Size reduction equipment

Size reduction equipment is divided into crushers, grinders, ultrafine grinders, and
cutting machines. Crusher do the heavy work of breaking large pieces of solid
material into small lumps. A primary crusher operates on run-of -mine material
accepting anything that comes from mine face and breaking it into 150 to 250 mm
lumps. A secondary crusher reduces these lumps into particles perhaps 6mm in
size. Grinders reduce crushed feed to powder. The product from an intermediate
grinder might pass a 40-mesh screen; most of the product from a fine grinder would
pass a 200-mesh screen with a 74 m opening. An ultrafine grinder accepts feed
particles no larger than 6mm and the product size is typically 1 to 5 m. Cutters give
particles of definite size and shape, 2 to 10mm in length.
The principal types of size-reduction machines are as follows:
A. Crushers (coarse and fine)
1. Jaw crushers
2. Gyratory crushers
3. Crushing rolls
B. Grinders (intermediate and fine)
1. Hammer mills; impactors
2. Rolling-compression mills
3. Attrition mills
4. Tumbling mills
C. Ultrafine grinders
1. Hammer mills with internal classification
2. Fluid-energy mills
3. Agitated mills
D. Cutting machines

1. Knife cutters; dicers; slitters

2. Principle of size reduction
3. Criteria for size reduction
4. An ideal crusher would (1) have a large capacity; (2) require a small power
input per unit of product; and (3) yield a product of the single size distribution
desired.
5. Energy and power requirements in size reduction
6. The cost of power is a major expense in crushing and grinding, so the factors
that control this cost are important.
7. 3.2 Crushing efficiency
8. 3.2.1 Empirical relationships: Rittingers and Kicks law
9. The work required in crushing is proportional to the new surface created. This
is equivalent to the statement that the crushing efficiency is constant and, for a
giving machine and material, is independent of the sizes of feed and product. If
the sphericities a (before size reduction) and b (after size reduction) are
equal and the machine efficiency is constant, the Rittingers law can be written
as

10.
11. where P is the power required,

is the feed rate to crusher,

is the average

particle diameter before crushing,

is the average particle diameter after
crushing, and Kr is Rittingers coefficient.
12.Kicks law: 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
finial particle size

13.
14.where Kk is Kicks coefficient.
15.3.2.2 Bond crushing law and work index
16.The work required to form particles of size Dp from very large feed is
proportional to the square root of the surface-to-volume ratio of the
product, sp/vp. Since s = 6/Dp, it follows that

17.
18.where Kb is a constant that depends on the type of machine and on the material
being crushed.
19.The work index, wi, is defined as the gross energy required in KWH per ton of
feed to reduce a very large feed to such a size that 80% of the product passes a
100 m screen. If Dp is in millimetres, P in KW, and in tons per hour, then
20.
21.If 80% of the feed passes a mesh size of Dpa millimetres and 80% of the
product a mesh of Dpb millimetres, it follows that

22.
23.Example: What is the power required to crush 100 ton/h of limestone if 80% of
the feed pass a 2-in screen and 80% of the product a 1/8 in screen? The work
index for limestone is 12.74.
24.Solution:
mm

=100 ton/h, wi =12.74, Dpa =2 25.4=50.8 mm, Dpb =25.4/8=3.175

25.