3/26/12


Par*cle
Size
reduc*on


CH
2040
–
Mechanical
Opera*ons

Basavaraj
M.
Gurappa

Department
of
chemical
engineering

IIT‐Madras


Par*cle
Size
reduc*on

Size
reduc*on
or
comminu*on
is
an
unit
opera*on
used
to
create


par*cles
of
a
certain
size
and
shape,
to
increase
the
surface
area


available
for
chemical
reac*on
or
to
liberate
valuable
minerals
held


within
the
par*cles



Solids
may
be
broken
in
many
different
ways
–
commonly
used


methods
are
‐

1.  Compression

2.  Impact

3.  ARri*on
or
rubbing

4.  CuSng


1

 3/26/12


Par*cle
Size
reduc*on

Size
reduc*on
or
comminu*on
is
an
unit
opera*on
used
to
create


par*cles
of
a
certain
size
and
shape,
to
increase
the
surface
area


available
for
chemical
reac*on
or
to
liberate
valuable
minerals
held


within
the
par*cles



Solids
may
be
broken
in
many
different
ways
–
commonly
used


methods
are
‐

1.  Compression

2.  Impact

3.  ARri*on
or
rubbing

4.  CuSng


1.  Compression
–
common
example
‐
Nutcracker



2.  Impact
–
common
example
‐
Hammer


3.  ARri*on
or
rubbing
–
common
example
‐
File



4.  CuSng
–
common
example
–
A
pair
of
scissors


Stressing
Mechanism


1.
Stress
applied
between
two
surfaces
–
at

low
veloci7es
–
0.01
to
10
m/s
(Crushing
+

AAri7on)


2.
Stress
applied
at
a
single
solid
surfaces

–
 at
 high
 veloci7es
 –
 10
 to
 200
 m/s

(Impact
fracture
+
AAri7on)


3.
 Stress
 applied
 by
 carrier
 medium
 –
 in
 wet


grinding
 to
 bring
 about
 dis‐agglomera7on
 or

breakage


2

 3/26/12


Energy
and
Power
requirements
in
comminu*on

Cost
of
power
is
a
major
expense
crushing
and
grinding


STAGES
DURING
SIZE
REDUCTION:

The
feed
material
is
distorted
and
strained


The
 work
 necessary
 to
 strain
 the
 material
 is
 stored
 temporarily
 in
 the

solids
as
mechanical
stresses


When
 addi*onal
 force
 is
 applied
 to
 the
 stressed
 par*cles,
 they
 are

distorted
beyond
their
ul*mate
strength
and
suddenly
ruptures
into

fragments
and
new
surface
is
generated

Ul7mate
strength
is
the
maximum
stress
that
a

material
 can
 withstand
 (without
 necking
 –

when
stretched
or
pulled)
or
rapture


Unit
area
of
a
solid
has
a
definite
amount
of
surface
energy
and
crea*on

of
 new
 surface
 requires
 work,
 which
 is
 supplied
 by
 the
 released

stresses
when
the
par*cle
break


Energy
and
Power
requirements
in
comminu*on

Crushing
Efficiency:
The
ra*o
of
the
surface
energy
created
by
crushing

ηe
to
the
energy
absorbed
by
the
solid
is
the
crushing
efficiency,





If
 es
 is
 the
 surface
 energy
 per
 unit
 area
 (feet
 *mes
 pounds
 force
 per

square
 foot)
 and
 Awb
 and
 Awa
 are
 the
 areas
 per
 unit
 mass
 of
 the

product
and
feed,
respec*vely,
the
energy
absorbed
by
a
unit
mass

of
the
material
Wn
is




es (Awb − Awa )
Wn =
ηe
SIZE
REDUCTION
is
the
least
energy
efficient
of
all
unit
opera*ons
–
that

is
 –
 the
 surface
 energy
 created
 by
 fracture
 is
 small
 in
 comparison

with
the
total
mechanical
energy
stored
in
the
material
at
the
*me

of
rupture.
Less
than
1%
of
the
energy
delivered
to
the
solids
is
used

to
create
new
(obtained
from
theory)


3

 3/26/12


Energy
and
Power
requirements
in
comminu*on

The
 energy
 absorbed
 by
 the
 solid
 Wn
 is
 less
 than
 that
 fed
 to
 the

machine.
Part
of
the
total
energy
W
is
used
to
overcome
fric*on
in

bearings
and
other
moving
parts,
and
rest
is
available
for
crushing.

