Laboratory Report on: Jaw Crusher and Pulverizer.

CHLAB151P

Prepared by:
Abelarde, Gian Karlo V.
Boyero, Gian Michael B.
Cruz, Adrian G.
Felisilda, Miguel Louise J.

Presented to:

Dr. Mona Freda Secondes.

August 18, 2019

 Abstract

Some raw materials used in the industry are too large for certain processes and so, size

reduction is utilized. It is a process of reducing larger sized particles to smaller or finer

sized particles. In this experiment the students are going to utilize the Bisco Disk

Pulverizer and the Braun Blake Jaw Crusher to determine the yield of the desired product

which is the undersize of mesh 14 for the crusher while it is the undersize of mesh 200
for the pulverizer, operation time, size variation and product lost due to sieving, crushing

and pulverizing. The experiment was done using different raw materials, for the crusher,

charcoal was used. The pulverizer however was fed with the raw material of charcoal and

chalk. After crushing and pulverizing, the product was then weighed and sieved through

Mesh 14, 25, 35, 40, 50, 60 and 200, which was individually weighed to determine size

variation. Comparing the operation time for each equipment with each feed material, the

researchers concluded that feeding the crusher with a material that is lesser in quantity

than the other but of the same mass leads to faster operation time and feeding the

pulverizer with materials that are higher in density which results in lesser quantity, would

lead to a much more longer operation time.

Introduction

Size reduction is currently being used more and more, especially with our growing

population and because of this, industries are struggling to supply this increasing demand.

Since raw materials are typically not optimally ready for use in the industry due to their

large sizes and shapes (Oden, n.d.). To remedy this size reduction is applied to meet

stringent specifications needed by different processes. For example, tree barks are cut

into splinters and chunks of ore are cut into workable sizes (McCabe, Smith, & Harriot,

1993). Size reduction is where solids that are larger in size are reduced to a smaller size

by mechanical action. There are several equipment used for size reduction and are usually

divided into four; and they are crushers, grinders, fine grinders, and cutters. We are only

going to focus about grinders and cutters as they are the only equipment available in the
 Unit Operations Laboratory. Crushers is an equipment used for coarse reductions of large

amounts of solids and Grinders are used to reduce intermediate-sized material to small

sizes or powder (Geankoplis, 1993).

OBJECTIVES:

The process of size reduction plays an important role in different fields such as

construction. Equipment such as the Jaw Crusher and Pulverizers are those that use this

concept which is evident in this experiment. The objectives of this experiment are:

 To determine the mass of the product and its losses during the experiment.

 To determine the size variation of the product in both equipment.

 To determine the time needed to fully crush/pulverize the feed material.

Theory

Mechanical size reduction is used to reduce the large sized particles to the

standard/desired sizes. Most of the time, solid particles are reduced to separate various

impurities present in the material.

The theory governing size reduction is the Rittenger's law, which states that the required

energy must be proportional to the created surface by the particles fragmentation. Also,

the Kick's law, states that a proportionality between the energy and the size reduction

ratio must be present. Lastly, the Bond’s law, states that the total work input represented

by a given weight of crushed product is inversely proportional to the square root of the

diameter of the product particles.

 Materials and Methods

a. Materials and Apparatus

1. Jaw Crusher

The feed material to be used in this equipment is charcoal since this material has suitable

hardness and the equipment is able to function on this material. Besides charcoal, we will

also be introducing another feed material which is the hollow blocks since this material is

in the same hardness as charcoal. Other materials to be used in this experiment are the

sieve and bucket for measuring the desired product particle diameter and collecting it, the

weighing scale for measurement of the products masses, brush for cleaning, and timer to

monitor the production time for each material.

2. Pulverizer

The feed material to be used in this equipment is charcoal since this material has suitable

hardness and the equipment is able to function on this material. The other feed material to

be used is chalk since it is with the same property with charcoal. The feed material to be

fed in the spout of the pulverizer must be approximately an inch in length for easy

feeding. Other materials to be used in this experiment are the sieve and bucket for

measuring the desired product particle diameter and collecting it, the weighing scale for

measurement of the products masses, brush for cleaning, and timer to monitor the

production time for each material.

b. Experimental Procedures:
 For Jaw Crusher:

1. For safety and precaution measures, always check on the equipment first. Check the

tightness of the screws, monitor the plug if it’s functional, and clean the equipment if any

source of dirt is found inside the equipment. Call the attention of a machine shop

supervisor or student assistant when equipment need special attention. After checking the

safety of the equipment, the top cover of the jaw crusher attached by two screws on its

side must be removed to be able to see the opening of the crusher.

2. Prepare the materials needed for the experiment.

3. Using a weighing scale, measure 100 grams of feed material (charcoal) and to be noted as

data for computations in the experiment.

4. Placed at the bottom of your equipment is the bucket that is to collect the crushed feed

material.

5. The crusher is then opened and plugged into the socket. A “start” button is pressed for the

machine to operate.

