MS-4012 Peralatan Mesin

di Industri Proses

Screening and Size Reduction

Andi Isra Mahyuddin
KK Perancangan Mesin
Fakultas Teknik Mesin & Dirgantara
Institut Teknologi Bandung
2019

Screening & Size reduction - AIM 1

 Overview
 Size Reduction
 Classification  screening
 size reduction process usually requires screening
 MS 4012:
– introduction to processes requiring size
reduction and equipments needed
– Term project, group of 3 on size reduction and
screening process. Report on review of a
particular equipment, including engineering
analysis.

Screening & Size reduction - AIM 2

 Term Project
 Report may be a size reduction or
classifying equipment
 Report should be brief but informative,
and include
– Process
– The way things work
– Selection, or design
– Plus and minus points ...
 Report due: Final Exam date (May ??,
2019)
Screening & Size reduction - AIM 3
Size Reduction

 Proses untuk memperoleh material

dengan ukuran atau kisar ukuran
tertentu
 memisahkan mineral atau kristal
senyawa kimia yang bersatu dalam
fasa padat

Screening & Size reduction - AIM 4

Size Reduction (2)
minerals - 0
 Size reduction & control
Size reduction and size control  requested size distributions from feed material.
Size reduction - crushing of rock and minerals
By tonnage this is by far the largest process operation in minerals processing. The goal is to produce
rock or (more seldom) mineral fractions to be used as rock fill or ballast material for concrete and
asphalt production. Quality parameters are normally strength, size and shape.
The size fractions are priced according to defined size intervals and can be reached by crushing
only.
Size reduction - crushing and grinding of ore and minerals
Size reduction of ores is normally done in order to liberate the value minerals from the host rock.
This means that we must reach the liberation size, normally in the interval 100 – 10 micron.
If the raw material is a single mineral (Calcite, Feldspar a.o.) the value normally lays in the
production of very fine powder (filler).
In order to maximise the value in size reduction of rock and minerals, we need both crushing and
grinding in various combinations.

Metso minerals: www. metsominerals.com

Screening & Size reduction - AIM 5

Size Reduction (2)
minerals - i
 Minerals  break into endless numbers of sizes and shapes. The
difficulty in size reduction lays in the art of limiting the number of over
and under sizes produced during the reduction.
 If this is not controlled, the mineral will follow its natural crystal
behaviour, normally ending up in over-representation of fines.
 Quality products from rock or minerals  keep the size reduction
curves as steep as possible.
 To achieve that goal we need to select the correct equipment out of
the repertoire for size reduction in a proper way.
 They are all different when it comes to reduction technique,
reduction ratio, feed size etc. and have to be combined in the
optimum way to reach or come close to the requested size
interval for the end product.

Metso minerals
Screening & Size reduction - AIM 6
Size Reduction (2)
minerals - ii
 Feed material
All operations in size reduction, both crushing and grinding are
determined by the feed characteristics of the minerals (rock/ore).
The key parameters we need are the “crushability or grindability”, also
called work index and the “wear profile”, called abrasion index.
 Reduction ratio
Reduction operations are performed in stages. All equipment
involved, crushers or grinding mills have different relation between
feed and discharge sizes. This is called reduction ratio.

Screening & Size reduction - AIM 7

Size Reduction (2)
minerals - iii
 The art of crushing
Crushing means different things for different operations and the
production goals are not always equal.
Crushing rock Crushing gravel Crushing ore

Limited reduction Limited reduction Maximum reduction

Cubical shape Cubical Shape Shape of no importance
Over and undersize Over and undersize Over and undersize of
important important minor importance
Flexibility Flexibility Flexibility of minor
Crushing and Screening Less crushing -more importance
screening More crushing - less
screening
Low production costs
High utilisation

Screening & Size reduction - AIM 8

Size Reduction (3)
 Industri proses: reduksi ukuran agar lebih reaktif
atau untuk mengektraksi bagian
 contoh:
– ore  mineral
– limestone  industri semen
– batubara  bahan bakar
– tebu dan bit  gula
– biji-bijian  tepung
– kayu pohon  kertas

Screening & Size reduction - AIM 9

Cement Making - Aberthaw

Screening & Size reduction - AIM 10

Aberthaw
Size Reduction (4)
 memerlukan proses screening atau
pengklasifikasian
 dibagi atas tiga tahap:
– kasar (coarse) - feed size: 5 - 250 cm >
– sedang (intermediate) - feed size: 2.5 - 7.5 cm
– halus (fine) feed size: 0.5 - 1.25 cm
 crushing and grinding
 Grinding  5 – 20 mm end-product
Screening & Size reduction - AIM 11
Size Reduction (4)
 Variabel operasi:
– kandungan air,
– rasio reduksi,
– free crushing & choke feeding,
– closed & open circuit
– ukuran, kekerasan dan struktur material