The
ra*o
of
energy
absorbed
to
the
energy
input
is
the
mechanical

efficiency:




 W
ηm = n

W
W e (A − Awa )
W = n = s wb
ηm ηmηe
m
If





is
the
feed
rate,
the
power
required
by
the
machine
is




 s (Awb − Awa )
me
P = Wm =
ηmηe

Energy
and
Power
requirements
in
comminu*on


 s (Awb − Awa )
me
P = Wm =
ηmηe

sp 6
By
defini*on
 =
vp Φs Dp

 s ⎛ 1
6 me 1 ⎞
P= −
ηmηe ρ p ⎜⎝ Φb Dsb Φ a Dsa ⎟⎠

Volume
surface
mean
diameter


4

 3/26/12


Empirical
Rela*onships:
RiSnger’s
law
and
Kick’s
law

RiSnger’s
 law
 (1867):
 Work
 required
 in
 crushing
 is

propor*onal
 to
 the
 new
 surface
 created.
 This
 hypothesis
 is

equivalent
 to
 the
 statement
 that
 the
 crushing
 efficiency
 is

constant
for
a
given
machine
and
feed
material.

6es
P ⎛ 1 1 ⎞ Kr =
= Kr ⎜ − Φηmηe ρ p
m ⎝ Dsb Dsa ⎟⎠ Spherici*es
of
feed
and
product
is
same


Kick
 (1885)
 proposed
 another
 "law,"
 based
 on


stress
 analysis
 of
 plas*c
 deforma*on
 within
 the

elas*c
limit,
which
states
that
the
work
required
 P ⎛D ⎞
for
crushing
a
given
mass
of
material
is
constant

= K k ln ⎜ sa ⎟
m ⎝ Dsb ⎠
for
the
same
reduc*on
ra*o,
that
is,
the
ra*o
of

the
 ini*al
 par*cle
 size
 to
 the
 final
 par*cle
 size.

This
leads
to
the
rela*on



Generalized
rela*on
for
RiSnger’s
law
and
Kick’s
law


⎛ P⎞ dD
d ⎜ ⎟ = −K ns
⎝ m ⎠ D s

Where
n=
1,
2
leads
to
Kick's
law
and
RiSnger's
law,
respec*vely.



Both
 Kick's
 law
 and
 RiSnger's
 law
 have
 been
 shown
 to
 apply
 over

limited
 ranges
 of
 par*cle
 size,
 provided
 Kk
 and
 Kr,
 are
 determined

experimentally
by
tests
in
a
machine
of
the
type
to
be
used
and
with
the

material
to
be
crushed.
They
thus
have
limited
u*lity.


5

 3/26/12


Bond’slaw
and
work
index

Work
 required
 to
 form
 par*cles
 of
 size
 Dp
 from
 very
 large
 feed
 is

propor*onal
 to
 the
 square
 root
 of
 the
 surface‐volume
 ra*o
 of
 the

product
sp/vp.
 sp 6
P K =
= b By
defini*on

vp Φs Dp
m Dp
Kb is
 a
 constant
 that
 depends
 on
 the
 type
 of
 machine
 and
 the

materials
being
crushed.



Kb is
related
to
work
index



Wi is
defined
as
the
gross
energy
requirement
in
kilowaRhours
per
ton

(2000
lb)
of
feed
needed
to
reduce
a
very
large
feed
to
such
a
size

that
80%
of
the
product
passes
through
a
100
–
micron
mesh.
If
Dp

m
is
in
millimeters,
P
is
kilowaRs
and






in
tons
per
hour


K b = 100 × 10 −3Wi

Bond’s
law
and
work
index


If
80%
of
the
feed
passes
a
mesh
size
of
Dpa
mm
and
80
%
of
the
product

passes
through
a
mesh
of
Dpb
mm,
then



P K
= b
m Dp
can
be
modified
to


P ⎛ 1 1 ⎞
= 0.3162Wi ⎜ − ⎟
m ⎝ D pb D pa ⎠

6

 3/26/12


Bond’s
law
and
work
index


Popula*on
Balance
Equa*ons

Popula*on
 Balance
 Modeling
 is
 a
 general
 engineering
 framework
 used
 to
 predict
 par*cle
 size

