UNIT2

ForCAT1

SIZEREDUCTION
 UNIT2
SYLLABUS

LAWSOFSIZEREDUCTION
ENERGYRELATIONSHIPINSIZEREDUTION
METHODOFSIZEREDUCTION
CLASSIFICATIONOFEQUIPMENTSCRUSHER
GRINDERS,DISINTEGRATORSFORCOARSE,
INTERMEDIATEANDFINEGRINDING
POWERREQUIREMENT
WORKINDEX
SIZEENLARGEMENT
PRINCIPLEOFGRANULATION,BRIQUETTING,
PELLETISATIONANDFLOCULLATION.
 OUTLINE
2.1LAWSOFSIZEREDUCTION
2.1.1RITTINGERSLAW
2.1.2KICKSLAW
2.1.3BONDSLAW
2.1.4WORKINDEX

2.2POWERREQUIRMENTS

2.3ENERGYRELATIONSHIPINSIZEREDUCTION

2.4METHODSOFSIZEREDUCTION

2.5CLASSIFICATIONOFSIZEREDUCTIONEQUIPMENTS
2.5.1CRUSHERS
2.5.2GRINDERS
2.5.3DISINTEGRATORSFORCOARSE,INTERMEDIATEANDFINEGRINDING
2.6SIZEENLARGEMENT
2.6.1PRINCIPLEOFGRANULATION
PRINCIPLEOFCOMMUNITION:

Insizereductionsolidparticlesarecutorbrokeninto
smallerparticlesorpieces.

Throughoutprocessindustriessolidsarereducedinsize
bydifferentmethodsfordifferentpurposes.

Chunksofcrudeorearecrushedintoworkablesize.

Syntheticchemicalsaregroundintopowders.

Sheetsofplasticsarecutintotinycubesor
diamonds.

 COMMONLYUSEDFORCEFORSIZEREDUCTION
Sl. TYPEOFFORCE USEDFOR DAYTODAY TYPICALMACHINES
No. EXAMPLE
1
COMPRESSION COARSEREDUCTION CRACKINGOF NUTCRACKER,
NUTS JAWCRUSHER,
ROLLERCRUSHERS,
GYRATORYCRUSHERS.
2 IMPACT MEDIUMTOFINE SHRINKINGOF IMPACTORSAND
PRODUCTS SOLIDUSING HAMMERMILLS
HAMMER
3 ATTRITIONOR YIELDSVERYFINE SHARPENINGOF BALLMILL,RODMILL
RUBBING PRODUCTS KNIVES
4 CUTTINGOR DEFINITEPARTICLE PLANNINGOF CUTTERSOR
SHREDDING SIZE WOOD SHREDDERS
 REQUIREMENTSOFANIDEALCRUSHEROR
GRINDER
Itshouldhavealargercapacity.
Itshouldconsumelesspowerperunitof
product.
Itshouldgiveaproductofuniformsizeor
desiredsizedistribution.
 ACTUALCRUSHERORGRINDER
Characteristicsofactualunit:

Theirwillbeeffectivenessinyieldingaproductof
uniformsize;whetherthefeedisuniformlysized
ornot.
Theproductalwayscontainsamixtureofparticle.
Insomecrushersthelargestparticleofproduct
canbecontrolledbutthefinescannotbe
controlled.
Insomeofthegrindersfinescannotbecontrolled
toanextentbutcannotbeeliminated.
 ENERGYANDPOWERREQUIREMENTSIN
CRUSHING
Cost of power is a major expense in crushing
andgrinding.
Therefore the factor which controls the cost is
veryimportant.
Bysizereductionnewsurfaceareaiscreated.
 CRUSHINGEFFICIENCY(C)

It is the ratio between surface energy and new

surfaceareacreatedbycrushingtotheenergy
absorbedbythesolids.
i.e.c=es(AwbAwa)
Wn
whereessurfaceenergy
Awaspecificsurfaceareaofproduct
Awbspecificsurfaceareaoffeed
Wnenergyabsorbedbythesolids
 CRUSHINGEFFICIENCY(C)

