UNIVERSITY OF ENGINEERING AND TECHNOLOGY,

PESHAWAR

MINERAL PROCESSING-II
ASSIGNMENT# 02
(COURSE CODE MinE_410)

NAME: MUGHEERA AYAZ

REG.NO: 20PWMIN0871

SUBMITTED TO:
DR. ISHAQ AHMED

DEPARTMENT OF MINING ENGINEERING,

PESHAWAR
 VARIOUS MODELS AVAILABLE FOR CRUSHER
(EQUATIONS)
CRUSHER:
A crusher is a mechanical apparatus meticulously engineered for the explicit
purpose of diminishing substantial geological formations into more manageable fragments such as
smaller rocks, gravel, or particulate matter. This specialized machinery finds extensive application
in the mineral processing industry, where its primary function is to meticulously reduce the
dimensions of raw materials, facilitating subsequent stages of processing.

IMPACT CRUSHER:
Impact crusher crushes material by striking energy. When it works,
the motor drives the rotor to rotate at a high speed, on which the blow bar is installed. As soon as
the material gets into the affecting area of the blow bar, they will be stroke by the blow bar and be
thrown to the impact devices around the rotor. The high speed forces the material to rebound from
the impact liner to the area where the blow bar effects until they have been crushed to the required
size. The clearance between the impact racks and the rotor can be adjusted to change the size and
shape of the end products.[5]

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EMPIRICAL MODEL FOR IMPACT CRUSHER:

BOND IMPACT CRUSHING WORK INDEX (CWi) MODEL):

For an impact crusher, the empirical model for impact is given below:

EQUATION:

1 1
P = 10 ⋅ Wi ⋅ C ⋅ ( − )
D𝑓𝑒𝑒𝑑 D𝑝𝑟𝑜𝑑𝑢𝑐𝑡

Where:
P: Power consumption

Wi: Bond Impact Crushing Work Index

𝐃𝒇𝒆𝒆𝒅 : Size of the feed material

𝐃𝒑𝒓𝒐𝒅𝒖𝒄𝒕 : Size of the product material

C: Constant

 This model is based on Bond's Third Theory of Comminution and relates the power consumption (P)
to the Bond Impact Crushing Work Index (Wi), the size distribution of the feed and product materials,
and a constant (C). The parameters in these models are typically determined through regression
analysis based on experimental data.

JAW CRUSHER:
The
electrical motor transmits power to the
eccentric shaft through v-belt and belt
pulley. Then the exciting force generated
by the eccentric shaft will make the
movable jaw move upwards and
downwards. This movement would
trigger the toggle plate to push the
movable jaw forwards and backwards.
When the movable jaw moves forth
towards the fixed jaw, materials in the
crushing cavity will be squashed or
chopped. Then the movable jaw travels
back, the chopped or squashed materials, which meet the requirement, will be discharged from the

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 outlet. Since the motor keeps working. The crusher will crush and discharge periodically to achieve
mass production. [5]

EMPIRICAL MODEL FOR JAW CRUSHER:

WHITEN CRUSHER MODEL:

Empirical models for jaw crushers are developed based on experimental data and observations of the
machine's performance under various operating conditions.

EQUATION:

𝑊𝑖 1 1
𝑃= ⋅( − )
10 . 𝑊𝑖50 D𝑓𝑒𝑒𝑑 D𝑝𝑟𝑜𝑑𝑢𝑐𝑡

Where:

P: Power consumption

Wi: Work Index

𝐃𝒇𝒆𝒆𝒅 : Size of the feed material

𝐃𝒑𝒓𝒐𝒅𝒖𝒄𝒕 : Size of the product material

 This model relates the power consumption (P) of a jaw crusher to the Work Index (Wi), which is a
measure of the energy required to reduce a material's particle size. 𝑫𝒇𝒆𝒆𝒅 Is the size of the feed
material, and 𝑫𝒑𝒓𝒐𝒅𝒖𝒄𝒕 is the size of the product. This model is a simplified version, and models
that are more sophisticated may include additional parameters and factors that influence the
performance of a jaw crusher. Additionally, engineers often use regression analysis to fit the model
to experimental data and determine the values of the model parameters.

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 VARIOUS MODELS AVAILABLE FOR SCREENS
(EQUATIONS):

1 DEWATERING VIBRATING SCREEN:

Type: Dewatering Vibrating Screen

Capacity: 15-120t/h

Application: fine grained dewatering, slime or tailings recovery, mineral and coal processing, etc.

