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UST CHEMICAL ENGINEERING DEPARTMENT 1

 CHE 2117

LECTURE 2
SCREENING
Engr. Divine Angela G. Sumalinog, Ph.D.
Engr. Aldrin Lorrenz A. Chan, M.Sc.
Course Instructors
Lecture Objectives
At the end of this lecture, the student should be able to
 Familiarize the different screening equipment, mesh materials
and standard sieve scales used in screening operation;
 Understand the mechanisms and types of screening operation;
 Construct and convert various types of particle size distribution
data; and
 Perform material balance to determine screen effectiveness in a
standard screening operation and in a rotary trommel screen.

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 screening

Screening
 Screening is a method of
separating particles according
to size alone.
 Separation of mixture of
particles of various sizes into
two or more fractions by a
screening surface.
 Applications: mining and mineral
processing, agriculture,
pharmaceutical, food, plastics, and
recycling

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 screening equipment

Screening equipment
 Grizzly Screen
 Shaking Screen
 Vibrating Screen
 Oscillating Screen
 Rotary Screen

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 screening surface

Screening surface
 Interwoven wire mesh (carbon
or stainless steel, phosphor
bronze)
 Cloth (silk, plastic, nylon,
fiberglass)
 Perforated plates
 Bars

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 standard sieve scales

Standard sieve scales

 US Tyler (Mesh 4-325)
 US ASTM (Mesh 4-325)
 British Standard Sieve
(BSS) (Mesh 5-300)
 Institute of Mining and
Metallurgy (IMMS) (Mesh
5-200)
 French standard sieves
(FSS) (Mesh 17-38)
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 standard sieve scales

Tyler
Standard
Sieve Series
Source: McCabe, 7th ed.
(Appendix 5)

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 screening operation

Screening schematic
• Mixture of differently-
Feed sized particles

• Larger than screen opening

• Retained on the screen

Oversize (Tails)

Undersize (Fines)
• Smaller than screen opening
Screen • Passes through the screen

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 screening operation

Types of Screening Operation

 Unsized function
 A single screen can make a single separation into two fractions, i.e.,
undersize and oversize.
 Sized function
 When a solid mixture is divided into many fractions by passing
through a series of screens.

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 screening operation

Mesh 1”

 The holes on the screen

Mesh 4 1”
 Mesh number
 Defined as the number of holes
per linear inch
 The higher the mesh number, 1”
the smaller is the screen
opening
Mesh 200 1”

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 screening operation

Mesh
 Screen aperture
 Clear opening in the screen surface
 Maximum clear space between the edges of
the screen opening. It is usually given in
inches or millimeter
1 𝑖𝑛.
𝐴𝑝𝑒𝑟𝑡𝑢𝑟𝑒 = − 𝐷𝑤𝑖𝑟𝑒
𝑀𝑒𝑠ℎ 𝑁𝑜.
 A Mesh 3 screen has 3 openings per inch
and the aperture is 1/3” minus the diameter
of the wire.

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 standard sieve scales

Tyler
Standard
Sieve Series
Source: McCabe
(Appendix 5)

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 screening operation

Indicating Particle Size

 Unsized Function
 Oversize 4 Mesh, +4, +4.76 mm
 Undersize 4 Mesh, -4, -4.76 mm
 Sized Function
 Through 4 on 6
 -4+6
 4/6
 -4.76 mm + 3.36 mm

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 particle size distribution

Particle Size Distribution

 Differential Screen Analysis (DSA)
 Data consist of Mesh No. (n) vs Weight fraction or % retained on the
screen (ΔΦn)
 Cumulative Screen Analysis - larger than Dp (CSA larger)
 Data consist of n vs Cumulative fraction larger than n (Φn)
 Cumulative Screen Analysis - smaller than Dp (CSA smaller)
 Data consist of n vs Cumulative fraction smaller than n (1-Φn)

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 particle size distribution

Particle Size Distribution

Feed
50 kg DSA
5 kg n ΔΦn
Mesh 6 6 0.10
20 kg 8 0.40
Mesh 8
10 0.24
12 kg
Mesh 10 14 0.12
6 kg 20 0.08
Mesh 14
pan 0.06
4 kg
Mesh 20 Total 1.00

