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Biomass from forestry and agricultural sources has recently drawn a lot of attention as a new source of feedstock for energy and bio products. Size reduction is an important step in preparation of biomass as a feedstock. Each conversion process needs its own specific size or size distribution of particles. Modeling the size reduction process helps to optimize the design and control of the process while ensuring biomass particle sizes for an efficient biofuel conversion process. The objective of this study was to apply the population balance method for modeling the size reduction process. The model was applied to switchgrass size reduction by a grinder. Two population balance parameters, grinding rate (s⁻¹) and breakage distribution function (dimensionless) were estimated using experimental grinding data. The time dependent balance equations were solved using the Euler technique. The accumulation and depletion of the particles belonging to each size category were simulated as a function of time. The simulation predicted the residence time of particles inside the grinder in a way that the ground particles could meet the size and size distribution specifications for the downstream process. The thesis also describes preliminary steps in size reduction. Ground particles were fractionated based on their size by sieving. Weibull distribution was found to be the best probability density function to fit the data.

Biomass from forestry and agricultural sources has recently drawn a lot of attention as a new source of feedstock for energy and bio products. Size reduction is an important step in preparation of biomass as a feedstock. Each conversion process needs its own specific size or size distribution of particles. Modeling the size reduction process helps to optimize the design and control of the process while ensuring biomass particle sizes for an efficient biofuel conversion process. The objective of this study was to apply the population balance method for modeling the size reduction process. The model was applied to switchgrass size reduction by a grinder. Two population balance parameters, grinding rate (s⁻¹) and breakage distribution function (dimensionless) were estimated using experimental grinding data. The time dependent balance equations were solved using the Euler technique. The accumulation and depletion of the particles belonging to each size category were simulated as a function of time. The simulation predicted the residence time of particles inside the grinder in a way that the ground particles could meet the size and size distribution specifications for the downstream process. The thesis also describes preliminary steps in size reduction. Ground particles were fractionated based on their size by sieving. Weibull distribution was found to be the best probability density function to fit the data.

Biomass from forestry and agricultural sources has recently drawn a lot of attention as a new source of feedstock for energy and bio products. Size reduction is an important step in preparation of biomass as a feedstock. Each conversion process needs its own specific size or size distribution of particles. Modeling the size reduction process helps to optimize the design and control of the process while ensuring biomass particle sizes for an efficient biofuel conversion process. The objective of this study was to apply the population balance method for modeling the size reduction process. The model was applied to switchgrass size reduction by a grinder. Two population balance parameters, grinding rate (s⁻¹) and breakage distribution function (dimensionless) were estimated using experimental grinding data. The time dependent balance equations were solved using the Euler technique. The accumulation and depletion of the particles belonging to each size category were simulated as a function of time. The simulation predicted the residence time of particles inside the grinder in a way that the ground particles could meet the size and size distribution specifications for the downstream process. The thesis also describes preliminary steps in size reduction. Ground particles were fractionated based on their size by sieving. Weibull distribution was found to be the best probability density function to fit the data. / Applied Science, Faculty of / Chemical and Biological Engineering, Department of / Graduate

In the comminution industry, cone crushers are widely used for secondary and subsequent stages of size reduction. For a given crusher, the achieved size reduction is governed by the closed-side setting. Hadfield Steel is commonly used to line the crushing members to minimize wear. Yet, liner wear caused by some rock types can still be excessive. Enlargement of discharge opening induced by wear of liners produces a drift in product size which, if unchecked, can lead to high volumes of re-circulating load. Alteration of closed-side setting is now commonly achieved via hydraulic means. However, compensation of liner wear still involves plant shut down and loss of production.

To improve upon the understanding and efficiency of the crushing/ i screening process, the Brenda Mines Limited secondary crushing plant was simulated. The plant consists of two stages of crushing, with a single stage of screening employed in closed circuit with the latter crushing stage. Acquisition of plant data was carried out according to full or modified factorial designs intended to cover normal operating ranges. The units sampled include a Symons Nordberg 7 - foot standard cone crusher, a Symons Nordberg 7 - foot short-head cone crusher and two Allis-Chalmers 8ft.x20ft. double deck virbrating screens. Sampling was carried out under conditions as close to steady state as was possible. All samples were screened at the plant using a standarized procedure. Raw data obtained around the screens was later adjusted by means of a least squares technique that assumes all measured values are in error. The models developed to describe both crushing operations are modifications of those used at Mt. Isa Mines Limited. The model parameters were empirically fitted to the observed data. Both models gave satisfactory performance. The model proposed for the vibrating screens was derived from small particle statistics. It is continuous over all size ranges and was judged to perform satisfactorily. Models for the short-head crushers and the screens can be extrapolated approximately twenty percent beyond their fitted data ranges. The fitted models were combined to enable a steady-state simulation of the complete secondary crushing plant. A study of the simulation was performed in accordance with a full factorial design modified to include intermediate ranges. Operating variables whose values were generated during the simulation remained within their fitted ranges, with the exception of the short-head crusher feedrate. Preliminary analysis of the simulation output shows that the results conform to expected and observed plant behavior. Further analysis with respect to short-head crusher power draw indicates that it may be possible to increase plant capacity under some conditions. The economic advantage of a digital simulation is demonstrated by the fact that the average cost for one computer run is approximately twenty cents. / Applied Science, Faculty of / Mining Engineering, Keevil Institute of / Graduate

