MODULE 2

SIZE REDUCTION
DEBASREE GHOSH
A S S I S TA N T P R O F E S S O R
D E P T. O F C H E M I C A L E N G I N E E R I N G
BIT MESRA

20-01-2021
DISCLAIMER

• This content provided herein are simply for

educational purposes and not for
any commercial purpose. Every effort has been made
to ensure that the content provided on this course is
accurate and helpful to the readers. However, this is
not an exhaustive treatment of the subjects. No
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material used herein. If missed, it is inadvertently.
SYLLABUS

• Rittinger’s law, Kick’s law, Bond’s law, Work index, Types of

comminuting equipment – Jaw Crushers, Gyratory Crusher, Roll
crushers; Grinders-hammer Mill, Ball Mill, Rod Mill etc. Dry and wet
grinding, open and closed circuit. Simulation of Milling operation
grinding rate function, breakage function.
INTRODUCTION
• 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.
• Comminution, crushing, disintegration, dispersion, grinding
and pulverization are the synonyms of size reduction.
ADVANTAGES OF SIZE
REDUCTION
• Uniformity in solid masses.
• Uniform flow
• Effective drying
• Surface area increases along with viscosity
• Uniform mixing
• Higher rate of absorption
• Improved dissolution rate.
MECHANISM OF SIZE REDUCTION
• The method of application of the force to the particles may affect the
breakage pattern.
• The four basic patterns may be identified, though it is sometimes difficult
to identify the dominant mode in any given machine.
• The four basic patterns are:
1. Impact —particle concussion by a single rigid force (Hammer).
2. Compression—particle disintegration by two rigid forces
(Nutcracker).
3. Shear/cutting —produced by a fluid or by particle–particle interaction.
4. Attrition —arising from particles scraping against one another or
against a rigid surface (a File).
COMPARISON

Impact Compression Shear/cutting Attrition

It gives coarse, medium Used for coarse Used to obtain definite Used to obtain fine
or fine products. reduction of hard shape & size product. products of soft,
material to fine size. nonabrasive materials
ENERGY REQUIREMENT FOR
CRUSHING
• The energy required for reduction in particle size of a solid is directly
proportional to the increase in surface area.
𝑑𝐸
• = −𝐶𝐿𝑝
𝑑𝐿
𝑳𝟏 𝑪 = 𝑲𝑲 𝒇𝒄
𝑬 = 𝑲𝑲 𝒇𝒄 𝒍𝒏
p = -1 𝑳𝟐 Kick’s law

p = -2 𝟏 𝟏 𝑪 = 𝑲𝑹 𝒇𝒄 Rittinger’s law
𝑬 = 𝑲𝑹 𝒇𝒄 −
𝑳𝟐 𝑳𝟏
p = -3/2 𝟏 𝟏 𝑬𝒊 Ei the work Bond’s law
𝑬=𝑪 − 𝑪=
√𝟏𝟎
𝟏/𝟐
𝑳𝟐 𝑳𝟏
𝟏/𝟐
index

𝑾𝒉𝒆𝒓𝒆, 𝒇𝒄 is the crushing strength of the material and

Work index (𝑬𝒊 ) is the equivalent amount of energy to reduce one ton of the
ore from a very large size to 100 um.
 ENERGY REQUIREMENT FOR
CRUSHING
• Bond terms Ei the work index, and expresses it as the amount of energy
required to reduce unit mass of material from an infinite particle size to a
size L2 of 100 μm.
Laws Postulation Equations Feed size
1. Rittinger’s Grinding work is 𝟏 𝟏 Fine grinding
Law (1867) related to the new 𝑾 = 𝒌𝟏 − (<0.05mm)
𝒙𝒑 𝒙𝒊
surface generated

2. Kick’s law Equal work is required 𝒙𝒇 Course

𝑾 = 𝒌𝟐 𝒍𝒏
(1885) to achieve equivalent 𝒙𝒊 grinding
relative reduction in (>50mm)
grain size.

