SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

EXERCISE 12.1
a) Rittinger's energy law postulated that the energy expended in crushing is
proportional to the area of new surface created. Derive an expression relating the
specific energy consumption in reducing the size of particles from x1 to x2 according
to this law.
b) Table 12.1.1 below gives values of specific rates of breakage and breakage
distribution functions for the grinding of limestone in a hammer mill. If values of
specific rates of breakage are based on 30 seconds in the mill at a particular speed,
determine the size distribution of the product resulting from the feed described in
Table 12.1.2 after 30 seconds in the mill at this speed.
Table 12.1.1: Specific rates of Breakage and Breakage Distribution Function for the
Hammer Mill
Interval (m)

106 - 75

75 - 53

53 - 37

37 - 0

Interval No. j

Sj

0.6

0.5

0.45

0.4

b(1,j)

b(2,j)

0.4

b(3,j)

0.3

0.6

b(4,j)

0.3

0.4

1.0

Table 12.1.2: Feed size distribution

Interval

Fraction

0.3

0.5

0.2

SOLUTION TO EXERCISE 12.1

(b) Generally, from Text-Equation 12.12:
j=i 1

dy i
=
{b(i, j).Sj.y j} Siy i
dt
j=1
For an increment in time equal to the time basis of the specific rate of breakage, Si:

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.1

j=i1

yi =

{b(i, j).S j.y j} Si yi

j=1

Change of fraction in interval 1:

change in mass fraction in size interval one,
y1 = 0 S1y1 = 0 0.6 0.3

= -0.18
Hence, new y1 = 0.3 - 0.18 = 0.12
Change of fraction in interval 2:
y2 = b(2,1) S1y1 S2y 2
= (0.4 0.6 0.3) (0.5 0.5)
= -0.178
Hence new y2 = 0.5 - 0.178 = 0.322
Change in fraction in interval 3:
y3 = [b(3,1) S1y1 + b(3,2) S 2 y2 ] S3y3
= [(0.3 0.6 0.3) + (0.6 0.5 0.5)] (0.45 0.2)

= +0.114
Hence, new y3 = 0.2 + 0.114 = 0.314
Change in fraction in interval 4:
y4 = [b(4,1) S1y1 + b(4,2) S2y 2 + b(4,3)S3y3 ] S4y 4

= [(0.3 0.6 0.3) + (0.4 0.5 0.5)] + [1.0 0.45 0.2] (0.4 0)

= +0.244
Hence, new y4 = 0.0 + 0.244 = 0.244
Checking:
Sum of predicted product interval mass fractions = y1+y2+y3+y4 = 1.000
Hence, product size distribution:
Interval No. (j)

Fraction

0.12

0.322

0.314

0.244

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.2

EXERCISE 12.2
Table 12.2.1 below gives information gathered from tests on the size reduction of coal
in a ball mill. Assuming that the values of specific rates of breakage, Sj are based on

25 revolutions of the mill at a particular speed, predict the product size distribution
resulting from the feed material, details of which are given in Table12.2.2.
Table 12.2.1 Results of ball mill tests on coal
Interval (m) 300-212

212-150

150-106

106-75

75-53

53-37

37-0

Interval no. j 1

Sj

0.5

0.45

0.42

0.4

0.38

0.25

0.2

b(1,j)

b(2,j)

0.25

b(3,j)

0.24

0.29

b(4,j)

0.19

0.27

0.33

b(5,j)

0.12

0.2

0.3

0.45

b(6,j)

0.1

0.16

0.25

0.3

0.6

b(7,j)

0.1

0.08

0.12

0.25

0.4

1.0

Table 12.2.2: Feed size distribution

Interval

Fraction

0.25

0.45

0.2

0.1

SOLUTION TO EXERCISE 12.2

Generally, from Text-Equation 12.12:
j= i 1

dy i
=
{b(i, j).Sj.y j} Siy i
dt
j=1
For an increment in time equal to the time basis of the specific rate of breakage, Si:
j= i 1

yi =

{b(i, j).S j.y j} Si yi

j= 1

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.3

Change of fraction in interval 1:

Change in mass fraction in size interval one,
y1 = 0 S1y1 = 0 0.5 0.25
= -0.125
Hence, new y1 = 0.25 - 0.125 = 0.125
Change of fraction in interval 2:
y2 = b(2,1) S1y1 S2y 2
= (0.25 0.5 0.25) (0.45 0.45)
= -0.1713
Hence, new y2 = 0.45 - 0.1713 = 0.2787
Change in fraction in interval 3:
y3 = [b(3,1) S1y1 + b(3,2) S 2 y2 ] S3y3
= [(0.24 0.5 0.25) + (0.29 0.45 0.45)] (0.42 0.2)
= +0.00473
Hence, new y3 = 0.2 + 0.00473 = 0.2047
Change in fraction in interval 4:
y4 = [b(4,1) S1y1 + b(4,2) S2y 2 + b(4,3)S3y3 ] S4y 4

