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Unit Operations
A. K. Majumder
Department of Mining Engineering
Indian Institute of Technology Kharagpur - 721 302, India
What is gravity
concentration?
Light
s
Heavie
s
The above two plots indicate that the time required for a particle to reach
its terminal velocity is quite short, ranging from 0.001 to 0.4 seconds.
Broad Classification
Flowing Film Concentrators
Centrifugal Separators
Separators based on Fluidization
Limitations?
Inefficient to treat very fine particles (1G separators)
Low throughput
Equipment selection
Non-availability of tailor made designs
Aim
To
Develop
Mathematical
Model
to
Modelling Strategy
Basic Assumption : Fully Developed Flow
Free surface
Velocity
profile
Overflow
Concentration
profile
Splitter
Underflow
Wall
Splitter Blade
Sample Collector
Dial Indicator
Adjustment Wedge
Flow thickening
Original splitter
Depth Gauge
Feed Box
Launder
Splitter
Assembly
Flow Meter
Vezin Samplers
Sump
Test Rig
1.0
0.8
Flow = 0.76 l/s
0.6
0.4
0.2
0.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Basic Equations
If Re < 600 then flow is laminar and
ux(y) =
gh sin
2
f
ux u
*2
1 y
h
y /
ux
u* y
A ln(
) B
*
u
Otherwise,
(Viscous sub-layer)
(Log profile)
y
q ( y ) u x ( y ) dy
0
hm u * 2
y u*
* y
u
q( y )
ydy
A ln(
) B dy
0
hm
y
q( y ) y ( y A ln y ) Ay (ln y 1) Ay
2
*h
u
m
y m
2
m
Where,
1.8
1.6
Velocity (m/s)
1.4
1.2
0.76 l/s
1.0
1.12 l/s
0.8
1.34 l/s
0.6
1.51 l/s
0.4
0.2
0.0
0.0
0.2
0.4
0.6
Fractional Depth
0.8
1.0
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
OBSERVATIONS
Theoretically
Predicted
Model Development
The basic Reynolds averaged Navier Stokes equations can
be written in cartesian form for this geometry as
u y
u x
0
x
y
u x
u x
p
u x
u y
l , xy t , xy l , xx t , xx g sin
x
y
x y
x
u y
u y
u x
u y
l , xy t , xy l , yy t , yy g cos
x
y
y x
y
u x ( x) f ( y )
du x
d
t g sin 0
dy
dy
dp
g cos 0
dy
t l
2
mix
du x
dy
l mix ky
putting
du x
t k y
dy
2
du x
du x
k y
gy sin C1 ( x) 0
dy
dy
2
p gy cos C 2 ( x) 0
Boundary condition: at
y hf
du x dy 0
du x
du x
g (h f y ) sin 0
k y
dy
dy
2
p g ( h f y ) cos
and
ux
u *
u
then
du
dy
1 du
1
y
2 2 1 0
(ky ) dy (ky )
h f
dy 2 ky
1 4 ky
y
1
h
f
1.8
1.6
Ve locity (m /s)
1.4
1.2
0.76 l/s
1.0
1.12 l/s
0.8
1.34 l/s
0.6
1.51 l/s
0.4
0.2
0.0
0.0
0.2
0.4
0.6
Fractional Depth
0.8
1.0
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
Velocity (m/s)
2.5
'Slurry'
2.0
1.5
1.0
0.5
0.0
0
100
200
300
400
Dimensionless Depth
500
600
LIMITATIONS
Contribution of Bagnold force to particle sorting process is unknown
water concentration is 1-
c ( h)
i 1
dci (h)
i
dh
Eddy Diffusivity
Sedimentation Flux :
dci (h)
q i v(h) ui (h) ci (h) i
dh
And for water
N
d
v ( h)
w
j 1
u jc j
j 1
j 1
1 c j w
cj
ui c j
dci (h)
j 1
i
ci (h) ui
N
N c
dh
j
1
j
w
j 1
j 1 j
and
Where
dh
( h)
( h)
h
h
( h)
(1 ) ku * H
H
H
2.439 u N
u*
cN ( y)
c N ( ) 1
y
1
h
f
c N ( )
h
f
2.439 u N
y u*
y
hf
hf
c N 1 ( ) 1
y
y
hf
hf
.... c1 ( ) 1
y
1
hf
y
hf
u*
2.439 u1
u*
2.439 u N 1
100
80
0.73 l/s
60
1.45 l/s
1.05 l/s
1.80 l/s
40
20
0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Fractional Recovery
1
0.8
196 microns
0.6
165 microns
137.5 microns
0.4
115.5 microns
0.2
0
0
0.5
1.5
D im e
.
7
l /
s
.
0
5
l
/
s
.
4
5
l /
s
1
.
8
18
16
14
12
10
4
0
w
t
%GB
8
6
4
2
0
0
0
.
0.