3 kg

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 particle size distribution

Particle Size Distribution

Feed
50 kg DSA CSA larger
5 kg n ΔΦn Φn
Mesh 6 6 0.10 0.10
20 kg 8 0.40 0.50
Mesh 8
10 0.24 0.74
12 kg
Mesh 10 14 0.12 0.86
6 kg 20 0.08 0.94
Mesh 14
pan 0.06 1.00
4 kg
Mesh 20 Total 1.00

3 kg

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 particle size distribution

Particle Size Distribution

Feed
50 kg DSA CSA larger CSA smaller
5 kg n ΔΦn Φn 1-Φn
Mesh 6 6 0.10 0.10 0.90
20 kg 8 0.40 0.50 0.50
Mesh 8
10 0.24 0.74 0.26
12 kg
Mesh 10 14 0.12 0.86 0.14
6 kg 20 0.08 0.94 0.06
Mesh 14
pan 0.06 1.00 0
4 kg
Mesh 20 Total 1.00

3 kg

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 particle size distribution

Particle Size Distribution

CSA
DSA larger

CSA
smaller DSA

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 screening material balance

Material Balance
Let F, D and B be the mass flow
Feed rates of the Feed, Overflow and
Underflow, respectively; and
D, xD F, xF
Overflow xF, xD and xB be the mass fraction
of the oversized material in the
3 streams.
Underflow
B, xB 1-xF, 1-xD and 1-xB are the mass
Screen fractions of the undersized
material in the 3 streams.
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 screening material balance

Material Balance Feed

D, xD F, xF
 Overall Material Balance Overflow
𝑭=𝑫+𝑩
 Oversize Material Balance
𝑭𝒙𝑭 = 𝑫𝒙𝑫 + 𝑩𝒙𝑩 Underflow
 Overflow to Feed Ratio
Screen
B, xB
𝑫 𝒙𝑭 − 𝒙𝑩
=
𝑭 𝒙𝑫 − 𝒙𝑩
 Underflow to Feed Ratio
𝑩 𝒙𝑫 − 𝒙𝑭
=
𝑭 𝒙𝑫 − 𝒙𝑩

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 screen effectiveness

Screen Effectiveness (E)

 A measure of success of the completeness of the separation.
 Irregularly sized materials could cause blind screens which
lowers the screen effectiveness.

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 screen effectiveness

Low screen effectiveness

Actual screens do not give perfect separations.
 Closest separations are obtained with spherical particles on
standard testing screens.
 Needle-like or fibrous or where the particle tend to aggregate
into clusters that act as large particles.
 Long, thin particles may strike the screen surface endwise and
pass through easily.
 Other particles of the same size and shape may strike the screen
sideways and be retained.
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 screen effectiveness

Screen Effectiveness (E)

 EA = recovery of oversized material Feed
𝑫𝒙𝑫 𝒙𝑭 − 𝒙𝑩 𝒙𝑫
𝑬𝑨 = = D, xD F, xF
𝑭𝒙𝑭 𝒙𝑫 − 𝒙𝑩 𝒙𝑭
Overflow

 EB = recovery of undersized material

𝑩(𝟏 − 𝒙𝑩 ) (𝒙𝑫 − 𝒙𝑭 )(𝟏 − 𝒙𝑩 )
𝑬𝑩 = = Underflow
𝑭(𝟏 − 𝒙𝑭 ) (𝒙𝑫 − 𝒙𝑩 )(𝟏 − 𝒙𝑭 )
Screen
B, xB

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 screen effectiveness

Screen Effectiveness (E)

 E = screen effectiveness Feed

𝑬 = 𝑬𝑨 𝑬𝑩 =
𝑫𝒙𝑫 𝑩(𝟏 − 𝒙𝑩 )
× D, xD F, xF
𝑭𝒙𝑭 𝑭(𝟏 − 𝒙𝑭 )
Overflow
𝒙𝑭 − 𝒙𝑩 𝒙𝑫 (𝒙𝑫 − 𝒙𝑭 )(𝟏 − 𝒙𝑩 )
𝑬= ×
𝒙𝑫 − 𝒙𝑩 𝒙𝑭 (𝒙𝑫 − 𝒙𝑩 )(𝟏 − 𝒙𝑭 )
Unsized Function Underflow