WORKING:

With flange-type exciter, driven by two motors for reverse self-synchronous rotation, so that the screen in
a straight line to do reciprocating motion in
order to achieve the purpose of grading
dewatering.

2. Screen frame with high-strength bolted

connection, the screen surface by the arc
section and the straight-line section
composition, durable structure.

3. According to the mechanical structure and

process parameters, the vibrator is arranged
above the center of gravity of the screen box.
This arrangement makes the trajectory of the screen machine elliptical at the feeding end, round in the
middle, discharge side is still elliptical, and that is elliptical-circular-elliptical.

APPLICATIONS:

1. Dewatering vibrating screen is mainly used for fine-grained dewatering and grading, slime or
tailings recovery.
2. Suitable for mineral processing, coal processing and other industries. [4]

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EMPIRICAL MODEL FOR DEWATERING VIBRATING
SCREENS:
Here's a simplified empirical model for dewatering vibrating screens:

DEWATERING EFFICIENCY MODEL:

An empirical model for dewatering vibrating screens can be developed to describe the relationship between
various operating parameters and the efficiency of the dewatering process.

EQUATION:
𝑄𝑖𝑛 − 𝑄𝑜𝑢𝑡
𝐷𝐸 = × 100
𝑄𝑖𝑛

Where:
DE: Dewatering efficiency

𝑸𝒊𝒏: Volumetric flow rate of incoming slur

𝑸𝒐𝒖𝒕: Volumetric flow rate of water out of the screen

This model represents the dewatering efficiency (DE) as a percentage, where 𝑄𝑖𝑛the volumetric flow is
rate of the slurry or water into the screen, and 𝑄𝑜𝑢𝑡 is the volumetric flow rate of water out of the screen.
The efficiency is a measure of how effectively the dewatering screen removes water from the material.

ROLLER CRUSHER:
The screen surface of the roller screen is composed of a number of
parallel-arranged screen shafts equipped with screen sheets, which are driven by a transmission device to
rotate the screen shaft, and the rotation
direction is the same as the material flow
direction. The gap between the screen shaft
and the screen sheets forms the screen hole,
the material less than the screen hole is
subject to the action of its own weight and
the rotating force of the screen shaft, and
becomes the material under the screen
through the screen hole, and the material
larger than the screen hole continues to
move forward along the screen surface to
become the material on the screen, and
finally realizes the classification of the
material. Electrical and mechanical

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overload protection is provided to prevent material from jamming the screen shaft. The screening particle
size needs to be adjusted according to the user's requirements, the clearance of the screen shaft and the size
of the screen sheet.

EMPIRICAL MODEL ROLLER SCREENS:

An empirical model for a roller
screen is given below:

PARTICLE SIZE DISTRIBUTION (PSD) MODEL FOR ROLLER

SCREEN:

EQUATION:

1−𝐸
𝑃𝑆𝐷𝑝𝑟𝑜𝑑𝑢𝑐𝑡(𝑑) = 𝑃𝑆𝐷𝑓𝑒𝑒𝑑(𝑑) ⋅
𝐸

Where:
𝑃𝑆𝐷𝑝𝑟𝑜𝑑𝑢𝑐𝑡(𝑑): Particle size distribution of the product

𝑃𝑆𝐷𝑓𝑒𝑒𝑑(𝑑): Particle size distribution of the feed

E: Screening efficiency

 This model relates the particle size distribution of the product to the particle size distribution of the
feed and the screening efficiency (E).

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 VARIOUS MODELS AVAILABLE FOR CLASSIFIERS
(EQUATIONS):
1. SPIRAL CLASSIFIER:
INTRODUCTION: Classifying equipment is used for classifying solid particles by means of different
sedimentation speed in slurry.

CAPACITY: 10～1785 t/d

IMPROVEMENT: An automatic elevating apparatus is added to the discharge opening. The scoop of the
ball mill makes the equipment run more smoothly.

ADVANTAGES:

1. A sand return automotive lifting device is added on the sand return end, and the configuration of big spoon bit is
canceled for ball mill.
2. 1-1.5 degrees of electricity can generally be saved per ton of ore.
3. Frequent maintenance of big spoon bit is avoided.
4. Uneven impact on large and small gear is retarded.

