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Abstract
In this experiment, we reduce the size of sand in the process called size reduction by ball mill and separate the various size of sand by using molecular sieves. The first machine, ball mill, is the machine that uses centrifugal and gravitational force to break sand into smaller particles. Once, the machine starts, the ceramic balls inside will rotate. When they reach the highest position, they will fall due to gravity and crush sand particle into smaller pieces. We adjust the speed of ball mill at 3 values; 20, 40, and 60 rpm. The more the speed increases, the smaller the sand particle. It will be this trend until it reaches the critical speed that is the speed that can crush sand the most resulting in smallest diameter of particle. Above the critical speed, both ceramic ball and sand move too fast that result in less contact to each other. The other machine, molecular sieves, is the machine that separates the size of sand by let the sand from the top sieve gradually falls down through each different size of sieve. The sand that we get on each sieve will have the diameter that bigger than the size of sieve. The result turns out to be different from theory due to the error in machine sealing and reuse of sample. The further study can be applied included the effects of the movement of machine and changing in crushing material on the milled particle size.

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Table of Contents

Abstract .................................................................................................................................................... i 1. 2. 3. 4. 5. 6. Introduction ..................................................................................................................................... 1 Theory ............................................................................................................................................. 1 Apparatus ........................................................................................................................................ 2 Procedure ........................................................................................................................................ 3 Experimental results and sample calculation .................................................................................. 4 Discussion ....................................................................................................................................... 8 Questions ................................................................................................................................... 8 7. 8. Conclusion and Recommendation .................................................................................................. 9 References ....................................................................................................................................... 9

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List of Tables and Figures

Table 5.1 Result of the sample before milling ........................................................................................ 4 Table 5.2 Result of the sample after milling at 20 rpm........................................................................... 4 Table 5.3 Result of the sample after milling at 40 rpm........................................................................... 4 Table 5.4 Result of the sample after milling at 60 rpm........................................................................... 5 Figure 5.1 Mass vs diameter of original sand ......................................................................................... 6 Figure 5.2 Mass vs diameter of milled sand at 20 rpm ........................................................................... 6 Figure 5.3 Mass vs diameter of milled sand at 40 rpm ........................................................................... 7 Figure 5.4 Mass vs diameter of milled sand at 60 rpm ........................................................................... 7 Figure 5.5 Diameter of particle vs rotational speed ................................................................................ 7

1. Introduction
In process industries, the materials sometimes need to be cut or broken down into small particles via the process called size reduction. After size reduction, the solid particles would be separated according to their size or diameter for appropriate using in reaction. In this experiment, we use ball mill machine to grind the particles into small size and use sieve to separate the different size of particles. The purpose is to identify the critical speed of ball mill machine that is the maximum speed that can grind the solid particles the most and determine the average diameter of crushed material.

2. Theory
The circular grinding (Ball), as is usually the size of the metal ceramic grinding balls, used will depend on the type of ore were crushed, and size of the material to be crushed. In principle, when the pot began to roll crusher, the ball mill will move up the wall of the grinding bowl until certain point they will fall. Typically, the grinding is caused by centrifugal force that will allow compounds within it to roll to adhere to the wall, but due to the force of gravity it will fall to the bottom of the ground as well. This force is controlled by the speed of rotation around the axis of the grinding bowl. However, when the speed reaches the critical speed, the effectiveness of milling will start to decline. The critical speed is the speed of rotation of the grinding bowl that is important for the size of the crushed material. The speed will cause the rate of grinding. At when Centrifugal force = Gravitational force;

where ; m = mass of the ball n = speed of rotation R = radius of the cylinder r = radius of the ball = angle of the ball with the perpendicular line

At the critical speed , = 0 and cos = 1 , n become the critical speed . The operating speed n must less than . In actual practice, it for a coarse grind using a speed of about 8090% of the critical speed. And finely ground using a speed of about 65-80% of the speed of the critical speed. Then ; To find the average diameter, can be determined by weight as following;

where;

= the average diameter by weight = the weight of solid on each tray = the average diameter of solid

3. Apparatus
Ball mill machine Sieve shaker Standard ASTM sieve set (6 sieves with size of 2, 1, 0.71, 0.5, 0.355, and 0.25 mm.) Balance Sand Ceramic balls Beaker Tray

4. Procedure
1. Winnow the sand with 2 mm. sieve by hand in order to remove the bigger size of the sand. 2. Select 6 sieves of sizes 2, 1, 0.710, 0.500, 0.355, and 0.250 mm. from the standard ASTM sieve set, and then weight all of the empty sieves and record. 3. Weight the sand for 0.5 kg and put 100 grams on the sieve. Put the top cover on and make sure that it is locked well. Turn on the sieve shaker which can be adjusted in power, cycle, and time. In this laboratory, the sieve shaker is set to be power=1, cycle=1, and time=1. After 1 minute, the machine will stop automatically. 4. Weight and record each sieve then put the sand in each sieve in a prepared container. 5. Weight the sand from step1 for 0.5 kg in order to put it in ball mill. 6. Insert the 6 mm. balls that were made from ceramic into the ball mill about half of the ball mill capacity. Then put 0.5 kg sand from step 5 into the ball mill. Close the cover and set the rotational speed to be 20 rpm (round per minute) and let it run for 62 rounds. After 62 rounds, stop the machine and put the sand and the balls out then separate the balls from the sand. 7. Take the sand to the molecular sieves and repeat step 3 and 4. 8. Repeat step 5 for two times but change the rotational speed to be 40 and 60 rpm and let it run for 125 and 180 rounds, respectively. 9. Clean and keep all of the equipments.