Screen
B, xB
𝑫𝒆𝒔𝒊𝒓𝒆𝒅 𝑼𝒏𝒅𝒆𝒔𝒊𝒓𝒆𝒅
𝑬= ×
𝑭𝒆𝒆𝒅𝒅𝒆𝒔𝒊𝒓𝒆𝒅 𝑭𝒆𝒆𝒅𝒖𝒏𝒅𝒆𝒔𝒊𝒓𝒆𝒅
Sized Function
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 unsized function

Example 1
It is desired to remove small particles from a crushed stone
mixture by screening through a 10-mesh screen. The screen
analysis of feed, overflow and underflow are given in the table.
a) Calculate the mass ratios of the overflow and underflow to
feed.
b) Plot Dp vs Screen analysis for the feed, overflow and
underflow
c) Find the effectiveness of the screen
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 unsized function

Example 1
Mesh Dp (mm) Feed Overflow Underflow
xF = 0.47
4 4.699 0 0 xD = 0.85
6 3.327 0.025 0.071 xB = 0.195
8 2.362 0.125 0.43 1
10 1.651 0.32 0.85 0.805
14 1.168 0.26 0.97 0.42
20 0.833 0.155 0.99 0.17
28 0.589 0.055 1.0 0.09
35 0.417 0.02 0.06
65 0.208 0.02 0.025
Pan 0.02 0
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 unsized function

Example 1
a) Overflow/Underflow to Feed ratio
Overflow to Feed ratio:
𝑫 𝒙𝑭 − 𝒙𝑩
= = 𝟎. 𝟒𝟐
𝑭 𝒙𝑫 − 𝒙𝑩

Underflow to Feed ratio:

𝑩 𝒙𝑫 − 𝒙𝑭
= = 𝟎. 𝟓𝟖
𝑭 𝒙𝑫 − 𝒙𝑩
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 unsized function

Example 1
b) Dp vs Feed/Overflow/Underflow
1

Mass fraction 0.8

Feed
0.6 Overflow
Underflow
0.4

0.2

0
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5
Dp (mm)

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 unsized function

Example 1
c) Screen Effectiveness
𝑫𝒙𝑫 𝑩(𝟏 − 𝒙𝑩 )
𝑬 = 𝑬𝑨 𝑬𝑩 = ×
𝑭𝒙𝑭 𝑭(𝟏 − 𝒙𝑭 )
𝒙𝑭 − 𝒙𝑩 𝒙𝑫 (𝒙𝑫 − 𝒙𝑭 )(𝟏 − 𝒙𝑩 )
𝑬= × = 𝟎. 𝟔𝟔𝟗
𝒙𝑫 − 𝒙𝑩 𝒙𝑭 (𝒙𝑫 − 𝒙𝑩 )(𝟏 − 𝒙𝑭 )

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 unsized function

Practice Problem
Using the same data in Mesh Dp (mm) Feed Overflow Underflow
Example 1, consider the
20-Mesh screen.
4 4.699 0 0

a) Calculate the overflow 6 3.327 0.025 0.071

and underflow to feed 8 2.362 0.125 0.43 1

ratios. 10 1.651 0.32 0.85 0.805
b) What is the 14 1.168 0.26 0.97 0.42
effectiveness of the 20-
mesh screen?
20 0.833 0.155 0.99 0.17

c) Why is the 20-mesh 28 0.589 0.055 1.0 0.09

screen an 35 0.417 0.02 0.06

effective/ineffective 65 0.208 0.02 0.025
screen? Pan 0.02 0

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 sized function

Example 2
It is desired to separate 1000 kg of a mixture of crushed solids into three
fractions, a coarse fraction retained on a 20-mesh screen; a middle
fraction passing through a 20-mesh screen and retained on a 65-mesh
screen; and a fine fraction passing through a 65-mesh screen. Two Tyler
Standard Screens are used to remove particles 20/65. Screen analysis of
the feed, coarse, medium and fine fractions are given. What are the
effectiveness of the 20 and 65 screens, given the following screen
analysis?

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 sized function

Example 2
It is desired to separate 1000 kg of a mixture of crushed solids into three
fractions, a coarse fraction retained on a 20-mesh screen; a middle
fraction passing through a 20-mesh screen and retained on a 65-
mesh screen; and a fine fraction passing through a 65-mesh screen.
Two Tyler Standard Screens are used to remove particles 20/65. Screen
analysis of the feed, coarse, medium and fine fractions are given. What
are the effectiveness of the 20 and 65 screens, given the following screen
analysis?