distribu*on
 in
 par*culate
 processes
 such
 as
 crystalliza*on,
 granula*on,
 pollutant
 forma*on,

aggrega*on,
 growth
 of
 microbial
 popula*ons,
 etc.
 When
 a
 process
 involves
 a
 large
 number

par*cles,
solu*on
of
the
PBE
is
necessary
to
determine
the
proper*es
of
the
resul*ng
product

and
 its
 dependence
 on
 processes
 that
 alter
 par*cle
 size
 distribu*on
 –
 for
 example
 –

coalescence,
breakage
and
surface
growth
 hAp://www.nonequilibrium.com/PatrickSpicerPhD1997.pdf


Example:
 The
 par*cle
 size
 distribu*on
 undergoing
 simultaneous


coagula*on
and
fragmenta*on
is
given
by
 Shear
 Induced
 Structural

Changes

The
forma*on
of
par*cles
comprised
 The
loss
of
par*cles
of
size

of
i
primary
par*cles
by
collisions
of
 i
by
fragmenta*on


smaller
j‐
and
k‐
sized
par*cles.




Coagula*on
 Breakup


The
 loss
 of
 par*cles
 of
 size
 i
 by
 The
forma*on
of
par*cles
of
size


collision
 with
 par*cles
 of
 any
 i
by
the
fragmenta*on
of
larger

other
size.
 par*cles.


7

 3/26/12


Simula*on
of
Milling
Or
Size
reduc*on
Opera*ons
by
PBE



The
 material
 in
 a
 mill
 or
 crusher
 at
 any
 *me
 is
 made
 up
 of

par*cles
 of
 many
 different
 sizes.
 The
 size
 distribu*on
 of
 the

products
 from
 various
 types
 of
 size
 reduc*on
 can
 be

predicted
 by
 the
 computer
 simula*on
 of
 milling
 opera*ons

using
PBM
approach.


Assump7on:
 Though
 all
 par*cles
 interact
 with
 one
 another


during
 the
 size‐reduc*on
 process,
 for
 purposes
 of
 computer

simula*on
 the
 material
 is
 imagined
 to
 be
 divided
 into
 a

number
 of
 discrete
 frac*ons
 (such
 as
 the
 ones
 retained
 on

the
 various
 standard
 screens)
 and
 that
 par*cle
 breakage

occurs
 in
 each
 frac*on
 more
 or
 less
 independently
 of
 the

other
frac*ons.



Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons


For
simultaneous
coagula*on
and
fragmenta*on:

The
forma*on
of
par*cles
comprised
 The
loss
of
par*cles
of
size

of
i
primary
par*cles
by
collisions
of
 i
by
fragmenta*on


smaller
j‐
and
k‐
sized
par*cles.




The
 loss
 of
 par*cles
 of
 size
 i
 by
 The
forma*on
of
par*cles
of
size


collision
 with
 par*cles
 of
 any
 i
by
the
fragmenta*on
of
larger

other
size.
 par*cles.


For
milling
opera7ons:

n −1
dxn
= −Sn xn + ∑ xu Su ΔBn,u
dt u =1
Grinding‐rate
func*on
 Breakage
func*on


8

 3/26/12


Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons



Grinding‐rate
func7on

Stack
of
nT
standard
screens


For
 any
 given
 value
 of
 n,
 let
 the
 upper


screens
 coarser
 than
n
 be
 designated
 by

Coarsest
to
finest


the
subscript
u
(u<n)



