieve analyzes the feed.
Take measurements of the cylindrical shell and the metallic balls.
Take known number of balls inside the cylinder.
Change the known weight of material to the mill, which is to be ground. Note the time t and start
ball mill for one or half hour.
Take out the product and perform the sieves analysis. Perform the sieve analysis of the feed at
first.
OBSERVATION:-
1. Number of balls =
2. Diameter of the mill =
3. Shape Factor (λ) =
4. Weight of the feed =
5. Number of revolution of mill per minute =
6. Energy consumption for empty run =
7. Energy consumption for crushing period =
8. Actual energy used for crushing of material =

Feed and Product Analysis

MO Lab 22-23
Conclusion -

MO Lab 22-23
 ROLL CRUSHER

AIM:- To study working of Roll Crusher

APPARATUS INVOLVED:- Roll Crusher, Sieve Shaker, Weight Balance, Weight Box.

THEORY:-

Two rolls one in adjustable bearing, rotate if opposite directions and the clearance between them
can be adjusted according to the size of feed and the required size of product. The machine is
protected, by spring loading, against damage from very hard material. both rolls may be driven,
or one directly and the other by fraction with the solids. The crushing rolls, which may vary from
a few a centimeters up to about 1.2m in diameter, are suitable for effecting a small size reduction
ratios (4:1) in a single operation, and it is therefore common to employ a number of pairs of rolls
in series, one above the other. Roll shell with either smooth or ridged surfaces are held in place
by keys to the main shaft the capacity is usually between one tenth and one third of that
calculation on the assumption that a continuous ribbon of the material forms between the rolls.

Figure shows an idealized system where a spherical or cylindrical particle of radius r 2 is being
fed to crushing rolls of radius r1. 2α is the angle of the Nip, the angle between the two common
tangents to the particle and each of the distance between the rolls. It will be seen from the

geometry of the system that the angle of nip is given by:

MO Lab 22-23
PROCEDURE:-
Take feed mass of 2 kg. measure the size of the feed and do the sieve analyses for the same.
Feed it in the roll crusher and allow it to get crushed for around 300 second.
Stop the crushing, collect the product and perform the sieve analysis.

Conclusion –

MO Lab 22-23
 AGITATION
AIM:- To study how the power consumption of an agitator changes with Reynolds and
Froude numbers.
APPARATUS:- An Agitator, which can be run at different speeds, is used agitated liquid in a
cylindrical tank with removable baffles.
PRINCIPLE:-
The success of many processing operation depend upon the effective agitation and mixing of
fluids taking part in those operations. The agitation equipment often consists of a tank or a
vessel, usually cylindrical in form and with a vertical axis. The proportion of the tank very
widely depending upon the nature of the operation. An impeller, which may be one of the many
different types used, is mounted on an overhang shaft, which is driven by motor either directly or
through a speed- reducing gear box. The agitators create certain flow patterns within the fluids
thereby ensuring their through mixing. The power required to drive the impeller is one of the
most important consideration in the design of the agitator. The power consumption depends upon
the flow patterns in the mixer and on the geometrical proportion of the agitation and the
acceleration due to gravity. These factors influence the power consumption. All these actors can
be expressed in terms of power number while the other factors represent by the Reynolds
number, the Froude number and the shape factor. The power number, at low values of Reynolds
number varies almost hereby with Reynolds number (Nre up to 10) Beyond Nre=300, the Froude
number influence the power number for unbaffled vessels.

PROCEDURE:-
Study the power consumption of the agitator at various speed when agitating glycerin mixture
with and without baffles. Tabulate the data and calculate the various factors with the help of the
following expression.

MO Lab 22-23
Where,
P = Power Consumed by agitator per unit time

Conclusion -

MO Lab 22-23
 FILTER PRESS
AIM:- To study the filter press.
THEORY:-
Filtration is the removal of solid particles from a fluid by passing the fluid through the filter
medium or septum on which the solids are deposited. Industrial filtration range from simple
straining to highly complex separations. The fluid may be liquid or a gas; the valuable stream
from filter may be the fluid, or the solids, or both. While the particles may be coarse or fine,
round or elongated, rapid or plastic or aggregate but here we deal only in solid-liquid. Filtration
technique employed in situation where the proportion of solids in suspension is large at most of
the solid particles are collected in filter cake that on subsequently be detained from the filter
medium that is cake filtration.
PRINCIPLE OF FILTRATION:-
In cake filtration operation during the initial period of the flow, solid particles are trapped within
the holes of the medium forming the filter medium. The rate of Filtration depends upon the
following:
1) Pressure drop across the fluid inlet.
2) Area of filtering surface.
3) Viscosity of filtrate.
4) Resistance of filter medium.
5) Resistance of cake.
Types of Filtration:-
- The method in which the pressure drop is constant over filter,
throughout the run, so that rate of filtration is maximum at the start of filtration and decreases
continuously towards the end of the run is called constant pressure filtration.
-
The method in which the pressure drop varies usually from minimum at the start of filtration to
the maximum at the end of filtration constantly throughout the run is called constant rate
filtration.
-

MO Lab 22-23
Such a filter although being replaced by cont. filter device has low cost, low maintenance. On the
other hand it requires large labor for periodic manual disassembling.
During filtration, the filter press controls the following functions.
1) Permits the delivery of feed slurry of the filter surface to it’s own duct.
2) Permits the forcing of feed slurry against the filter surfaces.
3) Permits the filter, which as passed through the filter surface to exist through it’s on duty.
4) Retain the solid that curve originally in the slurry
CONSTRUCTION:-
The common filter press consists of alternate plate & frame hung on a rack of forced tightly
together, on the side rails of the press using the side tags on the plate and frame. The filter
medium is then hung over the plates expanding over both phases of the plates.
WORKING:-
The feed is fed between the two frames in every individual chamber. The pressure builds up and
the filtrate passes through filter clothes. The plates have corrugation through which the filtrate
comes down as it is collected. Cont. formation of filter cakes takes place in each chamber. They
meet after some time to join the press. In this case the filtration is stopped and wash liquid is fed
through the cake to remove any soluble solid after which air is blowed to remove the residual
fluid from the cake.
ADVANTAGE OF FILTER PRESS:-
1) Simple in construction.
2) Low initial cost.
3) Very low maintenance.
4) Large filtering area / unit space occupied.
5) High operating pressure is easily obtained.
6) It is possible to alter the capacity.
7) The most joints are external so leakage is detected.
DISADVANTAGE OF FILTER PRESS:-
1) High labor demand.
2) Not suitable for high through pat.
3) Press frequently drip & leak making hours keeping in the area a problem.
Conclusion -

MO Lab 22-23