Particle Technology

SIZE REDUCTION
Maria Camila Cárdenas 1, Diego Fernando Castiblanco2 Maria Paz Ussa3
1. Faculty of Engineering, Universidad De La Sabana, mariacardbelt@unisabana.edu.co
2. Faculty of Engineering, Universidad De La Sabana, diegocamo@unisabana.edu.co
3. Faculty of Engineering, Universidad De La Sabana, mariaussu@unisabana.edu.co

Submitted on: May 24, 2023

1. Definition and generalities

Size reduction of particles involves the breakdown of larger solid particles into smaller
sizes, typically accomplished by applying intense shear or compressive forces that
deform particles and generate internal stresses which, when is strong enough, bring about
fractures (1). This procedure is instrumental in converting bulky or irregularly sized
materials into uniform, small particles that can be effectively used in diverse applications.
Properly executed particle size reduction can beneficially modify essential
physiochemical characteristics of the raw material(s). The effectiveness of specific
processes, such as emulsions and suspensions, frequently relies on precise and accurate
particle size reduction (2).
When conducting size reduction, several factors need to be considered:
1. Contact forces: Size reduction is achieved by applying compressive or shear forces
that deform particles and generate internal stresses. The fractures resulting from these
forces determine the size distribution, shape, and surface characteristics of the
fragments.
2. Material characteristics: The answer of particles to contact forces depends on
whether they are brittle or non-brittle. Brittle materials experiment elastic
deformation before suddenly failing at stress levels beyond a critical value. Failure
occurs catastrophically, resulting in a range of fragments. Non-brittle materials,
classified as ductile or tough, experiment plastic deformation or internal
rearrangement before failure occurs.
3. Imperfections and flaws: Brittle materials concentrate internal stress at
imperfections or microscopic flaws like cracks, air bubbles, or foreign inclusions.
These imperfections increase the probability of failure, and as the size is reduced, the
critical stress required for failure increases.
4. Grinding efficiency: The magnitude, rate, and frequency of contact forces determine
the efficiency of the size reduction process. Smaller particles contain fewer
imperfections, potentially leading to a grindability limit.
5. Chipping and abrasion: Brittle materials can experiment chipping, especially at
edges or corners of irregular particles, resulting in gradual breakdown and the
production of finer fragments. Abrasion through surfaces rubbing together can be
seen as a limiting case of the chipping mechanism.
6. Particle size distribution: The breakage of non-brittle materials often requires shear
forces, and cutting actions typically result in the production of relatively few
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fragments. The relative size of these fragments can vary widely, leading to a broader
particle size distribution.
7. Temperature and moisture: Temperature can affect a material's answer to stress,
with some tough materials becoming brittle at low temperatures. Moisture content
generally reduces brittleness and may make some materials more challenging to
grind. Temperature control is important for heat-sensitive materials.

2. Equipments types

There are various types of equipment commonly used for size reduction processes.
The selection of equipment depends on factors such as the nature of the material,
desired particle size range, throughput requirements, and specific application. The
equipment used to reduce particle size is generally called mills; equipment that grinds
large agglomerates is called “crushers” in English, while those that grind small
particles are called “mills”, of course, there is a whole range of sizes where the
applicability of this equipment overlaps. In Spanish we have no such differentiation,
and the equipment is usually referred to as "mills" (3).

Size reduction range Generic name of the equipment Type of equipment

Thick and intermediate "Crushers" Roller
Hammer
Intermediate and fine “Mills or Grinders" Attrition disc
Tumblings
Fluid energy
Fine and ultrafine "Ultrafine grinders"
Agitated
Table 1. Types of mills according to the size of the final product.

3. Equipment design
3.1 Crushing Rolls
A smooth roll crusher consists of two heavy metal rolls that rotate towards each other.
One roll moves in fixed bearings while the other moves in movable bearings. The
clearance between the rolls can be adjusted based on the feed and desired product size.
These rolls crush moderately large lumps, with one roll directly driven and the other
relying on friction. Roll shaft bearings are protected by a coiled spring to prevent
vibration damage. Material is fed from the top, compressed between the rolls, and
discharged from the bottom after size reduction (4).
3.2.1 Hammer mills
A hammer mill consists of hammers attached to a central shaft in a metal casing. Driven
by an electric motor or diesel engine, the rotor spins rapidly. Material is loaded through
a feed hopper, and the high-speed rotation of the hammers pulverizes it into smaller
particles. Further impact and grinding occur inside the grinding chamber, with particle
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size controlled by adjustable screen openings. The pulverized material is discharged

