Gravity Settling

Tank
Mechanical Operation
Chemical Engineering
 Gravity Settling Tank
• Definition :- Construction:-
It is the simplest type of
classifier. It consists of a
large tank with provisions
for a suitable inlet and
outlet.
With the help of gravity
settling tank we can
separates mixture of
different size of solid
particles.
Working :-
• A slurry feed enters the tank through an inlet connection. As soon as
the slurry feed enters the tank, its linear velocity decreases as a result
of the enlargement of cross-sectional area. Solid particles start to
settle under the influence of gravity.
• The faster-settling particles (coarse particles) will be collected at the
bottom of the tank near the inlet/entrance, while the slower-settling
particles (small particles) will be carried farther into the tank before
they reach the bottom of the tank. The very fine particles are carried
away in the liquid overflow from the tank.
Cone Classifier
Mechanical Operation
Chemical Engineering
Cone Classifier
• Definition :- • Construction :-
 A cone classifier is
simply a cone (conical
vessel), installed point
down, with a discharge
launder around the top
(of the cone).
 It is the simplest type
of classifier. It consists
of a large tank with
provisions for a suitable
inlet and outlet.
Working:-
• The feed is introduced in the form of a suspension through a fed inlet
provided at the center at the top. The coarse fraction (the partially
drained fraction containing the coarse material) collects at the point
of the cone (i.e., at the apex) and is withdrawn periodically or
continuously. The fine fraction along with the remaining portion of
the liquid is removed from the launder as an overflow. The separation
achieved with this unit is only an approximate one.
• Cone classifiers are used for relatively crude work because of low cost
of installation. They are used in ore-dressing plants.
Double-cone Classifier
Mechanical Operation
Chemical Engineering
Double-cone Classifier

• Definition :-
This classifier uses hydraulic
water for classification (a stream
of additional water supplied to a
classifier is called hydraulic
water).
Working :-
• The feed to be separated is fed in the form of a suspension to the
Centre of the inner cone. It flows downward through the inner cone
and out at a baffle at the bottom of the inner cone. Hydraulic water is
fed near the outlet for the coarse material. The solids from the inner
cone and a rising stream of water are mixed below the inner cone.
Then they flow through an annular space between the two cones.
Classification occurs in the annular space, the small/fine particles are
carried away in the overflow, whereas the large particles/coarse
particles settle against the hydraulic water to the bottom and are
removed periodically.
MECHANICAL
CLASSIFIERS
1. Rake Classifier

2. Spiral Classifier
Rake Classifier :-
• Definition :-
Rake Classifier is a equipment , with the help of this equipment we can
separates mixture of different size of solid particles.

• Construction :-
Working of Rake classifier :-
• The rake classifier such as the Dorr classifier consists of a rectangular tank with a
sloping/inclined bottom. The tank is provided with movable rakes (reciprocating
rakes). The feed in the form of suspension (slurry) is introduced continuously near
the middle of the tank. The lower end of the tank has a weir overflow (discharge
weir) from which the fines that are not settled leave with the overflow liquid.
• The heavy material (coarser particles) sink to the bottom of the tank. The rakes
scrap the settled solids and move them upwards along the bottom of the tank
towards the top/upper end of the tank from where they are discharged. The
reciprocating rakes keep the slurry in continuous agitation. The time of raking
stroke is so adjusted that fines do not have time to settle and so remain near the
surface of the slurry, while the heavy particles have time to settle [they settle,
scrapped upward and removed as a dense slurry (called the sand)].
Spiral Classifier
• Definition :-
Spiral Classifier is a equipment , with the help of this equipment we can
separates mixture of different size of solid particles.

• Construction :-
Working :-
• It is a mechanical classifier. The spiral classifier such as the Akins classifier consists
of a semicylindrical trough (a trough which is semicircular in cross-section) inclined
to the horizontal. The trough is provided with a slow-rotating spiral conveyor and a
liquid overflow at the lower end. The spiral conveyor moves the solids which settle
to the bottom upward towards the top of the trough.
• Slurry is fed continuously near the middle of the trough. The slurry feed rate is so
adjusted that fines do not have time to settle and are carried out with the overflow
liquid. Heavy particles have time to settle, they settle to the bottom of the trough
and the spiral conveyor moves the settled solids upward along the floor of the
trough towards the top of the trough from where they are discharged.
• Rake and spiral classifiers are used along with ball mills in closed-circuit grinding.
Cyclone separator/Cyclone/Liquid
cyclone/Hydroclone
Mechanical operation
Chemical Engineering
Cyclone separator
• Definition :-
A cyclone/cyclone separator is essentially a settling chamber in which the
gravitational separating force is replaced by a much stronger centrifugal
separating force (to increase the settling rate).

