CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY

[PARTICULATE TECHNOLOGY]

SCREENING

1. It is desired to separate a mixture of sugar crystals into two fractions, a coarse fraction retained on an 8-mesh
screen, and a fine fraction into passing through it. What is the screen effectiveness? Screen analysis of feed,
coarse and fine fractions show

Mass fraction of +8 particles in feed =0.46 Feed

Mass fraction of +8 particles in coarse material = 0.88 xF
Mass fraction of +8 particles in fine material = 0.32
Oversize (Coarse)
8 mesh xR

Undersize (Fine material)

xP
REQUIRED: Screen effectiveness, E
SOLUTION:
To calculate the screen effectiveness, the ff formula will be used where mass fractions (xp,xF,xR) are based on
the desired material
𝑥𝑥𝑃𝑃 (𝑥𝑥𝐹𝐹 − 𝑥𝑥𝑅𝑅 ) �1 − 𝑥𝑥𝑝𝑝 �(𝑥𝑥𝐹𝐹 − 𝑥𝑥𝑅𝑅 )
𝐸𝐸 = �1 − �
𝑥𝑥𝐹𝐹 (𝑥𝑥𝑃𝑃 − 𝑥𝑥𝑅𝑅 ) (1 − 𝑥𝑥𝐹𝐹 )(𝑥𝑥𝑃𝑃 − 𝑥𝑥𝑅𝑅 )
In screening process, the material which is usually desired is the fine material so xp,xF,xR should all be based on
the fine material which are -8 particles (through 8 mesh). Since the given mass fractions are in terms of +8
particles ( on 8 mesh), then
𝑥𝑥𝐹𝐹 = 1 − 0.46 = 0.54
𝑥𝑥𝑃𝑃 = 1 − 0.32 = 0.68
𝑥𝑥𝑅𝑅 = 1 − 0.88 = 0.12
Substituting,
𝐸𝐸 = 0.4517 𝑜𝑜𝑜𝑜 45.17%

SIZE REDUCTION

1. In crushing a certain ore, the feed is such that 80% is less than 50.8 mm in size and the product size is such that
80% is less than 6.35 mm. The power required is 89.5 kW. Based on the Bond equation the power required using the
same feed so that 80% is less than 3.18 mm is? (ans: 146.7 kW)

Ore Product
Crusher
x1 =50.8 mm x2 = 6.35 mm
Power required = 89.5 kW

REQUIRED: P if same feed is used and x2= 3.18 mm (using Bond’s equation)

SOLUTION:

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

BOND’S LAW

𝑃𝑃 1 1
= 1.46 𝐸𝐸𝐸𝐸 � − � where P in hP; T in tons/min ; Ei in kW.h/ton; X1 & X2 in ft
𝑇𝑇 �𝑋𝑋2 �𝑋𝑋1

𝑃𝑃 1 1
= 0.3162 𝐸𝐸𝐸𝐸 � − � where P in kW; T in tons/hr; Ei in kW.h/ton; X1 &X2 in mm
𝑇𝑇 �𝑋𝑋2 �𝑋𝑋1

To solve for unknown, we will need the work index, Ei, which remains constant for the same material and equipment.
Thus, we can get this from condition 1

Condition 1: P=89.5 kW, x1=50.8 mm, x2= 6.35 mm

𝑃𝑃 1 1
= 0.3162 𝐸𝐸𝐸𝐸 � − �
𝑇𝑇 �𝑋𝑋2 �𝑋𝑋1
89.5 1 1
= 0.3162𝐸𝐸𝐸𝐸 � − �
𝑇𝑇 √6.35 √50.8
𝐸𝐸𝐸𝐸𝐸𝐸 = 1102.3094

Since the same feed is used for condition 2, then T also remains constant

Condition 2: x1=50.8 mm, x2= 3.18 mm

1 1
𝑃𝑃 = 0.3162(1102.3094) � − �
√3.18 √50.8
𝑃𝑃 = 146.5545 𝑘𝑘𝑘𝑘

2. A material is crushed in a Blake Jaw Crusher and the average size of particles reduced from 50 mm to 10 mm
with the consumption of energy at the rate of 13 kW/kg.s. What is the energy consumption needed to crush the
same material of an average size 75 mm to an average size 25mm assuming (a) Kick’s Law applies (b)
Rittinger’s Law applies ? (ans 8.88 kW/kg.s)