HIGH SPIRAL CLASSIFIER OPERATION:

The grinded pulp is fed into a tank from the inlet in the middle of settlement region, and the slurry
classification sedimentation area is under the inclined tank. The spiral with low-speed rotation stirs the
slurry, so that the fine particles rise, and the coarse particles sink to the bottom of the tank. The overflow
dam is above the bearing center, which is under screw shaft, and is underneath overflow end. [1]

EMPIRICAL MODEL SPIRAL CLASSIFIERS:

EQUATION:

R = K1 (P - KO)
Where:

P = the classifier motor power

R = the ore recycle rate from the classifier

KO, K1 = Constant

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 0
P= KO + {1/K1T}∫−𝑡 𝑈𝑑𝑡

Where:

U = the rate of recycled material entering the classifier at time t

T = the retention time of material in the classifier (assuming plug flow)

P= power

2 HYDROCYCLONE CLASSIFIER:

Cone classifier, is a simple equipment

for classification, de-sliming and concentration. Its shape is an
inverted cone. The ore-feeding cylinder is arranged at the center of
the liquid surface, and the bottom edge of the cylinder does not enter
a certain depth below the liquid surface. The pulp is fed along the
tangential direction to the central cylinder and is released from the
bottom edge after buffering. The slurry is radial and flows out to the
surrounding overflow weir. In this process, the settling velocity is
greater than the velocity of liquid flow, and the coarse particles will
sink in the trough and be discharged through the bottom grit. Fine
particles are injected into the overflow tank with the surface slurry.
The ore-feeding granularity is generally less than 2mm. The grading
size is 75 μm or less. [2]

FIGURE SHOWs THE CONE CLASSIFIER

EMPIRICAL MODEL HYDROCYCLONE CLASSIFIERS:

The empirical model of hydro cyclone in give below:

LYNCH AND RAO MODEL FOR HYDROCYCLONES:

EQUATION:

𝑔𝑑𝑐 𝜇𝑚 0.2 𝑄 0.5

𝐷50 = ⋅( ) ⋅( )
(√𝜌 − 𝜌𝑚) ⋅ 𝑔 𝜇 𝐴

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Where:

𝑫𝟓𝟎:Cut size (particle diameter at which the classification efficiency is 50%)

𝒅𝒄: Cyclone diameter

ρ: Fluid density

ρm: Particle density

g: Acceleration due to gravity

μ: Fluid viscosity

μm: Particle viscosity

Q: Volumetric flow rate

A: Cross-sectional area

 This model relates the cut size (D50) of a hydro cyclone to various parameters, including the diameter
of the cyclone (dc), the density of the fluid (ρ), the density of the particle (ρm), the acceleration due to
gravity (g), the viscosity of the fluid (μ), the viscosity of the particle (μm), the volumetric flow rate
(Q), and the cross-sectional area (A).

VARIOUS MODELS AVAILABLE FOR GRINDING

MILLS (EQUATIONS):

1 ROD MILLS:

The rod mill is a horizontal rotating device transmitted by the gear. The materials are
transferred to the grinding chamber through the quill shaft uniformly. There are ladder liner and ripple liner

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and different specifications of grinding media in the chamber. The centrifugal force caused by rotation of
shell brings the grinding media to a certain height and impact and grind the materials. The fine materials
are discharged through the outlet, thus the grinding process is finished.[9]

EMPIRICAL MODEL FOR ROD MILL:

The empirical models for rod mill is given
below:

BOND ROD MILL WORK INDEX (RWI):

EQUATION:

𝑃80𝑟𝑜𝑑 𝑚𝑖𝑙𝑙
𝑅𝑊𝑖 =
𝑃80𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑏𝑜𝑛𝑑 𝑟𝑜𝑑 𝑚𝑖𝑙𝑙 − 13.2 ⋅ 𝐹80𝑟𝑜𝑑 𝑚𝑖𝑙𝑙𝑃80𝑟𝑜𝑑 𝑚𝑖𝑙𝑙

 The Bond Rod Mill Work Index is an empirical measure of the resistance of the material to grinding
in a rod mill. It is widely used for sizing rod mills in the mineral processing industry.
ENERGY-BASED MODELS FOR ROD MILLS:

EQUATION:

𝐶
𝑃 = 𝐶 ⋅ 𝐷 𝑎 ⋅ 𝐿𝑏 ⋅ 𝑁 𝑐 ⋅ (1 − 1.37 ⋅ )
𝐷

 An energy-based model that relates the power consumption (P) of a rod mill to its dimensions
(diameter D and length L), rotational speed (N), and a constant C representing the fraction of the
critical speed.

