SIZE REDUCTION

Ore is an aggregate of minerals and contains valuable and gangue minerals. The mineral beneficiation involves
separation of gangue minerals from ore. It has three steps
Liberation, Separation, Concentration.
1) Liberation of valuable mineral by size reduction.
2) Separation of coarse and fine particles.
3) Concentration to separate the gangue minerals to increase the metal grade.
If the first step is not done correctly, the second step will be incomplete.
SIZE REDUCTION
Size refers to physical dimension of an object. Reduction refers to decrement or the process of decreasing the
size. Size reduction is the operation carried out for reducing the size of bigger particles into smaller one of desired
size and shape with the help of external forces.
Size reduction is done through two major methods as, Crushing (down to 6- to 14-mesh) and Grinding (down to
micrometer sizes). Size reduction of ores is normally done in order to liberate the value minerals from the host rock.
It is done through crushing and grinding of ore and minerals. This is also called as liberation the economically
important mineral from its host rock. Crushing of rock and minerals is the major operation in minerals processing.
Crushing and screening is the first controlled size reduction stage in the process. This is the main process in
aggregate production and a preparation process for further size reduction. Grinding is the second stage of size
reduction (wet or dry) where the liberation size for individual minerals can be reached. Size reduction by crushing
has a size limitation for the final products. If further reduction is required, below 5-20 mm, grinding is done.
The two main purposes for a grinding process are: To liberate individual minerals trapped in rock crystals (ores) and
thereby subsequent enrichment in separation. To produce fines from mineral fractions by increasing the specific
surface.
OBJECTIVES OF SIZE REDUCTION
In the materials processing industry, size reduction or comminution 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.
 Break a material into very small particles in order to separate the valuable amongst the two
constituents.
 Achieve intimate mixing.
 To dispose solid wastes easily .
 To improve the handling characteristics.
 To mix solid particle more intimately.
ADVANTAGES OF SIZE REDUCTION
Content uniformity Uniform Flow Effective Drying Increases surface area or viscosity Uniform
mixing and drying