Lubert Joseph Campo
ENCH 5A
DODGE JAW CRUSHER
Principle of operation
The Dodge Crusher finds favor as the initial crusher in
small plants, and as a secondary crusher. It consists of a
heavy frame carrying a movable jaw supported in bearings
at the bottom. The jaw is one side of a triangular shaped
lever, and receives its motion from an eccentrically
operated vertical pitman, the jaw movement being
practically nothing at the bottom where supported and increasing to a maximum at the
top of the opening. Its capacity is governed by the opening at discharge point, but
weight for weight the Dodge will handle and crush a larger piece of rock than any other
crusher. It works well with dry ores and those free from talc and clay; it is simple and
easily operated and is especially adapted to small producing mines. The movable jaw is
pivoted at the bottom and connected to an eccentric shaft. The universal crushers are
pivoted in the middle so that the jaw can swing at the top and the bottom as well.
Maximum amplitude of motion is obtained at the top of the crushing plates.
Industrial Application
Small scale mining
Metallurgical
Construction
Advantages
Can take very large feed
Uniform product can be obtained
Large size reduction
Low operating cost
Low maintenance cost
Low energy requirement
Disadvantages
High tendency to choke
Can be used only for dry feed
References
Coulson and Richarson, Chemical Engineering(Particle Technology and Separation
Process) 5th edition
Towler and Sinott, Chemical Engineering design(Principles, Practice and Economics of
Plant & Process Design
[Link]
Lubert Joseph Campo
ENCH 5A
PIN MILL
Principle of Operation
Material is fed centrically by a dosing mechanism and
magnetic separator. Grinding is done by impact and
whirling between the concentrically mounted pin rows of the
rotating and the stationary discs. Particle size is determined
by the speed, number and type of pins.
Industrial Applications
Utilized for deagglomeration, mixing and homogenizing chemical and pharmaceutical
products as well as for cryogenic pulverizing applications.
Plastics
Food products
Pharmacetical industry
Chemical industry
Mining industry
Advantages
Easy access to the grinding chamber due to large door
Very fine powders due to high speed
Availability of special designs for cryogenic grinding
Disadvantages
Pins wear easily
References
Coulson and Richarson, Chemical Engineering(Particle Technology and Separation
Process) 5th edition
Towler and Sinott, Chemical Engineering design(Principles, Practice and Economics of
Plant & Process Design
[Link]
Lubert Joseph Campo
ENCH 5A
[Link]
[Link]
RONG ROLL MILL
Principle of operation
The mill comprises at least one grinding ring, at least
one roller fitted inside the grinding ring and at least one
unit fitted between the roller and the grinding ring. The
feed material is charged to a space before the grinding
path where it is subjected to centrifuging action.
Hereafter the material and the air are carried axially
through the mill. The material to be ground is fed
continuously by gravity, or pumped into a top feed
cylinder. As it moves down the cylinder, it is subjected to crushing and
shearing between the roller ridges and the stator. The grooves aid transport of pasty
material through the mill. Ground product is discharged at the bottom. Crushing force
is created mainly by the radial acceleration of the rollers, and shearing action is
induced in wet grinding by high velocity gradients between roller ridges and the stator.
Industrial Applications
Biomass processing
Mineral processing
Metal powders
pharmaceutical
coal and slurry fuels
Advantages
High capacity relative to equipment size
Dry and wet grinding
Slurry and paste grinding
Flexibility in operation
Combined operations and processing
Low energy consumption
References
Coulson and Richarson, Chemical Engineering(Particle Technology and Separation
Process) 5th edition
Towler and Sinott, Chemical Engineering design(Principles, Practice and Economics of
Plant & Process Design
Lubert Joseph Campo
ENCH 5A
[Link]
[Link]
PRILLING
Principle of operation
Prilling in which relatively coarse droplets are introduced into
the top of a tall,
narrow tower and allowed to fall against an upward flow of air.
This results in
somewhat larger particles than those formed in spray dryers.
Prilling towers must be of sufficient height for the particles to
be strong enough not to break on impact. Latent heat is
transferred from the drop to the air as it falls, and if significant
amounts of water are present evaporation also occurs,
increasing the cooling effect on the drop. It is important for the
temperature of the feed liquor to be as low as possible, just a
degree or two above its solidification point. Higher
temperatures require taller towers, as do larger particle sizes.
