7.

7 SOLVEDPROBLEMS ONCRUSHI
NGANDGRI
NDI
NG,
SCREENI
NGANDMI
XING,

Theor
eti
calBackgr
ound

Lawsofcr
ushi
ng:

Ri
tt
inger
’sLaw,

Wher
e, P=Powercons
umed

m =Feedr
ateofcr
usher

=Meanvol
ume-
sur
facedi
amet
erofpr
oduct

=Meanvol
ume-
sur
facedi
amet
eroff
eed

Kr=Ri
tt
inger
’scons
tant
.

Ki
ck’
sLaw,

Wher
e,Kk=Ki
ck’
scons
tant

Bond’
sLaw,

Wher
e, Wi=Bond’
swor
kindex,Kwh/t
on

Dpb =Pr
oductpar
ticl
esi
ze

Dpa =Feedpar
ticl
esi
ze
Scr
eenef
fect
ivenes
s:(
E)

Wher
e, xF =mas
sfr
act
ionofmat
eri
alAi
nfeed

xD =mas
sfr
act
ionofmat
eri
alAi
nover
flow

xB =mas
sfr
act
ionofmat
eri
alAi
nunder
flow

Pr
obl
em 7.
2 A cer
tai
n cr
ushert
akesr
ock whos
e aver
age par
ticl
e
di
amet
eri
s0.
025m andcr
ushesi
ttoapr
oductwhos
eaver
agepar
ticl
e
di
amet
eri
s0.
018m,att
her
ateof20,
000kg/hour
.Att
hisr
ate,t
hemi
ll
t
akes684(
kgf)(
m)/s
ec.ofpowerand35kgfm/s
ec.poweri
srequi
redt
o
r
uni
tempt
y.

(
i)Whatwoul
dbet
hepowercons
umpt
ionf
ors
amecapaci
ty,i
f
t
heaver
agepar
ticl
edi
amet
eri
nthe pr
oducti
s0.
008met
re.

(
ii
)How muchpowerwoul
dber
equi
redundercondi
ti
ons(
i)by
Ki
ck’
slaw?(
A.M.
I.
E.Exam;U.
O.I
.–1
976Summer
)

Sol
uti
on:

Rat
eofcr
ushi
ng=20,
000kg/hr=20t
ons
/hr
.

Let
, P=Powercons
umpt
ionf
orcr
ushi
ngonl
y

=P1–P0

Wher
e,P1=Powercons
umpt
ionbyt
hemi
lldur
ingcr
ushi
ng.

P0 =Powercons
umpt
ionbyt
hemi
llt
oruni
tempt
y.

So, P=(
684–35)
 =

ByRi
tt
inger
’sl
aw,

Wher
e,Pi
sh.
p.andi
nisT/hr
.

So, or
, kr=0.
0275

(
i)Let
,P’bet
hepowercons
umpt
ionf
ort
hiscas
e.

Dsb =0.
008m.

So,

or
,

(
ii
)ByKi
ck’
slaw,

or
,

So, k=2.
993

Powerr
equi
redundercondi
ti
ons(
i)
,

or
,
Pr
obl
em 7.
3Cal
cul
atet
heener
gy r
equi
red t
ocr
ush1
00 t
onnesper
hourofl
imes
tonei
f80% oft
hef
eedpas
sest
hroughas
creen3.
75cm
aper
tur
eand80% oft
hepr
oductpas
sest
hroughas
creenwi
th0.
03cm
aper
tur
e.Thewor
kindexf
orl
imes
tonei
s12.
74,whent
hecapaci
tyi
s
expr
ess
edi
ntonespermi
nut
e,ener
gyr
equi
redi
nHPands
izeoff
eed
andpr
oducti
nfeet
.

(
Sambal
purUni
.,SRMO–1
980December
)

Sol
uti
on:

ByBond’
slaw,

Wher
eWii
swor
kindex.

Dpb =0.
03cm = f
t.

Dpa =3.
75cm = f
t.

Wi=1
2.74

i
n=1
00t
ons
/hr
.= t
ons
/mi
n

= t
ons
/mi
n,

P=
 =1
95.
05kW =261
.56h.
p.

Pr
obl
em 7.
4.A mat
eri
ali
scr
ushed i
naBl
akej
aw cr
usherand t
he
aver
age s
ize of par
ticl
es i
sreduced f
rom 5cm t
o1.
3cm,wi
th
cons
umpt
ionofener
gyatt
her
ateof37(
wat
ts)(
hr.
)/(
met
rict
on)
.What
wi
llbe t
he cons
umpt
ion of ener
gy neces
sar
yto cr
usht
he s
ame
mat
eri
alof aver
age s
ize 8cm t
o an aver
age s
ize of 3cm? The
mechani
calef
fici
encyr
emai
nsunchanged.

