Particle Size Reduction

Particle Size Reduction and Enlargement
PARTICLE SIZE REDUCTION

Size Reduction is a process wherein particles of solids are cut or broken into smaller pieces.
Comminution is the generic term for size reduction.
OBJECTIVES:
Increases the reactivity of solids

Permits separation of unwanted ingredients by mechanical methods
Reduces the bulk of fibrous materials for easier handling and for waste disposal
CRITERIA FOR AN IDEAL CRUSHER OR GRINDER:
Have a large capacity

Require a small power input per unit of product
Yield a product of the single size or the size distribution desired
FORCES INVOLVED IN SIZE REDUCTION:

FORCE
Compression
Impact
ILLUSTRATION
PRINCIPLE
DESCRIPTION
EXAMPLE
Nutcracker
For coarse
reduction of
hard solids
Jaw
Crusher
Hammer
Gives coarse,
medium, or
fine product
Hammer
Mill
File
Yields very
fine product
from soft,
nonabrasive
material
Attrition
Mill
Shears
Gives
definite
particle size
and shape
Knife
Cutter
Attrition or
Rubbing
Cutting
Page 1
CRUSHING LAWS:
LAW
DESCRIPTION
EQUATION
The work required in

Rittingers
crushing is proportional to
law
the new surface created.
Kicks law
Bonds
law
The work required for

crushing is constant for
the same reduction ratio
that is the ratio of the
initial particle size to the
finial particle size.
The work required to form

particles from very large
feed is proportional to the
square root of the surfaceto-volume ratio of the
product.
= power
= feed rate
= Rittingers
coefficient
= feed
diameter
= product
diameter
= Kicks
coefficient
or
(
= Bonds
coefficient
= work index
which is defined
as the gross
energy required
in KWH per ton
of feed to reduce
80% of a very
large feed
WORK INDEX OF DIFFERENT SUBSTANCES:

MATERIAL
Bauxite
Cement Clinker
Cement Raw Material
Clay
Coal
Coke
Granite
Gravel
Gypsum Rock
Iron Ore (hematite)
Limestone
SPECIFIC GRAVITY
2.20
3.15
2.67
2.51
1.4
1.31
2.66
2.66
2.69
3.53
2.66
Page 2
WORK INDEX
8.78
13.45
10.51
6.30
13.00
15.13
15.13
16.06
6.73
12.84
12.74
2.74
9.92
Phosphate Rock
2.65
13.57
Quartz
2.63
15.87
Shale
2.57
14.30
Slate
2.87
19.32
Trap Rock
Source: Unit Operations of Chemical Engineering, McCabe, Table 28.2, pg. 967
SAMPLE PROBLEM:
What is the power required to crush 100 ton/h of limestone if 80 percent of the feed passes a 2-in.
screen and 80 percent of the product a 1/8-in. screen?
SOLUTION:
= 100 ton/h
= 2-in. x 25.4 = 50.8 mm
= 12.74 (from the table above)
= 1/8-in. x 25.4 = 3.175 mm
Page 3
SIZE REDUCTION EQUIPMENT:

A. Crushers: Slow-speed machines for coarse reduction of large quantities of solids
Gyratory Crusher
Roll Crusher
Jaw Crusher
Consist of a rectangular frame Consist of circular jaws in which During the crushing operation,
with a fixed jaw plate and a jaw the material is being crushed at the two rolls rotate toward each
stock carrying the moving jaw. some point.
other, resulting in crushing
TYPE
Jaw
Crusher
FORCE
Low capital and

maintenance
Compression
cost, Low
power
consumption
Gyratory
Compression
Crusher
Roll
Crusher
ADVANTAGES DISADVANTAGES SPECIFICATION APPLICATION
Compression
High crushing
capacity, Easy
to operate,
Low power
consumption
Simple
structure, Easy
maintenance,
Low
manufacturing
cost
Low productivity,
Bigger vibration,
Uneven particle
size
Capacity: 1,200
tons/h
Feed Size: 2.4 m
Product Size: 250
mm
Speed: jaws
open and close
250-400
times/min
Heavy mining,
Quarried
materials, sand
& gravel,
recycling
Complex structure,
High cost,
Inconvenient
transportation
Capacity: 4,500
tons/h
Feed Size: 1.8 m
Product Size: 650 mm
Speed: 125-425
gyrations/min
Heavy mining,
Quarried
materials
Low capacity, Need

to repair often
Capacity: 500
tons/h
Feed Size: 12-75
mm
Product Size: 12
mm-1 mm
Speed: 50-300
rpm
Quarried
materials, Sand
& gravel
Page 4
B. Grinders: Machines for intermediate duty
Disc Attrition Mill

