Professional Documents
Culture Documents
Mineral Processing
Size Reduction
Wahyu Wilopo
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Note!
• So, the trick when producing quality products from rock
or minerals (fillers excepted) is to keep the size reduction
curves as steep as possible.
• Normally that is what we get paid for - the shorter or
more narrow fraction - the more value!
• To achieve that goal we need to select the correct
equipment out of the repertoire for size reduction in a
proper way.
• They are all different when it comes to reduction
technique, reduction ratio, feed size etc. and have to be
combined in the optimum way to reach or come close to
the requested size interval for the end product.
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Feed Material
• All operations in size reduction, both crushing
and grinding are of course determined by the
feed characteristics of the minerals (rock/ore)
moving into the circuit.
• The key parameters we need are the
“crushability or grindability”, also called work
index and the “wear profile”, called abrasion
index.
• Values for some typical feed materials from
crushing of rocks, minerals and ore are
tabulated below.
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Reduction Ratio
• As seen above all size reduction
operations are performed in stages. All
equipment involved, crushers or grinding
mills have different relation between feed
and discharge sizes.
• This is called reduction ratio.
• Typical values below
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Crushing – Calculation of
Reduction Ratio
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Selection of Crushers
• Knowing the number of crushing stages
we can now start to select the correct
crusher for each reduction stage.
• Depending on operating conditions, feed
size, capacity, hardness etc, there are
always some options.
• For primary crushers, see below.
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Grinding – Introduction
Size reduction by crushing has a size limitation for the final
products. If we require further reduction, say below 5-
20mm, we have to use the processes of grinding
Grinding is a powdering or pulverizing process using the
rock mechanical forces of impaction, compression,
shearing and attrition.
The two main purposes for a grinding process are:
• To liberate individual minerals trapped in rock crystals
(ores) and thereby open up for a subsequent enrichment
in the form of separation.
• To produce fines (or filler) from mineral fractions by
increasing the specific surface.
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