6. The charcoal is then continuously feed into the spout of the crusher at constant and steady

rate to avoid jamming and choke feeding in the crusher.

7. The time of production start when the charcoal is first fed to the spout of the crusher. It is

the monitored using a timer.

8. Once all the charcoal is fed, the “stop” button is pressed to stop the operation of the

crusher. Production time monitoring stops the moment no product comes out of the

crusher and is noted.

9. The crushed product is then measured using a weighing scale. The data on mass of the

product is then noted.

10. After weighed, the product is then sieved. In each sieve, the remaining mass (oversize)

will then be measured using the weighing scale. The data gathered will be tabulated and

will serve as reference for later calculations.

For Pulverizer:

1. For safety and precaution measures, always check on the equipment first. Check the

tightness of the screws, monitor the plug if it’s functional, and clean the equipment if any

source of dirt is found inside the equipment. Call the attention of a machine shop

supervisor or student assistant when equipment need special attention.

2. After checking the equipment, the materials are then prepared.

3. The bucket is to be placed at the bottom of the equipment to collect the product once the

operation proceeds.

4. The pulverizer is then plugged into the socket to start the equipment. There is no “start”

or “stop” button in this equipment.

5. The charcoal is then fed to the spout in the door of the pulverizer.

6. Once the size reduction process is finished, safely unplug the equipment to stop the

operation. Use a brush to further collect the product stuck in the unreachable parts of the

equipment.

7. The charcoal product mass is then measured using a weighing scale and is sieved.

8. The mass of the oversize product in each sieve is then to be measured using again a

weighing scale. The masses obtained will be recorded in a tabular form and will be used

for future calculations.

9. The same procedure above (1-8) is to be used for the chalk feed material.
 Results and Discussion

The results of the experiment have been sufficient in providing answers to the objectives

that were set by the researchers. The Jaw Crusher and the Pulverizer both performed as

expected and the data fell within reasonable parameters.

For the case of the product obtained, and the subsequent calculation regarding the losses,

the masses of each sample material was weighed after the material was separated by sieves. It

is worth noting that the percent yields for chalk on the Jaw Crusher apparatus was very close

to that of Tanya’s. A similar result occurred for charcoal. While it could simply be

coincidental, the researchers believe that it is too close of a coincidence. The masses of the

product obtained were also not that far off from the weight of the sample, and a similar

statement can be said about the losses.

An average particle size or diameter was chosen to be that of the products ranging mesh

number 14 to mesh number 25. The average particle size between the two sizes amount to

just over 1mm (1.04436mm)

The time it took to crush/pulverize the material was also measured. It would appear that,

due to the innately brittle nature of the material, process times kept relatively low. Chalk

needed 26.6s for Crusher and 22.5 for the Pulverizer. For the Charcoal samples doing the

same experiment, a very similar situation happened. For Crusher, 44.5s was obtained. And

for the Pulverizer. 48.5s was measured.

Error Analysis
 Majority of the errors can be amounted to the machined itself. The machines, while in

good working conditions, appear to have some physical deficiencies. Apart from that, there is

always the risk that the values read or taken during the experiment would be slightly inaccurate.

And then, there is the concern regarding material collection process. It was be readily assumed

that some of the material was left behind as incalculable dust.

Conclusion

The experiment was ultimately able to sufficiently answer the objectives set. The group

managed to determine the amount of material after sieving and compared it to the original

amount of material that the group started with. The group also managed to select a desired

product size and an average particle diameter from that. And finally, the time taken to reduce the

size of a material was also tested.

The time it took for full size reduction to occur was also variable, leading the group to

believe that density plays a major role in determining the rate at which objects may undergo

size reduction.

References

Geankoplis, C. J. (1993). Transport processes and unit operations (3. ed). London: Prentice-Hall

Internat.

McCabe, W. L., Smith, J. C., & Harriot, P. (1993). Unit Operations of Chemical Engineering

(Fifth). McGraw-Hill Book Co.

Oden, C. (n.d.). The Application of Size Reduction.

Perry, R. H., & Green, D. W. (2008). Perry's chemical engineers' handbook. New York:

McGraw-Hill.

Appendix 1 Equations Used

1. Mass Balance (without accumulation): Mass of Feed = Mass of Product eqn.1

2. Mass of Losses: Mass of Loses = Mass of Feed – Mass of Product eqn.2

3. Mass of Losses due to Sieving = Total Mass of Product - Mass of Product After Sieving

eqn.3

4. Total Mass Losses =Mass loss due to sieving + Mass loss eqn.3

5. % Loss = (Total Mass Loss/ Total Feed Mass) 100

Appendix 2 Relevant Calculations

Raw Data:

For Jaw Crusher:

95.8 g Chalk

100g Charcoal

For Pulverizer:

95.8g Chalk

100g Charcoal
 Paper = 4.2g

Calculations for Jaw Crusher:

