CHAPTER 2

SCREEN ANALYSIS
Mrs. Rashmi Jadav
 SCREENING
A method of separating solid particles according to size alone is
called SCREENING.
 Solids may be separated from Solids in the dry state by method such
as screening, magnetic separation and electrostatic separation.
 Screening is an important operation for separating solid of size alone.
 It refers to the separation of solid material on the basis of size using
screens of known openings.
 Screening is the separation of the mixture of solid particles of various
sizes into two or more fraction by means of a screening surface.
 Industrial screens are made from metal bars, woven wire cloth, silk
bolting cloth, perforated slot plates.
 IMPORTANCE OF SCREENING (In Industry)
 Remove the fines from the a feed material before a reduction
equipment such as Jaw crusher, Ball Mill or Road mill.
 Prevent an incompletely crushed material from entering into other
unit operations.
 Produce a commercial or process grade material to meet specific
particle size limits.
 Remove the fines from a finished product prior to shipping.
CLASSIFICATION OF SCREEN ON THE BASIS OF
PERFORMANCE
i) IDEAL SCREEN & ii) ACTUAL SCREEN
 The objective of a screen is to accept a mixture of various sizes of
grains & separate it into two fraction, namely an underflow &
overflow.
 The Underflow is the one that is passed through the screen and it is
also called as undersized or minus (-) material and the overflow is the
one that is rejected by the screen, it means the material that remains
on the screen is called oversize or (+) plus material.
 An Ideal screen is the one which sharply separate the feed mixture in
such a way that a smallest particle in the overflow is just larger than
the largest particle in the underflow.
IDEAL SCREEN ACTUAL SCREEN

Yield Sharp separation Does not yield sharp separation

Efficiency of the screen is 100% Efficiency of the screen is less than

100%.
Such screen do not found in practice Such screen are available in
/ reality. practice.
The overflow will contain only The overflow may also contain
particles large than the cut diameter. particles small than the cut diameter.

Underflow will contain only particle Underflow may also contain particles
smaller than the cut diameter. larger than the cut diameter.
 MESH
The Mesh is the number of opening per linear inch counting from the
centre of any wire to a point exactly one inch distance.

SCREEN APERTURE / SCREEN SIZE OPENING

The minimum clear space between the edges of the opening in the
screening surface is termed as screen aperture / screen size opening.
 TYPES OF SCREEN ANALYSIS
i) Differential Analysis & ii) Cumulative Analysis

The screen analysis in which the weight fraction of the material retained
on each screen is reported in tabular or a graphical form as a function
of the mesh size / screen opening is called DIFFERENTIAL ANALYSIS.

The screen analysis in which the cumulative weight fraction of the

material retained (cumulative oversize) or passing through (cumulative
undersize) each screen is reported in tabular or a graphical form as a
function of the mesh size / screen opening is called CUMULATIVE
ANALYSIS.
 APPLICATION OF SCREENING
 Concrete Mixture Analysis
 Chocolate Mixtures Analysis
 Solubility of Medicine Analysis
 Basket Filters in Industry
 CAPACITY AND EFFECTIVENESS OF SCREEN
The capacity and effectiveness are MEASURES of the performance in
industrial screening.
The CAPACITY of a screen is the mass of material that can be failed
per unit time to a unit area of the screen.
The effectiveness of a screen (Screen efficiency) is a major of the
success of the screen in a closely separating undersize & oversize
materials.
DEFINATION & DERIVATION OF EFFECTIVES OF SCREEN
OVERALL SCREEN EFFICIENCY
Consider that the feed through a screen consist of material A & B, where A is
the oversize and B is the undersize material.
Out of the total materials fed through the screen, some part of it is removed
as overflow and remaining part of it, it is collected as underflow.
Let F be the mass flow rate of feed, (kg/hr)
D be the mass flow rate of overflow, (kg/hr)
B be the mass flow rate of underflow, (kg/hr)
xF be the mass fraction of material A in feed
xD be the mass fraction of material A in Overflow
xB be the mass fraction of material B in Underflow
DEFINATION & DERIVATION OF EFFECTIVES OF SCREEN
OVERALL SCREEN EFFICIENCY
The mass fraction of material B in feed, underflow and overflow are 1- xF, 1-
xD, and 1 - xB respectively.
Overall material balance over a screen is
F=D+B ………….(1)
Material balance of A over a screen
xF * F = xD * D + xB * B………..(2)
From Equation (1) we have
F - B = D ………..(3)
Substituting the value of D, from equation (3) into (2), we get
DEFINATION & DERIVATION OF EFFECTIVES OF SCREEN
OVERALL SCREEN EFFICIENCY
xF * F = xD (F – B) + xB * B……..(4)
xF * F = xF * F – xD * B + xB * B
(xD – xF) F = (xD – xB) B……….(5)
B / F = (xD – xF) / (xD – xB) ……..(6)
Similarly, elimination of B from equation 1 and 2 gives
D / F = (xF – xB) / xD – xB)………..(7)
The effectiveness of the screen (Screen efficiency) is a measure of the
success of the screen in closely separating undersize and oversize material.
The screen effectiveness based on the oversize of material is the ratio of
amount of oversize material A i.e. actually in the overflow to the amount of
oversize material A in the feed.
DEFINATION & DERIVATION OF EFFECTIVES OF SCREEN
OVERALL SCREEN EFFICIENCY
Screen effectiveness = EA = D * xD = Quantity of Oversize of Overflow….(8)
Based on material A F * xF Quantity of Oversize in the feed