The
grinding‐rate
func7on
Su
is
the
frac*on
of

Screen
n

the
material
of
a
given
size,
coarser
than
that

on
screen
n,
which
is
broken
in
a
given
*me.
If

xu
is
the
mass
frac*on
retained
on
one
of
the

upper
screens,
its
rate
of
change
by
breakage

to
smaller
sizes
is
given
by


dxu
= −Su xu
dt

Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons



Grinding‐rate
func7on

The
grinding‐rate
func7on
Su
is
the
frac*on
of

the
material
of
a
given
size,
coarser
than
that

on
screen
n,
which
is
broken
in
a
given
*me.
If

xu
is
the
mass
frac*on
retained
on
one
of
the

Coarsest
to
finest


upper
screens,
its
rate
of
change
by
breakage

to
smaller
sizes
is
given
by



Screen
n
 dxu
= −Su xu
dt
Suppose,
 for
 example,
 that
 the
 coarsest

material
in
the
charge
to
a
grinding
mill
is
4/6‐
mesh,
 that
 the
 mass
 frac*on
 of
 this
 material

xi,
 is
 0.05,
 and
 that
 one‐hundredth
 of
 this

material
 is
 broken
 every
 second.
 Then
 Su

would
be
0.01
s‐1
and
xi
would
diminish
at
the

rate
of
0.01
x
0.05
=
0.0005
s‐1



9

 3/26/12


Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons



Breakage
func7on

The
breakage
func*on
ΔBn,u
gives
the
size
distribu*on
resul*ng
from
the

breakage
 of
 the
 upper
 material.
 Some
 of
 the
 4/6‐mesh
 material,
 aqer

breaking,
would
be
fairly
coarse,
some
very
small,
and
some
in
between.

Probably
 very
 liRle
 would
 be
 as
 large
 as
 6/8‐mesh,
 and
 only
 a
 small

amount
 as
 small
 as
 200‐mesh.
 One
 would
 expect
 sizes
 in
 the

intermediate
range
to
be
favored.



Consequently
ΔBn,u
varies
with
both
u
and
n.



Furthermore
 it
 varies
 with
 the
 composi*on
 of
 the
 material
 in
 the
 mill,

since
 coarse
 par*cles
 may
 break
 differently
 in
 the
 presence
 of
 large

amounts
of
fines
than
they
do
in
the
absence
of
fines.



In
a
batch
mill,
therefore,
ΔBn,u
(and
Su
also)
would
be
expected
to
vary

with
*me
as
well
as
with
all
the
other
milling
variables.



Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons



If
ΔBn,u
and
Su
 
are
known
or
can
be
assumed,
the
rate
of
change
of
any

given
 frac*on
 can
 be
 found
 using
 PBE.
 For
 any
 frac*on
 except
 the

coarsest,
 the
 ini*al
 amount
 is
 diminished
 by
 breakage
 to
 smaller
 sizes

and
 simultaneously
 augmented
 by
 the
 crea*on
 of
 new
 par*cles
 from

breakage
 of
 all
 coarser
 frac*ons.
 If
 the
 input
 and
 output
 from
 a
 given

screen
are
at
equal
rates,
the
frac*on
retained
on
that
screen
remains

constant.
 Usually,
 however,
 this
 is
 not
 the
 case,
 and
 the
 mass
 frac*on

retained
on
screen
n
changes
according
to
the
equa*on:



n −1
dxn
= −Sn xn + ∑ xu Su ΔBn,u
dt u =1

10

 3/26/12


Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons



n −1
dxn
= −Sn xn + ∑ xu Su ΔBn,u
dt u =1
In
crushing
coal,
for
par*cles
larger
than
about
28‐mesh,
 Su
has
been
found
to

vary
with
the
cube
of
the
par*cle
size
and
the
breakage
func*on
to
depend
on

Dn
the
reduc*on
ra*o








according
to
the
equa*on


Du
β
⎛D ⎞
Bn,u =⎜ n⎟
⎝D ⎠ u

where
the
exponent
β
may
be
constant
or
may
vary
with
the
value
of
B.



Computer
simula*on
of
Milling
Or
Size
reduc*on
Opera*ons


β
⎛D ⎞
Bn,u =⎜ n⎟
⎝D ⎠ u

where
the
exponent
β
may
be
constant
or
may
vary
with
the
value
of
B.