FEED Crusher PRODUCT

X1= 50mm X2=10 mm
P/T=13 kW/kg.s

REQUIRED: P if X1=75mm X2=25mm using (a) Kick’s law (b) Rittinger’s Law

SOLUTION:

KICK’S LAW

𝑃𝑃 𝑋𝑋1
= 𝑘𝑘 log � �
𝑇𝑇 𝑋𝑋2

RITTINGER’S LAW

𝑃𝑃 1 1
= 𝑘𝑘 � − �
𝑇𝑇 𝑋𝑋2 𝑋𝑋1

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

a. Using Kick’s Law

Since no unit is specified for Kick’s eqn, then any unit can be used as long as they are consistent
The value of k is constant for the same material and equipment.

Condition 1: P/T=13 kW/kg.s ; X1=50 mm ; X2= 10 mm

𝑃𝑃 𝑋𝑋1
= 𝑘𝑘 log � �
𝑇𝑇 𝑋𝑋2
50
13 = 𝑘𝑘 log � �
10
𝑘𝑘𝑘𝑘
𝑘𝑘 = 18.5988
𝑘𝑘𝑘𝑘. 𝑠𝑠
Condition 2:
𝑃𝑃 75
= 18.5988 log � �
𝑇𝑇 25
𝑃𝑃 𝑘𝑘𝑘𝑘
= 8.8739
𝑇𝑇 𝑘𝑘𝑘𝑘. 𝑠𝑠

b. Using Rittinger’s Law

Condition 1: P/T=13 kW/kg.s ; X1=50 mm ; X2= 10 mm
𝑃𝑃 1 1
= 𝑘𝑘 � − �
𝑇𝑇 𝑋𝑋2 𝑋𝑋1
1 1
13 = 𝑘𝑘 � − �
10 50
𝑘𝑘𝑘𝑘
𝑘𝑘 = 162.5
𝑘𝑘𝑘𝑘. 𝑠𝑠
Condition 2:
𝑃𝑃 1 1
= 162.5 � − �
𝑇𝑇 25 75
𝑃𝑃 𝑘𝑘𝑘𝑘
= 4.3333
𝑇𝑇 𝑘𝑘𝑘𝑘. 𝑠𝑠

HANDLING OF SOLIDS

1. One hundred tons per hour of anthracite coal are to be moved horizontally a distance of 120 ft. Select a conveyor
of each of the three classes listed, and calculate the power required to operate the system. Choose the smallest
conveyor that will do the job. Assume a bulk density of 60 lb/ft3.

a. Screw conveyor b. Flight conveyor c. Belt conveyor

GIVEN: Anthracite Coal

T= 100 tons/hr ΔZ =120 ft ρbulk = 60 lb/ft3

REQUIRED: i. HP if (a) Screw (b) Flight (c) Belt

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

ii. Choose the Smallest conveyor that can do the job

SOLUTION:

a. Screw Conveyor
𝑙𝑙𝑙𝑙
(𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐) �𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶, � (𝑙𝑙𝑙𝑙𝑛𝑛𝑛𝑛𝑛𝑛ℎ, 𝑓𝑓𝑓𝑓)
𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 𝑚𝑚𝑚𝑚𝑚𝑚
33,000
𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 2000 𝑙𝑙𝑙𝑙 1ℎ𝑟𝑟 𝑙𝑙𝑙𝑙
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 100 � �� � = 3333.3333
ℎ𝑟𝑟 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 60 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑚𝑚𝑚𝑚𝑚𝑚

