Size Reduction Theory

15 Mar 2012

Mechanism of Size Reduction

Very high RPM Persistent mode only Grind Limit of the material
1.6 1.2

Transitory mode disappears Further increase in power/rpm will Persistent mode the particle size not decrease Higher RPM may undergo irreversible Particles Two Modes deformation plastic Characteristic of the Transitory mode 1150 material Persistent mode Low RPM Single mode
950 800 relative coarse size 650 500 400 200

Mass per m (%)

0.4

200

400

600

800

1000

1200

1400

1600

Particle Diameter (m)

Mechanism of Size Reduction

Size reduction is achieved through following mechanisms: Impact: particle concussion by a rigid force Compression: particle disintegration by two rigid forces Shear: produced by a fluid or by particle-particle interaction Attrition: arising from particles scraping against one another or against a rigid surface

Mechanism for Size Reduction

Process of absorption of energy for size reduction consists of two parts:
Opening of small fissures already present in the material Formation of new surface

Energy absorbed is manifested as increased surface energy

More energy required for grinding fines rather than coarse materials Very fine grinding may be impeded in some materials due the tendency to form aggregates held together by cohesive and van der Waals forces Chemical bonds may also be formed in some materials, such as cement clinker, quartz, etc

Typical energy efficiency is on the order of 0.1-2.0 %

= 100

Mechanism for Size Reduction

Process of absorption of energy for size reduction consists of two parts:
Opening of is consumed already present in the material Lost energy small fissures in: Formation of new surface Elastic deformation of particle

Energy absorbedparticle after fracture Compaction of is manifested as increased surface energy More energy required between the particles than coarse materials Overcoming friction for grinding fines rather Approximately 5% of Very fine grinding may be impeded in some materials due the tendency to Elastically deforming milling surfaces worlds totalcohesive and van der Waals forces energy form aggregates held together by Deformation of fractured particles Chemical bonds consumption is some materials, such as cement may also be formed in used Heat
clinker, quartz, etc for

size reduction

Typical energy efficiency is on the order of 0.1-2.0 %

= 100

Energy for Size Reduction

Basic assumption: energy required to produce a change dL for a particle of size L is a simple power function of L C and n are constants
=

Kick assumed n = -1
Energy requiredcrush a material is proportional to giving = to the ratio of size reduction C may be expressed as = mm Energy required to 1 size from 50 to 25 mm is and = reduce 2 fc is from 2 mm to the same as that required to reduce sizethe crushing strength of the material 1 mm KK is the Kicks Constant Kicks Law

Energy for size reduction

Rittinger assumed = 2
giving = 2
1 2 1 1

and =

KR is the Rittingers constant

Energy required to crush a material is proportional to the increase in the specific surface area

Energy for Size Reduction

Neither of these laws give an accurate estimate of the energy required for the size reduction! Kicks Law is more accurate for describing plastic deformation leading to fracture Coarse Crushing Rittingers Law is more accurate when the new surface is being created and the increase in surface per unit area is large Fine grinding Bond suggested an intermediate law where 3 =
2

Energy for size reduction

Bond assumed = 3
3 2 giving = 1 1

Ei is and = 2 work index of the material known as the 1 2 1 2 2 1 Energy required to reduce unit mass of the material 1 1 2 from infinite particle size1to a size Lq ofthe reduction ratio 2 is 100 m, when = 2 1 1 2 2 80% of the material willpass through a 1 2 hole (of = square size 100 m) (q = ) Bond defined C as = 5 giving = 100 2
1 2

1 1
2

Example
A sample of dust from the air in a factory is collected on a glass slide. If dust on the slide was deposited from one cubic centimetre of air, estimate the mass of dust in g/m3 of air in the factory, given the number of particles in the various size ranges to be as follows:
Size Range (m) 0-1 1-2 2-4 4-6 6-10 10-14

No. of Particles

2000

1000

500

200

100

40

It may be assumed that the density of the dust is 2600 kg/m3, and an appropriate allowance should be made for particle shape.

Ans: 0.25 g/m3

Examples
A material is crushed in a Blake jaw crusher such that the average size of particle is reduced from 50 mm to 10 mm with the consumption of energy of 13.0 kW/(kg/s). What would be the consumption of energy needed to crush the same material of average size 75 mm to an average size of 25 mm: a) assuming Rittingers law applies? b) assuming Kicks law applies? ER = 4.33 kJ/kg EK = 8.88 kJ/kg

Which of these results would be regarded as being more reliable and why?

Example
Sugar is ground from crystals of which it is acceptable that 80% pass a 500 m sieve (US Sieve No. 35), down to a size which it is acceptable that 80% pass a 88 m sieve (No. 170), and a 5 horsepower motor is found just sufficient for the required throughput. If the requirements are changed such that the grinding is only down to 80% through 125 m sieve (No. 120) but the throughput is increased by 50% would existing motor have sufficient power to operate the grinder? Assume Bonds equation holds true.

Example Solution
Subscript: 1 = first condition Subscript: 2 = second condition Given: 1 =
2 =
1.5 5
1 2 1 2

100 88106
1 2

88 500
1 2

Initial unknown throughput

100 125106

125 500

1 = = 0.72 2 1.5 5 The motor cannot handle increased throughput.

= 5.4

Only increase of 38% can be handled.

Example
A crusher was used to crush a material with a compressive strength of 22.5 MN/m2. The size of the feed was minus 50 mm and plus 40 mm, and the power required was 13.0 kW/(kg/s). The screen analysis of the product was:
Size of aperture (mm) through 6.0 on 4.0 on 2.0 on 0.75 on 0.50 on 0.25 on 0.125 through 0.125 Amount of product (%) all 26 18 23 8 17 3 5

What power would be required to crush 1 kg/s of a material of compressive strength 45 MN/m2 from a feed with an average size of minus 45 mm and plus 40 mm to a product of 0.50 mm average size?

Ans: 47.8 kW