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Size Reduction

This document discusses size reduction techniques and methods. Common size reduction machines use compression, impact, attrition or cutting. Comminution is a generic term for size reduction using crushers and grinders. The power required for comminution depends on factors like crushing efficiency, work energy input, average particle size, and empirical relationships like Rittinger's law and Kick's law. Bond proposed that work required is proportional to surface-to-volume ratio. Work index is defined as the energy to reduce feed to 80% passing 100 microns. Problems calculate power requirements and particle properties.

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RA Memije
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237 views16 pages

Size Reduction

This document discusses size reduction techniques and methods. Common size reduction machines use compression, impact, attrition or cutting. Comminution is a generic term for size reduction using crushers and grinders. The power required for comminution depends on factors like crushing efficiency, work energy input, average particle size, and empirical relationships like Rittinger's law and Kick's law. Bond proposed that work required is proportional to surface-to-volume ratio. Work index is defined as the energy to reduce feed to 80% passing 100 microns. Problems calculate power requirements and particle properties.

Uploaded by

RA Memije
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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S IZ E

R ED U C TIO N

SIZE RED U CTIO N


Applied to all the ways in which

particles of solids are cut or broken


into small pieces
Importance
Reducing the particle size increases the

reactivity of the solids


It permits separation of unwanted
ingredients by mechanical methods
It reduces the bulk of fibrous materials
for easier handling and for waste
disposal

CO M M O N LY U SED M ETH O D S
IN SIZE RED U CTIO N M ACH IN E
Compression
Impact
Attrition or rubbing
Cutting

CO M M IN U TIO N
A generic term for size reduction;

crushers and grinders are types of


comminuting equipment.

EN ERGY AN D PO W ER
REQ U IREM EN T IN
CO
M Mcost
IN UofTI
O
N
The
power is a major expense
in crushing and grinding, so the
factors that control the cost are
important.
Crushing efficiency, nc
The ratio of the surface energy created

by crushing to the energy absorbed by


the solid. es is the surface energy per
unit area, and Awb and Awa are the areas
per unit mass of product and feed. Wn is
the energy absorbed by a unit mass of

Pow er required by the m achine


Work energy input

Power

Average particle size

Power

Empirical relationship: RITTINGERS

AND KICKS LAW


Rittinger in 1867 states that the work

required in crushing is proportional to


the new surface created.
RITTENGERS LAW:

In 1885 Kicks proposed another law,

which states that the work required


for crushing a given mass of material
is constant for the same reduction
ratio, that is, the ratio of the initial
particle size to the final particle size.

BO N D CRU SH IN G LAW AN D W O RK
IN D EX
In 1952 Bond postulated that the

work required for crushing and


grinding to form particle of size Dp
from very large feed is proportional
to the square root of the surface-tovolume ratio of the product.

W ork index (KW -hr/ton)


Defined

as the gross energy


requirement in kilowatt hours per ton
(2000 lbs) of feed needed to reduce
a very large feed to such size 80%
of the product passes a 100-m
screen.

Material

Specific Gravity

Work index, Wi

BAUXITE

2.20

8.78

CEMENT CLINKER

3.15

13.45

CEMENT RAW MATL

2.67

10.51

CLAY

2.51

6.30

COAL

1.4

13.00

COKE

1.31

15.13

GRANITE

2.66

15.13

GRAVEL

2.66

16.06

GYPSUM ROCK

2.69

6.73

HEMATITE

3.53

12.84

LIMESTONE

2.66

12.74

PHOSPHATE ROCK

2.74

9.92

QUARTZ

2.65

13.57

SHALE

2.63

15.87

SLATE

2.57

14.30

TRAP ROCK

2.87

19.32

PRO BLEM 1
What is the power required to crush

100 ton/h of limestone if 80% of the


feed passes a 2-in screen and 80% of
the product a 1/8-in screen?

Problem 2
Trap rock is crushed in a gyratory crusher. The

feed is nearly uniform 2-in spheres. The


differential screen analysis of the product is
given in column 1 of table 1. The power
required to crush this material is 400 kW. Of
this 10 kW is needed to operate empty mill. By
reducing the clearance between the crushing
head and the cone, the differential screen
analysis of the product becomes that given in
column 2 in table 1. From Rittingers law and
Kicks law, calculate the power required for the
second operation. The feed rate is 110 ton/h.

Table 1
MESH

FIRST GRIND

SECOND GRIND

4/6

3.1

6/8

10.3

3.3

8/10

20.0

8.2

10/14

18.6

11.2

14/20

15.2

12.3

20/28

12.0

13.0

28/35

9.5

19.5

35/48

6.5

13.5

48/65

4.8

8.5

65/100

6.2

100/150

4.3

The

screen analysis shown on


problem 2 applies to a sample of
crushed quartz. The density of the
particles is 2650 kg/m3 (0.00265
g/mm3) and the shape factor is 2 and
sphericity is 0.571. For the material
between 28-mesh to 150-mesh in
particle size of the 2nd grind,
calculate (a) Aw in mm2/g and Dw
(mass mean diameter)

Volum e surface m ean


diam eter, ,defi
ned by;

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