EXPERIMENT NO 1

AIM OF THE EXPERIMENT

Perform the crushing operation by using jaw crusher or gyantory crusher for given sample.

MATERIAL REQUIRED
 Iron ore
 Jaw crusher
 Weight balance
 Sieve shaker
THEORY

Jaw crusher: Jaw crusher is used for the reduction of ore from mine having 1m in size to
100mm .sometimes feed may be 2-3 m in size.
Jaw crusher consists of two crushing faces the jaws, one of which is stationary and mounted rigidly
in the crusher frames while the other one moves alternatively towards the stationary jaw and away
from it by a small throw. In jaw crushers, the ore is squeezed repeatedly until it breaks and final
escape of the crushed product through the minimum rate at the bottom. The jaw crusher consists of
cast steel frame. Jaws are made up of cast steel lined with abrasion resistant metal, usually had fielf
(Mn) steel.

Energy Requirement: Energy consumption in jaw crusher depends upon following facts:-
1. Size of the feed
2. Size of the product
3. Capacity of crusher
4. Hardness of ores

Principle: The crushing action in jaw crusher result from stress applied to the ore particle by
moving. Jaw in the machine working against a stationary part. Due to this stress ore breaks into
smaller pieces

Advantages:

1. Low maintanace cost .

2. Production rates are high.
3. Less energy required than other crusher.
4. Jaw has long life.
 JAW CRUSHER

Procedure:

1. Initially 1 kg of dry iron ore is taken through a weight balance and feed into the jaw crusher.

2. The time taken for crushing and number of revolution are noted down.

3. The product size of each case was determined and the crushed product is feed into a stack of
sieve, vertically arranged in such a way that the sieve having longer opening are at the top and finer
opening are at the bottom.

4. The mass retained on each screen get calculated and the product size is measured graphically.

Table:

Reciprocal
Avg.
[Link] Sieve Mass Mass Cumulated of avg.
Sieve No. Particle
. Opening Retained Fraction Mass particle
size
size

Conclusion: From the above experiment we study the operational procedure of the Jaw Crusher.

1.
 EXPERIMENT NO 2

AIM OF THE EXPERIMENT:

To study the effect of grinding with frequency (RPM) in Ball mill.

MATERIALS / APPARATUS REQUIRED:

1. Ore / coal

2. Different sieve screens of ASTM size.

3. Ball mill

4. Weight balance

5. Ro-Tap sieve shaker

THEORY:
Ball mill is a tumbling mill, where in size reduction occurs as a result of impact of the balls, and by attrition. The
ball mill consists of a cylindrical shell rotating about it axis. Cylindrical mills are classified according to the mode
of product discharge taking place from the mill. Different parts of ball mills are:

1. Cylindrical shell

2. Inner surface or liner

3. Grinding media

4. Drive

The grinding process is attributed to 3 different stages of ball mill working.

i. Cascading
ii. Cataracting
iii. Centrifuging

If the speed of the ball mill is too low then only cascading occur, and particle lead to rolling down of the ball and
limiting grinding will occur. On the other hand, if the speed of the ball is very high (greater than critical speed)
centrifuging occur leading to little or no grinding. So the mill is to be operated between two extreme speed i. e
below critical speed of the mil.

Critical Speed of the Ball Mill:

The minimum rotational speed at which centrifuging occurs in a ball mill is defined as its critical speed. It has
already been noticed that no grinding takes place in the ball mill when it centrifuges. So the operating speed of the
mill should always be less than its critical speed enabling the media to deliver impacts at the toe or knee of the mill
to result in grinding.
Mathematically, critical speed is given by
 critical speed ( Nc )=
1
2π √ g
R−r

The effective speed of the ball mill should be 65-80% of the theoretical critical speed. The lower value is for wet
grinding while the higher value is opted for dry grinding.

Fig.11:(a)Different Stages &zones of( a) Ball mill (b)Forces working on the Grinding media

PROCEDURE:
 Take 1 kg of feed (-1/2” to + ¼”) in the ball mill. Place 10 numbers of balls in it. Allow the machine to
run for 10minutes.

 After 10 min remove the material and screen it through a 200- mesh screen the amount of fines obtained
is noted.

 Then take the same material mix it and add it to the ball mill.

