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Week 6 Lecture Slides

1. Crushing efficiency is the ratio of surface energy created by crushing to the energy absorbed by the solid, and is typically less than 1% due to the significantly higher energy absorbed compared to the surface energy created. 2. There are several laws that describe the energy required for size reduction of materials, including Rittinger's law, Kick's law, and Bond's law. 3. Common size reduction equipment includes crushers, grinders, and ultrafine grinders. Crushers are used for coarse size reduction while grinders and ultrafine grinders provide intermediate and fine grinding.

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73 views38 pages

Week 6 Lecture Slides

1. Crushing efficiency is the ratio of surface energy created by crushing to the energy absorbed by the solid, and is typically less than 1% due to the significantly higher energy absorbed compared to the surface energy created. 2. There are several laws that describe the energy required for size reduction of materials, including Rittinger's law, Kick's law, and Bond's law. 3. Common size reduction equipment includes crushers, grinders, and ultrafine grinders. Crushers are used for coarse size reduction while grinders and ultrafine grinders provide intermediate and fine grinding.

Uploaded by

Jahanzaib Faraz
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Ch.

E-203 PARTICLE TECHNOLOGY

Department of Chemical Engineering,


University of Engineering & Technology Lahore
Crushing efficiency

 Efficiency = Output / Input

 Crushing efficiency is the ratio of surface energy created by crushing to the energy

absorbed by the solid


 es = surface energy created per unit area

 ΔAw = specific surface created per unit mass

 Wn = mechanical energy absorbed per unit mass of material

 As es <<< Wn
2
 Efficiency <<< 1
Mechanical efficiency

 Mechanical efficiency = Energy absorbed by solid / Energy supplied to machine

Where W = Energy supplied to machine

3
Power requirement

 If m = feed rate

 Then P = mW

or

4
Laws of Size Reduction

 To express energy required for size reduction of a solid material in terms of the

sizes of feed and products.


 Energy required depends on:

 Amount of material

 Composition and structure

 Nature of equipment

 Size of particle

 For same reduction ratio, the energy required for reduction of unit mass of solid

material in a given machine is higher for smaller particles.

5
Rittinger Law (1867)

“Work required to crush a given amount of material is proportional to new surface


created/increase in specific surface”

 Hypothesis

 Energy requirement is usually 200-300 times that required for creation of new

surfaces.

6
Kick’s Law (1885)

“Work required for crushing a given amount of material is constant for same
reduction ratio”

 Unrealistic

 Same energy to convert 10 μm to 1 μm and 1 m to 10 cm

7
Bond’s Law (1952)

“Work required to form particle of size Dp from very large feed is proportional to square
root of the surface to volume ratio of the product”

8
Work Index

 Gross energy required in kWh per ton of feed needed to reduce very large feed to

such a size that 80% of the product passes a 100 μm screen

 If 80% of feed passes from mesh size Dpa and 80% of product of mesh size Dpb

9
Differential form of Laws

Generalized differential equation for given cases

 N = 1, Kick’s Law
 N = 2, Rittinger’s Law
 N = 1.5, Bond’s Law

10
SIZE-REDUCTION EQUIPMENTS

11
Size Reduction Equipments

The principal types of size-reduction machines are as follows:

A. Crushers (coarse and fine) Coarse mine material is crushed


1. Jaw crushers into lumps of 250 to 150 mm. Again
2. Gyratory crushers these lumps are broken into
3. Crushing rolls particle of 6 mm in size.

B. Grinders (intermediate and fine) Grinders reduce crushed feed to


1. Hammer mills, Impactors powder. The product from an
2. Attrition mills intermediate grinder might pass a
3. Tumbling mills 40-mesh screen and product from
a. Rod mills fine grinders pass a 200-mesh screen
b. Ball mills with a 74 m opening.
C. Ultrafine grinders
1. Fluid-energy mills
Feed < 6 mm
2. In. Classified H.M Product: 1- 50 m
3. Agitated Mills
D. Cutting machines
Give particles of definite size and
1. Knife cutters, slitters
shape, 2 to 10 mm in length
Crushers

 Slow-speed machines

 coarse reduction

 large quantities of solids

 The main types are


 jaw crushers
 gyratory crushers
 smooth-roll crushers
 Toothed-roll crushers

 The first three operate by compression and toothed-roll crushers tear the feed apart
as well as crush it.
Jaw Crushers

 Two jaw - V opening

 One – Fixed jaw – anvil jaw

 Other – moving jaw – swinging jaw

 Angle b/w jaws 20o – 30o

 Jaws are flat or slightly bulged

crushed at upper portion & then dropped and recrushed at narrow end
 250 – 400 times per min
Feed size = 1.8 m and product size = 250 mm
Capacity = 1200 ton/hr
Jaw Crushers
Gyratory Crushers

 Jaw crusher with circular jaws


 Conical crushing head
 Funnel shaped casing open at the top
 Crushing head is carried on heavy shaft
 solid broken and re-broken again & again
 125-425 gyrations per min
 motion – Slow
 Product – continuous
 Capacity – 4500 ton / hr
 Relatively less power as well as maintenance required
Gyratory Crushers
Crushing Rolls

