SIZE REDUCTION Inge particles of solids are cut or broken into small pieces | in food-processing industry - eg. grind wheat to flour in ore-processing & cement industries - eg eopper ores, nickel, cobalt | ores & iron ores are ground before chemical proce + reasons: 1. occurs in sizes that are too large to be used 2. so separation can be carried out sreases the reactivity 4. reduces bulk of materials for easier handling and for waste disposal SIZE REDUCTION methods: ry - coarse reduction of hard solids to coarse sizes 2, Impact/hammer | - gives coarse, medium or fine sizes 3. Attrition or rubbing a ~ yields very fine products | 4. Cutting <8 7 - give definite sizes, sometimes a definite shapeSIZE REDUCTION + An ideal crusher would: 1. have a large capacity 2. require a small power input per unit of product 3. yield a product of the single size distribution desired + cost of power is a major expense in size reduction equipment, so the factors that control this cost are important EFFICIENCY ‘Crushing efficiency, ne E ee ae sre tenth A wurface energy per unit area energy absorbed by a unit mass AvoAys= areas per unit mass of feed and product Mechanical efficiency, 7 ‘energy absorbed by the solid total energy input MyPOWER REQUIRMENT Power requirement by the size reduction machine is Grites | 1 = Wrine Stes |_ 1d PWT Le, BD, OD, eee 1®D, OD, | P= power required | m= feed rate 4 =volume-surface mean dia, of feed & product, respectively crushing effi ,= density of particle ¢, = surface energy per unit area 0,0, ty of feed and product, respectively 'OWER REQUIRED IN SIZE REDUCTION Rittinger’s law (applicable to coarse & intermediate size reduction): ‘work required in crushing is proportional to the new surface created PK, 1 m 3, “D,| P= power required K,=Rittinger’s coeMecient —K, =, t= feed rate DD, where yolume-surface mean dia. of feed & product, respect ‘Tc = crushing efficiency y = ratio of energy absorbed to energy input ,= density of particle = surface energy per unit area ©, = sphericity of feed and product, respectively some validity in grinding fine powdersKick’s Law Energy required to reduce a material in size was directly proportional to the size-reduetion ratio where P= power required Ku is the Kick’s coefficient feed rate D,,,D,, = volume-surface mean dia. of feed & product, respectively CRUSHING EFFICIENCY nd?s Law : work required using a large-size feed is proportional to the square root of the surface/volume ratio of the product K, =constant th = feed rate 180% of the feed passes a mesh size of D,,mm and 80% of the product passes a mesh size of D,, mm, P 03162 ih where W,= work index DyyDyy = dia. of feed & product, respectivelys WORK INDEX ‘Gross energy (kWih)required per ton of feed needed to reduce a very large feed (D,= =) to such a size that 80% of the product passes a 100 Hm screen, co) Tontewny [Nota Include friction inthe [== — = = crusher & power Smear ze war = aan a —r ae 798 Example 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 sereen? 2. 80% of feed (ore) is less than 5.08 em in size and the product size is such that 80% is less than 0.685 em. The power required is 89.5 kW. What will be the power required using the same feed so that 80% is less than 0.3175 cm? 3. A certain crusher accepts a feed rock having a volume-surface mean diameter of 2 em and discharges a product of volume-surface mean diameter of 0.5 cm, The power required to crush 10 ton/h is 8 HP. What should be the power consumption if the capacity is increased to 12 t and the volume-surface mean diameter is reduced to 0.4 em? Use Rittinger’s law.Example ‘crush a material with a feed size of -5.08 em +3.81 ‘cm and the power required was 3.73 KWiton, The screen analysis of the product was as follows: Size of aperture (em) | _% product 0.63 - 0.38 26 0.203, 18 0.076 23 0.081 8 0.025 17 0.013 8 ‘What would be the power required to crush I ton/h of the same material from a feed of 4.44 m +3.81 cm to a product of average product sixe 0.051 em? Use Rittinger's law. SIZE REDUCTION EQUIPMENTS selection of equipments: 1) input size 2) product size 3) hardness 4) brittleness 5) plasticity ©) flammability major types: crushers, ultrafine grinders, grinders & cutting machinesCRUSHERS * Slow-speed machine for coarse reduetion of large quantities of + break large pieces of solid material into small lumps Primary crusher - accepts anything from mine & breaks into 150-250. mm Secondary crusher - reduces lumps into 6 mm main types: 1) Jaw crushers 2) Gyratory crushers 3) smooth-roll crushers 4) toothed-roll crushers Gyratory crusher GRINDERS + for intermediate duty (from crushers (o grinders for further reduction) + reduce crushed feed to powder + product from intermediate grinder might pass a 40-mesh screen + product from fine grinder would pass a 200-mesh screen (74m screen) commercial grinders: 1) Hammer mills & impactor 2) rolling-compression machines 3) Attrition mills 4) Tumbling mills Spin millGRINDERS for intermediate duty (from crushers to grinders for further reduction) + reduce crushed feed to powder + product from intermediate grinder might pass a 40-mesh screen + product from fine grinder would pass a 200-mesh sereen (74m sereen) ‘commercial grinders: 1) Hammer mills & impactor 2) rolling-compression machin 3) Attrition mills 4) Tumbling mills Spin mill SIZE REDUCTION EQUIPMEN’ Itrafine grinder Produce particles averaging I - 20 um in size Dry powder High-speed hammer mills with internal or external classification Fluid-energy or jet mills Wet powder Agitated mills Cutting mact Produce cubes, in squares or diamonds Application Esp 12 rubber & plastics [In recycling paper & plastic materialsal SIZE REDUCTION t — = a EQUIPMENTS my ") In Cement industry