For coal, coefficient= 2.5

2.5(3333.3333)(120)
𝐻𝐻𝐻𝐻 = = 30.3030 ℎ𝑃𝑃
33000

To solve for diameter of the screw conveyor the table below is used. Since from the table, capacity is in cu ft/hr, then
we need to convert

𝑙𝑙𝑙𝑙 𝑓𝑓𝑓𝑓 3 60𝑚𝑚𝑚𝑚𝑚𝑚 𝑓𝑓𝑓𝑓 3

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = 3333.3333 � �� � = 3333.3333
𝑚𝑚𝑚𝑚𝑚𝑚 60 𝑙𝑙𝑙𝑙 ℎ𝑟𝑟 ℎ𝑟𝑟

Under coal, we determine the screw diameter which will be able to handle 3333.3333, thus

Light Nonabrasive Material Heavy Nonabrasive Material Heavy Abrasive Material

Diameter of e.g. Grain e.g. Coal e.g. Ash
Screw, in. Capacity, Capacity,
Capacity, cu.ft/hr Max. rpm Max. rpm Max. rpm
cu.ft/hr cu.ft/hr
3 74 250 37 125 … …
4 171 220 86 110 46 90
5 304 210 150 105 85 85
6 500 200 255 100 135 80
7 820 190 410 95 200 75
8 1180 180 590 90 300 75
9 1600 175 780 85 400 70
10 2050 160 1030 80 516 65
12 3300 150 1660 75 820 60
14 4000 140 2000 70 1200 55
16 7000 130 3400 65 1630 50
18 9000 120 4500 60 2100 45
20 12000 115 5800 55 2860 46
We choose screw diameter= 16 in since its maximum capacity is 3400 which is above 3333.3333 ft3/hr.

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 16 𝑖𝑖𝑖𝑖

b. Flight conveyor
𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 + 10𝐿𝐿
𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 =
1000
From the table below, we determine constants a, b
Since the coal is being moved horizontally, then angle of inclination = 0 degree

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Inclination w/ Horizontal 0° 5° 10° 15° 20° 25° 30° 35° 40° 45°
Anthracite 0.343 0.42 0.50 0.586 0.66 0.73 0.79 0.85 0.90 0.945
a Bituminous 0.60 0.69 0.76 0.83 0.88 0.95 1.02 1.08 1.13 1.15
Ashes 0.54 0.62 0.72 0.80 0.85 0.90 0.97 1.03 1.06 1.10
Flights & chain
supported on blocks
0.03 0.03 0.03 0.029 0.028 0.027 0.026 0.025 0.023 0.020
w/c slide directly on the
b
track
Flights supported by 3
0.004 0.004 0.004 0.004 0.004 0.004 0.003 0.003 0.003 0.003
½ -in rollers
a = 0.343
Since it was not stated whether flights have blocks or rollers, we will compare their HP; b = 0.03 or 0.004

For S, since it was not stated, we will assume it to be S=100 fpm which is the common speed for flight conveyors

For W, assume dimensions of 8 x 18 so width of flight= 18 in

1 𝑙𝑙𝑙𝑙
𝑊𝑊 = (18 𝑖𝑖𝑖𝑖 )(𝟐𝟐) = 𝟑𝟑𝟑𝟑𝟑𝟑𝟑𝟑/𝒇𝒇𝒇𝒇
𝑖𝑖𝑖𝑖 𝑜𝑜𝑜𝑜 𝑤𝑤𝑤𝑤𝑤𝑤𝑤𝑤ℎ. 𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟𝑟 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓

Note: W was multiplied by 2 since it is the weight for both runs

Flight Conveyors
4 x 10 to 6 x 18 0.5 lb/in. of width per running foot
8 x 18 to 10 x 24 1.0 lb/in. of width per running foot
Belt Conveyors 1.0 lb/in. of width per running foot