MSc (Eng), Faculty of Engineering and the Built Environment, University of the Witwatersrand, 2011 / Most of the remaining coalfields in South Africa are found in arid areas where process water is scarce and given the need to fully exploit all the coal reserves in the country, this presents a great challenge to the coal processing industry. Hence, the need to consider the implementation of dry coal beneficiation methods as the industry cannot continue relying on the conventional wet processing methods such as heavy medium separation. Dry coal beneficiation with an air dense-medium fluidized bed is one of the dry coal processing methods that have proved to be an efficient separation method with separation efficiencies comparable those of the wet heavy medium separation process. Although the applications of the fluidized bed dry coal separator have been done successfully on an industrial scale, the process has been characterized by relatively poor (Ecart Probable Moyen), Ep values owing to complex hydrodynamics of these systems. Hence, the main objectives of this study is to develop a sound understanding of the key process parameters which govern the kinetics of coal and shale separation in an air fluidized bed focusing on the effect of the particle size, shape and density on the performance of the fluidized separator as well as developing a simple rise/settling velocity empirical model which can be used to predict the quality of separation. As part of this study, a (40 x 40x 60) cm air fluidized bed was designed and constructed for the laboratory tests. A relatively uniform and stable average bed density of 1.64 with STDEV < 0.01 g/cm3 was achieved using a mixture of silica and magnetite as the fluidizing media. Different particle size ranges which varied from (+9.5 -16mm), (+16 -22mm), (+22 -31.5mm) and (+37 -53mm) were used for the detailed separation tests. In order to investigate the effect of the particle shape, only three different particle shapes were used namely blockish (+16 -22mm Blk), flat (+16 -22mm FB) and sharp pointed prism particles (+16 – 22mm SR).Different techniques were developed for measuring the rise and settling velocities of the particles in the bed. The Klima and Luckie partition model (1989) was used to analyze the partition data for the different particles and high R2 values ranging from (0.9210 - 0.9992) were recorded. Average Ep iii values as low as 0.05 were recorded for the separation of (+37 -53mm) and (+22 -31.5mm) particles under steady state conditions with minimum fluctuation of the cut density. On the other hand, the separation of the (+16 -22mm) and (+9.5 – 16mm) particles was characterized by relatively high average Ep values of 0.07 and 0.11 respectively. However the continuous fluctuation or shift of the cut density for the (+9.5 -16mm) made it difficult to efficiently separate the particles. Although, particle shape is a difficult parameter to control, the different separation trends that were observed for the (+16 -22mm) particles of different shapes indicate that particle shape has got a significant effect on the separation performance of the particles in the air fluidized bed. A simple empirical model which can be used to predict the rise/settling velocities or respective positions of the different particles in the air fluidized bed was developed based on the Stokes’ law. The proposed empirical model fitted the rise/settling data for the different particle size ranges very well with R2 values varying from 0.8672 to 0.9935. Validation of the empirical model indicate that the model can be used to accurately predict the rise/settling velocities or respective positions for all the other particles sizes ranges except for the (+9.5 – 16mm) particles where a relatively high average % error of (21.37%) was recorded. The (+37 -53mm) and (+22 -31.5mm) particles separated faster and more efficiently than the (+16 -22mm) and (+9.5 -16mm) particles. However, the separation efficiency of the particles can be further improved by using deeper beds (bed height > 40cm) with relatively uniform and stable bed densities. Prescreening of the coal particles into relatively narrow ranges is important in the optimization of dry coal beneficiation using an air fluidized bed since different optimum operating conditions are required for the efficient separation of the different particle size ranges and shapes. The accuracy and the practical applicability of the proposed empirical model can be further improved by carrying out some detailed rise/settling tests using more accurate and precise equipment such as the gamma camera to track the motion of the particles in the fluidized bed as well as measuring the actual bed viscosity and incorporate it in the model.

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