5. Experimental results and sample calculation


Table 5.1 Result of the sample before milling Size of sieve (m) 2000 1000 710 500 355 250 0 total= Weight of empty sieve (g) 138.6 129.9 127.7 123.4 119 118 121.5 878.1 Weight of sand 0 0 0 45.6 28.7 16.4 9.4 100.1 Dpi (m) Xi Xi Dpi

605 427.5 302.5 125

0.456 0.287 0.164 0.094 1.001

275.88 122.70 49.61 11.75

Table 5.2 Result of the sample after milling at 20 rpm Size of sieve (m) 2000 1000 710 500 355 250 0 total= Weight of empty sieve (g) 138.6 129.9 127.7 123.4 119 118 121.5 878.1 Weight of sand 0 0 0 30 31.9 22.3 15.7 99.9 Dpi (m) Xi Xi Dpi

605 427.5 302.5 125

0.300 0.320 0.223 0.157 1

181.50 136.80 67.46 19.63

Table 5.3 Result of the sample after milling at 40 rpm Size of sieve(m) 2000 1000 710 500 355 250 0 total= Weight of empty sieve(g) 138.6 129.9 127.7 123.4 119 118 121.5 878.1 Weight of sand 0 0 0 32.4 30.4 22.2 15.5 100.5 Dpi (m) Xi Xi Dpi

605 427.5 302.5 125

0.322 0.302 0.221 0.154 0.999

194.81 129.11 66.85 19.25

Table 5.4 Result of the sample after milling at 60 rpm Size of sieve(m) 2000 1000 710 500 355 250 0 total= Weight of empty sieve (g) 138.6 129.9 127.7 123.4 119 118 121.5 878.1 Weight of sand 0 0 0 28.2 26.5 23.5 16.3 94.5 Dpi (m) Xi Xi Dpi

605 427.5 302.5 125

0.300 0.280 0.250 0.172 1.002

181.50 119.70 75.63 21.5

Radius of the ball mill, R, = 10.4 10-2 m Radius of ceramic balls, r, = 3 10-3 m From, cos = Critical Speed, nc = Dw = sigma

= 1.57 rad/s

Dw, original = 275.88 + 122.7 + 49.61 + 11.75 = 460 m

From the same formula Dw, 20rpm = 405.4 m Dw, 40rpm = 410.02 m Dw, 60rpm = 398.33 m n20rpm = n40rpm = n60rpm = = 0.33 rad/s = 0.67 rad/s = 1 rad/s

Xi VS Dpi of original sand


700 600 500 400 300 200 100 0 0 0.1 0.2 Xi 0.3 0.4 0.5

Dpi

Dpi

Figure 5.1 Mass vs diameter of original sand

Xi VS Dpi of 20rpm
200 150 Dpi 100 50 0 0 0.1 0.2 Xi 0.3 0.4 Dpi

Figure 5.2 Mass vs diameter of milled sand at 20 rpm

Xi VS Dpi of 40rpm
700 600 500 400 300 200 100 0 0 0.1 0.2 Xi 0.3 0.4

Dpi

Dpi

Figure 5.3 Mass vs diameter of milled sand at 40 rpm

Xi VS Dpi of 60rpm
700 600 500 400 300 200 100 0 0 0.1 0.2 Xi 0.3 0.4 Dpi

Dpi

Figure 5.4 Mass vs diameter of milled sand at 60 rpm

Dw and n
412 410 408 406 404 402 400 398 396 0 0.2 0.4 0.6
n

Dw

Dw

0.8

1.2

Figure 5.5 Diameter of particle vs rotational speed

6. Discussion
From theory, as the speed of rotation in ball mill goes up, the size of particle, in this case sand should be smaller due to the higher centrifugal force acting on the particle. The result shows out in a different trend from the theory. The size of particle fluctuates with the speed of rotation but it can be clearly seen that the size is less than particle size before milling. This result from many factors such as the size of the sample that is reused which include the milled sample from the previous experiment, the milling machine is not sealed and allows the leak of sand while rotating result in the loss of sample and force that is applied on the sample is not uniform throughout the process, also the sieve shaker is operated about one minute which is too low to obtain the accurate result. Questions

1. What can be use for determine the effectiveness of ball milling machine? Ans. The size of particle reduced after the milling process.

2. Why the effectiveness of the machine goes up as the speed of rotation goes up? Ans. The centrifugal force applied on the particle is increased from the relation: Force n2 (speed of rotation).

3. Why the effectiveness drops when the speed of rotation reaches the critical speed? Ans. The milling machine rotates too fast make the particle and the ceramic ball move at very high speed and some will float in the air at the center of rotation due to higher in centrifugal force, not gravitated down and touch each other, make the collation decrease so the effectiveness decreases.

4. How many types of standard sieves? What are the different? Ans. There are two types. One is shaken by hand called testing sieve. Another is used with the sieve shaker called ASTM sieve.

7. Conclusion and Recommendation


In conclusion, we have separated the sand according to its size by mean of sieving. The lower sieve it gets to the smaller it is. After which, we conduct an experiment to minimize the sand particle size using a ball mill. Ball mill is, in a simple method, a rotating device used for crushing smaller particles by big hard particles. Here, the small particles are sand, and the big one is ceramic pebbles. Theoretically, spinning them together should produce smaller-diameter sand. However, in practice we encounter several problems, such as unwell-sealed orifice of the ball mill, which lets the sand out, and therefore do not function properly. The sizes turn out to fluctuate; however, it manages to shrink the particles diameters down from time to time judging from the higher amount of fine particles in the bottom of the sieve. There are ways to improve the results, these include fixing the mills seal, prolonging the sieving time, and so forth.

8. References
http://en.wikipedia.org/wiki/Ball_mill http://www.usstoneware.com/Theory%20and%20Practice%20for.pdf

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