3. Bond’s law Grinding work is 𝟏 𝟏 Intermediate

(1952) related to the length of 𝑾 = 𝒌𝟑 − grinding
√𝒙𝒑 √𝒙𝒊
new cracks formed (50mm-
0.05mm)
 ENERGY UTILISATION
• One of the first important investigations into the distribution of the energy
fed into a crusher was carried out by OWENS who concluded that energy
was utilized as follows:
a. In producing elastic deformation of the particles before fracture occurs.
b. In producing inelastic deformation which results in size reduction.
c. In causing elastic distortion of the equipment.
d. In friction between particles, and between particles and the machine.
e. In noise, heat and vibration in the plant, and
f. In friction losses in the plant itself.
Note: only about 10 per cent of the total power is usefully employed.
 ENERGY UTILISATION
• The new surface produced in size reduction was directly proportional
to the energy input. For a given energy input the new surface produced
are independent of:
(a) The velocity of impact,
(b) The mass and arrangement of the sample,
(c) The initial particle size, and
(d) The moisture content of the sample.
• The experimental results showed that, provided the new surface did
not exceed about 40 m2/kg, the new surface produced was directly
proportional to the energy input.
ENERGY REQUIREMENT FOR
CRUSHING
Material Crushing energy

Theoretical Actual

Sodium chloride 0.08 J/m2 90J/m2

Quartz 5J/m2 77J/m2

CRITERIA FOR
COMMINUTION
• Crusher and grinders are comminuting equipment.
• These equipment are having very large capacity
• Energy efficient or energy required per unit product size is low.
• The yield obtained are of single size.
CHARACTERISTICS OF
COMMINUTED PRODUCT
• Product obtained are not uniform in size. Size analysis is required for such nonuniform product.
• For homogeneous feed, the product is to some extent uniform in size and properties.
• The ratio of largest to smallest particles obtained in comminution is approximately 104 .
Crushing efficiency
𝑒𝑠 (𝐴𝑤𝑝 − 𝐴𝑤𝑓 )
𝜂𝑐 =
𝑊𝑛
𝑒𝑠 = surface energy per unit area
𝐴𝑤𝑝 , 𝐴𝑤𝑓 = area per unit mass of product & feed
𝑊𝑛 = energy absorbed per unit mass
Mechanical efficiency of crushing is
𝑊𝑛 𝑒𝑠 (𝐴𝑤𝑝 − 𝐴𝑤𝑓 )
𝜂𝑚 = =
𝑊 𝜂𝑐 𝑊
𝑒𝑠 (𝐴𝑤𝑝 − 𝐴𝑤𝑓 )
𝑊=
𝜂𝑐. 𝜂𝑚
𝑊= the energy input required for crushing & to overcome the friction of moving parts of the
equipment.
 METHODS OF CRUSHING

free
Methods of feeding open circuit
crushing grinding
choke
feeding
closed circuit
grinding
FREE CRUSHING

• Feeding the material at a comparatively low rate.

• The product can readily escape.
• Its residence time in the machine is therefore short and the
production of appreciable quantities of undersize material is avoided.
CHOKE FEEDING

• The material remains in the crusher for a longer period.

• The capacity of the machine is low.
• The energy consumption is high because of the cushioning action
produced by the accumulated product.
• comparatively small amount of materials is to be crushed.
• This type of feeding is applicable to complete the whole of the size
reduction in one operation
 TYPES OF CHOKE FEEDING
• open circuit grinding: the material is passed only once through the
equipment.
• Closed circuit grinding: the product containing material which is
insufficiently crushed, the product is separated and return the oversize
material for a second crushing.
CLASSIFICATION OF SIZE REDUCTION
EQUIPMENT
NATURE OF THE MATERIAL
TO BE CRUSHED
• Hardness
• Structure
• Moisture content
• Crushing strength
• Friability
• Stickiness
• Soapiness
• Explosive materials
• Materials yielding dusts that are harmful to the health
CRUSHING EQUIPMENT

Course crushers Intermediate crushers Fine crushers

Stag jaw crushers Crushing rolls

Dodge jaw crushers Disc crusher

Gyratory crushers Edge runner mill

Other coarse Hammar mill, single roll

crushers crusher, pin mill, Symons disc
crusher
JAW CRUSHER
 GYRATORY CRUSHER

• [Link]
DISCUSS

• Write down the client features of jaw & gyratory crushers?