Industrial Applications
Fertilizer Production(urea and ammonium nirate)
Advantages
Able to create ideal spherical particles
Available in wide range capacity
Disadvantages
Low quality prills
Emmision of dust
References
Coulson and Richarson, Chemical Engineering(Particle Technology and Separation
Process) 5th edition
Towler and Sinott, Chemical Engineering design(Principles, Practice and Economics of
Plant & Process Design
[Link]
[Link]
Lubert Joseph Campo
ENCH 5A
[Link]
EXTRUDERS
Principle of Operation
Extrusion is the process of shaping
material by forcing it to flow through a
shaped opening in a die. Extruded
material emerges as an elongated
piece with the same profile as the
opening.
Industrial applications
Metal Industry(aluminum, brass, copper, lead, magnesium, zinc, steel, titanium)
Plastic Industry
Pipe production
Brick manufacturing
Advantages
Continuous
High production volumes
Low cost
Efficient melting
Good mixing
Disadvantages
Limited complexity of parts
Limited to cross section shape products
References
[Link]
[Link]
Lubert Joseph Campo
ENCH 5A
MULLER MIXER
Principle of operation
A muller, is an open-pan mixer in which heavy
rollers are driven over the material. A plow or
scrapers is also incorporated to lift and turn the
solids. In some mullers the pans also rotate in
the opposite direction to the rollers. Muller
wheels are mounted on independent, springloaded suspensions. As the molding sand
mixture increases in volume and strength, the
mullers react by raising and increasing the
mulling pressure. This is a versatile and inexpensive source of mixing energy which
provides the kneading and compression action of mulling.
Industrial applications
Paint industries
Pharmaceutical
Abrasives
Soap
Foundry
Carbon mixing
Putty
Advantages
Adaptive tooling
Effectively breaks up lumps and aggregates
Larger batch capacity
Disadvantages
Cannot be adapted to vacuum or different pressures
Not suitable for fluid materials
High cost and power requirements
Treats materials roughly
References
Towler and Sinott, Chemical Engineering design(Principles, Practice and Economics of
Plant & Process Design
Lubert Joseph Campo
ENCH 5A
[Link]
[Link]
[Link]
TRICKLING FILTER
Principle of operation
The trickling filter consists of a
cylindrical tank and is filled with a high
specific surface area material, such as
rocks, gravel, shredded PVC bottles, or
special pre-formed plastic filter media.
A high specific surface provides a large
area for biofilm formation. Organisms that grow in the thin biofilm over the surface of the
media oxidize the organic load in the wastewater to carbon dioxide and water, while
generating new biomass.
Industrial Applications
Waste water treatment plant
Advantages
Effective treatment
Efficient ammonia removal
Low power requirement
Low operating cost
Simple and reliable process
Disadvantages
Additional treatment needed
Generates sludge(requires treatment and removal)
High clogging chance
High maintenance cost
Potential odor problems
References
[Link]
[Link]
Lubert Joseph Campo
ENCH 5A
SIMPLE BOWL CENTRIFUGE
Principle of operation
Centrifuges can be categorized as either sedimentation or
filtration units. Sedimentation centrifugation units rely on the
density difference between the solid and liquid being separated.
As the slurry enters the spinning centrifuge, it forms an annulus
next to the bowl wall. Because of the centrifugal force, the denser
material moves outwardly toward the wall of the centrifuge bowl.
At the same time, the liquid overflows from the bowl or is picked
up by a skimmer. Quite often, the solid must be removed from the
centrifuge manually or with a cutter knife. It can also be removed
continuously with a screw conveyor. On the other hand, filtration
centrifuges filter the material with a rotating basket fitted with a
filter medium, where the centrifugal force of rotation expels the
liquid through the filter. In tubular-bowl centrifuges, feed enters
from the bottom of the cylindrical bowl. A distributor and baffle assembly accelerates the
incoming liquid to rotor speed. Then, a baffle separates the feed into its components
(two liquid layers for liquid/liquid separations, or solid and liquid layers for solid/liquid
separations). The outer layer, which consists of the heavier components, becomes
concentrated against the wall, while the inner layer, which consists of thelighter
components, floats on top.
Industrial applications
Diesel purification
Pharmaceutical
Food industries
Paint industries
Biomass separation
Gum clarification
Beverage industry
Advantage
Can be used for liq-liq and solid-liq separation
Disadvantage
foaming of liquids may occur
Lubert Joseph Campo
ENCH 5A
References
[Link]
[Link]
[Link]
GAS CENTRIFUGE
Principle of operation
The gas centrifugation process allows gas to constantly
flow in and out of the centrifuge. The gas centrifuge
consists of a cylindrical rotor, a casing, an electric motor,
and three lines for material to travel. The gas centrifuge is
designed with a casing that completely encloses the
centrifuge. The cylindrical rotor is located inside the casing,
which is evacuated of all air to produce a near frictionless
rotation when operating. The motor spins the rotor, creating
the centripetal force on the components as they enter the
cylindrical rotor. There are two output lines, one located at
the top of the centrifuge and the other located at the
bottom. The heavier molecules will segregate to the bottom
of
the centrifuge while the lighter molecules will segregate to
the top of the centrifuge. The output lines take these separations to other centrifuges to
continue to the centrifugation process.