= [(0.19 0.5 0.25) + (0.27 0.45 0.45) + (0.33 0.42 0.2)] (0.4 0.1)

= +0.0661
Hence, new y4 = 0.1 + 0.0661 = 0.1661
Change in fraction in interval 5:
y5 = [b(5,1) S1y1 + b(5,2) S2y 2 + b(5,3)S3 y3 + b(5,4)S4 y 4 ] S5y 5
= [(0.12 0.5 0.25) + (0.2 0.45 0.45) + ( 0.3 0.42 0.2) + (0.45 0.4 0.1)] (0.38 0)
= +0.0987
Hence, new y5 = 0 + 0.0987 = 0.0987
Change in fraction in interval 6:
y6 = [b(6,1) S1y1 + b(6,2) S2y 2 + b(6,3)S3y3 + b(6,4)S4 y4 + b(6,5)S5y5 ] S6y6
= [(0.1 0.5 0.25) + (0.16 0.45 0.45) + (0.25 0.42 0.2) +
+ ( 0.3 0.4 0.1) + (0.6 0.38 0)] (0.25 0)
= +0.0779
Hence, new y6 = 0 + 0.0779 = 0.0779

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.4

Change in fraction in interval 7:

y7 = [b(7,1) S1y1 + b(7,2) S2 y2 + b (7,3)S3 y3 +
b(7,4)S4y 4 + b(7,5)S5y5 + b(7,6)S 6y6 ] S7y 7

= (0.1 0.5 0.25) + (0.08 0.45 0.45) + (0.12 0.42 0.2 ) +

+( 0.25 0.4 0.1) + (1.0 0.25 0) (0.2 0)
= +0.04878
Hence, new y7 = 0 + 0.04878 = 0.04878
Checking:
Sum of predicted product interval mass fractions = y1+y2+y3+y4+y5+y6+y7= 0.9999
Hence product size distribution:
Interval

Fraction

0.125

0.2787

0.2047

0.1661

0.0987

0.0779 0.04878

EXERCISE 12.3
Table 12.3.1 gives information on the size reduction of a sand-like material in a ball
mill. If the values of specific rates of breakage Sj are based on 5 revolutions of the
mill, determine the size distribution of the feed materials shown in Table 12.3.2 after
5 revolutions of the mill.

Table 12.3.1: Results of ball mill tests

Interval (m)

150-106

106-75

75-53

53-37

37-0

Interval No. (j)

Sj

0.65

0.55

0.4

0.35

0.3

b(1,j)

b(2,j)

0.35

b(3,j)

0.25

0.45

b(4,j)

0.2

0.3

0.6

b(5,j)

0.2

0.25

0.4

1.0

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.5

Table 12.3.2: Feed size distribution

Interval

Fraction

0.25

0.4

0.2

0.1

0.05

SOLUTION TO EXERCISE 12.3

Generally, from Equation 12.12:
j= i 1

dy i
=
{b(i, j).Sj.y j} Siy i
dt
j=1
For an increment in time equal to the time basis of the specific rate of breakage, Si:
j= i 1

yi =

{b(i, j).S j.y j} Si yi

j= 1

Change of fraction in interval 1:

Change in mass fraction in size interval one,
y1 = 0 S1y1 = 0 (0.65 0.25)

= -0.1625
Hence, new y1 = 0.25 - 0.1625 = 0.0875
Change of fraction in interval 2:
y2 = b(2,1) S1y1 S2y 2
= (0.35 0.65 0.25) (0.55 0. 4)
= -0.1631
Hence new y2 = 0.4 - 0.1631 = 0.2369
Change in fraction in interval 3:
y3 = [b(3,1) S1y1 + b(3,2) S 2 y2 ] S3y3
= [(0.25 0.65 0.25) + (0.45 0.55 0.4)] (0.4 0.2)
= +0.05963
Hence, new y3 = 0.2 + 0.05963 = 0.2596
Change in fraction in interval 4:
y4 = [b(4,1) S1y1 + b(4,2) S2y 2 + b(4,3)S3y3 ] S4y 4

= [(0.2 0.65 0.25) + (0.3 0.55 0.4) + (0.6 0.4 0.2 )] (0.35 0.1)

= +0.1115

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.6

Hence, new y4 = 0.1 + 0.1115 = 0.2115

Change in fraction in interval 5:
y5 = [b(5,1) S1y1 + b(5,2) S2y 2 + b(5,3)S3 y3 + b(5,4)S4 y 4 ] S5y 5
= [(0.2 0.65 0.25) + (0.25 0.55 0.4) + (0.4 0.4 0.2) + (1.0 0.35 0.1)] (0.3 0)
= +0.1545
Hence, new y5 = 0.05 + 0.1545 = 0.2045
Checking:
Sum of predicted product interval mass fractions = y1+y2+y3+y4+y5 = 1.0
Hence product size distribution:
Interval

Fraction

0.0875

0.2369

0.2596

0.2115

0.2045

SOLUTIONS TO CHAPTER 12: SIZE REDUCTION

Page 12.7