• What are different types of jaw crusher?
• Discuss the advantages & disadvantages of jaw & gyratory crushers
GRINDERS-HAMMER MILL
GRINDERS-HAMMER MILL
• Hammer mills contain a high-speed rotor turning inside a casing.
• The feed dropped from the top & are broken by the sets of swing
hammers pinned to a rotor disk.
• During grinding the feed cannot escape and struck by hammers.
• Therefore, particles shatters into pieces and further size is reduced by
rubbing action of hammers and pushed through the sieve at discharge
opening.
• Generally the diameter of rotor disk is 150-455mm with 4-8 swing
hammer. Product obtained are 25mm or 20mesh in size. The speed of
hammer tips may reach up to 110m/s. Capacity is 0.1-15 ton/hr for finer
sizes then 200mesh (product).
• Tough fibrous solids like leather, soft wet pastes, hard rock can be crushed
in hammer mill.
• Commercial mills typically reduce 60 to 240 kg of solid per kWh.
BALL MILL
BALL MILL
• Size reduction occurs by impact of balls in ball mill.
• In a large mill the shell diameter is 3m & length is 4.25m. The balls are of 25-
125mm in diameters.
• During the time of rotation, the balls are picked up by the mill and carried nearly
to the top, where they break contact with wall and fall to bottom and picked up
again.
• Centrifugal force helps the balls to stay connected with wall and with each other
during the upward movement.
• Some of the ball do some grinding by slipping & rolling over each other while in
contact with wall.
• Increase in speed of mill increases the power consumption.
• Higher speed of ball mill increases the productivity but at very higher speed, the
balls are carried over and the situation is called centrifuging.
• The speed at which centrifuging occurs is called critical speed. No grinding is
possible at this speed. Therefore, the speed of ball mill must be less than equal to
the critical speed.
 BALL MILL
• The force balance at A is:
• 𝑚𝑔 𝑐𝑜𝑠𝛼 = 𝑚 4𝜋 2 𝑛2 (𝑅 − 𝑟)
4𝜋2 𝑛2 (𝑅−𝑟)
Or 𝑐𝑜𝑠𝛼 =
𝑔

At critical speed:
𝛼 = 0 & 𝑛 = 𝑛𝑐 = 𝑐𝑟𝑖𝑡𝑖𝑐𝑎𝑙 𝑠𝑝𝑒𝑒𝑑
1 𝑔
𝑛𝑐 =
2𝜋 𝑅 − 𝑟
ROD/TUBE MILL & BALL MILL

• A tube mill is a continuous mill with a long cylindrical shell.

• The product obtained is 2to 5 times shorter than that obtained from ball
mill.
• The working of tube mill is like ball mill.
• The half of the volume of the mill is filled with balls or tubes and void
fraction in the mass of balls or tubes at rest is 0.4.
• Both dry & suspension grinding are possible in these mills.
• Rod mills yield 5-200ton/h of 10 mesh product & ball mills produce 1-
50tons/h of power of which 70-90% would pass a 200mesh sieve.
• Power required: 4kWh/metric ton for rod miil & 16kWh/metric ton.
OTHER SIZE REDUCTION
EQUIPMENT
• Ultrafine grinders: Fluid energy mill, agitated mills, colloid mill (product
size 1-20µm)
• Cutting machines : knifes, dicers, slitter etc
DRY & WET
GRINDING/MILLING
• For small scale milling the choice between wet & dry milling not
makes any significant difference.
• Air is the fluid medium in dry milling and water, or liquid is fluid
medium in wet milling.
• In case of dry milling fluid fills the whole equipment. On the other-
hand a portion of equipment is filled with liquid in wet grinding.
• Around 30% less energy is consumed in wet grinding than that of dry
grinding.
ENERGY CONSUMPTION IN
CRASHING
PERFORMANCE OF
CRUSHING EQUIPMENT
• For efficiency of crusher depends on:
1. appropriate size & shape of feed.
2. Uniform feed rate
3. Removal of product in regular interval.
4. Separation of unbreakable particles.
5. Crushing with heat removal system for low melting or heat
sensitive materials
SIMULATION OF MILLING
OPERATION
• The size distribution of products obtained from various size reduction
equipment can be predicted by computer simulation.
• The proper mathematical modelling with appropriated assumptions can
give actual result.
• In case of crushing, the two controlling parameters are grinding rate
function (𝑆𝑢 ) & breakage function (∆𝐵𝑛,𝑢 ).
• Grinding rate function (𝑆𝑢 ) is the fraction of material of given size, coarse
than that on screen, which is broken in each time.
𝑑𝑥𝑢
• Therefore, 𝑑𝑡
= −𝑆𝑢 𝑥𝑢
• 𝑥𝑢 is the mass fraction retained on one of the upper screens.
SIMULATION OF MILLING
OPERATION
• Breakage function (∆𝐵𝑛,𝑢 ) gives the size distribution resulting from the
breakage of upper material.
• Breakage function depends on size & composition of the materials in the mill.
• There fore, the size distribution equation can be written as:
𝑑𝑥𝑛
• = −𝑆𝑢 𝑥𝑛 + σ𝑛−1
𝑢=1 𝑆𝑢 𝑥𝑢 . ∆𝐵𝑛,𝑢
𝑑𝑡
• Assumptions
1. A stack of standard screen is considered. The stack consists of n number
of screens. They are numbered from top to bottom i.e n=1 for top or
coarsest size.
2. 𝑥𝑢 is the mass fraction retained on one of the upper screens (𝑢 < 𝑛).
3. For any fraction except the course, the initial amount is diminished by
breakage to smaller sizes and augmented by the creation of new surfaces.
4. For coal, the grinding rate vary with the cube of particle size and breakage
function varies with the reduction ratio (Dn/Du).
SIMULATION OF MILLING
OPERATION
𝐷𝑛 𝛽
𝐵𝑛,𝑢 =
𝐷𝑢