1. Chalk

a. Time of Crushing: 26.6 seconds

b. Mass of Chalk = Chalk + Paper = 93.1g

c. Mass of Chalk after Sieving = 88.2g

d. Mass loss = 95.8-88.9 = 6.9

e. Mass loss due to sieving = 88.9-88.2 = 0.7

f. Total Mass loss = 0.7+6.9 = 7.6g

g. %loss = (33/93.1)100 = 7.933194154%

7.6
h. %Yield = 88.2 (100) = 8.616780045%

1. Charcoal

a. Time of Crushing: 44.5 seconds

b. Mass of Charcoal = Charcoal + Paper = 93.7- 4.2 =89.5

c. Mass of Charcoal after Sieving = 85.5g

d. Mass loss = 100 – 93.7 = 6.3

e. Mass loss due to sieving = 89.5 – 85.5 = 4g

f. Total mass loss = 6.3 + 4 = 10.3g

g. % loss = (10.3/100)100 = 10.3%

4.5
h. %Yield= 85.5 (100) = 5.263157895%
 Calculations for Pulverizer

1. Chalk

a. Time of Pulverizing = 22.5 seconds

b. Mass of Chalk = 86.3g

c. Mass of Chalk after sieving = 86.1g

d. Mass of losses = 95.8 – 86.3 = 9.5g

e. Mass loss due to sieving = 86.3 – 86.1 = 0.2

f. Total Mass losses = 0.2 + 9.5 = 9.7

g. %loss = (9.7/86.3)100 = 11.23986095 %

7.5
h. %Yield=86.1 (100) = 8.710801394%

2. Charcoal

a. Time of Pulverizing = 48.5 seconds

b. Mass of Charcoal = 100g

c. Mass of Charcoal after sieving = 98.5g

d. Mass of losses = 100 – 98.9 = 1.1g

e. Mass loss due to sieving = 98.9– 98.5 = 0.4g

f. Total Mass losses = 1.1 + 0.4 = 1.5g

g. %loss = (1.5/100)100 = 1.5 %

5.5
h. %Yield = 98.5 = 5.583756345%
 Appendix 3 Tables

Data:

Table X: JAW CRUSHER- CHARCOAL (masses). Table 1 Represents the masses of the

Charcoal obtained per sieve.

Screen

Mesh Opening Mass Tare Net

Weight Weight

14 1.410 mm 85.5 g 4.2 g 81.3 g

25 0.707 mm 8.7 g 4.2 g 4.5 g

35 0.500 mm 7.5 g 4.2 g 3.3 g

40 0.420 mm 7.3 g 4.2 g 3.1 g

 50 0.297 6.8 g 4.2 g 2.6 g

mm

60 0.250 mm 5.4 g 4.2 g 1.2 g

200 0.074 mm 4.7 g 4.2 g 0.5 g

pan -

Table X: PULVERIZER- CHARCOAL (masses). Table 2 represents the masses of the

charcoal

Obtained per sieve.

Screen

Mesh Opening Mass Tare Net

Weight Weight

14 1.410 mm 5.8 g 4.2 g 1.6 g

25 0.707 mm 9.7 g 4.2 g 5.5 g

35 0.500 mm 12.5 g 4.2 g 8.3 g

40 0.420 mm 17.4 g 4.2 g 13.2 g

50 0.297 19.4 g 4.2 g 15.2 g

mm

60 0.250 mm 21.9 g 4.2 g 17.7 g

200 0.074 mm 21.8 g 4.2 g 17.6 g

pan - 131.9 g 112.5 g 19.4 g

Table X: JAW CRUSHER- CHALK (masses). Table 3 represents the masses of the

Chalk obtained per sieve.

Screen

Mesh Opening Mass Tare Net

Weight Weight

14 1.410 mm 66.7 g 4.2 g 62.5 g

25 0.707 mm 11.8 g 4.2 g 7.6 g

35 0.500 mm 10.8 g 4.2 g 6.6 g

40 0.420 mm 8.8 g 4.2 g 4.6 g

50 0.297 7.4 g 4.2 g 3.2 g

mm

60 0.250 mm 7g 4.2 g 2.8 g

200 0.074 mm 5.2 g 4.2 g 0.9 g

pan -
Table X: PULVERIZER- CHALK (masses). Table 4 represents that masses of the chalk

Obtained per sieve.

Screen

Mesh Opening Mass Tare Net

Weight Weight

14 1.410 mm 56.5 g 4.2 g 52.3 g

25 0.707 mm 11.7 g 4.2 g 7.5 g

35 0.500 mm 17.7 g 4.2 g 13.5 g

40 0.420 mm 10.3 g 4.2 g 6.1 g

50 0.297 6.2 g 4.2 g 2g

mm

60 0.250 mm 5g 4.2 g 0.8 g

200 0.074 mm 7.1 g 4.2 g 3.9 g

pan - 112.5 g 112.5 g 0g