HP using flights & chain supported on blocks w/c slide directly on the track

𝑎𝑎𝑎𝑎𝑎𝑎 + 𝑏𝑏𝑏𝑏𝑏𝑏𝑏𝑏 + 10𝐿𝐿

𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 =
1000
0.343(100)(120) + 0.03(36)(120)(100) + 10(120)
𝐻𝐻𝐻𝐻 = = 18.276
1000

HP using flights supported by 3 ½- in rollers

0.343(100)(120) + 0.004(36)(120)(100) + 10(120)

𝐻𝐻𝐻𝐻 = = 7.044
1000

c. Belt Conveyor
𝐹𝐹(𝐿𝐿 + 𝐿𝐿𝑜𝑜 )(𝑇𝑇 + 0.03𝑊𝑊𝑊𝑊) + 𝑇𝑇∆𝑍𝑍
𝐻𝐻𝐻𝐻 =
990
For F, since the type of bearing was not stated, we will compare both; F= 0.05 or 0.03
For Lo, we will also compare both so, Lo = 100 or 150
For W, using the table below

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

Flight Conveyors
4 x 10 to 6 x 18 0.5 lb/in. of width per running foot
8 x 18 to 10 x 24 1.0 lb/in. of width per running foot
Belt Conveyors 1.0 lb/in. of width per running foot

W=( 1lb/in width. ft )(in belt width) (2)

Note : for W it was multiplied by 2 since the belt conveyor has 2 runs (back and forth)

First run (top) Second run (bottom)

To solve for W, we need to determine first the belt width. We can use the following tables

Maximum Lump Size and Speeds for Conveyor Belts

Belt Maximum lump Cross Normal Maximum Belt Speeds, fpm

width, in size,in sectional Speed,
Uniform With area of fpm Free-flowing Average Abrasive
Size 90% load, ft2 material material material
fines
14 2 3 0.11 200 400 300 250
16 2 ½ 4 0.14 200 500 300 250
18 3 5 0.18 250 500 400 300
20 3 ½ 6 0.22 300 600 400 300
14 4 ½ 8 0.33 300 600 500 350
30 6 11 0.53 350 700 500 350
36 8 15 0.78 400 800 600 400
42 10 18 1.09 400 800 600 400
48 12 21 1.46 400 800 600 400
54 14 24 1.90 450 800 600 400
60 16 28 2.40 450 800 600 400

Belt width, Cu. yd/hr at Maximum capacity with materials of Various Bulk Densities, tons/hr at
in. 100fpm 100 fpm
3 3
25 lb/ft 50 lb/ft 75 lb/ft3 100 lb/ft3 150 lb/ft3
14 23.6 8 16 24 32 48
16 31.1 10 21 31 42 63
18 39.6 13 27 40 54 81
20 49.3 16 33 49 66 99
24 72.4 24 49 73 98 147
30 116.7 39 79 118 158 237

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36 173.3 57 115 172 230 345

42 242.2 82 165 247 330 495
48 324.4 110 220 330 440 660
54 422.2 142 285 427 570 855
60 533.3 180 360 540 720 1080

Since the belt width that we will choose should be able to handle the given capacity, we need to determine first the
maximum capacity at maximum speed of the different belt widths, thus by ratio and proportion

max 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @ max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @100𝑓𝑓𝑓𝑓𝑓𝑓

=
max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 100 𝑓𝑓𝑓𝑓𝑓𝑓

But, data for capacity @ 100 fpm with bulk density= 60 lb/ft3 is not yet available, thus by interpolation we get

Maximum capacity with materials of Various Bulk Densities, tons/hr at 100 fpm
50 lb/ft3 60 lb/ft3 75 lb/ft3
16 19.2 24
21 25 31
27 32.2 40
33 39.4 49
49 58.6 73
79 94.6 118
115 137.8 172
165 197.8 247
220 264 330
285 341.8 427
360 432 540

Anthracite coal is an average material . Thus, using the formula

max 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @ max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 (90% 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓) @100𝑓𝑓𝑓𝑓𝑓𝑓

=
max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 100 𝑓𝑓𝑓𝑓𝑓𝑓

Maximum Assume 90% fines

Maximum Speed Maximum capacity at
Belt width, in. capacity at Capacity @ 100 fpm
Average material maximum Speed
100 fpm
14 300 19.2 19.2*0.9 =17.28 51.84
16 300 25 22.5 67.5
18 400 32.2 28.98 115.92

Since the max capacity of 18 in belt is 115.92 which is greater than the feed 100 tons/hr, then we can use this.