Similarly, the screen effectiveness based on the undersize material is given

by
EB = B * (1 – xB) / F *(1 – xF) ……. (9)
The overall effectiveness of a screen can be given by
E = EA * EB ……. (10)
Where E is the overall effectiveness of the screen
DEFINATION & DERIVATION OF EFFECTIVES OF SCREEN
OVERALL SCREEN EFFICIENCY
Substituting the values of EA & EB from equation (8) & (9) into equation (10),
we get
E = D * B * xD (1 – xB) / F2 * xF * (1 – xF)………(11)
Substituting the values of D / F and B / F from equation (7) and (6) into
equation (11), we get
E = (xF – xB) (xD – xF) xD (1 – xB) / (xD – xB)2 (1 – xF) xF ........ (12)
 TYPES OF SCREENING EQUIPMENT
Screening Equipment can be classified on the basis of size of material
as the screens may be required to pass grains ranging from several
mm In diameter down to 200 mesh.
i. Grizzlies (Fixed inclined screens) are used for the coarse screening of
large lumps.
ii. Trommels (revolving screens) are generally for fairly large material.
iii. Shaking and vibrating screens are used in coarse range and also
for fine sizing.
 MOTIONS OF SCREEN
In the screening operation,
coarse particles passed
easily through the large
opening in a stationary
surface but for fine
particles the screen must
be agitated by shaking
gyrating or vibrating it
mechanically or electrically.
The figure show typical
screen motion
 GRIZZLIES / GRIZZLY SCREEN
CONSTRUCTION
 A grizzly is a grid of parallel metal bar set in a inclined stationary
frame, with a slope of 30 to 45 degree. The slope, and therefore the
path of the material is parallel to the length of the bars.
 The length of the bar may be upto 3 meters and the spacing between
the bars is 50 to 200 mm. The material of the construction of the bar
is manganese steel to reduce wear.
 Usually the bar is shaped in such a way that its top is wider than the
bottom, and hence the bars can be made fairly deep for strength
without been choked by material passing partway through them.
 A stationary grizzly is usually used for a dry free flowing material and
is not satisfactory for a moist and sticky material.
FIGURE
 GRIZZLIES / GRIZZLY SCREEN
WORKING
 A coarse feed (say from a primary crusher) is fed at the upper end of
the grizzly. Large chucks roll & slide to the lower end, whereas small
lumps having size less than the opening the bars fall through the grid
into a separate collector.
 If the angle of inclination to the horizontal is greater, greater is the
output but the lower is the screen efficiency.
 Stationary inclined woven metal screens operating in the same way
that separate particles 12 to 100 mm in size.
A grizzly finds it greatest application in the separation of the
undersize (Fines) from the feed to a primary crusher. A stationary
grizzly is the simplest of all separating devices. It requires no power
and it the least expensive to install and maintain.
 GRIZZLIES / GRIZZLY SCREEN (CONT.)
WORKING (CONT.)
 As the openings in the grizzly have a tendency to get blocked by
wedge shaped particles, the labour requirement for operating in the
grizzly is high and it is difficult to change the openings in the bars.
 Grizzles are used for only the coarsest and roughest separations.