 Heavy rolls rotating at slow speeds


 two heavy smooth faced metal rolls
 turning on parallel horizontal axis
 compression b/w rolls and then drop out
 turn to each other with same speed
 50 – 300 rpm
 narrow faces as compared to diameter
 feed 12 – 75 mm
 product 12 – 1 mm
 R.R < 5
Crushing Rolls

19
Toothed Roll crusher

 Roll faces – corrugations, breaker bar, teeth


 may be One roll or Two rolls
 One roll working again a stationary curved breaker plate
 Disintegrators – two corrugated rolls – different speeds
 Small high-speed rolls with transverse breaker bars on its face turning toward a large
slow speed smooth rolls
versatile but cannot handle very hard material
 Compression + Impact + Shear
Feed < 500 mm
 Capacity upto 500 tons/hr
Toothed Roll crusher

21
Grinders

 The term grinder describes a variety of size-reduction machines for intermediate


and fine duties.

 The product from a crusher is often fed to a grinder, in which it is reduced to


powder.

 The types of commercial grinders are hammer mill, impactors, attrition mills and
tumbling mills.
Hammer Mills

 High speed rotor


 Cylindrical casing
 Horizontal shaft
 Swing hammers attached with rotor
 Hammers – impact + rubbing
 Discharge opening – Screen
 Feed (top) – Break(casing) – Product (bottom)
 4 – 8 hammers on single shaft
 Intermediate – 25 mm to 20 mesh size
 Fine - < 200 mesh at 0.1 to 15 ton/hr
 Versatile
 Capacity & Power req. – feed nature
 Reduce 60 – 240 kg per kWh
24
Impactor

 Heavy duty hammer mill except screen


 Impact alone
 Primary reduction machine
 Capacity = 600 TPH
 Nearly equi-dimensional particle
26
Rolling Compression Machines

 Cylindrical rollers
 Stationary anvil ring or casing
 Horizontal shaft
 Moderate speed
 Plows – lifting the material
 Some time ring or bowl is driven
 Product swept with the help of air
 Capacity = 50 ton / hr
 99% product pass through 200 mesh
Attrition Mills

 For soft solids


 corrugated or flat faces of rotating circular disk
 Horizontal axis , sometimes vertical
 Single runner mill – one disk is stationary and one rotates
 Double runner mill– both disks are driven – high speeds
 Product – very fine / powders
 Air is drawn – to get product
 cooling is essential
 Speed – 350 to 700 rpm ( single )
- 1200 to 7000 rpm (Double)
 Capacity 0.5 to 8 ton/hr , - < 200 mesh
 8 – 80 kWh per ton
Tumbling Mills

 Cylindrical shell
 Slowly turning about its horizontal axis
 Half filled by solid grinding medium
 Grinding medium
 metal rods in Rod mill
 balls of metal, rubber or wood in Ball mill
 pebble, porcelain or zircon spheres in pebble mill

 Operation - Continuous or Batch


 Impact + attrition
 Product - fines
Rod Mills

 Rolling compression + attrition


 Several sizes of rods – 25 to 125 mm in diameter
 intermediate grinders
 20 mm feed to 10 mesh product

Ball Mill or Pebble Mills

 Impact + Compression
 ball 25 to 125 mm
 Pebble 50 to 175 mm
Capacity & Power requirement in Tumbling mills

 Amount of Energy supplied depends upon


 Mass of grinding media
 speed of rotation
 Max. distance of fall

 Best predicted by computer simulation based on experimentation

 Rod mill – 5 to 200 ton/h of 10-mesh product – 4 kWh/t


 Ball mill – 1 to 50 ton/h of 70 to 90% of 200-mesh – 16 kWh/t
Ultrafine Grinders

 All particles passing a standard 325-mesh (44 μm)


 high speed hammer mill with internal classification
 Fluid energy or jet mills
 Agitated mill (wet)
 Colloid Mills
Fluid Energy Mills

 Particles suspended in high velocity gas stream (fluidization)


 Elliptical or circular path
 inter - particle interaction + striking + rubbing
 Coarse particles remain in circulation
 product – 0.5 to 10 μm
Feed – 1 ton/hr - non sticky
 1 – 4 kg of steam or 6 – 9 kg of air
per kg of product
Agitated Mills

 Small batch non rotary mills


 solid grinding medium (hard solids like balls or pebbles)
 vertical vessel – 4 to 1200 L
 filled with liquid and suspended medium
 feed is agitated by the impeller
 Feed - Concentrated slurry
 Product – bottom (through the screen)
 product – 1μm or finer
35
Colloid Mills

 Feed pumped between closely spaced surfaces


 One moving relative to other
 cooling is required
 low capacity – 2 to 3 L/min – 440 L/min
 Feed - Concentrated slurry
 product – 1μm or finer
Cutting Machines

 feed – sticky , hard and elastic


 size reduction with fixed dimensions
 cut, chop or tear the feed
 rotary knife cutters or Granulator
 Rubber and plastics
Knife cutter

 Horizontal rotor in cylindrical chamber


 200 – 900 rpm
 2 to 12 flying knives with sharp edges
 1 to 7 stationary knives
 feed – reduces several hundred times
 knives at angle or parallel to each other
 Granulators yield more or less irregular particles while cutters
yield cubes, thin square or diamond shapes

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