 Grind it for another 5 min. then again screen it. This gives the amount of fines obtained for a grinding
time of 15 min. Repeat the same for 20-30 min
TABULATION:
Sl. Sieve Sieve [Link] Mass Mass Cumulativ Reciprocal of
No. No openin size (Dpi) Retained Functio Massfunctio Avg. Particle
g n n Size(1/Dpi)
GRAPH
 Plot a graph between reciprocal of avg. particle size (1/Dpi) vs cumulative mass fraction is plotted.

 Plot a graph between % fines vs frequency of grinding.

CALCULATION:
The area under the avg. particle size (1/Dpi) Vs cumulative mass fraction graph is calculated, and the reciprocal
of that area gives the avg. product size.
CONCLUSION:
From the above experiment, we plotted the graph between reciprocal of avg. feed size (1/Dpi) vs cumulative
mass fraction, and avg. product size was calculated mechanically, and also concluded that fineness increases
with increase in crushing frequency up to critical speed, and above critical speed there is no grinding takes
place.
 EXPERIMENT NO 3

AIM OF THE EXPERIMENT:

To separate a mixture of two minerals of different densities by gravity concentration using Wilfley Table, and
determine the efficiency of Tabling process.

MATERIALS / APPARATUS REQUIRED:

1. Ore / coal

2. Different sieve screens of ASTM size

3. Ball mill

4. Weight balance

5. Wilfley Table

6. Water

THEORY:

 Tabling takes place on the Shaking or Wilfley table. The Shaking or Wilfley table essentially consist of a
substantially plane surface called the deck. The table is slightly inclined to the horizontal from the left to
right and shaken with an asymmetrical motion in the direction of the long axis. Asymmetrical motion makes
the stroke of the table faster in one of the directions and slower in reverse.
 Usually a slow forward with a rapid return is used during the operation of the Wilfley table. This causes the
mineral particles to crawl along the longitudinal cleats or riffles that are fixed on the table surface in the
direction of the table movement. The wash water flows over the table at right-angles to the direction of jog.
A feed of 25% solids by weight is introduced through the feed box at the upper corner of the table, and as
the feed particles hit the deck they are fanned out by a combination of differential motion, and transversely
flowing water.
 The jolt during the return stroke causes the heavier particles to work-down the bed to form the bottom layer.
The lighter gangue materials are thrown into suspension, and are discharged out over the edge of the table
opposite to the feed box by the wash water.
 The heavier minerals finally arrange themselves on the smooth unriffled proportion of the table when they
encounter the full force of the wash water. The middlings are collected in that portion of the table
intermediate between concentrate & tailings. A finer feed requires a higher reciprocating speed but a smaller
stroke length while a coarser feed requires larger stroke length with reduced reciprocating speed. Hence the
stroke length along with the reciprocating speed of the table can be adjusted as per the feed material to be
classified on the table.
 Fig 12:Schematic Diagram of Wilfley Table

PROCEDURE:
 Weigh accurately 25 gm of (-35, +60 mesh) coal, and add 25 gm of sand. Then mix it up thoroughly using
Ball mill for 15-30 min. Then, prepare a slurry of fluid out of this mixture.
 Charged the slurry along with water at a particular flow rate in the feed point. Collect the sand in a
collection tray at the heavy mineral discharge end, Collect the coal at the tailing / light mineral discharge
end, and recycles the middling obtained.
 Dry the collected coal and sand. Then weigh it.
 Repeat the same procedures for different flow rates
CALCULATION:
The efficiency of the Tabling process gets calculated by using the following mathematical formula

𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 (𝑖𝑛 %)= ⌊

Wt of t h e collected coal
×100 ]
amount of coal∈feed

CONCLUSION:
 Hence, the coal and sand was separated out from the mixture, and efficiency was calculated.

EXPERIMENT NO 4

AIM OF THE EXPERIMENT:

Beneficiation of Ore pulp mix using Froth Floatation Cell.

Materials / Apparatus Required:

1. Ore / coal

2. Different sieve screens of ASTM size

3. Froth Floatation Cell

4. Weight balance

5. Water

6. Pine oil

THEORY:
Froth Flotation Process:
1. Flotation is the most widely used method of wet concentration of ores for separating the valuable constituent of
the ore from the worthless gangue. The process is primarily a surface phenomenon based on the adhesion of some
mineral particles to air, and simultaneous adhesion of other particles to water in the pulp.