The surface energy created by fracture is

smallincomparisonwiththetotalmechanical
energy stored in the material at the time of
rupture.
Mechanical energy is converted in to heat.
Crushingefficiencycisverylow(0.061%).
 MechanicalEfficiency(m)
EnergyabsorbedbysolidsWnislessthanthat
fedtothemachinerypartsofthetotalenergy
W, which is used for rotating, bearing and
othermovingparts.
Rest of the total energy is used for material
crushing.
Itisaratioofsurfaceenergyandnewsurface
areacreatedbycrushing.
m=es(AwbAwa)
W*c
 LAWSOFCRUSHINGORLAWSOF
COMMUNITION
RITTINGERSLAW
KICKSLAW
BONDSLAW

 RITTINGERSLAW
Rittingerslawstatesthattheworkrequiredincrushing
isproportionaltothenewsurfaceareacreated.
P 6es 1 1

m m c p
D sb D sa
b a
If the sphericities a and
b are equal and the
mechanical efficiency is constant in the above
equationcanbecombinedintoasingleconstantKR
1 1

P

Kr
m D sb D sa
 KICKSLAW
Kicks law states that the energy necessary for
crushing a given mass of material is
proportional to the logarithmic of reduction
ratio(i.e.theratiooftheinitialparticlesizeto
thefinalparticlesize).
This means that the energy required is same
whenthereductionratioisthesame.
D Sa
P
=

K k ln
m D Sb
 BONDSLAW
Bondslawstatesthattheworkrequiredtoformparticlesofsize
Dpfromverylargefeedinproportionaltothesquarerootof
thesurfacetovolumeratiooftheproduct(i.e.Sp/Vp)

P Sp

m Vp
Sp D p
2
weknowthat

D p 3
Vp

Sp 6

Vp D p

P 6

m Dp
P Kb

where K b is a constant which depends
m Dp
on the type of machine and on the material being crushed.
 WORKINDEX
Workindex(Wi)isdefinedasthegrossenergyinKwh/tonfora
particle.
Averylargefeedisreducedtosuchasizethat80%oftheproduct

passesthrougha100mscreen.

IfDpisinmm,PisinkW,misinton/hr.
Kb
Wi
100 *10-3
K b Wi 100 *10 3
K b 0.3162Wi
Theworkindexincludesthefrictioninthecrusherandthepower
givenbyaboveequationisthegrosspower.

WORKINDEXESFORDRYCRUSHINGORWETGRINDING
Material Specificgravity Workindex,Wi
Bauxite 2.20 8.78
Cementclinker 3.15 13.45
Cementrawmaterial 2.67 10.51
Clay 2.51 6.30
Coal 1.4 13.00
Coke 1.31 15.13
Granite 2.66 15.13
Gravel 2.66 16.06
Gypsumrock 2.69 6.73
Ironore(hematite) 3.53 12.84
Limestone 2.66 12.74
Phosphaterock 2.74 9.92
Quartz 2.65 13.57
Shale 2.63 15.87
Slate 2.57 14.30
Traprock 2.87 19.32
 RELATIVEAPPLICABILITYOFTHESELAWSOF
CRUSHING.
Sl.
No. RittingersLaw KicksLaw BondsLaw
1 Energyconsumedin Energyrequiredis Energyrequiredis
comminutionis proportionaltothevolumeof proportionaltothe
proportionaltonewsurface geometricallysimilarbodies lengthofcrack
produced initiatingbreakage
2 P 1 1 P D Sa P Kb
K K k ln
m
r
D sb D sa
m Dp
m D Sb
3 TherangeofFinegrindingis TherangeofCrushingisthe TherangeofCoarse
therangeofRittingers rangeofKicksLaw grindingistherangeof
theory Bondstheory
4 Bestapplicableincement BestapplicableinFood BestapplicableinOre
industry Industry processing
 ALTERNATEDERIVATIONOFCRUSHINGLAWS
A number of empirical laws have been put forward to estimate the
amountofenergyrequiredforsizereduction.Thefollowingarethe
lawsputforward.
1.Rittingerslaw.
2.Kickslaw.
3.Bondslaw.
Alltheselawscanbederivedfromthebasicdifferentialequation
dE p
1
-c L
dL
ThisequationstatesthattheenergydErequiredtoeffectasmall
changedLinsizeofunitmassofmaterialisasimplepowerfunction
ofsize.
dE -2 -2

