SIZE

REDUCTION
By
Engr. SHAHID MIRZA
Dated: 7
th
December, 2012
Size Reduction
Definition :
Size reduction is applied to all the ways in
which solids are cut or broken into smaller
pieces.
or
Disintegration of the solid substance by
mechanical forces without altering their
state.
Fundamentals
Methods of Size Reduction
Impact
For coarse, medium or fine particles,
Example: hammer
Compression
For coarse type materials,
Example: nut cracker
Attrition
Very fine articles of soft non abrasive
materials
Example: file
Cutting
To attain definite particle shape or size
Example: knife cutters
Different ways to attain Size Reduction
Factors effecting Size Reduction
Manner in which load is applied

Magnitude of the load
Nature of the material
Nature of the force
Rate of application of a force
Stringent market specification
Easy transport and handling of solid particles
Increases the reactivity of solids especially in catalytic
reactions
It permits separation of unwanted ingredients by
mechanical separations
Create appropriate particle sizes for subsequent processing
Create a free-flowing material.
Improve material blending & prevent segregation by
making different sized products with similar particle size
distributions.
Why to Reduce Size
Energy Consumed In Crushing
Elastic deformation of the particles before fracture
occur;
Inelastic deformation which results in size
reduction;
Elastic distortion of the equipment;
Friction between particles and the machine;
In noise, heat & vibration in the plants;
Friction losses in the plant itself:
Characteristics of Ideal Crusher
Have a large capacity

Require a small power input per unit of product

Yield a product of the single size or the size
distribution required

Energy Requirement
Three laws governing Energy requirements are as
given below:
Kicks law
Rittengers law
Bonds law
The basic differential equation which states that the energy dE
require to affect a small change dL in the size of the unit mass
of the material is simple power function of the size.
P
dE
CL
dL
=
RITTINGERS Law
Rittinger, assumed that the energy required for size reduction is directly
proportional, to the change in surface area. This leads to a value of -2 for
p in equation as area is proportional to length squared. If we put:

C = K
R
f
C

and so
dE / dL = K
R
f
C
L
-2
where K
R
is called Rittinger's constant, and integrate the resulting form of
we obtain:
E = K
R
f
C
(1/L
2
1/L
1
)
where,
K
R
is the Rittengers Constant (m
4
/kg)

f
C
is the Crushing strength of material (N/m
2
)

L
1
is the feed size (m)
L
2
is the product size (m)
KICKS Law


Kick assumed that the energy required to reduce a material in size
was directly proportional to the size reduction ratio L
1
/L
2
.This
implies that p is equal to -1 in equation 1.

Hence on integrating
C = K
R
f
C
and putting the limits we get

E = K
K
f
C
ln (L
1
/L
2
)

where,
K
K
is the Kicks law constant (m
3
/kg)

f
C
is the crushing strength of the material (N/m
2
)
L
1
is the feed size (m)
L
2
is the product size (m)
BONDS Law
Bond defines the quantity Ei the work index:
The amount of energy required to reduce unit mass of the material
from an infinitely large particle size down to such a size that 80% of
the product passes a 100m .
Bonds crushing equation would be





where,
E
i
is the work index (J/kg)
q is the reduction ratio (L
1
/L
2
) (-)
L
1
is the feed size (m)
L
2
is the product size (m)

2
100 1
1
i
E E
L
q
(
=
(
(

Work Index for different materials
Material Work Index
kWatts h/Ton
Material Work Index
kWatts h/Ton
Bauxite 8.78 Phosphorus
Rock
2.74
Clinker 3.15 Quartz 2.65
Clay 2.51 Slate 2.57
Coal 1.40 Trap Rock 2.87
Gravel 2.66 Granite 1.31
Gypsum 2.69 Shale 2.63
Iron Ore 3.53 Coke 1.31
Lime stone 2.66
Crushing Efficiency
Crushing efficiency is defined as the ratio of the surface energy
created by crushing to the energy absorbed by the material.
= E
s
(A
wb
A
wa
)