2 BALL MILL:

This machine is two lattice-type ball mill. The materials from the feeding fittings enter
the first bin of the milling machine via the feeding hollow axis evenly when it works. There is a ladder-like
or ripple-like scale board in the first bin, and different specification steel balls are installed in the bin. When
the cylinder rotates, which generating centrifugal force to carries steel balls to a certain height and then
balls fall to strike and grind the material. After primary grinding in the first bin, the material then enters
into the second bin via a single layer partition board. There is a scaleboard and steel balls in the second bin,
so the materials are further ground. In the end, output material board discharges the powder.[9]

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 FIGURE SHOWS THE BALL MILL

EMPIRICAL MODEL FOR BALL MILL:

The empirical model for ball mill is given
below:

BOND BALL MILL WORK INDEX (BWI):

EQUATION:

𝑃80𝑏𝑎𝑙𝑙 𝑚𝑖𝑙𝑙
𝐵𝑊𝑖 =
𝑃80𝑠𝑡𝑎𝑛𝑑𝑎𝑟𝑑 𝑏𝑜𝑛𝑑 𝑏𝑎𝑙𝑙 𝑚𝑖𝑙𝑙

 The Bond Ball Mill Work Index is an empirical measure of the energy required for grinding in a ball
mill and is widely used for sizing ball mills in the mineral processing industry.

AUSTIN'S MODEL:
EQUATION:

𝑃 = 5.34 ⋅ 𝐷 −2.5 ⋅ 𝐿0.5 ⋅ 𝑁 0.33

 Austin's empirical model relates the power consumption (P) of a ball mill to its dimensions (diameter
D and length L), rotational speed (N), and is often used for sizing ball mills.

12/1/2024 Page 12
REFRENCES:
[1] Spiral classifier. (n.d.). Xinhaimining.com. Retrieved January 13, 2024, from
https://m.xinhaimining.com/product/classifying/spiral-classifier

[2] Large Capacity Desliming Hopper Cone Classifier for Ore Mud Separation. (n.d.).
Made-in-china.com. Retrieved January 13, 2024, from https://oasis2021.en.made-in-
china.com/product/GdtfTZOPCMVu/China-Large-Capacity-Desliming-Hopper-Cone-Classifier-
for-Ore-Mud-Separation.html

[4] Dewatering Vibrating Screen. (n.d.). Winnermanufacturing.com. Retrieved

January 13, 2024, from

https://www.winnermanufacturing.com/products/Dewatering-Vibrating-

Screen.html?campaignid=13154996558&adgroupid=140304344050&feeditemid

=&targetid=kwd-

301474183322&device=c&creative=644438321752&keyword=single%20deck%2

0vibrating%20screen&gad_source=1&gclid=CjwKCAiA44OtBhAOEiwAj4gpOVP

UA7sVDkUlwapPMREn4pbBzyD5jyuln095_CU8B61O6n7quQELXhoCIrQQAvD

_BwE

[5] Jaw crusher. (n.d.). Zxcrusher.com. Retrieved January 13, 2024, from

https://www.zxcrusher.com/crushing-equipment/jaw-crusher.html?pc-en-B22-

ID=352308195537&adgroup=57778394342&type=c&keyword=crusher%20equip

ment&gad_source=1&gclid=CjwKCAiA44OtBhAOEiwAj4gpOWHl8hdQvmnlUJ9

FRpX26Lpv8UNTqHd03r4O8CNoZCdica5YveRCsRoCbbsQAvD_BwE

[9] Ball mill. (2023, June 12). Shanghai DingBo Heavy Industry Machinery Co.,

LTD; Shanghai Dingbo Heavy - 13 Years Crusher Manufacturer.

https://www.shdingbo.com/ball-

12/1/2024 Page 13
 mill/?gclid=Cj0KCQiAhomtBhDgARIsABcaYynclGbVdeTJ0OZyEpWipVyxaW_a

MaIXNFx-nwBzFAwcWLkds7YvfNMaAuyDEALw_wcB

THANK YOU

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