Rod Mill
Hammer Mill
The material is struck and Particles are rubbed between Rods slide downward and roll
shattered by the descending the grooved flat faces of circular over one another reducing the
hammers until it is fine enough. discs.
particle size of the feed.
TYPE
FORCE
Hammer
Mill
Impact and
Attrition
Disc
Attrition
Mill
Rod Mill
Attrition
Compression
and Attrition

For tough
Easy to
Noisy and can
fibrous solids
Capacity: 0.1-15
operate, Low
generate dust
like bark or
tons/h
initial
pollution, Less
leather, steel
Product Size: 25
investment,
uniform particle
turnings, soft
mm 20 mesh
Low
size, Less energy
wet pastes,
Speed: 110 m/s
maintenance
efficient
sticky clay,
hard rock
Fast, efficient
and reliable
fine grinding,
Low power
consumption,
Low
maintenance
Easily cleaned,
Dust-free
operation,
High capacity,
Automatic
operation
Less energy
efficient, Needs
specific input size
Rods wear easily,

Less energy
efficient
Page 5
Capacity: - 8
tons/h
Feed Size: 12
mm
Product Size: 200
mesh
Speed: 350-700
rpm
Tough organic
materials such
as wood pulp
and corn grits
Capacity: 30
tons/h
Feed Size: 20
mm
Product Size: 10
mesh
Used in the
mineral
industry to
grind materials
such as
phosphate,
limestone,
magnesite, and
bauxite
C. Ultrafine Grinders: Reduce solids to such fine particle
Agitated Mill
Fluid Energy Mill
The particle feed is mixed with The feed in the mill are filled
air as it is fed into the mill inlet
with liquid with grinding medium
and produces the force that
and a column vibrates the vessel.
reduces the size of particles.
TYPE
Fluid
Energy
Mill
Agitated
Mill
Colloid
Mill
Colloid Mill
Intense fluid shear in a high
velocity stream is used to
disperse particles or liquid
droplets.
FORCE
Impact
Air needed is
free, Has a
large range of
sizes available,
Produces
homogeneous
blend
Impact
Self-cleaning,
Produces
homogeneous
blend
Impact
Self-cleaning,
Durable, Has a
wide variety of
uses
Energy Consuming,
Wears easily
Capacity: 1 ton/h
Feed Size: 12
mm
Product Size: 10 m
Pressure: 7 atm
For chemicals,
pigments and
food
processing
Needs solid
grinding medium
such as balls,
pellets, and sand
grains
Capacity: 4-1,200
L/min
Feed Size: 7 m
Product Size: 1
m
For grinding
hard materials
such as silica or
titanium
dioxide
Capacity: 440
L/min
Feed Size: 15 m
Product Size: 5
m
Speed: 50 m/s
For syrups,
milk, purees,
ointments,
paints, and
greases
High power
consumption,
Wears easily
Page 6
D. Cutting Machine: For fixed dimension of particles
Rotary Knife Cutter

Through
moving
and
stationary
knives,
feed
particles are cut to produce
particles
with
fixed
dimensions.
TYPE
Rotary
Knife
Cutter
FORCE
Cutting
Produces
particles with
definite size
and shape
Feed particles may

be cut several
times to achieve
the desired size
Page 7
Product Size: 5-8

mm
Speed: 200-900
rpm
2-12 Flying
Knives
1-7 stationary
bed knives
For paper and

plastic
materials

Particle Size Reduction

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Particle Size Reduction and Enlargement