IfPisputequalto2, dL - c L dE - c L dL
then Integrate,
-2
dE - c L dL
1 1
E c
L - 2
2 L1
 1
Writingc=KrfC 1
L2 L1

Sincethesurfaceofunitmassofmaterialisproportionalto1\L,the
interpretationofthislawisthattheenergyrequiredforthesize
reductionisproportionaltotheincreaseinsurfacearea.
IfPisputequalto1.
Then,
dE=CL1dL=CdL
L
Integrating, E 2 L

0
Ede C ln L
L
1

L L
E C ln 2 C ln 1
L1 L2
writing ,
C K k fC
L 3
E K k f C ln 1
L2
ThisisKickslaw.
Supposetheenergyrequiredisdirectlyrelatedtoreductionratio(L1/L2)
and that the energy required to crush a given amount of material
from 2cm to 1cm size is the same as that required to reduce the
size from 0.5cm to 0.25cm.In eq(2) and (3), K r and
K k are
respectivelyknownasRittingersconstantandKicksconstant.Both
theconstantsaredimensionless.
Bondslawisintermediatetoboththeselaws
PutP=1.5ineq(1),
dE
CL1.5 dE CL1.5 dL
dL
Integrating,
E L
2

0 dE L CL1.5
dL
1

1 1 1 1
E 2C Kb
L 2 L1 L 2 L1
Where2C=Kb
 PROBLEMSONCRUSHINGANDGRINDING

PROBLEM1:
Amaterialiscrushedinajawcrusherandtheaveragesize
of particle is reduced from 50mm to 10mm. Consuming
energy at the rate of 13kW/Kg/sec. What will be the energy
needed to crush the samematerial of average size 75mmto
anaveragesizeof25mm?(AssumeRittingerslawappliesand
Kicks law applies). Which of the results would you record
beingmorereliableandwhy?

SOLUTION:
Case(1),
forreducingparticlesizefrom50mmto10mm.
P
13kW / Kg / sec P 1 1
m 1
D
Sb1
m D Sa1
3
Dsa1 50mm 50 x10

3
Case(2), D sb1 10 mm 10 x10
forreducingparticlesizefrom75mmto25mm

P
Energy Needed ?
m 2
P 1 1
Dsa2 75mm 75 x10 3

D
Sb2
m D Sa2

Dsb2 25mm 25 x10 3

(i)AssumingRittinger'sLawapplies:
AccordingtoRittingerslaw,

P 1 1
K r
for case1
m 1 DSb1 DSa1

P 1 1
K r
for case 2
m 2 DSb2 DSa2

Dividingtheabovetwoequationsweget,
1 1
13 10 x10 3
50 x10 3

P
m 2
1
25 x 10 3
1
75 x 10 3

80
26.67
P
m2

13x 26.67
80
4.33kW/kg/sec
(ii)AssumingKickslawapplies.
BykickslawFor case(i)
P Dsa1
K k ln eq 3

m 1 Dsb1
For case(ii)
P Dsa 2
K ln eq 4
m 2
k
Dsb 2
where K k Kick ' s constant
eq3 eq4
P m
ln Dsa1 Dsb1
P m