Schematic Diagram Flotation Process

[Link] process is the most efficient, but is the most complex of all ore beneficiation processes. In this process
adhesion is made between air bubbles, and small mineral particles in such a way that they rise in that pulp. The
floating mineralized froth is then skimmed off while the other minerals are retained in the pulp. This fact is well-
known flotation proper.

3. Floatation Cell Function of aeration element is based on step diffuser design. Acceleration in the aeration tube
generates a vacuum, which sucks the necessary process air, which forms bubbles in the stock. Bubbles remove the
particles from the stock suspension.

4. Floatation Cell Dirt laden bubbles rise to the top of the cell, forming a foam layer. The foam layer gets skimmed
off into the foam collecting chamber.

5. Froth flotation is employed widely in metallurgical industries and coal.

6. In the pneumatic flotation cells compressed air is directly blown into the pulp while in the sub-aeration cell a
rotating impeller serves as a pump, which draws in air through the hollow shaft of the impeller and distributes the
same into the pulp to produce the froth. In the laboratory, usually a rotating, hollow impeller type sub-aeration cell
is used.

Froth Flotation Cell Operation

PROCEDURE:
 Take 45gm weight of finely ground coal, and 5gm weight of sand. Mix it thoroughly.
 Add 5 ltr of water to the cell and start the unipellets. Then, add 2/3 drops of pine oil (floating agent collector),
and a pinch of detergent to create a stable froth.
 Now, add the coal & sand mixture into the flotation cell, Skim off the froth, and collect the same through the
reservoir.
 Then, dry the collected froth, and find out the separation efficiency.

Observation & Calculation:

Measure the following parameters
 Weight of initial coal taken (W1)
 Weight of sand taken (W2)
 Weight of sand dried froth taken (W3)
 Weight of filter paper
 Total weight of filter, and coal
 Weight of the dried coal (W4)

So,
using the above data, we can calculate the separation efficiency using the following formula

×100]
W4
Separation efficiency (in %) =[
w2
Conclusion:
Hence, we have studied about froth flotation cell, and the efficiency of the machine was found out.
EXPERIMENT-5
AIM OF THE EXPERIMENT:
To study about the magnetic separator, and the effect of magnetic field on efficiency of the process.
MATERIALS / APPARATUS REQUIRED:
1. Ore
2. Different sieve screens of ASTM size.
3. Magnetic separator
4. Weight balance

THEORY
It is a technique which is used to separate the mineral particles from gangue particles on the basis of its magnetic
properties. Actually there are three types of magnetic materials,
1. Ferro magnetic – strong magnetic field
2. Para magnetic – weak magnetic field
3. Dia magnetic – no magnetic field

Type:
 On the basis of magnetic intensity
o Low intensity magnetic separator
o High intensity magnetic separator

 Again, on the basis of medium

o Dry magnetic separator
o Wet magnetic separator

Basic Principle of Magnetic Separation Process

It works on the principle of mutual attraction of unlike charges, and mutual repulsion of like charges (Coulomb’s
law). On the basis of electrostatic charge, a body is said to be positively charged if it is deficient in electrons and is
said to be negatively charged if it has excess of electrons.

Fundamental concept of magnetic separation:

1. Low intensity magnetic separator are used for the separation of highly magnetic materials.

2. High intensity magnetic separator are used for the separation of weak magnetic materials.
 SchematicDiagramofMagneticSeparation

Procedure:

 Weight 5-6 kg of feeding ore of particular size by a digital weight balance.

 Switch on the impeller motor, and also the motor of the rake.
 Allow addition of the feed sample through the feed at a steady rate.
 Collect the ore under the flow of magnetic field thrown away from the separator
 Also collect the free flow placed nearer to the separator, and switch off the machine.
 Calculate the efficiency.

Calculation:
The efficiency of the magnetic separation calculated by using the formula given below
weight of the collected magnetic materials
Efficiency (¿ % )= × 100
weight of the total feed material

Conclusion:
Hence, we studied about the magnetic separator, and also calculated the efficiency of magnetic separation.