APPLICATION
 SCALPING
 SEPERATING
 SCREENING
 WASHING
 TROMMEL
CONSTRUCTION
A Trommel is revolving screen consisting of a cylindrical frame
surrounded by wire cloth or perforated plate (which acts as a
screening surface). It is open at one or both ends and inclined at a
slight angle to the horizontal so that the material is advanced by the
rotation of the cylinder. These units revolve at relatively low speeds of
15 to 20 rpm.
 A Trommel is a mechanically operated screen consisting of a slowly
rotating perforated cylinder (or cylindrical frame) surrounded by wire
cloth (or perforated plate) with its axis at a slight angle to the
horizontal.
 TROMMEL
CONSTRUCTION
 The performance is the screening surface may be of the same size
throughout (i.e. over the whole length of the cylinder) or may be of
different size in which case the small size perforation section is near
the feed end. It is driven at the feed end through a gear mechanism.
It has a feed point at the upper end, an undersize product discharge
below the screening surface and a oversize discharge at the opposite
end (lower end).
FIGURE
 TROMMEL
WORKING
 The material to be screened is fed at the upper end and gradually
moves downward screening surface towards the lower end. In doing
so, the material passes over the apertures of gradually increasing
sizing (as the single cylinder is provided with perforation ranging from
the finest desired at the feed end to the coarsest at the discharged
end.
 If the single cylinder is provided with the screen having three different
size perforation then we get four fractions. The finest material is
collected as the underflow in the compartment near the feed and the
oversize material (coarsest) is withdrawn from the discharge end.
Such type of arrangement is usually used for smaller capacities.
 TROMMEL AND TROMMEL ARRANGEMENTS
WORKING (cont.)
 With this type of trommel, there is tendency of blockage of the
apertures by the large material and the screen with the finest
opening being weakest it is subjected to the lower wear.
 The operating speed of a trommel is 30 to 50% of the critical speed
(the critical speed is the one at which the material is carried
completely round in contact with the screening surface).

APPLICATION
• Mineral industries.
• solid-waste processing industries.
 COMPARISION / DIFFERENCE
GRIZZLIES TROMMELS
These are stationary inclined These are revolving screens
screens
Usually, screen is a grid of metal bar Usually, screen is a perforated
cylindrical member.
Openings in screen are larger Openings in screens are smaller
They handle large size feed They handle small size feed

Capacity is large Capacity is relatively small

Labour requirement is large Labour requirement is low

Cheap construction Relatively expensive construction

 VIBRATING SCREEN
CONSTRUCTION
 In some situation, the screen is rapidly vibrated with small amplitude
to keep the material moving and prevent blinding as far as possible.
Vibrating screens are commonly used in industry where large capacity
and high efficiency are desired.
 The vibration may be produced mechanically or electrically, according
to we have mechanically vibrated screen and electrically vibrated
screen.
 The vibration may be produced either mechanically or electrically with
frequency of 1800 or 3600 or even more per minute. Mechanical
vibrations are generally passed on from high speed eccentrics to the
casing and from there to inclined screens to that the whole assembly
is vibrated.
 VIBRATING SCREEN
CONSTRUCTION (cont.)
 Electrical vibrations are generally passed on from heavy duty
solenoids directly to the screens so that only screens are vibrated.
 Vibrating screens may be mounted in a multideck fashion (not more
than three decks) with the coarsest screen at the top, either
horizontally or inclined upto 45 Deg.
 Figure shows a directly vibrated (Electrically) screen. Electrically
vibrated screen are widely used in chemical industry. The vibrating
screens have accuracy of sizing, increased capacity per square meter
and low maintenance cost per ton of material.
 VIBRATING SCREEN
WORKING
 In case of the single screen, the vibration are given to screen to effect
the separation of solid particles into two size fraction. In case of
vibrating screen (generally consist of three decks), the material to be
separated is fed to the top screen and simultaneously the screen are
vibrated either electrically or mechanically at a frequency of 1000 to
3500 per minute.
 Due to vibration the particles in the screen are kept moving and due
to inclination given to screen, the over size material travel along the
screen and is collected separately.
 The undersize material is passes through screen and is collected.
Four fractions are obtained with a three decks screen.
FIGURE
ASSIGNMENT
THANK YOU