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REPORT ON THE FABRICATION OF SIEVE SYSTEM

CHAPTER ONE

INTRODUCTION

1.1 Background of the Study

The fabrication of sieve systems plays a crucial role in various industrial and research applications, where accurate separation of materials based on particle size is essential. Sieve systems are employed in diverse fields such as construction, pharmaceuticals, agriculture, and environmental studies. The effectiveness of these systems hinges on their design and fabrication, which influences their efficiency and accuracy in sorting materials. This study aims to investigate the design, fabrication, and performance of sieve systems, focusing on optimizing their functionality to meet industry standards and requirements.

Size sorting (termed ‘sieving’ or ‘screening’) is the separation of solids into two or more fractions on the basis of differences in size. Sieving is a simple technique for separating particles of different sizes. A sieve such as used for sifting flour has very small holes. Coarse particles are separated or broken up by grinding against one-another and screen openings. Depending upon the types of particles to be separated, sieves with different types of holes are used. Sieves are also used to separate stones from sand. Sieving is defined as a method in which two or more components of different sizes are separated from a mixture on the basis of the difference in their sizes (Adhapure, 2021). It is a physical mechanical process by which solid particles of different sizes are separated when they are passed through a sieve. The particles with a size greater than the pore or hole of the screen remain in it; while the smallest, with diameters smaller than the pores, freely penetrate the surface. Sieves are used extensively in the following areas.
-    In the construction area, sieving is used to separate sand, specifically in the cement industry. This process is essential to evaluate the particle size distribution of a granular material. This procedure is called grading and is very useful in civil engineering.

-    In soil study laboratories, sieves with graduated pore size are used. These sieves allow to separate and study the different components of the soil based on the size of their components.
-    There is great diversity in filtration systems that work with the principle of sieving to separate solid particles from liquid media.

-    At industrial level there are duplex or double filter filters inserted along water, fuel or oil pipes. These double filters, or double basket, allow to eliminate polluting particles from the system of these fluids by double sieving.

-    In the food industry, the sieving process forms part of the quality control that will allow the product to be marketed. Sifting is used to obtain smooth textures during the preparation of foods such as sauces, soups and custards.

-    In addition, sieving is used to decorate desserts, sprinkling for example icing sugar, cocoa powder, among others.

Sieving can be classified according to the moisture condition of the mixtures as wet sieving and sieving. Dry sieving is carried out for those mixtures of particles that by nature contain little or no moisture. It also refers to the sieving of substances or mixtures of particles that were previously subjected to drying processes. This type of sieving is more frequent, it is used in products that are sold in dry powder and a good example is the flour and grain flours for foods. In wet sieving water or other fluids are added to the mixture. This is done in order to facilitate the dragging or passing of the finer particles through the sieve. This is a more efficient and effective sieving. The disadvantage is that in many instances, the product still has to undergo some form of drying in order to package them. But it is very popular in preparation of certain Nigerian foods.
There are different types of sieving where different processes and instruments are employed. The nature of the component substances is first analyzed and assessed before a suitable method is adopted for their separation. There are many factors  to consider when choosing the right screening method. Depending on particle type  i.e the number of particles and the size and density of the particles and materials that need to be separated. It is the usual practice to use different types of sieves with different hole sizes (apertures) to separate coarse and fine aggregate. Half-height sieves are used when a small amount of material needs to be sifted; Microplate Sieves are used when the particle size of the material is very fine. On the other hand, Wet scrubber Sieves are used to clean materials and stir with enough water to separate the fines. Such materials are is in the range of 20 µm. Finally, there is the Extra Deep Screen which is normally used in large quantities of materials and is widely used in the construction industry and then the Air Jet Sieve used where the sample is dispersed by air blown out of a rotating nozzle. The measuring range may be extended to ten microns.

1.2 Statement of the Problem

Despite the critical role of sieve systems in material separation, many existing systems face challenges such as inefficient particle size distribution, inadequate throughput, and high maintenance costs. These issues can impact the overall efficiency and reliability of processes that depend on accurate material separation. The problem lies in identifying the key factors that affect the performance of sieve systems and developing solutions to enhance their effectiveness and durability.

1.3 Objectives of the Study

The main objective of this study is to determine the effectiveness of different design and fabrication approaches for sieve systems in improving their performance and reliability. Specific objectives include:

i. To evaluate the impact of different sieve mesh materials on separation efficiency.

ii. To determine the optimal design parameters for maximizing throughput and minimizing maintenance.

iii. To find out the cost-benefit ratio of various fabrication techniques for sieve systems.

1.4 Research Questions

i. What is the impact of different sieve mesh materials on separation efficiency?

ii. What is the optimal design for maximizing throughput and minimizing maintenance in sieve systems?

iii. How does the cost-benefit ratio of various fabrication techniques affect the overall performance of sieve systems?

1.5 Research Hypotheses

Hypothesis I

H0: There is no significant impact of different sieve mesh materials on separation efficiency.

H1: There is a significant impact of different sieve mesh materials on separation efficiency.

Hypothesis II

H0: There is no significant optimal design parameter for maximizing throughput and minimizing maintenance in sieve systems.

H2: There is a significant optimal design parameter for maximizing throughput and minimizing maintenance in sieve systems.

Hypothesis III

H0: There is no significant difference in the cost-benefit ratio of various fabrication techniques for sieve systems.

H3: There is a significant difference in the cost-benefit ratio of various fabrication techniques for sieve systems.

1.6 Significance of the Study

This study is significant as it provides insights into the design and fabrication of sieve systems, which are fundamental to various industrial processes. By identifying optimal design parameters and evaluating different materials and fabrication techniques, the study aims to enhance the performance, efficiency, and cost-effectiveness of sieve systems. This can lead to improved productivity and reduced operational costs in industries that rely on precise material separation.

1.7 Scope of the Study

The study focuses on the design and fabrication of sieve systems, specifically examining the impact of different mesh materials, design parameters, and fabrication techniques. It does not cover other aspects such as the operation and maintenance of sieve systems beyond their initial design and fabrication stages. The study will be limited to laboratory and field trials conducted within the context of industrial applications.

1.8 Limitations of the Study

The study may encounter limitations such as variations in material quality, constraints in experimental setups, and potential biases in data interpretation. Additionally, the generalizability of the findings may be affected by the specific conditions under which the trials are conducted. These limitations should be considered when applying the study's conclusions to broader contexts.

1.9 Definition of Terms

Sieve System: A mechanical device used for separating materials based on particle size through a mesh or perforated surface.

Mesh Material: The material used to create the sieve's filtering surface, which can affect its performance in separating particles.

Throughput: The rate at which material passes through the sieve system.

Fabrication Techniques: Methods used to construct and assemble sieve systems, including welding, machining, and assembly processes.

Cost-Benefit Ratio: A measure comparing the costs of fabrication techniques with the benefits they provide in terms of performance and efficiency.