Screening & Size reduction - AIM 12

Size Reduction (5)
 Jenis:
– kasar (coarse) material keras:
• jaw crusher: e.g. Blake and Dodge,
• Gyratory,
– kapasitas untuk panjang, L dan gape, G:
• T = 0,6 LS (Taggart)
–T = kapasitas, ton/jam
–L = panjang bukaan
–S = lebar terbesar keluaran
Screening & Size reduction - AIM 13
Size Reduction (6)
– kasar (coarse) material lunak:
• Bradford breaker: batubara,
• hammer mill,
• squirrel-cage disintegrator
– sedang (intermediate):
• Cone crusher etc.,
– halus (fine): fine grinding (penggilingan)
• shear load
• jenis: roller mill, ball mill, rod mill

Screening & Size reduction - AIM 14

Size Reduction - Basic ways
 There are four basic ways to reduce
material: by impact, attrition, shear or
compression. All crushers employ one, or a
combination of these four methods.
 Impact
– sharp, instantaneous impingement of one
moving object against another -
– gravity & dynamic impact

Screening & Size reduction - AIM 15

Size Reduction - impact
– Dynamic impact has definite advantages for the
reduction of many materials and is specified under the
following conditions:
 When a cubical particle is needed.
 When finished product must be well graded, and meet
intermediate sizing as well as top and bottom specifications.
 When ores must be broken along natural cleavage lines in
order to free and separate undesirable inclusions (such as
mica in feldspars).
 When materials are too hard and abrasive for hammermills,
but where jaw crushers cannot be used because of particle
shape requirements, high moisture content or capacity.

Screening & Size reduction - AIM 16

Size Reduction - impact
Impactor

The bottom of the PCC

Reversible Impactor is
open, allowing sized
materials to pass through
almost instantaneously.
Liberal clearance between
hammers and the breaker
blocks eliminates attrition.
Crushing is by impact
only.

Screening & Size reduction - AIM 17

Size Reduction - Attrition
 the reduction of materials by scrubbing it between
two hard surfaces.
– consumes power and exacts heavier wear on hammers
and screen bars, but
– practical for crushing less abrasive materials such as
pure limestone and coal.
– Attrition crushing is most useful in the following
circumstances:
 When material is friable or not too abrasive
 When a closed-circuit system is not desirable to control top
size.

Screening & Size reduction - AIM 18

Size Reduction - attrition
 When a PCC Non-
Reversible Hammermill is
used for reduction,
material is broken first by
impact between hammers
and material and then by
a scrubbing action
(attrition) of material
against screen bars.

Screening & Size reduction - AIM 19

Size Reduction - shear
– Shear consists of a trimming or cleaving action
rather than the rubbing action associated with
attrition.
– usually combined with other methods, e.g. single-
roll crushers use shear, impact and compression
methods combined.
– Shear crushing is usually called for under these
circumstances:
 When material is somewhat friable and has relatively low
silica content.
 For primary crushing with a reduction ratio of 6 to 1.

Screening & Size reduction - AIM 20

Size Reduction - shear
shear

Reducing large feed by

a combination of shear,
impact and
compression. PCC
Hercules Single-Roll
Crushers are noted for
low headroom
requirements and large
capacity.

Screening & Size reduction - AIM 21

Size Reduction - compression
– Compression
– Done between two surfaces.
– Jaw crushers using the compression method
are suitable for reducing extremely hard and
abrasive rock.
– compression should be called for in these
circumstances:
 If the material is hard and tough, abrasive and not
sticky
 When the material will break cubically
Screening & Size reduction - AIM 22
Size Reduction - compression
compression
The PCC Pennsylvania Jaw
crushes by compression without
rubbing. Hinged overhead and
on the centerline of the crushing
zone, the swinging jaw meets the
material firmly and squarely.
There is no rubbing action to
reduce capacity, to generate fines
or to cause excessive wear of jaw
plates.

Screening & Size reduction - AIM 23

 Crusher selection
1. Will it produce the desired output size and shape at the required
capacity?
2. Will it accept the largest input size expected?
3. What is its capacity?
4. Will it choke or plug?
5. Can it pass uncrushable debris without damage to the crusher?
6. How much supervision of the unit is necessary?
7. Will it meet product specifications without additional crushing stages
and auxiliary equipment?
8. What is the crusher's power demand per ton per hour of finished
product?