W
n
where
is the crushing efficiency
E
s
is the energy per unit area A
wb
A
wb
is the surface area per unit mass of product
A
wa
is the surface area per unit mass of feed
W
n
is the power input to the crusher
Most of the energy is lost in Friction while the rest is available for
crushing.
Comparing the laws
It is common practice to assume that
Kicks proposal is applicable for large particle size
(coarse crushing and crushing).
Rittingers for very small particle size (ultrafine
grinding).
Bond formula being suitable for intermediate
particle sizethe most common range for many
industrial grinding processes.
Comparing the laws
It is generally advisable to rely on the past
experience of equipment manufacturers and on tests
in order to predict energy requirements for the
milling of a particular material.
Problem 1
A material is crushed in a Blake Jaw Crusher such
that the average size of the particle is reduced
from 50mm to 10mm with the consumption of
energy at the rate of 13.0 kW / (kg/s). What will be
the consumption of energy needed to; crushed the
same material of average size 75mm to an average
size of 25mm:
(a) Assuming Rittingers law applies ?
(b) Assuming Kicks law applies ?
Which of these results would be regarded as being
more reliable and why ?
Food is grinded from 6 mm to 0.12 mm particle
diameter using a mill with a 7.5 kW motor. What
reduction in throughput rate would you expect if the
material was reduced to 0.08mm instead of 0.12
mm?
Problem 2
Methods of Crushing
Choke Crushing:
The machine is kept full of
the material
The discharge of the product
is impeded to stay for longer
period.
Free Crushing:
It involves the feeding of the
material at a comparatively
low rate so that the product
can escape, readily.
The time of stay in the
machine is short.

Suitable for small amount
When entire size reduction is
completed in one step



Large feed is there
Energy consumption is
optimized
Low degree of crushing is
required
WET & DRY CRUSHING
Power consumption.
Capacity.
Removal of the Product.
Dust formation.
Solid handling.
Open & Closed Circuit Grinding
Open Circuit Grinding
When the plant is operated such that the feed is
passed into the equipment once only.
No Attempt is made to return the oversize
particles to the machine for further reduction.
Open & Closed Circuit Grinding
Closed Circuit Grinding
When the plant is operated such that the
oversize particles are refluxed into the
equipment until the desired size is attained.
Low power consumption is there and thus is
preferred in industry.





Product
CHOICE OF EQUIPMENT
Factor Effecting Choice of Machine
for Crushing
Hardness
Structure
Crushing Strength
Stickiness
Soapiness
Explosive Material
Harmful Material
Factors Influencing Choice of Size Reduction
Equipment

Feed Size Product Size
Coarse Crushers
60 1.5 inch 2 0.75 inch
Intermediate Crushers
2 0.75 inch 0.75 inch 200 mesh
Fine Crushers /
Grinders
0.75 inch 200
mesh
About 275 mesh
Ultra Fine Crushers
275 mesh Upto 325 mesh
Type of Equipments
Coarse Crushers





Intermediate
Crushers
Blake Jaw Crusher
Dodge Jaw Crusher
Gyratory Crusher


Crushing Rolls
Disc Crushers
Edge Runner Mill
Hammer Mill
Single Roll Crusher
Continuing...
Fine Crushers




Ultra Fine Crushers
Roll mill
Net Pendulum Mill
Griffin Mill
Ring Roll Mill
Ball Mill

