ASSIGNMENT 1: UNIT OPERATIONS

Particle Size
Average particle

Screen Opening
Dpi (mm)

Mass Fraction

4.699

0.0000

6
8
10

3.327
2.369
1.651

0.0251
0.1250
0.3207

14
20

1.168
0.833

0.2570
0.1590

28
35

0.589
0.417

0.0538
0.0210

0.711
0.503

48
65
100
150

0.295
0.208
0.147
0.104

0.0102
0.0077
0.0058
0.0041

0.356
0.252
0.178
0.126

200
Pan

0.074
-

0.0031
0.0075

0.089
0.037

Mesh

diameter

Retained, xi

1.0305

Sample calculations of average particle diameter

pi mm
D
4.013
2.845
2.007
< 1.5mm

1.409
1.001

156.8595

xi

D pi

xi
pi 3
D
0

0.0063
0.0439

0.0
0.0

0.1598
0.1824

0.0
0.0

0.1588
0.0757

0.1
0.1

0.0418
0.0287
0.0306
0.0326

0.1
0.2
0.4
1.0

0.0325
0.0348
0.2027

2.0
4.3
148.

 pi mesh 4 = 4.699+3.327 =4.013

D
6
2

1. The size of 35 kg crushed rocks has been analyzed using sieving method. The results of
the sieving process are tabulated in the Table 1. The density of the particle is 1550 kg/m3
and the shape factor are a =0.8 and = 0.69
Calculate:
(a) The specific area of particles ( Aw) (mm2/g) for the material between 4-mesh and pan.
xi
6

S p
D pi
6
AW =
( 1.0305 )=5781.21 mm2 /g
0.69 (0.001550)
AW =

(b) Number of particles in mixture (Nw) (particles/g) for the material between 4-mesh and
pan

xi
1

3
a p
Dpi
1
N W=
(156.8595 )=126499.6 mm2 / g
0.8( 0.001550)
N W=

(c) Volume surface mean diameter (Ds) (mm)

s=
D

Di

pi

1
=0.97 mm
1.0305

(d) If 70% of the crushed glass must have size less than 1.5mm, please state whether or not
the particles need to be crushed again?

The particle need to be crushed again because, only 52.92% of the

average particle size is less than 1.5mm
pi > 1.5mm = (xi =0.0251+0.1250+0.3207=
Refer to the table particle with D

0.4708x100= 47.08%) whereas particle with

pi < 1.5mm = (1-0.4708=

D

0.5292x100=52.92%).Thus it need to be crushed again to achieve 70%.

Size Reduction
2. State four 4 types of equipments employed in particles size reduction. Elaborate the
principles of those equipments.
Crusher
-

Do the heavy work of breaking large pieces of solid material into small pieces

A slow speed machines for coarse reduction of large quantities of solids

Primary crusher can break the solids into 150-250mm size

Secondary crusher could reduced the particle from primary crusher to 6mm in size

Crusher reduces the solid size by compression

Grinder
Reduce crushed feed to powder
Product from a crusher is often fed to a grinder for further reduction.

 The product from an intermediate grinder might pass a 40-mesh screen.

Most products from a fine grinder would pass a 200- mesh screen with 74 m opening.
Reduce the solid size by impact and attrition, sometimes combine with compression

Ultrafine grinder
Reduce solids to fine particles
Accepts feed particles not larger than 6 mm.
The product size is typically 1 to 50 m.
Reduce the solid size by attrition

Cutting machine
Give particles of definite size and shape 2-10mm in length
Reduce the size by cutting, dicing and slitting

3. 110 tons/h of trap rock is crushed in a gyratory crusher. The feed is nearly uniform 2-in
spheres and produced the product of 0.08 in.size. Using the Bond method, estimate the
work necessary for the crushing process.
m=110

ton/hr

D Pa=2 x 25.4=50.8 mm D Pb=0.08 x 25.4=2.032 mm

W i (trap rock)=19.32

Thus by using Bonds Law

P Kb
=
DP
m

K b=0.3162W I

P
=0.3162 W I
m

1
1

D Pb D Pa

P
=0.3162(19.32)
110

P=377.12 kW

1
1

( 2.032
50.8 )