Screening & Size reduction - AIM 24

 Crusher selection (cont.)
9. How does it resist abrasive wear?
10.Does it operate economically with minimum maintenance?
11.Does it offer dependable and prolonged service life?
12.Is there convenient availability of replacement parts?
13.Does it have acceptable parts replacement cost?
14.Does it have easy access to internal parts?
15.Is the crusher versatile?
16.How does the initial cost of the machine compare with its long term
operating costs?
17.Is experienced factory service readily available?

Screening & Size reduction - AIM 25

Closed Circuit Crusher System

PCC
Screening & Size reduction - AIM 26
 Klasifikasi

 Menggunakan permukaan yang dapat

memisahkan material dg kisar ukuran
berbeda

Screening & Size reduction - AIM 27

Pengayakan (Screening)

 Pemisahan material berdasarkan ukuran partikel

 pada umumnya dilakukan dalam rangka
mempersiapkan material tersebut untuk proses
lanjutan
 Juga digunakan dalam analisis keefektifan
proses lain seperti grinding atau crushing.

Screening & Size reduction - AIM 28

Screening
 Pengayakan (screening): memisahkan partikel
berdasarkan ukuran menjadi dua bagian atau lebih.
 Pemisahan berlangsung pada permukaan ayak yang
berfungsi sebagai kaliber penyaring, dengan hasil
material yang lebih homogen ukurannya.
 Material terayak disebut material minus
(minus/undersize particles), sedangkan sisanya disebut
material plus (plus/oversize particles)

Screening & Size reduction - AIM 29

Contoh:
– Pada proses kimia
laju reaksi kimia diantara partikel padat dan fluida
sebanding dengan luas permukaan yang ditentukan
oleh ukuran partikel.
– Penambangan Batubara
dijual berdasarkan klasifikasi yang ditentukan oleh
ukuran partikel.
– Proses pembuatan beton
memerlukan kerikil dengan kisaran ukuran tertentu
untuk memperoleh kepadatan dan kekuatan yang
terbaik, penggunaan semen yang minimum.

Screening & Size reduction - AIM 30

Klasifikasi Pengayak

 Pengayak dapat diklasifikasikan atas:

– pengayak grizzly (grizzly screen)
– pengayak silindrik (revolving screen)
– pengayak sirkuler (rotary screen)
– pengayak kejut (shaking screen), dan
– pengayak getar (vibrating screen).

Screening & Size reduction - AIM 31

Pengayak grizzly

 permukaan terdiri dari profil batang (profile bars) yang

disusun secara paralel, sehingga celah-celah
diantaranya dapat meloloskan material minus.
 Profil batang dibuat dari baja yang memiliki ketahanan
aus tinggi, seperti baja yang mengandung unsur
mangan (Mn).
 Grizzly statis

Screening & Size reduction - AIM 32

Grizzly statis
Pengumpanan

Material
minus

Material plus

Screening & Size reduction - AIM 33

Pengayak Silindris
 Konstruksi menyerupai silinder / kerucut yang
berputar pada sumbunya
 single atau compound
 kecepatan 15-80 rpm
 dinding silinder berfungsi sebagai permukaan
pengayak
 kecepatan operasi optimal: 0.33 - 0.45 kecepatan
kritis

Screening & Size reduction - AIM 34

Pengayak Silindris (2)
Permukaan pengayak
material
masuk

material material minus

plus

Pengayak Trommel: cocok untuk partikel berukuran besar,

kapasitasnya tidak begitu besar, efisiensi relatif rendah dan laju
keausan tinggi Screening & Size reduction - AIM 35
Pengayak Kejut
 Rangka empat persegi dipasang dengan sudut
kemiringan yang kecil terhadap bidang
horizontal.
 Rangka ini mengalami gerak linier bolak-balik
pada bidang sejajar permukaan pengayak,
dengan siklus 30-800 rpm dan amplitudo 25-
1000 mm.
 Juga biasa digunakan untuk mentransportasikan
material (conveying).
Screening & Size reduction - AIM 36
Pengayak Kejut (2)

 Kelebihan: ruang yang dibutuhkan tidak terlalu

besar, dan daya lebih rendah.
 Perancangan struktur penyangga sulit
 Kapasitas lebih rendah dibandingkan dengan
pengayak getar kecepatan tinggi (high speed
vibrating screen).

Screening & Size reduction - AIM 37

Pengayak Getar (1)

 Paling banyak digunakan

 kapasitas lebih besar
 efisiensi tinggi (terutama untuk ukuran
partikel kecil)
 konstruksi ringan

Screening & Size reduction - AIM 38

Pengayak Getar (2)
 tidak membutuhkan ruang yang besar
 biaya perawatan rendah
 klasifikasi berdasarkan: kriteria modus getar,
permukaan pengayak, mekanisme penggetar,
posisi penggetar (vibrator mounting), kondisi
permukaan pengayak dan konstruksi penahan
pengayak.

