CRUSHING LAWS

By :NIKHIL ANAND
Roll No. - 212/08
4th Semester, Metallurgy & Materials Engineering
National Institute of Technology, Jamshedpur

CONTENTS
Introduction
General types of crusher
Different laws of crusher
Rittingers law
Kicks law
Bonds law
Limitations of comminution laws
Practical measures of grinding efficiency
Gross & Zimmereley laws
Conclusion
Reference

Introduction
The comminution or size reduction process is an important unit operation in the process
industries in which solid materials are broken or cut into smaller sizes by the application of
mechanical stress. Solids can be reduced in size by crushers and grinders which employ
compression, impact, attrition, shear, or combinations thereof. Depending on the degree of
particle size reduction desired, the end result is achieved in one or several steps. Devices that
are used for size reduction operations can be classified into primary and secondary crushers,
grinders.
The primary crushers are slow-speed machines that reduce the run-of-mine product into
15-25 cm lumps. A secondary crusher reduces these lumps to 5 mm product. Grinders reduce
the products of crushing operations into powder. An intermediate grinder typically produces a
product that passes a 40-mesh screen. Fine grinders reduce feed into product that passes a
200-mesh screen. Ultrafine grinders can convert the product of secondary crushers into 1-10
product. Cutting machines produce particles with a definite size and shape in the 2-10 mm
size range.
Size reduction machines can be classified as follows:
a. Primary and secondary crushers
1. Gyratory crushers
2. Jaw crushers
3. Roll crushers
b. Intermediate and fine grinders
1. Impact mills
a. Hammer mills
b. Centrifugal pin mill
2. Attrition mills
3. Tumbling mills
a. Ball and pebble mills
b. Rod mills
c. Tube mills; compartment mills
4. Rolling-compression mills
a. Ring roll mills

b. Bowl mills
c. Ultrafine grinders
1. Fluid-energy mills
2. Agitated mills
3. Impact mills with internal classification
Many experiments have been conducted to determine the efficiency of power utilization in
crushing and grinding processes, i.e. to determine the ratio of the energy actually expended to
effect a specify size reduction to that theoretically required from this efficiency, we can
estimate the energy lost due to factors such as the movement of the working parts of the
equipment ,the friction in the bearings and the dissipation as heat and sound. [1]

Types of crushers
Jaw crusher
Gyratory crusher
Cone crusher

Jaw crusher
Jaw Crusher is used in mining, metallurgy, construction, highway, railway, irrigation and
Chemical industries and jaw crushers have the features of high reduction ratio, even
Powder-sizes, low power consumption and easy maintenance. The crushing strength of
the jaw crusher material is up to 350 Mpa.

Working of Jaw Crushers

Jaw Crusher is ideally suitable for primary and secondary crushing. It is carefully
designed to provide superior quality and performance with low power consumption and
Easy maintenance.
Jaw crusher reduces large size rocks or ore by compressing, a fixed jaw, mounted in a
V alignment is the stationary breaking surface, while the moveable jaw plate exerts
force on the rock by compressing it against the fixed jaw plate. The space at bottom of
the V, aligned jaw plate is the output size gap, or the maximum size of the crushed
product. Due to the features of simple structure, reliable performance, convenient
maintenance and safe use, our jaw crushers of various models are widely used in the crushing
operation in metallurgy, mining, building materials, chemical industries and cement
enterprises.

Operating principle and structural features Of Jaw

Crushers
The crusher mainly consists of:
1) Frame
2) Fixed jaw plate
3) Left and right protecting boards
4) Movable jaw plate
5) Movable jaw
6) Eccentric shaft
7) Toggle plate
8) Toggle seat
9) Components and parts such as oil pressure lifter
The motor drives eccentric shaft via a delta belt fixed in a grooved pulley, which can
make movable jaw move repeatedly so as to crush materials in crushing cavity. Fixed jaw
plate of frame front wall is fastened depending on left and right protecting boards and holding
down bolts, while movable jaw plate is pressed tightly on movable jaw depending on battens.
When the jaw plates are abraded (usually under side of the jaw Toggle plate can not only bear

the weight of movable jaw, but also protect other parts of the machine from hurting. When
un-broken foreign materials come into crushing cavity which results in heavy load increase of
toggle plate, the toggle plate breaks down itself to cut off the heavy load so as to protect other
parts of the jaw crushers. Toggle seat is fastened on ear seat of the jaw crushers two sides by
draw bolts; depend on hydraulic pressure lifter (lifting bolts) to lift out toggle seat, change
pad thickness, and i.e. be able to adjust the width of discharge outlet.[2]

Gyratory crusher
A gyratory crusher is similar in basic concept to a jaw crusher, consisting of a concave
surface and a conical head; both surfaces are typically lined with manganese steel surfaces.
The inner cone has a slight circular movement, but does not rotate; the movement is
generated by an eccentric arrangement. As with the jaw crusher, material travels downward
between the two surfaces being progressively crushed until it is small enough to fall out
through the gap between the two surfaces.
A gyratory crusher is one of the main types of primary crushers in a mine or ore processing
plant. Gyratory crushers are designated in size either by the gape and mantle diameter or by
the size of the receiving opening. Gyratory crushers can be used for primary or secondary
crushing. The crushing action is caused by the closing of the gap between the mantle line
(movable) mounted on the central vertical spindle and the concave liners (fixed) mounted on

the main frame of the crusher. The gap is opened and closed by an eccentric on the bottom of
the spindle that causes the central vertical spindle to gyrate. The vertical spindle is free to
rotate around its own axis. The crusher illustrated is a short-shaft suspended spindle type,
meaning that the main shaft is suspended at the top and that the eccentric is mounted above

the gear. The short-shaft design has superseded the long-shaft design in which the eccentric is
mounted below the gear.[3]