through a chute or conveyor for collection or further processing (5).
3.2.2 Attrition mills
Attrition mills are grinding machines that use rubbing and collision between surfaces to
reduce particle size. They are commonly used in food processing, pharmaceuticals, and
chemicals industries for fine grinding and blending. The mill consists of a rotating shaft
with spaced discs or plates containing abrasive surfaces. The spacing between the discs
can be adjusted for grinding intensity. Material is fed into the gap between the rotating
discs, where collisions and rubbing cause particles to break apart. Further reduction
occurs as particles pass through narrow gaps, with factors like rotational speed and disc
gap influencing the size reduction process (4).
3.2.3 Tumbling ball mills
Tumbling mills are grinding equipment consisting of a rotating cylindrical shell filled
with grinding media like steel balls or rods. The grinding process involves the cascading
and impact of the media on the material. As the mill rotates, the media is lifted and falls
back, creating a tumbling motion. This motion leads to the impact and crushing of the
material, resulting in size reduction through a combination of impact, abrasion, and
attrition. The grinding process can be controlled by adjusting the speed and filling ratio
of the media. Tumbling mills find application in various industries for dry or wet grinding
and pulverizing of materials (5).

3.3.1 Fluid energy mills

Fluid energy mills, also known as jet mills or fluidized bed jet mills, utilize high-speed
jets of compressed gas or air to fluidize and impact particles for grinding. These mills
generate a turbulent fluidized bed in a grinding chamber, suspending particles in the air
stream. Through multiple collisions and high-velocity impacts, particles undergo size
reduction. The key principle is the creation of high-speed gas or air jets that establish a
dynamic and fluidized grinding environment. The process is highly adjustable, enabling
control over the final particle size by varying parameters like pressure and feed rate. Fluid
energy mills offer efficient grinding and narrow particle size distribution but come with
drawbacks of high energy consumption and limited capacity for coarse grinding.
3.3.2 Agitated mills
Agitated mills, also known as stirred media mills, consist of a cylindrical grinding
chamber with a rotating agitator or impeller. These mills are designed for fine grinding
and dispersion of particles by agitating the grinding media and the material being
processed. The grinding chamber is filled with media, such as beads or balls, which
collide and friction against the particles in the material. The agitator or impeller creates
intense agitation, promoting efficient grinding or dispersion. Agitated mills can operate
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in wet or dry conditions and offer advantages such as high grinding efficiency, narrow
particle size distribution, and versatility in processing various materials (7).
4. Particularities of the equipment