Screening & Size reduction - AIM 39

Pengayak Getar (3)
penggetar

rangka

material masuk

material plus

pegas

rangka penumpu material minus Permukaan pengayak

Skematik pengayak getar

• Rangka pengayak ditumpu pegas.

• Getaran dihasilkan oleh penggetar yang dipasang pada kerangka pengayak.
• Tiap pegas penumpu dapat terdiri dari pegas tunggal, atau beberapa pegas
paralel, sesuai dengan kapasitas pengayak.
• Disamping ditumpu, pengayak getar juga dapat digantung pada tali, dengan
perantaraan sistem pegas.
Screening & Size reduction - AIM 40
Pengayak Getar (4)
 Pengayak getar dapat dipasang pada posisi horisontal
atau miring
– Pada posisi horizontal modus getar harus memungkinkan
material plus dapat bergerak menuju ujung keluaran.
– Untuk posisi miring, gaya yang dibutuhkan relatif lebih kecil
karena efek gaya grafitasi.
 Permukaan pengayak dapat berupa:
– pelat berlubang (perforated plate),
– anyaman kawat (wire woven cloth),
– atau susunan profil batang berjajar (profile bars),

Screening & Size reduction - AIM 41

Pengayak Getar (5)
 Permukaan tunggal (single deck),
– juga dapat memiliki dua atau lebih permukaan yang
disusun bertingkat (multiple decks/probability
screen), sehingga sekaligus material dapat
dipisahkan menjadi beberapa kelompok material
yang lebih homogen.
 Meskipun kebanyakan profil permukaan adalah lurus,
namun beberapa perusahaan membuat jenis permukaan
yang melengkung dari ujung pengumpanan ke ujung
keluaran (banana screen).

Screening & Size reduction - AIM 42

 Unjuk Kerja Pengayak
 Efektivitas - efisiensi
– ditentukan berdasarkan:
• perolehan produk dengan ukuran yang diinginkan
dari pengumpanan (feed), dan
• fraksi massa material yang diinginkan pada
pengumpanan, produk dan keluaran (reject) 
sampling
– faktor yang mempengaruhi: kecepatan
pengumpan, kemiringan, kandungan air.

Screening & Size reduction - AIM 43

 Unjuk Kerja Pengayak
 Kapasitas
– ditentukan berdasarkan:
• jumlah pengumpanan per satuan waktu (ton / jam)
• cara lain: ton/sq.ft area/mm aperture/24 hr.
– umumnya, jika efisiensi boleh rendah,
kapasitas .
– Faktor lain: blinding, kandungan air, proporsi
material pengumpanan

Screening & Size reduction - AIM 44

 T U G A S (1)
 Kelompok: 3 orang  ?? kelompok (?)
 Topik size reduction dan screening yang ditemui
di industri proses, maupun lainnya ...
– industri pengguna: food processing, cosmetic,
pharmaceutical, mining/mineral processing, construction,
powerplant, chemical, bioprocess/biotech, recycling, ….
 Bahasan tentang proses pada ‘industri terpilih’
dengan penekanan pada peran peralatan yang
ditinjau.
 Bahasan pada SATU PERALATAN tertentu
dengan bahasan dan analisis lebih rinci.
 Format  Powerpoint
 Presentasi Kelompok  Selected groups ++ 45
Screening & Size reduction - AIM
 T U G A S (2)
 Bahasan rinci mencakup:
– spesifikasi / kemampuan alat
– Konsumsi energi
– kapasitas dan efisiensi
– perbandingan dengan alat sejenis
 Literatur/info
– perpustakaan: TK, TA & MS - ITB
– perpustakaan industri
– industri dan lain-lain (internet: website industri)
– Industri di sekitar Bandung / saat KP.
 Kelompok & Topik: ASAP
 Due date: Senin, 15 April 2019 (topik - ?)
 Report: Senin, 13 Mei 2019
Screening & Size reduction - AIM 46
 T U G A S (3)
Literatur, contoh:
 Shreve’s Chemical Process Industries

 Chemical Process Equipment

 Unit Operations

 Various internet sites: Siko, PCC and others

http://encyclopedia.che.engin.umich.edu/Pages/MaterialsHandling/SizeReduction/Siz
eReduction.html

http://encyclopedia.che.engin.umich.edu/Pages/SeparationsMechanical/menu.html

 Books at ChE and Mining E Dept.

Screening & Size reduction - AIM 47

Screening & Size reduction - AIM 48
Screening & Size reduction - AIM 49
Screening & Size reduction - AIM 50
 https://youtu.be/JMVxN55yqto

Screening & Size reduction - AIM 51