Belt width =18 in

W=( 1lb/in width. ft )(18 in) (2) = 36 lb/ running ft

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For S, by ratio and proportion

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠

=
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
𝑆𝑆 400
=
100 115.92
𝑺𝑺 = 𝟑𝟑𝟑𝟑𝟑𝟑. 𝟎𝟎𝟎𝟎𝟎𝟎𝟎𝟎 𝒇𝒇𝒇𝒇𝒇𝒇

ΔZ=0 (since horizontal)

For Plain Bearings

𝐹𝐹(𝐿𝐿 + 𝐿𝐿𝑜𝑜 )(𝑇𝑇 + 0.03𝑊𝑊𝑊𝑊) + 𝑇𝑇∆𝑍𝑍

𝐻𝐻𝐻𝐻 =
990
0.05(120 + 100)(100 + 0.03(36)(345.0656) + 0
𝐻𝐻𝐻𝐻 =
990
𝐻𝐻𝐻𝐻 = 5.2519

For Anti-Friction Bearings

0.03(120 + 150)(100 + 0.03(36)(345.0656) + 0

𝐻𝐻𝐻𝐻 =
990
𝐻𝐻𝐻𝐻 = 3.8673

Conclusion

Among the three conveyors, the smallest one is the screw conveyor having a diameter of 16 in. However,
based on HP, the belt conveyor has the least power requirement. Thus, in terms of operating cost (for power), it is
best to choose the belt conveyor.

2. A screw conveyor is to be installed to convey 800 bushels of wheat per hour over a distance of 80 ft. Determine
the size (diameter), speed (rpm) and the horsepower requirements for the installation. (1 bushel= 1.2444ft3)

GIVEN:

800 bushels of wheat/hour L=80 ft

REQUIREMENT: Dscrew, S, HP
SOLUTION:

a. Diameter of Screw
To use the table below, convert capacity to ft3/hr first

𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑒𝑒𝑒𝑒𝑒𝑒 1.2444𝑓𝑓𝑓𝑓 3 𝑓𝑓𝑓𝑓 3

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 = 800 � � = 995.52
ℎ𝑟𝑟 1𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑒𝑒𝑒𝑒 ℎ𝑟𝑟

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

Light Nonabrasive Material Heavy Nonabrasive Material Heavy Abrasive Material

Diameter of e.g. Grain e.g. Coal e.g. Ash
Screw, in. Capacity, Capacity,
Capacity, cu.ft/hr Max. rpm Max. rpm Max. rpm
cu.ft/hr cu.ft/hr
3 74 250 37 125 … …
4 171 220 86 110 46 90
5 304 210 150 105 85 85
6 500 200 255 100 135 80
7 820 190 410 95 200 75
8 1180 180 590 90 300 75
9 1600 175 780 85 400 70
10 2050 160 1030 80 516 65
12 3300 150 1660 75 820 60
14 4000 140 2000 70 1200 55
16 7000 130 3400 65 1630 50
18 9000 120 4500 60 2100 45
20 12000 115 5800 55 2860 46
Since 1180>995.52, we choose 8 in

𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 8 𝑖𝑖𝑖𝑖

b. Speed in rpm

Using the eqn by ratio and proportion,

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠

=
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
𝑆𝑆 180
=
995.52 1180
𝑆𝑆 = 151.8590 𝑟𝑟𝑟𝑟𝑟𝑟

c. Horsepower

𝑙𝑙𝑙𝑙
(𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐) �𝐶𝐶𝐶𝐶𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝, � (𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙ℎ, 𝑓𝑓𝑓𝑓)
𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 𝑚𝑚𝑚𝑚𝑚𝑚
33,000

