Chapter Ten: Particle Size Reduction and Size Separation


• particle-machine wall friction

Introduction to Size Reduction
Comminution - size reduction
Influence of Material Properties
on Size Reduction
Crack Propagation and Toughness
Crack Propagation - localized stresses
produce strains large enough to cause
bond rupture and propagate the crack
• related to the strain energy (Griffith's
theory). Stress is concentrated on the
tip of the crack
• heat
• sound
• vibration
Rittinger's Hypothesis - relates the
energy used in size reduction process to
the new surface area produced
Kick's Theory - energy used in
deforming or fracturing a set of particles
of equivalent shape is proportional to the
ratio of change in size

Plastic flow - allows strain energy Bond's Theory - energy used in crack
relaxation without crack propagation propagation is proportional to the new
• requires energy crack length produced
• Irwin and Orowan's theory
• ease of communition depends on the Influence of Size Reduction on
brittleness or plasticity of the material
Size Distribution
• With particle diameters <5 um,
Surface Hardness
interactive cohesive forces
- devised by German mineralogist,
predominate over comminution
Mohs' scale
stresses which eventually results in
- quantitative measurement was devised
particle agglomeration.
by Brinell
- hardness quantifies the deformation
characteristics of the bulk solid Size Reduction Methods
Cutting Methods
Energy Requirements of Size
Reduction Process
• elastic deformation of particles
• plastic deformation of particles without
fracture
Cutter Mill - series of knives attached to a
• deformation ti initiate cracks that cause horizontal rotor which act against a series
fracture
of knives attached to the mill casing
• deformation ofmetal machine parts
• reduction occurs by fracture of particles
• interparticulate frictiom
• self-classifying

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Compression Methods
Size reduction range:
End-runner mill - carried out on a small
laboratory scale during development
using a mortar and pestle
Roller mill - two cylindrical rollers
mounted horizontally
Impact Methods
Size reduction range:
Hammer mill - consists of a series of four
hammers, hinged on a central shaft
which is enclosed within a rigid metal
case
• angular velocity is a strain up to 80 s-1
which is so high particles undergo
brittle fracture
• square, rectangular or herringbone
slots are often used
• hammers may be square-faced,
tapered to a cutting edge or have a
stepped form
Vibration mill - an alternative to hammer
milling
• filled approximately 80% total volume
with porcelain or stainless steel balls
• reduction occurs by repeated impact
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• efficiency is greater than that for
conventional ball milling
Attrition Methods
Size reduction range: 1 -100+
Roller mill - size reduction of solids in
suspensions, pastes, or ointments
• 2-3 porcelain or metal rollers are
mounted horizontally with an
adjustable gap (20 um)
• rollers are rotated at different speeds
• materials are transferred from the
slower to faster roller
Combined Impact and Attrition
Methods
Size reduction range:
Ball
mill - consists of a hollow cylinder
mounted such that it can rotate on its
horizontal longitudinal axis
• contains balls that occupy 30 - 50% of
total volume
• large balls - break down coarse feed
materials
• smaller balls - form fine product by
reducing void spaces
• Too much feed (amount of material in
a mill) produces a cushioning effect
• Too little feed causes loss of efficiency
and abrasive wear of mill parts
• GREATEST FACTOR: Speed of
rotation
Fluid energy mill - circular design is most
common. Consists of a hollow toroid
(shaped like a doughnut) with a diameter
of 20 - 200 mm.
• a fluid, usually air is injected as a high-
pressure jet
• high velocity of air = zones of
turbulence
• high kinetic energy = impaction with
other particles
• Turbulences - ensures level of level-
level particle collisions are high to
produce size reduction
• Particle size classifier - to retain
particles until sufficiently fine
Pin mill - two discs closely spaced pins
rotate against one another at high
speeds
Selection of Particle Size
Reduction Method
• Cost of size reduction increases as
particle size decreases
Refer to Table 10.1
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Introduction to Size Separation
Objectives of Size Separation
Solid Separation - a process by which
powder particles are removed from gases
or liquids and has two main aims:
1. to recover valuable products or by-
products
2. to prevent environmental pollution
Size Analysis - designed to provide
information on the size characteristics of
a powder
Size Separation - integral part of
production process (produce product for
separate handling and subsequent
processing)
Size Separation Efficiency
Separation efficiency - a function of the
effectiveness of a given process in
separating particles into oversize and
undersize fractions
Grade efficiency - complete size
classification
Sharpness index - quantifies the
sharpness of cut-off in a given size range
Size Separation Methods
Sieving
• requires processing of larger volumes
• sieves are often larger in area and of
more robust construction
Agitation methods - achieved by Elutriation
electrically induced oscillation,

mechanically induced vibration,

or gyration
• output efficiency of sieve gyration is
greater than of oscillation or vibration
methods

Brushing methods - a brush is used to

reorientate particles on the surface of a - a technique in which the fluid flows in
sieve and prevent apertures to be an opposite direction to the
blocked sedimentation movement

Centrifugal methods - particles are Cyclone

thrown outwards on to a vertical
cylindrical sieve under the action of a
high-speed rotor
• current of air assists in the sieving
process

WET SIEVING is generally MORE

EFFICIENT than dry sieving methods. - most common type of cyclone is the
reverse flow cyclone
Sieve number - used as a method in
quantifying particle size

Sedimentation

- utilizes the differences in settling

velocities of particles with different
diameters and those related to Stoke's
equations
• a chamber containing a suspension of
solid particles in a liquid, usually water

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