Cyclones/cyclone separators are used for the separation of solids from fluids.
They offer one of the least expensive means of dust collection (separation of
dust particles from gases). They utilize a centrifugal force to effect the
separation which depends on particle size and/or on particle density. Thus,
cyclones are used to effect a separation on the basis of particle size or particle
density or both.
Construction
Working :-
• The slurry feed is pumped into the cylindrical section tangentially.
Coarse or heavy solids thrown out against the walls, travel down the
sides of the cone section and are discharged in a partially dewatered
form from the apex, while the smaller or lighter solids along with the
remaining portion of water are removed from the downward
extending pipe at the top. Liquid cyclones are used in degritting
operations in alumina production, classifying pigments and ore-
dressing practice.
Hydraulic Jig :-
Mechanical operation
Chemical Engineering
Hydraulic Jig :-
• Definition :-
 It is types of a jig.
 A jig is a mechanical device used for the separation of materials of different specific gravities by
pulsating a stream of liquid (usually water) flowing through a bed of materials resting on a screen.
 Jigs separate solids by difference in density and size.
• Principle:-
 It works on the principle of density.
• Construction :-
 It consists of a rectangular section tank with a tapered bottom. The tank is divided into two
portions/compartments by a vertical baffle.
 In one compartment, a plunger is incorporated. It operates in a vertical direction giving a pulsating
motion to the liquid.
 In the other compartment, a screen is incorporated. The separation of material is carried out over
this screen.
 Working:-
The material to be separated is fed over a screen and is subjected
to a pulsating action by oscillating liquid with the help of a
reciprocating plunger. During the upward stroke of the plunger,
input water is taken into the jig and there is no net flow through
the bed of solids. During the downward stroke, water inlet is
closed and particles on the screen are brought into suspension
and they segregate according to their size and density such that
the dense material is collected near the bottom of screen.

The following four fractions are obtained from the jig :

1. Small and dense material passing through the screen
collected at the bottom of the tank.
2. Small size less dense material in the liquid overflow.
3. Large size dense material segregated near a screen
removed through a gate at the side.
4. Large size less dense material segregated above the
dense material removed through a gate at the side.
Froth flotation cell :-
Mechanical operation
Chemical Engineering
Froth flotation cell :-
• Definition :-
 Froth flotation processes are used for the separation of finely divided solids.
 Flotation refers to an operation in which one solid is separated from another by floating one of
them at or on the liquid surface.
 This technique is commonly used in mineral dressing.
• Principle :-
 Separation by froth flotation depends on differences in the surface properties of the materials.
• Construction :-
 The mechanically agitated flotation cell consists of a tank having square or circular cross-section.
 It is provided with an agitator which violently agitates the pulp. A compressor / blower is used to
introduce air into the system through a downpipe surrounding the impeller shaft.
 The bottom of the tank is conical and is provided with a discharge for tailings. An overflow is
provided at the top for mineralized froth (or froth) removal.
Working:-
• Water is taken into the cell, material is fed to the cell. The promotors and frothers are added.
• Agitations are given and air is bubbled in the form of fine bubbles.
• Air-avid particles due to reduction in their effective density, will rise to the surface and be held
in the froth before they are discharged from the overflow.
• Hydrophilic particles will sink to the bottom and removed from the discharge for tailings.
• Promotors : These are materials which are adsorbed on the surface of the particles forming a
unimolecular layer. A commonly used promotor is sodium ethyl xanthate.
• Collectors : These are materials which form surface films on the particles. A commonly used
collector is pine oil.
• Frothing agents/Frothers : These are materials which induce the formation of a froth (which
produce a froth) of sufficient stability in order to retain the particles of the constituent which
is to be floated to be discharged as an overflow. Commonly used frothers include liquid soaps,
pine oil, cresylic acid, methyl amyl alcohol and methylisobutylcarbinol.
SEPARATION OF SOLID
PARTICLES BASED ON
ELECTRICAL AND
MAGNETIC PROPERTIES
Mechanical operation
Chemical Engineering
SEPARATION OF SOLID PARTICLES
BASED ON ELECTRICAL AND
MAGNETIC PROPERTIES.
1. Electrostatic Separation.