Bn,u
 is
 the
 total
 mass
 frac*on
 smaller
 than
 size
 D


 n
 .
 It
 is
 a
 cumula*ve
 mass

frac*on,
 in
 contrast
 with
 ΔBn,u,
 which
 is
 the
 frac*on
 of
 size
 
D
 n
 
 (retained

between
screens
n
and
n
+
1)
resul*ng
from
breakage
of
par*cles
of
size





∙


Du

β
 in
 above
 Eq.
 is
 constant,
 implies
 ‐
 that
 the
 par*cle‐size
 distribu*on
 of
 the

crushed
 material
 is
 the
 same
 for
 all
 sizes
 of
 the
 ini*al
 material.
 The
 value
 of

ΔBn,u
 in
 crushing
 4/6‐mesh
 material
 to
 8/10‐mesh
 will
 be
 the
 same
 as
 in

crushing
 6/8‐mesh
 par*cles
 to
 10/14‐mesh,
 since
 the
 size‐reduc*on
 ra*o
 is

the
same.



11

 3/26/12


Size
Distribu*on
by
PBE
‐
Problem


A
batch
grinding
mill
is
charged
with
material
of
the
composi*on
shown

in
Table.



Size
Distribu*on
by
PBE
‐
Problem

The
 grinding‐rate
 func*on
 Su
 is
 assumed
 to
 be
 0.001
 s‐1
 for
 the
 4/6‐
mesh
par*cles.
Breakage
func*on
Bn,u
is
given
by


β
⎛D ⎞
Bn,u =⎜ n⎟
⎝D ⎠
u
with
β
=
1.3..



Both
Su
and
Bn,u
are
assumed
to
be
independent
of
*me.
(a)
How
long

will
 it
 take
 for
 the
 frac*on
 of
 4/6‐mesh
 material
 to
 diminish
 by
 10

percent?
 (b)
 Tabulate
 the
 individual
 breakage
 func*ons
 ΔBn,u
 for
 the

28/35‐mesh
frac*on
and
for
all
coarser
frac*ons.
(c)
How
will
the
values

of
 xn
 vary
 with
 the
 *me
 during
 the
 first
 6
 h
 of
 opera*on?
 Use
 a
 *me

interval
Δt
of
30
s
in
the
calcula*ons.



12

 3/26/12


Size
Distribu*on
by
PBE
‐
Problem


(a)
 How
 long
 will
 it
 take
 for
 the
 frac*on
 of
 4/6‐mesh
 material
 to

diminish
by
10
percent?



For
the
4/6‐mesh
material
there
is
no
input
from
coarser
material

dxu
= −Su xu
dt (Mass
 frac*on
 of
 material

on
4/6‐mesh

xu,initial = 0.0251
Su = 0.001s −1 (given)

xu, final = 0.0251 × 0.9 = 0.02259

1 dxu T 1 0.02259 dxu

dt = −
Su xu ∫ 0
dt = −
Su ∫0.0251 xu
T = 105.3 s

Size
Distribu*on
by
PBE
‐
Problem


(b)
Tabulate
the
individual
breakage
func*ons
ΔBn,u
for
the
28/35‐mesh

frac*on
and
for
all
coarser
frac*ons.


Calcula*on
 of
 breakage
 func*on
 Bn,u:
 When
 n
 and
 u
 are
 equal,
 or

whenever
n
<
u,
ΔBn,u=
O.
The
total
mass
frac*on
smaller
than
6/8‐mesh

resul*ng
from
breakage
of
4/6‐mesh
par*cles,
B2,1
is
from
the
following

equa*on


β
⎛ Dn ⎞
Bn,u = ⎜ ⎟
Coarsest
to
finest


Screen
n

⎝D ⎠ u
1.3
⎛ 2.362 ⎞
B2,1 = ⎜ = 0.6407
⎝ 3.327 ⎟⎠
ΔB2,1
 is
 the
 frac*on
 of
 the
 broken
 material
 retained
 on
 8
 mesh
 =