1

ln Dsa 2 Dsb 2
2

13 ln 50
10
ln(5)
ln 75 25 ln(3)
P
m

2

(iii)Sincethesizereductionis
P m 13 lnln53
2
undercoarserange,Kicks
8.874kW/kg /sec
lawismorereliable.
PROBLEM2:
In a crushing operation, a 50mm feed was
reducedinsize,suchthat80%ofproductwas
passingthrough5mmsizescreen.Theenergy
consumedwas15kWhr/ton.Nowitisdesired
to alter the product size such that the 80%
passes through 4mm screen. Calculate the
energyrequiredinthesecondoperation?
SOLUTION:
ByBondscrushinglaw,
case ( i )
P 1 1
Kb 1
1
m
D sb 1 D sa 1
P
15 kWh / ton
m 1
D sb 1 50 mm 50 10 3 m
D sa 1 5 mm 5 10 3 m
case ( ii )

P 1 1
K b 2

m 2 D sb 2 D sa 2
P
Energy Required ?
m 2
D sa 2 50 mm 50 10 3 m
D sb 2 4 mm 4 10 3 m
divide eq1 by eq2,
1 1
3
15 5 10 3
50 10


P
m2
1
1
3
4 10 3
50 10
14.142 4.472 9.67

15.811 4.472 11.339
P 15 11.339

m 2 9.67
17.589kWhr/ton
Energy required for second operation 17.589kWhr/ton
PROBLEM3:
In the crushing of iron ore 80% of feed passes
through 5mm screen and 80% of product
passes through 0.5mm screen. Now it is
desiredtoaltertheproductsizesuchthat80%
of the same passes through 0.2mm screen.
What is the percentage increase in power
consumption?
SOLUTION:
ByBondslaw,

case(i )

P 1 1
K 1
m 1
b
D Dsa1
sb1
case(ii )

P 1 1
K 2
2
m
b
D Dsa 2
sb 2
where K b is a constant.
Dsb1 0.5mm 0.5 10 3 m
Dsa1 5mm 5 10 3 m
Dsa 2 5mm 5 10 3 m
Dsb 2 0.2mm 0.2 10 3 m
divide eq2 by eq1,
1

P
m2

0.2 10 3
1
3
5 10

P
m1 1

1
3
0. 5 10 3
5 10
70.71 14.14 1.85

44.72 14.14 1
P P

%increase 2 1
m m
P

m 1
56.57 - 30.58

30.58
84.99%
%increase in power consumption 85%
PROBLEM4:
3kWhastobesuppliedtoamachinecrushingmaterial
at the rate of 0.3kg/sec from 12.5mm cubes to a
producthavingthefollowingsizes.
1)80%3.175mm
2)10%2.25mm
3)10%2.5mm
Whatwouldbethepowerwhichhavetobesupplied
to this machine to crush 0.3kg/sec of the same
materialfrom7.5mmcubesto2mmcube?

SOLUTION:
n
Dn n D n
0.8 3.175 0.252
0.1 2.500 0.040
0.1 2.250 0.044
Assuming Rittinger' s law applies : n
0.336
Dn
By Rittinger' s law
P1 1 1

K r eq1

m1 sb1
D Dsa1

Dsa1 12.5mm 12.5 10 3 m

Dsb1 2.976mm 2.976 10 3 m
P1 3kW

m1 0.3kg / sec
P2 1 1
K
r eq 2

m2 Dsb 2 Dsa 2
Dsa 2 7.5mm 7.5 10 3 m
Dsb 2 2mm 2 10 3 m
P2 ? kW

m1 0.3kg / sec
Divide eq1 by eq2
P1 1 1


m1 sb1
D D sa1

P2 1 1

m2 D
sb1 Dsa1
3 1 1
3

0.3 2.976 10 12.5 10 3
P 1 1

0.3 2 10 3 7.5 10 3
3 336.02 80

P2 500.00 1.33
286.02

366.67
3 366.67
P2 4.29W
286.02
Assuming Kicks law applies,
D sa 1
P1
K k ln D eq 3
m1 sb1
For case(ii)
D sa 2
P2
K k ln D eq 4
m2 sb 2
where K k Kick ' s constant
divide eq3 by eq4