4.1 Crushing Rolls

The speed of rolls varies from 50 to 300 rev/min. crushing rolls are secondary crushers
accepting feed 12 to 75 mm in size and yielding products <12 mm (4).
Advantages and disadvantages
Crushing rolls offer efficient compression-based size reduction, handling various feed
sizes and producing uniform products. They are versatile for primary and secondary
crushing of minerals, ores, coal, and hard rock, with high capacity for large volumes.
However, drawbacks include high energy consumption, limitations in extreme particle
sizes, and maintenance requirements with potential downtime due to wear and tear.
4.2.1 Hammer mills
Hammer mills typically feature 4 to 8 hammers on a single shaft, allowing for efficient
crushing. They can effectively reduce intermediate-sized particles from 25 mm down to
a fine size of 20 mesh, making them versatile for various materials. With the ability to
achieve fine grinding, hammer mills can produce particles as small as <200 mesh (7).
Advantages and disadvantages
Hammer mills are versatile and efficient in handling various materials and particle sizes.
They offer fast processing and improved productivity. With a lower initial investment,
they are cost-effective for smaller-scale operations. However, they can generate high
noise levels and dust, requiring control measures. Regular maintenance and part
replacement are necessary for optimal performance and longevity.
4.2.1 Attrition mills
Attrition mills operate at speeds ranging from 100 to 500 RPM. They can accept feed
sizes ranging from coarse particles (around 5 mm) to finer sub-millimeter particles. The
size of the products produced by attrition mills typically falls within the range of 1 to
100 micrometers (µm) (4).
Advantages and disadvantages
Attrition mills offer versatility in handling a wide range of materials and provide
efficient size reduction through grinding and collision. They can be scaled to different
production capacities. However, they consume high energy, require regular
maintenance, and generate fine dust, necessitating dust control measures for a clean
working environment.
4.2.2 Tumbling ball mills
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Tumbling mills operate at variable speeds depending on the application, typically ranging
from 70% to 80% of the critical speed. The accepting size of the feed can vary widely,
but it is generally in the range of several millimeters to a few centimeters. The size of the
yielding products also varies depending on factors such as the material being ground and
the desired particle size. In general, tumbling mills can produce fine particles ranging
from micrometers to several millimeters in size. However, specific ranges and sizes can
vary significantly depending on the mill design, grinding media, and process conditions
(5).
Advantages and disadvantages
Tumbling mills offer versatility in handling various materials and provide effective size
reduction through grinding and impact. They can be scaled to different production
capacities. However, they consume high energy, require regular maintenance and
replacement of worn parts, and may have limited control over particle shape.
4.3.1 Fluid energy mills
Fluid energy mills operate at high speeds, typically ranging from 500 to 3,000 feet per
minute, depending on the specific design and application. The accepting size of the feed
can vary widely, but it is generally in the range of a few micrometers to a few millimeters.
Fluid energy mills can produce fine particles with sizes as small as a few micrometers,
making them suitable for micronization and fine grinding applications. The yielding
products can have a narrow particle size distribution, often within a range of 1 to 10
micrometers, but specific ranges can vary depending on the process parameters and
material properties (6).
Advantages and disadvantages
Fluid energy mills offer precise control over particle size distribution and high grinding
efficiency, making them ideal for applications requiring fine particles. They are versatile,
handling a wide range of materials. However, they have high energy consumption, limited
capacity for coarse grinding, and can generate heat, which may affect heat-sensitive
materials.
4.3.2 Agitated mills
Agitated mills typically operate at rotational speeds ranging from 500 to 3,000
revolutions per minute (rpm). They can accept a wide range of feed sizes, with the lower
limit depending on the specific mill design and material properties. Agitated mills can
produce fine particles in the submicron to micron range, allowing for precise particle size
control and achieving narrow particle size distributions (7).
Advantages and disadvantages
Agitated mills offer efficient particle size reduction and the ability to achieve a narrow
particle size distribution. They are versatile, handling various materials and processing
Particle Technology

both wet and dry substances. However, they have high energy consumption, require
regular maintenance, and may not be ideal for coarse grinding tasks or materials with
larger particle sizes.
5 Applications
Some of the most important applications of size reduction are described below (1).
• Pharmaceuticals: Size reduction is essential in pharmaceutical manufacturing for
several reasons, such as improving drug dissolution rates, enhancing drug
bioavailability, and achieving uniform particle size for dosage forms like tablets and
capsules.
• Food Processing: Size reduction is employed in food processing to achieve desired
texture, enhance flavor release, improve mixing and blending, and enable the
production of powdered ingredients or products such as spices, flour, and sugar.
• Minerals and Mining: Size reduction plays a significant role in minerals processing
and mining operations. It is utilized to liberate valuable minerals from ores, reduce
the particle size of mineral concentrates, and prepare materials for further processing,
such as flotation or leaching.
• Cement and Construction Materials: Size reduction is crucial in the cement industry
for grinding raw materials, such as limestone and clay, into fine powder. Additionally,
it is employed in the production of construction materials, such as aggregates, to
achieve specific particle size distributions.

6 References
(1) Konyves, M. J. M. (2019). Particle Size Reduction: Technologies and Applications.
Wiley. Taken from https://www.microfluidics-mpt.com/applications/particle-size
reduction#:~:text=Particle%20size%20reduction%20is%20the,use%20of%20high%
20shear%20forces.
(2) Ziegler, G., & Hogg, R. (1999). Particle size reduction. Industrial chocolate
manufacture and use, 115-136.
(3) Castelló Gómez, M. L., Barrera Puigdollers, M. C., Pérez Esteve, E., & Betoret Valls,
N. (2017). Reducción del tamaño de partícula y tamizado de partículas.
(4) Kumar, A., & Krishnan, R. Y. (2020). A review on the technology of size reduction
equipment. International Journal of ChemTech Research, 13(1), 48-54.
(5) OKUDA, S., & CHOI, W. S. (1980). Investigation study on actual size-reduction
equipment in various industrial fields. Journal of the Society of Powder Technology,
Japan, 17(7), 383-391.
(6) Goldstein, N., & Diaz, L. F. (2005). Size reduction equipment review. BioCycle,
46(1), 48-53.
(7) Trezek, G. J. (1973). Size reduction equipment. Compost Sci., 14(5), 22–25.
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