MECHANICAL OPERATION

(CEO-I) 3320013
Semester - 03

Kartik R. Desai
Head, CHED, NGPP

Chapter II: Screen Analysis

Chapter II: Screen Analysis

Need of screen analysis:
A method for finding the particle-size distribution
of any loose, flowing, conglomerate material by
measuring the percentage of particles that pass
through a series of standard screens with holes
of various sizes.

Chapter II: Screen Analysis

Ideal and actual screen:
Ideal screen = which sharply
separates the feed mixture in such a
way that smallest particles in
overflow is just larger than the
largest particle in the underflow.
Actual screen = which dont yield a
sharp separation, the screen analysis
of overflow and underflow are similar.

Chapter II: Screen Analysis

Ideal screen:
1) Efficiency of the screen
is 1.
2) Not found in practice.
3) Perfect separation of
particles are obtained.
4) Separation is based on
cut diameter of
particle.

Actual screen:
1) Efficiency of the
screen is less than 1.
2) Practically available.
3) Perfect separation is
not obtained.
4) Separation is based
on size & shape of
particle.

Chapter II: Screen Analysis

Types of screen analysis:
1) Cumulative analysis
2) Differential analysis

Chapter II: Screen Analysis

Application of screen analysis:
Gradation is usually specified for each engineering
application it is used for. For example, foundations
might only call for coarse aggregates, and therefore
an open gradation is needed.
Gradation is a primary concern in pavement mix
design. Concrete could call for both coarse and fine
particles and a dense graded aggregate would be
needed. Asphalt design also calls for a dense graded
aggregate.
Gradation also applies to subgrades in paving, which
is the material that a road is paved on. Gradation, in
this case, depends on the type of road (i.e. highway,
rural, suburban) that is being paved.

Chapter II: Screen Analysis

Capacity and effectiveness of
screen:
Capacity = is the mass of material
that can be fed per unit time to unit
area of the screen.
Effectiveness = measure of the
success of the screen in closely
separating undersize and oversize
material.

Chapter II: Screen Analysis

Derivation of formula for overall
effectiveness of screen:
E = (XF XB) (XD XF) XD (1 XB)
(XD XB)2 (1 XF) XF
Where

XF = mass fraction of material A in feed

XD= mass fraction of material A in
overflow
XB = mass fraction of material A in
underflow

Chapter II: Screen Analysis

Types of screen:
The screens can be classified into following
types:
Grizzlies
Trommels
Mechanically shaking screens
Vibrating Screens
Oscillating screens
Reciprocating screens

Chapter II: Screen Analysis

Grizzlies:

These consist of a set of parallel bars held apart by spacers at some

predetermined opening.
Bars are frequently made of manganese steel to reduce wear.
A grizzly is widely used before a primary crusher in rock- or orecrushing plants to remove the fines before the ore or rock enters the
crusher.
It can be a stationary set of bars or a vibrating screen.
Stationary grizzlies:
These are the simplest of all separating devices and the least
expensive to install and maintain.
They are normally limited to the scalping or rough screening of dry
material at 0.05 m (2 in) and coarser and are not satisfactory for
moist and sticky material.
The slope, or angle with the horizontal, will vary between 20 and
50.
Stationary grizzlies require no power and little maintenance.
It is difficult to change the opening between the bars, and the
separation may not be sufficiently complete.

Chapter II: Screen Analysis

Flat grizzlies:
These, in which the parallel bars are in a
horizontal plane, are used on tops of ore and coal
bins and under unloading trestles.
This type of grizzly is used to retain occasional
pieces too large for the following plant equipment.
These lumps must then be broken up or removed
manually.
Vibrating grizzlies:
These are simply bar grizzlies mounted on
eccentrics so that the entire assembly is given a
back-and-forth movement or a positive circle
throw.

Chapter II: Screen Analysis

Revolving Screens :
Revolving screens are also called Trommel screens,
They consist of a cylindrical frame surrounded by wire
cloth or perforated plate, open at both ends, and
inclined at a slight angle.
The material to be screened is delivered at the upper
end, and the oversize is discharged at the lower end.
The desired product falls through the wire cloth
openings. The screens revolve at relatively low speeds
of 15 to 20 r/min.
Their capacity is not great, and efficiency is relatively
low.

Chapter II: Screen Analysis

Mechanical Shaking Screens:

These screens consist of a rectangular frame which holds wire

cloth or perforated plate and is slightly inclined and suspended
by loose rods or cables or supported from a base frame by
flexible flat springs.
The frame is driven with a reciprocating motion. The material
to be screened is fed at the upper end and is advanced by the
forward stroke of the screen while the finer particles pass
through the openings.
In many screening operations such devices have given way to
vibrating screens.
Shaking screens, such as the mechanical-conveyor type made
by may be used for both screening and conveying.
The advantages of this type are low headroom and low power
requirement.
The disadvantages are the high cost of maintenance of the
screen and the supporting structure owing to vibration and low
capacity compared with inclined high-speed vibrating screens.

Chapter II: Screen Analysis

Vibrating Screens:

These screens are used when large capacity and high

efficiency are desired. The capacity, especially in the
finer sizes, is so much greater than that of any of the
other screens that they have practically replaced all
other types when efficiency of the screen is an
important factor.
Advantages include accuracy of sizing, increased
capacity per unit area, low maintenance cost per ton of
material handled, and less installation space and
weight.
The vibrating screens basically divided into two main
classes:
(1) mechanically vibrated screens and (2) electrically
vibrated screens. In electrically or electromagnetic
vibrating screens, the screen itself is vibrated, and in
mechanically vibrated screen, the whole assembly is
vibrated.

Electromagnetic vibrating screen

Mechanically vibrating screen

Chapter II: Screen Analysis

Oscillating Screens:
These screens are characterized by low speed
oscillations [5 to 7 oscillations per second (300 to
400 r/min)] in a plane essentially parallel to the
screen cloth.
Screens in this group are usually used from 0.013
m (1/2 in) to 60 mesh. Some light free-flowing
materials, however, can be separated at 200 to
300 mesh.
Silk cloths are often used.

Chapter II: Screen Analysis

Reciprocating Screens:
An eccentric under the screen supplies oscillation, ranging from
gyratory [about 0.05-m (2-in) diameter] at the feed end to
reciprocating motion at the discharge end.
Frequency is 8 to 10 oscillations per second (500 to 600 r/min), and
since the screen is inclined about 5, a secondary high-amplitude
normal vibration of about 0.0025 m (110 in) is also set up.
They are not designed for handling heavy tonnages of materials
like rock or gravel.

Chapter II: Screen Analysis

Gyratory Screens and Riddles:
These are boxlike machines, either round or square,
with a series of screen cloths nested atop one
another.
Oscillation, supplied by eccentrics or counterweights,
is in a circular or near circular orbit.
Machines of this type are operated continuously.
The size ranges from 0.6 to 1.5 m (24 to 60 in).
Gyratory Riddles screens are driven in an
oscillating path by a motor attached to the support
shaft of the screen.
The gyratory riddle is the least expensive screen on
the market and is intended normally for batch
screening.