For grain, coefficient =1.3

Since density is not given, from Perry’s HB ρave= 48 lb/ft3. Assume ρave≈ρbulk = 48 lb/ft3

𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑒𝑒𝑒𝑒𝑒𝑒 1.2444𝑓𝑓𝑓𝑓 3 48𝑙𝑙𝑙𝑙 1ℎ𝑟𝑟 𝑙𝑙𝑙𝑙

𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 = 800 � �� 3 �� � = 796.416
ℎ𝑟𝑟 1𝑏𝑏𝑏𝑏𝑏𝑏ℎ𝑒𝑒𝑒𝑒 𝑓𝑓𝑡𝑡 60𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑚𝑚𝑚𝑚𝑚𝑚

1.3(796.416)(80)
𝐻𝐻𝐻𝐻 = = 2.5099
33000

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

6. A belt conveyor is required to deliver gravel at a rate of 175 tons/hr. The conveyor is to be 180ft between centers if
pulleys with a rise of 18 ft and discharge over the end. Choose the smallest conveyor that will do the job and
calculate the power required to operate the system. Compare using plain bearings and anti-friction bearings.

GIVEN: BELT CONVEYOR

L=180 ft
Δz = 18 ft 180 ft
T= 175 tons/hr 18 ft

REQUIRED:
a. smallest belt conveyor that can do the job
b. HP for plain bearings and anti-friction bearings

SOLUTION:

a. Width of belt conveyor

In order to determine the belt width, we will first need to determine the maximum capacity (at maximum speed)
at different belt widths. We can do this by using the formula from ratio and proportion which is
max 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @ max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @100𝑓𝑓𝑓𝑓𝑓𝑓
=
max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 100 𝑓𝑓𝑓𝑓𝑓𝑓

Maximum Lump Size and Speeds for Conveyor Belts

Belt Maximum lump Cross Normal Maximum Belt Speeds, fpm

width, in size,in sectional Speed,
Uniform With area of fpm Free-flowing Average Abrasive
Size 90% load, ft2 material material material
fines
14 2 3 0.11 200 400 300 250
16 2 ½ 4 0.14 200 500 300 250
18 3 5 0.18 250 500 400 300
20 3 ½ 6 0.22 300 600 400 300
14 4 ½ 8 0.33 300 600 500 350
30 6 11 0.53 350 700 500 350
36 8 15 0.78 400 800 600 400
42 10 18 1.09 400 800 600 400
48 12 21 1.46 400 800 600 400
54 14 24 1.90 450 800 600 400
60 16 28 2.40 450 800 600 400

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[PARTICULATE TECHNOLOGY]

Belt width, Cu. yd/hr at Maximum capacity with materials of Various Bulk Densities, tons/hr at
in. 100fpm 100 fpm
25 lb/ft3 50 lb/ft3 75 lb/ft3 100 lb/ft3 150 lb/ft3
14 23.6 8 16 24 32 48
16 31.1 10 21 31 42 63
18 39.6 13 27 40 54 81
20 49.3 16 33 49 66 99
24 72.4 24 49 73 98 147
30 116.7 39 79 118 158 237
36 173.3 57 115 172 230 345
42 242.2 82 165 247 330 495
48 324.4 110 220 330 440 660
54 422.2 142 285 427 570 855
60 533.3 180 360 540 720 1080

For gravel (abrasive material), we take the bulk density ρb= 105 lb/ ft3. Since the capacity at 100 fpm for this density
is not directly available from the table, we interpolate.

