Mechanism of size reduction

There are four mechanisms of size reduction

equipment:
Impact: the particles
are broken-up by a
single rigid force.
Compression: the
particles are broken-up
by two rigid forces. It is
most applicable when
material is hard and
abrasive but not sticky.

 Shear: the particles are

compressed between
edges of two hard
surfaces moving
tangentially.

Attrition: arising from

particles scraping
against one another or
against a rigid surface.

Size Reduction Energy Requirement

Size reduction is a function of input and output of
particle size, hardness, strength and other properties of
solids.
Various theories for energy requirement of size
reduction process have been developed, among these
theories are:
Rittingers theory
Kicks theory
Bonds theory

 Generally energy required to reduce particles size is

inversely proportional to the size power (n).

Rittingers theory:
The energy (E) required for size reduction of unit mass is
proportional to the change in a particle size.
10

 Kicks Theory:
The energy used in deforming a set of particles of equivalent
shape is proportional to ratio of change in size.
11

Bonds theory:
The energy required to deform set of particles is
proportional to the change in dimensions.
12

The applicability of the theories:

The prediction of energy requirements by the three
approaches depends on the areas of product size.
It is common practice to assume that Kicks is applicable
for large particle size (coarse crusher).
Rittingers is more applicable for very small particle size
(ultra-fine grinding).
Bonds formula suitable for intermediate particle size (
most common range for many industrial grinding
processes).

Size Reduction Equipment

Crushers (coarse and fine)
1. Jaw crushers
2. Gyratory crushers
3. Crushing rolls
Grinders (intermediate and fine)
1. Hammer mills
2. Attrition mills
3. Tumbling mills
a. Rod mills
b. Ball mills

Ultrafine grinders
1. Fluid-energy mills
Cutting machines
1. Knife cutters, slitters

Jaw crusher

Roll crushers

Hammer mill

Ball Mill