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Many solid materials occur in sizes that are too large to be used
and must be reduced. Often the solids are reduced in size so that
the separation of various ingredients can be carried out. In
general, the terms crushing and grinding are used to signify the
subdividing of large solid particles into smaller particles.
In the materials processing industry, size reduction is usually
carried out in order to increase the surface area because, in most
reactions involving solid particles, the rate of reactions is
directly proportional to the area of contact with a second phase.
Grinding operations are very extensive in the ore-processing and
cement industries. Copper ores, nickel and cobalt ores, and iron
ores, for example, are ground before chemical processing.
Limestone, marble, gypsum and dolomite are ground to use as
fillers in paper, paint, and rubber. Raw materials for the cement
industry, such as lime, alumina and Silica are ground on a very
large scale.
The energy required to effect size reduction is related to the
internal structure of the material and the process consists of two
parts, first opening up any small fissures which are already
present, and secondly forming new surface. Solids may be
reduced in size by a number of methods
1- Compression or crushing in generally used for reduction
of hard solids to coarse sizes.
2- Impact gives coarse, medium or fine sizes.
3- Attrition or rubbing yields fine products.
4- Cutting is used to give definite sizes.
1
Classification of size reduction equipment
dE n
kL
dL
2
where
dE : the differential energy required.
dL : the change in a typical
dimension.
L : the typical length dimension.
k, n : are constants.
dE kk fc
dL L
L1
E k k f c ln
L2
Where
Kk : Kick's constant
fc : the crushing strength.
1 1
E k R f c
L
2 L 1
Where:
3
kR : Rittinger's constant.
100 1
E E 1
i
L 2 q
Where:
L: measured in microns
Ei: (the Work Index) is the amount of energy required to
reduce unit mass of the material from an infinitely large particle
size down to a particle size of 100 μm.
q : the reduction ratio where q = L1/L2 .
d
n i d i
4
n
v 3
i d i