Maximum capacity, tons/hr at 100 fpm

Belt Width
100 lb/ft3 105 lb/ft3 150 lb/ft3
14 32 33.6 48
16 42 44.1 63
18 54 56.7 81
20 66 69.3 99
24 98 102.9 147
30 158 165.9 237
36 230 241.5 345
42 330 346.5 495
48 440 462 660
54 570 598.5 855
60 720 756 1080

We can now solve the maximum capacity @ maximum speed. Assume that the feed contains 90% fines, thus

max 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑦𝑦 @ max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 (𝟎𝟎. 𝟗𝟗𝟗𝟗)(𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 @100𝑓𝑓𝑓𝑓𝑓𝑓)

=
max 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 100 𝑓𝑓𝑓𝑓𝑓𝑓
Max Capacity at Max
Belt width, in Max speed, fpm Capacity @ 100 fpm
Speed, tons/hr
14 250 33.6 75.6
16 250 44.1 99.225
18 300 56.7 153.09
20 300 69.3 187.11

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CHE 511A: SEPARATION PROCESSES AND INTRO TO PARTICULATE TECHNOLOGY
[PARTICULATE TECHNOLOGY]

Since the maximum capacity at 20 in belt width, 187.11 tons/hr, is higher than the actual capacity, 175 tons/hr, it will
be able to deliver the gravel. Thus

𝑆𝑆𝑚𝑚𝑎𝑎𝑙𝑙𝑙𝑙𝑒𝑒𝑠𝑠𝑡𝑡 𝑏𝑏𝑒𝑒𝑙𝑙𝑡𝑡 𝑤𝑤𝑖𝑖𝑑𝑑𝑡𝑡ℎ 𝑡𝑡ℎ𝑎𝑎𝑡𝑡 𝑐𝑐𝑎𝑎𝑛𝑛 𝑑𝑑𝑜𝑜 𝑡𝑡ℎ𝑒𝑒 𝑗𝑗𝑜𝑜𝑏𝑏 = 20 𝑖𝑖𝑛𝑛

b. HP for plain bearings and anti-friction bearings

𝐹𝐹(𝐿𝐿 + 𝐿𝐿𝑜𝑜 )(𝑇𝑇 + 0.03𝑊𝑊𝑊𝑊) + 𝑇𝑇∆𝑍𝑍
𝐻𝐻𝐻𝐻 =
990
For plain bearings F=0.05, Lo=100
For anti-friction bearings F=0.03; Lo=150

1.0𝑙𝑙𝑏𝑏 𝑙𝑙𝑏𝑏
𝑊𝑊 = (20 𝑖𝑖𝑛𝑛)(2𝑟𝑟𝑢𝑢𝑛𝑛𝑠𝑠) = 40
𝑖𝑖𝑛𝑛 𝑜𝑜𝑓𝑓 𝑤𝑤𝑖𝑖𝑑𝑑𝑡𝑡ℎ. 𝑟𝑟𝑢𝑢𝑛𝑛𝑛𝑛𝑖𝑖𝑛𝑛𝑔𝑔 𝑓𝑓𝑜𝑜𝑜𝑜𝑡𝑡 𝑟𝑟𝑢𝑢𝑛𝑛𝑛𝑛𝑖𝑖𝑛𝑛𝑔𝑔 𝑓𝑓𝑜𝑜𝑜𝑜𝑡𝑡

Flight Conveyors
4 x 10 to 6 x 18 0.5 lb/in. of width per running foot
8 x 18 to 10 x 24 1.0 lb/in. of width per running foot
Belt Conveyors 1.0 lb/in. of width per running foot

For S, se use the formula from ratio and proportion

𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
=
𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
S 300
=
175 187.11
𝑆𝑆 = 280.5836 fpm
for Plain Bearings

0.05(180 + 100)�175 + 0.03(40)(280.5836)� + 175(18)

𝐻𝐻𝑃𝑃 = = 10.4180
990
for Anti-Friction Bearings
0.03(180 + 150)�175 + 0.03(40)(280.5836)� + 175(18)
𝐻𝐻𝑃𝑃 = = 8.2988
990

Thus, in terms of power requirement, it is better to use anti-friction bearings

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