4
F
r
a
cti
o
0.
n
a
D
e
0.
p
th
18
Dimensionless Velocity
16
14
12
~40 wt.%GB
10
8
6
4
2
0
0
0.2
0.4
0.6
0.8
Fractional Depth
l
/
s
1
0.9
0.8
0.7
196 Microns
0.6
165 Microns
0.5
137.5 Microns
0.4
115.5 Microns
0.3
0.2
0.1
0
0.001
0.01
0.1
Fractional Depth
P r e d ic te
C o mp ar a tiv e
196
M
i
c
rons
165
M
i
c rons
137.5
Pl ot
M
ic rons
115. 5
M
i
c rons
1. 0
0. 8
0. 6
0. 4
0. 2
0. 0
0.0
0. 2
0.4
Ac t
ua l
0.6
S oli
ds
0. 8
1.0
S pl
it
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
P r e d ic t
C o mpa r a t iv e
196
M
ic rons
165
M
i
c r ons
137. 5
P lo t
M
i
c rons
115. 5
M
i
c r ons
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0
.2
0.4
Ac t
ua
l
0.6
S ol
ids
0
.8
1.0
Sp l
it
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
Fractional Recovery
1.0
0.8
GB at 2.3 l/s
0.6
0.4
0.2
0.0
0.0
0.5
1.0
1.5
2.0
2.5
3.0
0.8
0.6
0.2
0
0.001
0.01
0.1
Fractional Depth
0.06
0.05
0.04
GB 196 Microns
GB 165 Microns
0.03
GB 137.5 Microns
GB 115.5 Microns
0.02
0.01
0
0.001
0.01
0.1
Fractional Depth
P r e d ic te d
C om pa r a tiv e
1
9
6
M
i
cro n
s
16
5
M
i cro
ns
1
37
.5
Plo t
M
i
cro n
s
1
15
.5
M
i cro
ns
1 .0
0 .8
0 .6
0 .4
0 .2
0 .0
0
.0
0 .2
0 .4
Ac tual
0
.6
S olid s
0
.8
1
.0
S pli t
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
P r e d ic te d
C o mp ar ative
19
6
M
i
c ro
n
s
1
65
M
i
c ro
n
s
1
37
.5
P lo t
M
i cro
ns
1
1
5 .5
M
i
c ro
n
s
1.0
0.8
0.6
0.4
0.2
0.0
0 .0
0 .2
0
. 4
Actu al
0
.6
S o lids
0
.8
1
.0
S plit
1.0
0.8
0.6
0.4
0.2
0.0
0.0
0.2
0.4
0.6
0.8
1.0
Possible Applications
Modeling of Unit Operations based on Flowing Film
Concentration like Pinched Sluices, Reichert Cones,
Tables, Trays, Spirals etc.
Modeling of Centrifugal Separators like Falcon C Series,
MGS etc.
Modeling Slurry Flow Behaviour in Open Channels like
in Rivers, Canals etc.
Modeling Slurry Transportation
Centrifugal Separators
1. Cyclone Separators
Hydrocyclones
(Versatile unit)
Knelson Concentrator
Falcon Concentrator
Kelsey Jig
Mozley Multi Gravity Separator
Sl.No
1
2
3
1
2
3
4
5
6
7
8
9
12
15
Riffle 2
G Forces
Riffle 3
Riffle 4
Riffle 5
N in RPM
30.2
43.4
61.2
24.6
35.4
49.9
19.0
27.3
38.6
13.4
19.3
27.2
7.8
11.3
15.9
17.17
25.81
31.49
37.84
39.62
42.26
46.10
48.57
51.04
60.74
67.36
23.87
24.85
30.24
34.07
39.47
43.56
46.08
48.25
51.38
57.65
65.25
1000.0
1200.0
1425.0
80
1000 rpm
70
Settling Velocity (cm/s)
Pressure
(PSI)
Riffle 1
15 psi
60
Riffle 1
50
Riffle 2
40
Riffle 3
30
Riffle 4
3 psi
Riffle 5
20
1 psi
10
0
1.2
1.4
1.6
1.8
2.2
2.4
Overflow
Feed
Diameter
of
Cyclone
Included
angle
Spigot
Underflow
Possible Inferences
Case 1: No particle having specific gravity
more than 0.1 from the desired separation
density should report to overflow.
Case 2: Similarly, no particle having specific
gravity less than 0.1 from the desired
separation
density should
report
to
underflow.
Unfortunately, in reality this doesnt happen
like this. Why?
Arguments
Case 1: This can happen if a broad size
range of particles is processed.
Case 2: This cannot happen as in the
spigot region (for a DMC) the medium
density is always higher than the feed
medium density. So, in the definition
the incorporation of negative sign
needs rethinking.