1‐0.6407
=
0.3593




13

 3/26/12


Size
Distribu*on
by
PBE
‐
Problem


The
total
mass
frac*on
smaller
than
8/10‐mesh
resul*ng
from
breakage

of
4/6‐mesh
material,

 1.3
⎛ 1.651 ⎞
B3,1 = ⎜ = 0.4021
⎝ 3.327 ⎟⎠

In
general,
the
individual
breakage
func*ons
are
found
from
the
rela*on



ΔBn,u = Bn −1,u − Bn,u

Thus
the
mass
frac*on
of
the
broken
4/6‐mesh
material
retained
on
the

10‐mesh
screen
=
0.6407‐0.4021=0.2386


Breakage
Func*ons

When
n
=
u,
Bn,uis
unity


When
u=1,
0.6407
of
the
broken
par*cles
from
the
4/6‐mesh
material
is

smaller
than
8‐mesh,
0.4021
smaller
than
10‐mesh,
0.2564
smaller
than

14‐mesh,
and
only
0.0672
smaller
than
35‐mesh.



14

 3/26/12


Mass
Frac*ons
Calcula*ons


(c)
 How
 will
 the
 values
 of
 xn
 vary
 with
 the
 *me
 during
 the
 first
 6
 h
 of

opera*on?
Use
a
*me
interval
Δt
of
30
s
in
the
calcula*ons.



Let
xn,t
be
the
mass
frac*ons
retained
on
the
various
screens
at
the
end

of
t
*me
increments
Δt.
Then
x1,0,
x2,0,
etc.,
are
the
ini*al
mass
frac*ons


dxn n −1
Δxn n −1
= −Sn xn + ∑ xu Su ΔBn,u = −Sn xn + ∑ xu Su ΔBn,u
dt u =1 Δt u =1

n −1
xn,t +1 = xn,t − Sn xn,t + ∑ xu,t Su ΔBn,u
u =1

n −1
xn,t +1 = xn,t (1 − ΔtSn xn,t + Δt ∑ xu,t Su ΔBn,u
u =1

Mass
Frac*ons
Calcula*ons


15

 3/26/12


Mass
Frac*ons
Calcula*ons


Ball
Mills


16

 3/26/12


Ball
Mills
–
How
does
grinding/size
reduc*on
happen?


o When
the
mill
is
rotated,
the
balls
are
picked
up
by
the
mill
wall
and
carried

nearly
 to
 the
 top,
 where
 they
 break
 contact
 with
 the
 wall
 and
 fall
 to
 the

boRom
to
be
picked
up
again.


o Centrifugal
force
keeps
the
balls
in
contact
with
the
wall
and
with
each
other

during
 the
 upward
 movement.
 While
 in
 contact
 with
 the
 wall,
 the
 balls
 do

some
grinding
by
slipping
and
roIling
over
each
other,
but
most
of
the
grinding

occurs
at
the
zone
of
impact,
where
the
free
faIling
balls
strike
the
boRom
of

the
mill.


o The
 faster
 the
 mill
 is
 rotated,
 the
 farther
 the
 balls
 are
 carried
 up
 inside
 the

mill
 and
 the
 greater
 the
 power
 consump*on.
 The
 added
 power
 is
 profitably

used
because
the
higher
the
balls
are
when
they
are
released,
the
greater
the

impact
at
the
boRom
and
the
larger
the
produc*ve
capacity
of
the
mill.


o If
the
speed
is
too
high,
however,
the
balls
are
carried
over
and
the
mill
is
said

to
be
centrifuging.
The
speed
at
which
centrifuging
occurs
is
called
the
cri*cal

speed.
LiRle
or
no
grinding
is
done
when
a
mill
is
centrifuging,
and
opera*ng

speeds
must
be
less
than
the
cri*cal.



FORCES
in
a
BALL
in
BALL
MILL

The
 posi*on
 or
 height
 at
 which
 the
 outermost
 balls
 lose
 contact
 with

the
wall
of
the
mill
depends
on
the
balance
between
gravita*onal
and

centrifugal
forces.



Consider
 the
 ball
 at
 point
 A
 on
 the


periphery
 of
 the
 mill.
 Let
 the
 radii
 of
 the

mill
and
of
the
ball
be
R
and
r,
respec*vely.