(
i) Us
ingRi
tt
inger
’sl
aw;

(
ii
) Us
ingKi
ck’
slaw.(
A.M.
I.
E.Exam.
,U.
O.I
.Summer1
978)

Sol
uti
on:

(
i) Ri
tt
inger
’sl
aw i
s;

P=37andm =1
.

=1
.3

=5.
0

Hence

Fort
hes
econdcas
e,l
etP’bet
hepowercons
umpt
ion.

So, …(
2)

Di
vidi
ng,(
2)by(
1),
Sol
ving,

(
ii
) Expr
ess
ionf
orKi
ck’
slaw i
s,

So, …(
3)

Fort
hes
econdcas
e,l
et bet
hepowerr
equi
red.

So, …(
4)

Di
vidi
ng(
4)by(
3),

Sol
ving,

Pr
obl
em 7.
5.Onet
oneperhourofdol
omi
tei
spr
oducedbyabal
lmi
ll
oper
ati
ngi
ncl
osedci
rcui
twi
tha1
00mes
hscr
een.Thes
creenanal
ysi
s
(
wei
ght%)i
sgi
venbel
ow.Cal
cul
atet
hes
creenef
fici
ency.

Mes
h Feed Over
size Under
size
35 7.
07 1
3.67 0
48 1
6.60 32.
09 0
65 1
4.02 27.
12 0
1
00 1
1.82 20.
70 2.
32
1
50 9.
07 4.
35 1
4.32
200 7.
62 2.
07 1
3.34
-
200 33.
80 0 70.
02
1
00.
00 1
00.
00 1
00.
00
(
A.M.
I.
E.Exam.
,U.
O.I
.1982Summer
)

Sol
uti
on:

Scr
eenef
fici
ency =

Wi
tha1
00mes
hscr
een,cumul
ati
vemas
sfr
act
ionsar
egi
venbel
ow:

Forf
eed = 49.
51

Forover
size = 93.
58

Forunder
size = 2.
32 (
from s
creenanal
ysi
stabl
e).

Ther
efor
e,xF = 0.
4951

xD = 0.
9358
 xB = 0.
0232

Ef
fici
encyoft
hes
creen=91
.32%.

Pr
obl
em 7.
6.Onet
oneperhourofdol
omi
tei
spr
oducedbycr
ushi
ng
andt
hens
creeni
ngt
hrougha1
4mes
hscr
een.Accor
dingt
othes
creen
anal
ysi
s(i
nwei
ghtper
cent
)gi
venbel
ow,cal
cul
ate:

(
a)Thet
otall
oadt
othecr
usher
,

(
b)Theef
fect
ivenes
soft
hes
creen.

Scr
eenanal
ysi
s:

Mes
h Feed Under
size Over s
ize
% % circul
ati
ng
load,%
4on 1
4.3 - 20
8on 20.
0 - 28
1
4on 20.
0 0 28
28on 28.
5 40 24
48on 8.
6 30 0(
thr
ough
28mes
h)
1
00on 5.
7 20
1
00t
hrough 2.
9 1
0
1
00.
0 1
00.
0 1
00
(
A.M.
I.
E.Exam.
,U.
O.I
.1982Summer
)
Sol
uti
on:

Fr
om s
creenanal
ysi
s,t
hecumul
ati
vef
ract
ionsf
ora1
4mes
hscr
een
ar
easunder
:

Forf
eed = 54.
3i.
e.0.
543

Over
size = 76.
0i.
e.0.
76

Under
size = 0

Al
so,weknow t
hat
,

Wher
e,Bi
sthepr
oduct(
under
size)

B=1t
onne/hr

xD =0.
760

xF=0.
543

xB =0

So, or
,F=3.
5tonnes
/hour

Thel
oadt
ocr
usher=3.
5tonnes
/hr
.

(
b)

Theef
fect
ivenes
soft
hes
creeni
s62.
48%.

Pr
obl
em 7.
7.As
ilt
ysoi
lcont
aini
ng1
4% moi
stur
ewasmi
xedi
nal
arge
mul
lermi
xerwi
th1
0.0 wei
ghtpercentofa t
racercons
ist
ing of
dext
ros
eandpi
cri
caci
d.Af
ter3mi
nut
esofmi
xing1
2random s
ampl
es
wer
etaken f
rom t
hemi
x and anal
ysed col
ori
met
rical
lyf
ort
racer
mat
eri
al.Themeas
uredconcent
rat
ionsi
nthes
ampl
eswer
e,i
nwei
ght
percentt
racer
,10.
24,9.
30,7.
94,1
0.24,1
1.08,1
0.03,1
1.91
,9.
72,9.
20,
1
0.76,1
0.97and1
0.55.