P1 D sa 1
ln

m1 D sb1
D
P2 ln sa 2
D
sb 2
2
m
3
ln 4 .2
0 .3
P2 ln 3 .75
0 .3
P2 2 .763 kW
PROBLEM5:
Anoreiscrushedfrom2.5cmto0.025cmintwosteps
from 2.5cm to 0.25cm. How would you expect the
totalpowerconsumption tobedistributed between
the two steps when calculated by Kicks and
Rittingerslaw?Giveyourcomments.
SOLUTION:
First step :
Dsa1 2.5cm 2.5 10 2 m
Dsb1 0.25cm 0.25 10 2 m
P
Power required in kW/kg/sec

m 1
By Rittinger' s law,
P
K 1 1 eq1
r
Dsb1 Dsa1
m 1
For second step :
Dsa 2 0.25 10 2 m
Dsb 2 0.025 10 2 m
P
Power required in kW/kg/sec

m 2
P
K 1 1 eq 2
r
Dsb 2 Dsa 2
m 2
Divide eq1 by eq2,
P 1 1
D D

m 1 sb1 sa 1

P 1 1
D D

m 2 sb 2 sa 2

1 -2
1
0.25 10 25 10 2

1 2
1
0.025 10 0.25 102
4000 - 400 3600 1
0.1
40000 - 4000 36000 10
P P
10
m 2 m 1
According to above equation the power required for second step
is 10 times the power required for first step.
ByKickslaw,
First step :
D 2. 5 10 2
sa1
10
D sb1 0.25 10 2
Second step :
D sa2 0.25 10 2
10
D sb 2 0.025 10 2

Sincethereductionratioissameinboththecases,thetotal
powersuppliedwillbeequallydistributedbetweentwosteps.

PROBLEM6:
Whatisthepowerrequiredtocrush100ton/hoflimestone
if80percentofthefeedpassesa2in.screenand80
percentoftheproducta1/8in.screen.Workindexfor
limestoneis12.74.(UnitConversion:1inch=25.4mm)
SOLUTION:

P 1 1
K b

Where, K b 0.3162Wi
m D D
pb pa
PROBLEM7
A crusher is used for reducing limestone of crushing
strength 70 MN/m2 from 6 mm diameter of average
size to 0.1 mm diameter average size requires 9 kW.
The same machine is used to crush dolomite at the
samerateofoutputfrom6mmdiameteraveragesize
to a product which consists of 20% with an average
diameterof0.25mm,60%withanaveragediameterof
0.125mm,thebalancehavinganaveragediameterof
0.085 mm. Estimate the power required to drive the
crusher, assuming that the crushing strength of the
dolomite is 100 MN/m2 and crushing follows
Rittingerslaw.
SOLUTION:
n
Dn n D n
0.2 0.25 mm 800
0.6 0.125 mm 4800
0.2 0.085 mm 2352.9
n
D 7952.9
Assuming Rittinger' s law applies : n

By Rittinger' s law
P1 1 1

K r eq1

m1 sb1
D Dsa1

Dsa1 6.0mm 6 10 3 m
Dsb1 0.1mm 0.110 3 m
P1 9kW
P2 1 1

Kr eq 2

m2 Dsb 2 Dsa 2
Dsa 2 6mm 6 10 3 m
1
Dsb 2 0.126 10 3 m
7952.9
P2 ? kW

m1 m2
Divide eq2 by eq1
P2 1 1

m 2 Dsb 2 Dsa 2


P1 1 1

m1 D
sb1 Dsa1
1 1

P 3
6 10 3
2 0.126 10
9 1 1

0.110 3 6 10 3

9 7769.84
P2 7.11kW
9833.33