The
center
of
the
ball
is,
then
R
‐
r
meters

(or
 feet)
 from
 the
 axis
 of
 the
 mill.
 Let
 the

radius
 AO
 form
 the
 angle
 α
 with
 the

ver*cal.


Two
forces
act
on
the
ball
–


Gravita*onal
force

Centrifugal
force


17

 3/26/12


FORCES
in
a
BALL
in
BALL
MILL


Force
 of
 gravity
 ‐
 mg/gc
 where
 m
 is
 the


mass
of
the
ball.



Centrifugal
force
‐
m(R
‐
r)
ω2/gc
where
ω
=

2πn
and
n
is
the
rota7onal
speed.



The
 centripetal
 component
 of
 the
 force
 of


gravity
 is
 (mg/gc)cos(α),
 and
 this
 force

opposes
the
centrifugal
force.



As
long
as
the
centrifugal
force
exceeds
the
centripetal
force,
the
par*cle
will

not
 break
 contact
 with
 the
 wall.
 As
 the
 angle
 a
 decreases,
 however,
 the

centripetal
force
increases,
and
unless
the
speed
exceeds
the
cri*cal,
a
point
is

reached
where
the
opposing
forces
are
equal
and
the
par*cle
is
ready
to
fall

away.
The
angle
at
which
this
occurs
is
found
by
equa*ng
the
two
forces


FORCES
in
a
BALL
in
BALL
MILL


g m ⎡⎣ 4π 2 n 2 (R − r) ⎤⎦
m cos(α ) =
gc gc
4π 2 n 2 (R − r)
cos(α ) =
g
At
the
cri*cal
speed,
α=
0,
cos(α)
=
1,
and

n
becomes
the
cri*cal
speed
nc


1 g
nc =
2π R−r
Tumbling
 mills
 run
 at
 65
 to
 80
 percent
 of
 the
 cri*cal
 speed,
 with
 the

lower
values
for
wet
grinding
in
viscous
suspensions.


18

 3/26/12


FORCES
in
a
BALL
in
BALL
MILL


g m ⎡⎣ 4π 2 n 2 (R − r) ⎤⎦
m cos(α ) =
gc gc
4π 2 n 2 (R − r)
cos(α ) =
g
At
the
cri*cal
speed,
α=
0,
cos(α)
=
1,
and

n
becomes
the
cri*cal
speed
nc


1 g
nc =
2π R−r
Tumbling
 mills
 run
 at
 65
 to
 80
 percent
 of
 the
 cri*cal
 speed,
 with
 the

lower
values
for
wet
grinding
in
viscous
suspensions.


Factors
that
affect
choice
of
size
reduc*on
equipment


Stressing
mechanics


Size
of
feed
and
product


Material
proper*es


Carrier
medium


Mode
of
Opera*on


Capacity


19

 3/26/12


Factors
affec*ng
choice
of
size
reduc*on
equipment


Stressing
mechanics


Size
of
feed
and
product


Material
proper*es


Carrier
medium


Mode
of
Opera*on


Capacity


Factors
affec*ng
choice
of
size
reduc*on
equipment


Stressing
mechanics


Size
of
feed
and
product

Hardness/Toughness,
 cohesivity/
Material
proper*es
 adhesivity,
 Abrasiveness,
 Fibrous

nature

Carrier
medium
 Air
or
Liquid


Mode
of
Opera*on
 Batch
 or
 con*nuous.
 Choice
 depends


on
 throughput,
 process
 and

Capacity
 economics



20

 3/26/12


Type
of
milling
circuits


Open
 circuit
 milling
 –
 material


passes
 through
 the
 mill
 only
 once,

and
the
only
controllable
variable
is

the
 residence
 *me
 of
 the
 material,

Feed
 rate
 governs
 product
 size
 –

the
system
is
inflexible


Closed
circuit
milling
–
the
material

leaving
 the
 mill
 is
 subjected
 to

some
 form
 of
 classifica*on
 with

oversize
 being
 returned
 to
 the
 mill

with
the
feed
material.
Such
system

is
more
flexible
–
product
mean
size

and
 size
 distribu*on
 may
 be

controlled.



Type
of
milling
circuits

Closed
circuit
dry
milling


Closed
circuit
wet
milling


21