Wt%
35.47
25.46
10.92
5.40
9.45
12.05
1.25
Cumulative Wt%
35.47
60.93
71.85
77.25
86.70
98.75
100.00
Hydrodynamic Analyses
10
8
7
31 mm
26 mm
22.5 mm
17.5 mm
12.5 mm
8 mm
3.25 mm
0.25 mm
2
1
0
1200
B
1300
1400
1500
1600
1700
1800
1900
2000
2100
Overflow
Underflow
Calculated Feed
% Clean
% Ash % of Feed % Reject % Ash % of Feed % Weight % Ash
Coal
Coal
0
18.35
11.24
26.22
26.22
16.48
1.5
0
100.0
0
5.02
10.65
16.73
23.62
30.62
39.05
0
0
9.49
5.82
13.57
13.57
8.53
0.78
0.00
51.7
0
0
0
0
5.02
30.52
25.3
39.16
100.0
0
0
0
0
22.81
33.03
40.05
60.06
0
0
0
0
2.423
14.729
12.210
18.899
48.3
0
9.49
5.82
13.57
15.99
23.26
12.99
18.90
100.0
0
5.02
10.65
16.73
23.50
32.15
39.99
60.06
31.14
% Distribution
100.00
100.00
100.00
100.00
84.85
36.67
5.98
0.00
Distribution Point
Distribution Curve
100
90
80
70
60
50
40
30
20
10
0
SG75
SG50
SG25
1.2
1.4
1.6
1.8
Observations
This is basically a probability function based
approach mathematically no problem.
Ep value is calculated based on a SG50 value
of 1.62.
But SG50 is a variable itself, it depends on
process and design variables as well as
operators skill.
Therefore, Ep doesnt reveal the true
efficiency of the equipment.
An Illustrative Example
The
Graphical Explanation
Target
Compared
My Comments
In coal washing the objective is to have a product of
specific quality (ash content) of maximum quantity
whereas the conventional approach of analyzing the
data appears to be based on maximizing the quantity
definitely not at a specific quality.
Therefore, it is felt that the so called density of
separation has got hardly any objective oriented
relevance.
The true efficiency of a gravity circuit should be
evaluated based on direct comparison of product
(quality and quantity) with the targets prior to
separation.
Coal Washing
1. Majumder, A. K. and Barnwal, J. P. (2004) Development of a new coal
washability index. Minerals Engineering, 17:93-96. (Elsevier)
2. Majumder, A. K., Barnwal, J. P. and Ramakrishnan, N. (2004) A new
approach to evaluate the performance of gravity based coal washing
equipment. International Journal of Coal Preparation and Utilization,
24:1-8. (Taylor & Francis)
3. Majumder, A. K., Shah, H. and Barnwal, J. P. (2006) Comparative study on
magnetite medium stability in a Vorsyl separator and in a heavy medium
cyclone. International Journal of Coal Preparation and Utilization,
26:165-179. (Taylor & Francis)
4. Majumder, A. K., Shah, H., Choubey, S., Barnwal, J. P., Kundu, A. K. and
Dhillon, P. S. (2009) Applicability of a dense medium cyclone and Vorsyl
separator for upgrading non-coking coal fines for use as a blast furnace
injection fuel. International Journal of Coal Preparation and Utilization,
29: 23-33. (Taylor & Francis)
5. Majumder, A. K.and Barnwal, J. P. (2011) Processing of Coal Fines in a
Water Only Cyclone, Fuel, Volume 90 (2) PP 834-838. (Elsevier)
Hydrocyclone
1. Majumder, A. K., Yerriswamy, P. and Barnwal, J. P. (2003) The fish hook
phenomenon in centrifugal separation of fine particles. Minerals
Engineering, Vol. 16, Issue 10: 1005-1007.
2. Majumder, A.K., Shah, H., Shukla,P. and Barnwal, J.P. (2007) Effect of
operating variables on the shape of fish-hook curves in cyclones,
Minerals Engineering, Volume 20, pp.204-206 (Elsevier).
3. Aurlien Davailles, Eric Climent, Florent Bourgeois and Arun Kumar
Majumder (2012) Analysis of swirling flow in hydrocyclones operating
under dense regime, Minerals Engineering, Volume 31, pp.32-41.
(Elsevier)
4. Shah, H., Majumder, A. K. and Barnwal, J. P.(2006) Development of
water split model for a 76 mm cyclone. Minerals Engineering,Vol.19,
Issue 1:102-104 (Elsevier)
Solid-Fluid Interactions
1. Majumder, A. K. (2007) Settling velocities of particulate systems - a
critical review of some useful models. Minerals and Metallurgical
Processing, 24(4): 237 242. (SME)
2. Majumder, A. K. and Barnwal, J. P. (2004) A computational method to
predict particles free terminal settling velocity. IE (I) Journal (MN), 85:
17-19.
Controversial Topics
1. Majumder, A. K. and Barnwal, J. P. (2006) The concept of separation
density in coal preparation revisited. MGMI Transactions, Vol. 102,
No. 1 & 2: 69-73.
2. Barnwal, J. P and Majumder, A. K. (2006) Definition of near density
materials in coal preparation revisited. MGMI Transactions, Vol. 102,
No. 1 & 2: 89-92. (Awarded Silver Medal)
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