Cone crusher
The Cone crusher is suitable for crushing various mid-hard and above midhard ores and
rocks. It has the advantage of reliable construction, high production activity, easy adjustment
and less cost in operation. The spring release system of crusher acts an overload protection
system that allows tramp to pass through the crushing chamber without damage to the
crusher. Two kinds of sealed formation dry oil and water are used, the plaster stone and
engine oil are separated, and reliable performance is ensured.

Working of cone Crusher

Cone crusher crushes materials by the working surface between the movable cone and fixed
cone. The movable cone of the cone crusher is supported by spherical bearing and fixed on a
hanging erect shaft which is set in the eccentric sleeve, and the sleeve is set on the stopping
and pushing bearing. The movable cone and erect shaft are driven by the eccentric shaft
sleeve together. The eccentric shaft sleeve is driven by horizontal shaft and fimbriated gear,
and the wheel of the conveyor belt is driven by motor through v-belts. The lower part of
vertical shaft is installed in the eccentric sleeve. When the eccentric sleeve of cone crusher
rotates, there is a conical surface lined out by the shaft. When the movable cone comes near
the fixed cone, rocks are grinded into pieces, when the cone leaves, grinded materials is

discharged from the discharge hole. The fixed cone can be ascended or descended by
adjusting setting to adjust the width of discharge hole; consequently the output size is
determined.

Cone Crusher Features:

1) High quality and productivity
2) Short downtime
3) Easy maintenance, low expense
4) Unparalleled in medium and fine crushing [4]

A general comparison of Jaw, Gyratory & Cone crusher [5]

Type

Hardness

Abrasion
limit

Jaw crusher

Soft to very
hard

No limit

Gyratory
crusher

Soft to very
hard

Abrasive

Cone
crusher

Medium
hard to very
hard

Abrasive

Moisture
content
Dry to
slightly
wet, not
sticky

Reduction
ratio
3/1 to 5/1

Dry to
slightly
wet, not
sticky
Dry or
wet, not
sticky

4/1 to 7/1

3/1 to 5/1

Main use
Quarried
materials,
sand &
gravel,
recycling
Quarried
materials
Sand &
gravel

Different laws of crusher

Rittingers law
Kicks law

 Bonds law

Rittingers law
The energy expended during comminution is proportional to the area of the new surface
produced as a result of particle fragmentation.

Kicks law
The energy is proportional to the size reduction ratio.

Bonds law
The total work input represented by a given weight of crushed or ground product is inversely
proportional to the square root of the diameter of the product particles.

Limitations of comminution
laws
Experimentally determined size & shape is highly
arbitrary
The size and shape which can be determined by these methods is not very perfect .it is
determined on the average method .The methods discussed above cant measure the
accurate area of the particles. So that we cant get the accurate result.

 Difficult to determine surface parameter of finer

particles
It is very difficult to determine accurate area of the finer particles by the above discus
method. There is no suitable method is aviable for the determining the area of the fine
particles.

Even if the above conditions are determined, the

surface areas of cracks presents in big particles
would be remains unaccounted.
If all the above conditions are considered then the area of the cracks which are present
in the particles cant be calculated. So, it is the major drawbacks of the calculating the
area of the particle surface.

Practical measures of grinding

efficiency
The operator s measure of grinding efficiency can hardly be rigorous in view of what has
been said above concerning the imprecision of efficiency measurements based on energy
output/energy input. Actually practical test of grinding efficiency can be summed up in the
query.
How many tons can be put through a mill , and ground to a given size,per day,and at what
energy expenses in kilowatt-hour per ton? In other word , to the practical operator on an
efficient grinding operation connotes one efficient not only in terms of liow power cost, but
also one efficient in the sence that is made full use of the possible capacity of the mill.by
leaving out of the consideration the capacity measure of grinding efficiency, there is
substituted for the energy/energy factor of the rigorous efficiency a ratio of weight ground to
energy input .This would be regarded as abominable efficiency. [4]

Gross & Zimmereley laws

Gross and zimmerley have experimentally proved with a drop-weight apparatus that the new
surface produced in crushing is directly proportional to the energy consumed in the process.
This may be seen in the graph.

Kg.cm per gram of

quartz

Sq .cm.surface
produce in crushing
1 gram

0
5
10
15
20
25
30

0
100
200
300
400
500
600

CONCLUSION

Efficiency is very complex phenomenon

Each and every factor must not be so easy to considered

Different conditions must be considered

Efficient utilization of both energy and mass

Reference
1
2
3
4
5

www.informaworld.com
www.crusher-mill.com,
http://en.wikipedia.org/wiki/Crusher
principle of mineral dressing by A.M. Gaudin
http://en.wikipedia.org/wiki/Crusher