(Chen-1104) Particulate Technology: Lecture 13 - Equipment For Size Reduction

(CHEN-1104) PARTICULATE
TECHNOLOGY
Lecture 13 – Equipment for Size
Reduction
Course Instructor: Engr. Asim Ali
24-04-2019
1
Department of Chemical Engineering
Contents
 Size Ranges for different size reduction
equipment
 Size Reduction Equipment
 Tumbling Mills
 Ball Mill
 Uses of Ball mill
 Conical Ball mill
2
Contents
 Simulation of Ball mill
 Cement mill
 Ultrafine Grinders
 Cutters
 Recommended Books
3
Size Ranges for Different
Size Reduction Equipment
Equipment Feed Size Product Size
Coarse
1500 – 40 mm 50 – 5 mm
Crusher
Intermediate
50 – 5 mm 5 – 0.1 mm
Crusher
Fine Grinder 5 – 2 mm < 0.1 mm
down to 0.01
Colloid Mills 0.2 mm
μm
4
Size reduction equipment are generally divided

into following:
1. Crushers
2. Grinders
3. Ultrafine Grinders
4. Cutting machines
5 Department of Chemical Engineering


Tumbling Mills
 Ball mill
 Pebble mill
 Rod mill
 Tube mill
 Compartment mill
8

Ball Mill
 Steel shell is lined with high-carbon steel plate,
porcelain, silica rock, or rubber
 The grinding medium is lengths of chain or balls
of metal, rubber, or wood

Ball Mill
 Ball mills are used for intermediate and fine
reduction of abrasive materials
 Ball mills can be used for continuous or batch
operation
10

Ball Mill
 The grinding medium is carried up the side of the
shell nearly to the top, from where they fall on
the particles underneath
11

Ball Mill
 The size reduction is carried out by impact as
the grinding medium i.e., balls fall from near the
top of the shell
12

Ball Mill
 In conical ball mills, feed enters from the left
through a 60° cone into the prmary grinding
zone, and leaves through the 30° cone to the
right
13

Ball Mill
 Ball mill generally contains balls of different sizes
 As the shell rotates, the large balls move toward
the point of maximum diameter, and the small
balls migrate toward the discharge
14

Ball Mill
 The initial breaking of the feed particles is done
by the largest balls dropping the greater distance
 Small particles are ground by small balls
dropping a much smaller distance
15

Ball Mill
 The energy used in lifting the grinding units is
utilized in reducing the size of the particles
 When the mill is stopped, balls occupy one-half
the volume of the mill
16

Ball Mill
 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 bottom to be picked up again
17

Ball Mill
 Centrifugal force keeps the balls in contact with
the wall and fall to the bottom to be picked up
again
18

Ball Mill
 While in contact with the wall, the balls do some
grinding by slipping and rolling over one another,
but most of the grinding occurs at the zone of
impact, where the free falling balls strike the
bottom of the mill
19

Ball Mill
 If the speed is too high, balls are carried over
and the mill is said to be centrifuging
 The speed at which the centrifuging occurs is
called the critical speed
20

Ball Mill
From the balance between the gravitational and
centrifugal forces, the critical speed 𝒏𝒄
𝟏 𝒈
𝒏𝒄 =
𝟐𝟐 𝑹−𝒓
g = acceleration due to gravity
R = radius of the mill
r = radius of grinding medium

21

Ball Mill
 The operating speed n of the ball mill must be
less than 𝒏𝒄
 Ball mills run at 65 – 80 % of the critical speed
 For wet grinding ball mill is rotated slowly
22

Uses of Ball Mill
In addition to being used in cement industry, ball
mills are used to grind and blend materials for use
in mineral dressing processes, paints,
pyrotechnics, ceramics and selective laser
sintering
23

Conical Ball Mill

Conical Ball Mill

Cement Mill

Cement Mill

Ultrafine Grinders
 Ultrafine Grinders reduce the feed into product

by attrition
 The feed size is restricted to 6 mm
 The product size is from 1 to 50 μm

Cutters
 The cutting action of cutters depends upon the

type of cutter used
 Cutters, dicers, and slitters are typical cutters
 The product size is from 2 to 10 mm

Recommended Books
1. McCabe Warren L, Smith Julian C, Harriott Peter.,
“Unit Operations, 7th Edition, 2010, McGraw-Hill
Inc.
2. Coulson J. M, Richardson J. F., “Chemical

Engineering- Particle technology and separation
processes” Vol 2, 5th Ed. 2007, Pergamon Press.
3. Martin Rhodes, “Introduction to Particle

Technology, 2nd Ed. 2008, John Wiley & Sons, Ltd.
Recommended Books
4. Richard G. Holdich, “Fundamentals of Particle

Technology”, 2002, Midland Information
Technology and Publishing.
5. Enrique Ortega-Rivas, “Unit Operations of

Particulate Solids: Theory and Practice” 2012,
CRC Press.
6. Hans Rumpf, “Particle Technology”, 4th Edition.

2013.


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(CHEN-1104) PARTICULATE

Course Instructor: Engr. Asim Ali

 Size Reduction Equipment

 Uses of Ball mill

 Conical Ball mill

Size reduction equipment are generally divided

6 Department of Chemical Engineering

7 Department of Chemical Engineering

Department of Chemical Engineering

 Steel shell is lined with high-carbon steel plate,

porcelain, silica rock, or rubber

 The grinding medium is lengths of chain or balls

of metal, rubber, or wood

Department of Chemical Engineering

 Ball mills are used for intermediate and fine

reduction of abrasive materials

 Ball mills can be used for continuous or batch

Department of Chemical Engineering

 The grinding medium is carried up the side of the

shell nearly to the top, from where they fall on

the particles underneath

Department of Chemical Engineering

 The size reduction is carried out by impact as

the grinding medium i.e., balls fall from near the

top of the shell

Department of Chemical Engineering

 In conical ball mills, feed enters from the left

through a 60° cone into the prmary grinding

zone, and leaves through the 30° cone to the

Department of Chemical Engineering

 Ball mill generally contains balls of different sizes

 As the shell rotates, the large balls move toward

the point of maximum diameter, and the small

balls migrate toward the discharge

Department of Chemical Engineering

 The initial breaking of the feed particles is done

by the largest balls dropping the greater distance

 Small particles are ground by small balls

dropping a much smaller distance

Department of Chemical Engineering

 The energy used in lifting the grinding units is

utilized in reducing the size of the particles

 When the mill is stopped, balls occupy one-half

the volume of the mill

Department of Chemical Engineering

 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 bottom to be picked up again

Department of Chemical Engineering

 Centrifugal force keeps the balls in contact with

the wall and fall to the bottom to be picked up

Department of Chemical Engineering

 While in contact with the wall, the balls do some

grinding by slipping and rolling over one another,

but most of the grinding occurs at the zone of

impact, where the free falling balls strike the

bottom of the mill

Department of Chemical Engineering

 If the speed is too high, balls are carried over

and the mill is said to be centrifuging

 The speed at which the centrifuging occurs is