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 sized function

Example 2 Streams:
Mesh
F
Feed
P
Coarse
Q
Medium
R
Fines
-4+6 2.51 3.27 0.5 0
-6+8 12.5 13.59 11.26 0
-8+10 32.07 38.04 18.03 1.65
F -10+14 25.7 27.17 22.53 16.63
1000 kg -14+20 15.9 16.3 13.52 21.38
-20+28 5.38 1.36 18.03 9.03
P -28+35 2.1 0.27 8.11 2.38
-35+48 1.02 0 4.51 0.48
20
-48+65 0.77 0 3.42 0.24
Q -65+100 0.58 0 0.09 13.3
65 -100+150 0.41 0 0 9.74
R -150+200 0.31 0 0 7.36
pan 0.75 0 0 17.81
100 100 100 100

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 sized function

Example 2 Streams:
Mesh
F
Feed
P
Coarse
Q
Medium
R
Fines
-4+6 2.51 3.27 0.5 0
-6+8 12.5 13.59 11.26 0
Fraction 1 -8+10 32.07 38.04 18.03 1.65
+20 -10+14 25.7 27.17 22.53 16.63
F
1000 kg -14+20 15.9 16.3 13.52 21.38
-20+28 5.38 1.36 18.03 9.03
P -28+35 2.1 0.27 8.11 2.38
Fraction 2
-35+48 1.02 0 4.51 0.48
20 -20+65
-48+65 0.77 0 3.42 0.24
Q (undesired)
-65+100 0.58 0 0.09 13.3
65 -100+150 0.41 0 0 9.74
Fraction 3
R -65 -150+200 0.31 0 0 7.36
pan 0.75 0 0 17.81
100 100 100 100

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 sized function

Example 2 Streams:
Mesh
F
Feed
P
Coarse
Q
Medium
R
Fines
-4+6 2.51 3.27 0.5 0
-6+8 12.5 13.59 11.26 0
F 1 -8+10 32.07 38.04 18.03 1.65
1000 kg -10+14 25.7 27.17 22.53 16.63
F1, F2, F3 -14+20 15.9 16.3 13.52 21.38
P -20+28 5.38 1.36 18.03 9.03
P1, P2, P3 -28+35 2.1 0.27 8.11 2.38
2
-35+48 1.02 0 4.51 0.48
Q -48+65 0.77 0 3.42 0.24
Q1, Q2, Q3 -65+100 0.58 0 0.09 13.3
-100+150 0.41 0 0 9.74
3
R -150+200 0.31 0 0 7.36
R 1, R 2, R 3 pan 0.75 0 0 17.81
100 100 100 100

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 sized function

Example 2
Solving for F1, F2 and F3:
F1 = (sum of mass fractions of all fraction 1 particles in F stream)*(Feed rate)
F2 = (sum of mass fractions of all fraction 2 particles in F stream)*(Feed rate)
F3 = (sum of mass fractions of all fraction 3 particles in F stream)*(Feed rate)

F1 = (1000 kg)*(0.8868) = 886.8 kg

F2 = (1000 kg)*(.0927) = 92.7 kg
F3 = (1000 kg)*(0.0205) = 20.5 kg
*Do the same for other streams

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 sized function

Example 2 F
1000 kg
F1 = 886.8
F2 = 92.7
F3 = 20.5 P
Material Balance Equations P1 = 0.9837P
Overall: 1000 = P + Q + R P2 = 0.0163P
Fraction 1: 886.8 = 0.9837P + 0.6584Q + 0.3966R P3 = 0
Fraction 2: 92.7 = 0.0163P + 0.3407Q + 0.1213R
Fraction 3: 20.5 = 0.0009Q + 0.4821R Q
Q1 = 0.6584Q
Q2 = 0.3407Q
Solving simultaneously (3 unknowns, 3 equations):
R Q3 = 0.0009Q
P = 736.010 kg
Q = 221.882 kg R1 = 0.3966R
R = 42.108 kg R2 = 0.1213R
R3 = 0.4821R

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 sized function

Example 2 F
1000 kg
F1 = 886.8
F2 = 92.7
F3 = 20.5 P
Screen Effectiveness P1 = 724.01
𝐷𝑒𝑠𝑖𝑟𝑒𝑑 𝑈𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑 S P2 = 12.00
𝐸= ∗ S 1, S 2, S 3 P3 = 0
𝐹𝑒𝑒𝑑𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝐹𝑒𝑒𝑑𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑

