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Size Reduction

Size reduction is commonly used in industrial processes to increase surface area and reaction rates. It allows for more intimate mixing of particles and helps meet product specifications. Some common methods of size reduction include crushing, grinding, cutting, impact, attrition, and shearing. Ball mills are frequently used to grind materials into fine powders through the impacts of balls dropping from the top of the cylindrical shell. Size reduction provides advantages like improved content uniformity, flow, extraction, and dissolution rates while potential disadvantages include degradation, poor mixing, and contamination.

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42 views6 pages

Size Reduction

Size reduction is commonly used in industrial processes to increase surface area and reaction rates. It allows for more intimate mixing of particles and helps meet product specifications. Some common methods of size reduction include crushing, grinding, cutting, impact, attrition, and shearing. Ball mills are frequently used to grind materials into fine powders through the impacts of balls dropping from the top of the cylindrical shell. Size reduction provides advantages like improved content uniformity, flow, extraction, and dissolution rates while potential disadvantages include degradation, poor mixing, and contamination.

Uploaded by

Biji
Copyright
© © All Rights Reserved
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Necessity of size reduction

In process industries, this operation is usually carried out in order:


a)To increase the surface area to enhance the rate of a physical or chemical process. In most of
the reactions and unit operations (e.g., leaching) involving solid particles, the rate increases by
increasing the area of contact between solid and second phase since the rate is proportional to
the area of contact between the phases involved. In leaching, the rate of extraction increases
because of the increased area of contact between solid and the solvent
b)To affect the separation of two constituents in cases where one is dispersed in small isolated
pockets.
c)To meet stringent specifications regarding the sizes of commercial products.
d)To accomplish intimate mixing of solids in a solid-solid operation since the mixing is more
complete if the particle size is small.
e)To improve dissolution rate, solubility, binding strength and dispersion properties.

Industrial use:
1) Pharmaceutical size reduction is used to – control of the rates of dissolution and
absorption, control of chemical reactions, and control of physical characteristics.
2) Particle size reduction is used to- reduce grain to a desired size for various filler
applications, and support the distribution of the end product by: exposing a greater surface
area for digestion; improving the ease of handling certain ingredients; improving the mixing
characteristics of certain ingredients; improving pelleting efficiency; and improving pellet quality.
3) In chemical industries size reduction is used to- essential to increase reactivity of
solids, improvement of solvent efficiency and also easy flow of products.

Crushing and Grinding


A crusher is a machine designed to reduce large rocks into smaller rocks, gravel, or
rock dust. Crushers may be used to reduce the size, or change the form, of waste
materials so they can be more easily disposed of or recycled..Crushing is the
process of transferring a force amplified by mechanical advantage through a
material made of molecules that bond together more strongly, and resist
deformation more, than those in the material being crushed do.
Grinding means subdividing to a finer product than crushing. The grinding of solid
materials occurs through mechanical forces that break up the structure by overcoming
the interior bonding forces. After the grinding the state of the solid is changed: the
grain size, the grain size disposition and the grain shape. Grinding may serve the
following purposes in engineering:
● increase of the surface area of a solid
● manufacturing of a solid with a desired grain size
● pulping of resources

Types of force:
Crushing: when an external force applied on a material excess of its strength, the material
fails because of its rupture in many directions. The particles produced after crushing are
irregular in shape and size.
Impact: When a material is subject to sudden blow of force in excess of its strength, it fails.
For example, cracking of nut with help of a hammer.
Cutting: Size reduction is accomplished by forcing a sharp and thin knife through the
material.For example: Cutting of fruits and vegetable by sharp knife to reduce the size.
Attrition: Rubbing away or wearing down by friction. The material is pulverized between
two toothed metal disks rotating in opposite directions.
Shearing: It is a process of size reduction which combines cutting and crushing.
Methods of operating crushers:
Ball Mill:

A ball mill is a type of grinder used to grind or blend materials for use in mineral dressing
processes, paints, pyrotechnics, ceramics, and selective laser sintering. It works on the principle
of impact and attrition: size reduction is done by impact as the balls drop from near the top of
the shell.
A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell
may be either horizontal or at a small angle to the horizontal. It is partially filled with balls.
The grinding media are the balls, which may be made of steel, stainless steel, ceramic, or
rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistant
material such as manganese steel or rubber lining. Less wear takes place in rubber lined
mills. The length of the mill is approximately equal to its diameter.

Ball mills are used extensively in the mechanical alloying process in which they are used for
grinding and for cold welding, producing alloys from powders.
The ball mill is a key piece of equipment for grinding crushed materials, and it is widely used
in production lines for powders such as cement, silicates, refractory material, fertilizer, glass
ceramics, etc., as well as for ore dressing of ferrous and non-ferrous metals. The ball mill
can grind ores and other materials, wet or dry.

Ball mill method:


Ball milling is a grinding method that grinds nanotubes into extremely fine powders. During the
ball milling process, the collision between the tiny rigid balls in a concealed container will
generate localized high pressure. Usually, ceramic, flint pebbles and stainless steel are used.

Ball mill used:


Ball mills are commonly used for crushing and grinding the materials into an extremely fine
form. The ball mill contains a hollow cylindrical shell that rotates about its axis. This cylinder is
filled with balls that are made of stainless steel or rubber to the material contained in it.

Particle size reduction:


Size reduction is a process in which the particle size of a solid is made smaller. The term size
reduction is applied to ways in which particles of solids are cut or broken into smaller pieces.
Size reduction is necessary if the starting material is too coarse, and the final product needs to
be a fine powder.

Advantages of Size Reduction: Disadvantages of Size :

● Content uniformity · * Drug degradation


● Uniform flow · * Poor Mixing ·
● Effective extraction of drug * Contamination ·
● Effective drying ·
● Improves physical stability.
● The rate of sedimentation decreases by reducing particle size ·
● Improves dissolution rate ·
● Improves rate of absorption.
● Smaller the particle, greater is the absorption. ·
● Increases surface area and viscosity ·
● Facilitates bioavailability,
● uniform mixing and drying

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