Cal
cul
atet
hemi
xingi
ndex. (
A.M.
I.
E.Exam.1
984Wi
nter
)

Sol
uti
on:

Cal
cul
ati
onf
or and

Sampl
eNo.
1
. 0.
1024 +0.
0008 0.
0064
2. 0.
0930 -0.
0086 0.
7396
3. 0.
0794 -0.
0222 4.
9284
4. 0.
1024 +0.
0008 0.
0064
5. 0.
1108 +0.
0092 0.
8464
6. 0.
1003 -0.
001
3 0.
0169
7. 0.
1191 +0.
0175 3.
0625
8. 0.
0972 -0.
0044 0.
1936
9. 0.
0920 -0.
0096 0.
921
6
1
0. 0.
1076 +0.
0060 0.
3600
1
1. 0.
1097 +0.
0081 0.
6561
1
2. 0.
1055 +0.
0039 0.
1521
Tot
al 1
.21
94 1
1.89
 Themi
xingi
ndexi
s0.
0347.

Pr
obl
em 7.
8.A cer
tai
ncr
usheraccept
saf
eedofr
ockhavi
nga
vol
umes
urf
acemeandi
amet
erof1
.9cm anddi
schar
gespr
oduct
of0.
5cm.Thepowerr
equi
redt
ocr
ush1
2000kg/hri
s6.
94kW.
Whats
houl
dbet
hepowercons
umpt
ioni
fthecapaci
tyi
sreduced
t
o10000kg/hrandt
hevol
umes
urf
acemeandi
amet
erofpr
oduct
i
s 0.
38cm. The mechani
cal ef
fici
ency r
emai
ns unchanged.
As
sumeRi
tt
inger
’sl
aw i
sappl
icabl
e. (
A.M.
I.
E.Exam.1
983
Wi
nter
)

1
.A s
creenwi
thanaper
tur
eof6mes
hBSSi
str
eat
ingaf
eedwi
th
66% of+6mes
handpr
oduci
nganover
sizef
ract
ioncont
aini
ng
89%of+6mes
hpar
ticl
es.I
ftheunder
sizef
ract
ioncont
ain2%of
+ 6 mes
h par
ticl
es,cal
cul
atet
he ef
fect
ivenes
soft
he s
creen.
(
Sambal
purUni
.1982Dec)

I
nit
ialcondi
ti
on,
Andappl
yingRi
tt
inger
’sl
aw

Feeddi
amet
erdf=1
.9cm

Pr
oductdi
amet
er,dp=0.
5cm

Powercons
umpt
ion,p=6.
94kW

Mas
sfl
ow r
ateofcr
ushi
ng,i
n=1
2,000kg/hr

Ri
tt
inger
’scons
tant
,KR =?

gi
vent
heequat
ionf
orRi
tt
ingerl
aw,ands
ubs
tit
uti
ngt
heval
ue

TheRi
tt
ingercons
tanti
sobt
ainedas3. 0-4 kW cm hrkg-1
924x1

Nextcondi
ti
on

df=1
.9cm

dp=0.
38cm

i
n=1
0000kg/hr

(
Sincemechani
calef
fici
encyr
emai
nst
hes
ame)

p=?
Al
so

powercons
umed=8.
26kW.

Pr
obl
em 7.
8.As
creenwi
thanaper
tur
eof6mes
hBSSi
str
eat
ing
af
eedwi
th66% of+6mes
handpr
oduci
nganover
sizef
ract
ion
cont
aini
ng89% of+ 6mes
hpar
ticl
es.I
ftheunder
sizef
ract
ion
cont
ain2% of+6mes
hpar
ticl
es,cal
cul
atet
heef
fect
ivenes
sof
t
hes
creen.(
Sambal
purUni
.1982Dec)

Aper
tur
eofs
creeni
s6mes
h

Fr
act
ionoff
eedof+6mes
h=66%=0.
66=xF

Fr
act
ionofover
sizeof+6mes
h=89%=0.
89=xD

Fr
act
ionofunder
sizeof+6mes
h=2%=0.
02=xB

Ef
fect
ivenes
soref
fici
encyoft
he+6mes
hscr
een=?

Ther
efor
eef
fici
encyoft
hes
creengi
venas
:

Ef
fect
ivenes
sorEf
fici
ency=
Ef
fect
ivenes
sofs
creen=76%.