2. Magnetic Head Pulley .

3. Magnetic Drum Separator .

4. Ball-Norton Type Separator (Magnetic separators as concentrators).

Electrostatic Separator :-
• Definition :-
Electrostatic separation is a method of separation of solid particles based on the differential
attraction or repulsion of charged particles under the influence of an electric field. Basically,
the difference in electrical properties of different materials is responsible for such a
separation.
• Principle:-
If one or more of the materials of a granular mixture can acquire a surface charge on or just
before entering an electrostatic field, the grains/particles of that material will be attracted
towards the active electrode or repelled from it depending upon the sign of the charge on
the grains/particles.
• Construction :-
The electrostatic separator shown in Fig. 4.10 consists of a grounded rotor/rotating drum, a
hopper for feeding the solids, an active electrode, situated/placed at a small distance from
the drum and collecting bins.
Working :-
• The solids to be separated are fed on to a rotating drum, either
charged or grounded, from a hopper.
• The conductive particles in a very short time will assume the potential
of the rotating drum, which is opposite to that of an active electrode
and hence, they get attracted towards the active electrode.
• The non-conductive material is repelled by the electrode and
attracted by the drum.
• The non-conductive material falls down straight under the influence
of gravity and is collected in a separate bin.
Magnetic Head Pulley
Mechanical operation
Chemical Engineering
Magnetic Head Pulley:-
• Definition :-
 Magnetic head pulley is a types of magnetic separators equipment.
 Magnetic separation is a method of separating solid particles by means of a magnetic field. In
this method, materials having different magnetic attractability are separated by passing them
through a magnetic field. The difference in magnetic properties of different materials is
responsible for such a separation.
• Principle :-
 It works on the principle of Magnetic Properties.
• Construction :-
 A magnetic pulley/magnetised pulley is used for the removal of tramp-iron from the products
handled on a belt conveyor.
 Magnetic pulleys (either electromagnetic or permanent-magnetic) having a diameter up to
1500 mm and a width up to 1500 mm are available. The belt speed ranges from 53 m/min for a
pulley of diameter of 300 mm to 150 m/min for a pulley of 1500 mm diameter.
Working :-
• A magnetic pulley is incorporated in a belt conveyor (carrying the
charge/feed to a machine/equipment) at the discharge end. As the
material is conveyed over this pulley, the magnetically inert
material/non-magnetic material drops-off the belt (or is discharged
from the belt) in a normal manner, whereas the magnetic material
adheres to the belt and falls off from the underside where the belt
loses contact with the pulley (i.e., when the belt leaves the magnetic
field of the pulley).
• The material to be separated must be supplied in the form of a thin
sheet/layer in order to subject all the particles to a magnetic field of
the same intensity (power is applied to the magnetic pulley).
Magnetic Drum Separator
Mechanical operation
Chemical Engineering
Magnetic Drum Separator
• Definition :-
 Magnetic drum separator is a types of magnetic separators equipment.
 Magnetic separation is a method of separating solid particles by means of a
magnetic field. In this method, materials having different magnetic attractability are
separated by passing them through a magnetic field. The difference in magnetic
properties of different materials is responsible for such a separation.
• Principle :-
 It works on the principle of Magnetic Properties.
• Construction :-
 A magnetic drum separator consists of a rotating drum incorporating stationary
magnet assembly. The magnet arc covers approximately 165 degrees towards the
discharge side of the drum.
Working :-
• The feed is admitted at the top and is allowed to fall on the rotating
drum. The non-magnetic material is discharged in the normal manner,
while the magnetic material adheres to the drum and falls off the
underside when the drum loses the contact of the magnet assembly.
Ball-Norton Type Separator
(Magnetic separators as
concentrators)
Mechanical operation
Chemical Engineering
Ball-Norton Type Separator :-
• Definition :-
 Ball-Norton is a types of magnetic separators equipment.
 Magnetic separation is a method of separating solid particles by means of a magnetic field. In
this method, materials having different magnetic attractability are separated by passing them
through a magnetic field. The difference in magnetic properties of different materials is
responsible for such a separation.
• Principle :-
 It works on the principle of Magnetic Properties.
• Construction:-
 A typical concentrator used for separating magnetic ores from the associated mineral matter is
the Ball-Norton machine. It consists of two horizontally staggered belt conveyors running
parallel, one above the other as shown in. A hopper is provided for feeding the feed material
to the lower belt and a stationary magnet assembly is incorporated in the upper belt conveyor
near the discharge end.
Working :-
• The material to be separated is fed to the lower belt in the form of a
thin sheet and is conveyed under the second belt where it is
subjected to a magnetic field. The nonmagnetic material is discharged
in the normal manner, whereas the magnetic material adheres to the
lower side of the upper belt and thus carried some distance away
from the discharge point of non-magnetic materials. It ultimately
drops-off the belt in a separate compartment when it leaves the
magnetic field, i.e., when the belt loses the contact of the magnet
assembly. In this way the magnetic material is separated from the
non-magnetic material.