𝑂𝑣𝑒𝑟𝑠𝑖𝑧𝑒𝑑 𝑈𝑛𝑑𝑒𝑟𝑠𝑖𝑧𝑒𝑑 Q
𝐸= ∗ Q1 = 146.09
𝐹𝑒𝑒𝑑𝑜𝑣𝑒𝑟𝑠𝑖𝑧𝑒𝑑 𝐹𝑒𝑒𝑑𝑢𝑛𝑑𝑒𝑟𝑠𝑖𝑧𝑒𝑑 Q2 = 75.60
R Q3 = 0.20
Solving for Stream S:
R1 = 16.70
OMB for Mesh 20: F = P + S → S = F – P
R2 = 5.11
Fraction 1: 𝑺𝟏 = 𝑭𝟏 − 𝑷𝟏 = 𝟏𝟔𝟐. 𝟕𝟗 𝒌𝒈 R3 = 20.30
Fraction 2: 𝑺𝟐 = 𝑭𝟐 − 𝑷𝟐 = 𝟖𝟎. 𝟕𝟎 𝒌𝒈
Fraction 3: 𝑺𝟑 = 𝑭𝟑 − 𝑷𝟑 = 𝟐𝟎. 𝟓𝟎 𝒌𝒈

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 sized function

Example 2 F
1000 kg
F1 = 886.8
F2 = 92.7
F3 = 20.5 P
Screen Effectiveness P1 = 724.01
𝑂𝑣𝑒𝑟𝑠𝑖𝑧𝑒𝑑 𝑈𝑛𝑑𝑒𝑟𝑠𝑖𝑧𝑒𝑑 P2 = 12.00
𝐸= ∗
𝐹𝑒𝑒𝑑𝑜𝑣𝑒𝑟𝑠𝑖𝑧𝑒𝑑 𝐹𝑒𝑒𝑑𝑢𝑛𝑑𝑒𝑟𝑠𝑖𝑧𝑒𝑑 S P3 = 0
S1 = 162.79
𝑃1 𝑆2 + 𝑆3 S2 = 80.70 Q
𝐸20 = ∗ = 𝟎. 𝟕𝟑𝟎 S3 = 20.50 Q1 = 146.09
𝐹1 𝐹2 + 𝐹3 Q2 = 75.60
R Q3 = 0.20
𝑄1 + 𝑄2 𝑅3
𝐸65 = ∗ = 𝟎. 𝟗𝟎𝟐 R1 = 16.70
𝑆1 + 𝑆2 𝑆3
R2 = 5.11
R3 = 20.30

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 rotar y trommel screen

Rotary Trommel Screen

 A mechanical screening machine consisting
of a perforated cylindrical drum that is
normally elevated at an angle at the feed
end.
 Physical size separation is achieved as the
feed material spirals down the rotating drum,
where the undersized material smaller than
the screen apertures passes through the
screen, while the oversized material exits at
the other end of the drum.
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 rotar y trommel screen

Rotary Trommel Screen

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 rotar y trommel

Example 3
It is desired to separate a 1000-kg mixture of crushed stone clinker in a
rotary trommel to obtain three products, namely stream D, C and B
passing through 150, 35 and 10 mesh screens, respectively. Find the
effectiveness of each screen using the given screen analysis.

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SCREEN MESH FEED COARSE MIDDLE FINE VERY FINE
-3+4 2.5 0.087
-4+6 7.5 0.208 0.039
-6+8 12.4 0.417 0.01
-8+10 7.4 0.243 0.01
-10+14
-14+20
21.3
8.2
0.045 0.521
0.156 0.075
EXAMPLE 3
-20+28
-28+35
7.5
3.8
0.182
0.053
0.017
0.061
C DATA
-35+48 8.1 0.029 0.238
-48+65 11.6 0.395
-65+100 5.3 0.17 0.088
-100+150 1.4 0.041 0.059
-150+170 2.1 0.003 0.588
-170+200 0.7 0.206
-200+270 0.2 0.059
UST CHEMICAL ENGINEERING DEPARTMENT 45
 CHE 2117

LECTURE 2
SCREENING

EN D O F LECTURE