• 𝐵𝑛,𝑢 is the total mass fraction smaller than size Dn. It is a cumulative
mass fraction or (∆𝐵𝑛,𝑢 ).
• 𝛽 is constant.
• For same reduction ratio (∆𝐵𝑛,𝑢 ) will be constant.
• In Eularian method
𝑛−1
𝑑𝑥𝑛 ∆𝑥𝑛
= = −𝑆𝑛 𝑥𝑛 + ෍ 𝑆𝑢 𝑥𝑢 . ∆𝐵𝑛,𝑢
𝑑𝑡 ∆𝑡
𝑢=1
NUMERICAL
A batch grinding mill is charged with material of the composition shown in
table. The grinding rate function is 0.001 per sec for 4/6 mesh particles. 𝛽 =
1.3 for breakage function. Both breakage function & grinding rate function
are independent of time.
(a) How long will it take for the fraction of 4/6 material diminish by 10%?
(b) Tabulate the individual breakage functions for 28/35 mesh fractions and
for all coarse fractions.
(c) how will the values of xn vary with time during the first 6h of operation?
Use a time interval of 30s in calculation.

Table: initial mass fractions & grinding-rate functions

Mesh n or u Dn ot Du (mm) xn,0 Sn or Su X10^4 (1/sec)
4/6 1 3.327 0.0251 10
6/8 2 2.362 0.1259 3.578
8/10 3 1.651 0.3207 1.222
10/14 4 1.168 0.257 0.4326
14/20 5 0.833 0.159 0.1569
20/28 6 0.589 0.0538 0.0554
28/35 7 0.417 0.021 0.0196
HINTS
𝑑𝑥𝑢
(a) 𝑑𝑡
= −𝑆𝑢 𝑥𝑢
1 𝑥𝑢,𝑓𝑖𝑛𝑎𝑙 1 0.02259
∴ 𝑡𝑟𝑒𝑞 = − ln =− ln
𝑆𝑢 𝑥𝑢.𝑖𝑛𝑖𝑡𝑖𝑎𝑙 0.001 0.0251
(b)
𝑑𝑥𝑛 ∆𝑥𝑛
(c) = = −𝑆𝑛 𝑥𝑛 + σ𝑛−1
𝑢=1 𝑆𝑢 𝑥𝑢 . ∆𝐵𝑛,𝑢
𝑑𝑡 ∆𝑡
𝑛−1

𝑜𝑟 𝑥𝑛,𝑡+1 = 𝑥𝑛,𝑡 + ∆𝑡 −𝑆𝑛 𝑥𝑛,𝑡 + ෍ 𝑆𝑢 𝑥𝑢,𝑡 . ∆𝐵𝑛,𝑢

𝑢=1
𝑛−1

∴ 𝑥𝑛,𝑡+1 = 1 − 𝑆𝑛 ∆𝑡 𝑥𝑛,𝑡 + ∆𝑡 ෍ 𝑆𝑢 𝑥𝑢,𝑡 . ∆𝐵𝑛,𝑢

𝑢=1