High Speed Hammer Mill
Agitated Mill
Fluid Energy Mill
Jaw Crushers Working Principle
They are coarse size reduction machines.
They basically works under the influence of
Compression & Rubbing Force.
One jaw is fixed called the anvil and the other is
moving jaw.
Two types
Blake Jaw crusher
Dodge Crusher
Mechanical Construction of Blake Jaw Crusher
Two jaws (anvil and the moving one)
Crushing plates are made up of manganese steel.
Max. space is at the top so max. pressure for large
particle is exerted at the top.
One to the toggle plates is made weaker so as to
protect the equipment.
Heavy flywheel is used as the load is intermittent.
Power requirement depends upon the size &
capacity thus varying from 7 to 70 kW (feed rate of
10kg/s)
Diagram of Blake Jaw crusher
Difference Between Blake Jaw Crusher &
Dodge Crusher
Blake Jaw Crusher
Moving jaw is pivoted at the
top.
Uniform product is not
obtained
Max movement at the
bottom.
More widely used.
Little tendency to clog.
Takes in small feed due to
small opening at the top.
Dodge Crusher
Moving jaw is pivoted at the
bottom.
More uniform product.
Min movement at the
bottom.
Less widely used
Tendency to clog
Takes in large feed due to
larger opening at the top.
Dodge Jaw Crusher
Jaw Crusher
Advantages
Little head room required.
Easy replacement of worn parts.
Easy adjustment of set opening.
Disadvantages
Expensive, heavy foundations necessary due to
intermittent crushing action.
Emergency stopping impossible due to fly wheels.
Re-start with choked crushing chamber impossible.
Flat objects may pass uncrushed.
A special feeder for constant feed rate is needed to
prevent choking.
BALL MILL
Mechanical Construction
Simplest of the size reducing machines
Rotating hollow cylinder
Axis could be horizontal or at a small angle to the
horizontal
Outlet is covered with a coarse screen to prevent
ball escape
Inner surface is lined with manganese steel
(abrasion-resistant), stoneware or rubber.
Coefficient of friction
Lift bars
Continuing...
Feed intake is of 50mm size
Efficiency increment with hold up time
Balls occupy 30% - 50% of the volume
Optimum diameter proportional to the square root of
the feed size
Large / small balls
Pebbles
Compound mill

Figure













Compound mill
Terminology of Zone










Motion with in a ball mill
Factors Influencing the Size of the Product
Rate of the feed
Properties of the feed
Weight of the balls
Diameter of the balls
Slope of the mill
Speed of the rotation of the mill
Level of the material in the mill

Usage of the ball mill
Wet or dry
Cost of insulation
Inert atmosphere
Grinding medium
All degrees of hardness
Batch or continuous
Open or closed circuit grinding
Critical Speed of the ball mill
A rotational speed at which a ball fails to loose
contact with the wall of the mill is known to be the
critical speed.
It is denoted by

where,
n
c
= critical speed of the Ball mill
g = gravitational acceleration
R = inner radius of the ball mill
r = radius of the balls

1
2 ( )
c
g
n
R r t
=

Figure
r
O
A
o
R - r
R
c
mg
g
cos
c
mg
g
o
2
( )
c
m R r w
g

r
Derivation
Consider a single ball in operation reached at a
point A on the periphery of the mill.
Let
radius of the mill = R
radius of the ball = r
The distance from the centre of the mill O and
the centre of the ball (R r) while is the angle
between the vertical and the radius AO.
At A two forces are acting on the ball
(1) Force of gravity
(2) Centrifugal force
(1) Force of gravity
As we know that F = mg for horizontal plane but here
it is angled (). So reviving it into rectangular
components, we get
mg cos
mg sin
As F = mg is not dimensionally consistent so we
introduce g
c
. Hence we get
mg cos / g
c

mg sin / g
c
The component that keeps the ball in circular motion
is the centripetal component of the force of gravity i.e.

-------- (i)
cos
c
mg
g
o
(2) Centrifugal force
Centrifugal force = mv
2
/ r
1
where v = r
1
when ( being = 2tn)
Now centrifugal force becomes


where r
1
= ( R r )
introducing the conversion factor g
c


------------- (ii)
2 2
1 1
1
( ) mv m r
r r
e
= =
2
2
( )
( )
c
m R r
m R r
g
e
e
=

Operating speed should be 60% to 80% of the
Critical speed.
1
2 ( )
c
g
n
R r t
=

Differentiate between Ball mill & Tube mill

Ball Mills
Length to Diameter ratio
Close to 1
Usage
Batch & Continous
Holding time
Less
Compartments
Usually 1
Compound mill
Product size
Usually fine

Tube Mills

Usually 4,3 1

Usually batch

High

Usually 2 or more
Compartment mill

Fine or ultra fine
Differentiate between Ball mill & Rod mill
Ball Mills
Length to Diameter ratio
Close to 1
Usage
Batch & Continous
Holding time
Less
Compartments
Usually 1
Compound mill
Product size
Usually fine
Product Quality
Not uniform
Rod Mills

Usually 3,2 1

Usually batch

High

Only one

Ultra fine

Uniform