Industrial applications
Separation of radioactive isotopes in nuclear plants
Advantages
High efficiency
Small number of stages required
Disadvantages
Most technical is hardy available due to nuclear secrecy
References
[Link]
[Link]
id=Frg8AAAAIAAJ&pg=PA104&lpg=PA104&dq=gas+centrifuge+advantage&source=bl&
ots=2gigY9oCuW&sig=asIv45JpokNdHFE5AH5RD0KuXFU&hl=en&sa=X&ei=F05zVM_
pAZD28QXEiYGoCw&ved=0CDUQ6AEwBA#v=onepage&q=gas%20centrifuge
%20advantage&f=false
Lubert Joseph Campo
ENCH 5A
ELECTROSTATIC PRECIPITATOR
Principle of operation
Electrostatic precipitators, such as the one
shown here, work by exposing particles in the
feed stream to an electrostatic field. The
particles are small and easilty collect a
charge. The charged particles are then
collected and removed by collectors that are
oppositely charged. The collectors get
covered with particles and are cleaned off
periodically. The particles are generally
discarded but can be further processed if
profitable. Electrostatic precipitators can be
designed for horizontal flow or vertical flow, as in the schematic below. The feed gas
enters near the bottom and rises to the top. As it enters, the stream passes electrodes
that give the particles a charge, usually negative. When the stream reaches the
collectors, the particles are attracted to the grounded surface that is oppositely charged.
The feed stream, now free of particles, exits out the top of the precipitator. Electrostatic
precipitators usually have efficiencies of greater than 99%.
Industrial application
Industrial air pollution control
Particle emission reduction
Vent exhaust in food processing
Advantages
High efficiency (up to 99% particle removal)
Collected particles can be recovered
Low pressure drop
Disadvantages
Clogging may occur
Safety hazards with high voltage electrodes
Large space requirements
Lubert Joseph Campo
ENCH 5A
References
[Link]
cipitators/[Link]
ION EXCHANGER
Principle of operation
Ion exchange is based on sorption, the
transfer of solutes from fluid to solid
particles. Undesired anions or cations from
a liquid are exchanged for ions of the
same charge within a resin. Ion exchange
occurs on a resin. Fixed bed ion
exchangers are the most basic and most
commonly used type of ion exchanger.
The resin beads are housed in vertical,
cylindrical pressure vessels made of steel
or rubber-lined stainless steel. Spargers at
the top and bottom of the fixed bed ion
exchanger distribute the liquid containing
undesired ions and support the resin. The resin contains desired ions of the same
charge as the undesired ions, and permanently bound co-ions of the opposite charge.
The undesired ions bind to the fresh resin, shown by the purple resin beads in the
animation below, causing the desired ions to transfer to the liquid. Exhausted resin,
shown by the green beads in the animation below, is depleted of desired ions and is
regenerated by contact with a downflow of high concentration of the desired ions. If the
column is operated in batch mode, it will run until equilibrium is reached.
Industrial applications
Waste treatment plants
Chemical and water recovery
Advantages
Requires less maintenance
Disadvantages
Less efficiency near equilibrium
References
Lubert Joseph Campo
ENCH 5A
[Link]
mns/[Link]
REVERSE OSMOSIS
Principle of operation
Feed solutions have significant
osmotic pressure, which must be
overcome
by
the
hydrostatic
pressure applied as the driving
force. Osmotic pressure is the result
of the system attempting to move
toward equilibrium. The pure water
will attempt to flow through to the
salt solution side of the membrane,
a process known as osmosis, to
create equal concentrations of salt on both sides. The pressure needed to overcome
osmosis is known as osmotic pressure.
Industrial application
Water purification
Industrial water processing
Water for medical use
Purification of water for steam cycle
Production of ultrapure water for
semiconductors
Water softening
Pharmaceutical industry
Food processing
Advantages
Efficient desalination
Low replacement cost
Long lifespan
Can be operated at high pH
Disadvantages
fabrication
of
microelectronics
and
Lubert Joseph Campo
ENCH 5A
Pressure requirement to counter the osmotic pressure of the system.
Capital and operating costs are high.
Membrane fouling can occur, which results in lower osmotic pressure.
Pretreatment of the feedwater may be necessary to reduce the concentration of
particles that cause fouling.
Reference
[Link]
[Link]