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PPMO 4-0-4
PARTICLE CHARACTERISATION
Single particles
• The simplest shape of a particle is the sphere in that, because of its symmetry,
any question of orientation does not have to be considered, since the particle looks
exactly the same from whatever direction it is viewed and behaves in the same
manner in a fluid, irrespective of its orientation. No other particle has this
characteristic.
• Frequently, the size of a particle of irregular shape is defined in terms of the size
of an equivalent sphere although the particle is represented by a sphere of
different size according to the property selected.
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PPMO 4-0-4
Some of the important sizes of equivalent spheres are
(a) The sphere of the same volume as the particle.
(b) The sphere of the same surface area as the particle.
(c) The sphere of the same surface area per unit volume as the particle.
(d) The sphere of the same area as the particle when projected on to a plane
perpendicular to its direction of motion.
(e) The sphere of the same projected area as the particle, as viewed from above,
when lying in its position of maximum stability such as on a microscope slide for
example.
(f) The sphere which will just pass through the same size of square aperture as the
particle, such as on a screen for example.
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PPMO 4-0-4
• A measure of particle shape which is frequently used is the sphericity, ϕ,
defined as
surface area of sphere of same volume as particle 6v p
surface area of particle De S p
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PPMO 4-0-4
Example 1: Calculate the sphericity of a (a) cube of length l, (b) cylinder of dia 1 cm and
height 3 cm, (c) rectangular cuboid of length 4 cm, width 2 cm and height 6 cm.
Solution:
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(a) Sphericity of cube: Volume of cube = volume of sphere l 3 rp3 D3p
6 3 6
De 3 l 1.2407 l
Dp
6v p 6 l3 l
So, 0.8059
De S p 1.2407 l 6l 2
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φ
0.8059
0. 725
0.777
1
Tetrahedron
Octahedron
Φ = 0.846
Φ = 0.671
Φ = 0.84
Φ = 0.895
Torus
The particle size can be measured using a wide range of measuring techniques
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Methods of size reduction
Solids can be broken in many different ways but only four are
commonly used in size reduction machines
(1) Compression− particle disintegration by two rigid forces
(2) Impact− particle concussion by a single rigid force
(3) Attrition or Rubbing− arising from particles scraping against
one another or against a rigid surface
(4) Shear− produced by a fluid or by particle–particle interaction.
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Energy Requirement for Size Reduction
Although it is impossible to estimate accurately the amount of energy
required in order to effect a size reduction of a given material, a
number of empirical laws have been proposed.
The three basics laws of energy requirement for size reduction are
1. Kick’s Law
2. Rittinger’s law
3. Bonds law
These three laws may all be derived from the basic differential
equation which states that the energy dE required to effect a
dE p
CL small change dL in the size of unit mass of material
dL
is a simple power function of the size 15
For Rittinger’s law: p = −2
for Rettinger's law C = K R f c ,
dE
so CL2 c
f is the crushing strenght of the material
dL K is the Rettinger's constant
R
1 1 P 1 1
E K R fc K R
L2 L1 m L2 L1
P Power required for crushing
m = mass flow rate (ton/hr) or feed rate of crushing
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For Kick’s law: p = −1
for Kick law C = K K f c ,
dE
so CL1 fc is the crushing strenght of the material
dL K is the Kick's constant
K
L P L
E K K fc ln 1 K K ln 1
L2 m L2
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Bond’s Law; p = − 3/2
• Bond has suggested a law intermediate between Rittinger’s and
Kick’s laws, by putting p = −3/2
dE Writing Kb = xWi
so CL3/2
dL The value of x changes as
1 1 x = 10 when L in µm
E Kb Kb = 0.3612Wi when L in mm
L1/2 L1/2
2 1
E 1 1 P 1 1
0.3162Wi 0.3162Wi
fc L L m L L
2 1 2 1
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Bond terms Wi the work index, and expresses it as gross energy
required in killowatt hour per short-ton of feed (kWh/ton of feed) to
reduce a very large particle to such a size that 80% of the product will
pass through a 100 µm 0r 0.1 mm screen.
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Solution:
a) Rittinger’s law. P K R 1 1 , P 37, m 1 metric tonn
m L2 L1
1 1
Thus 37 K R K R 65
1.3 5
Thus the energy required to crush 8 cm material to 3 cm is
1 1
P / m 65 13.54 W.hr/metric tonn
3 8
P L
b) Kick’s law K K ln 1
m L2
5
Thus 37 K K ln K K 27.4
1.3
Thus the energy required to crush 8 cm material to 3 cm is,
8
P / m 27.4 ln 26.67 W.hr/metric tonn
3
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Example 2: Calculate the energy required to crush 100 tons/hr of
limestone if 80% of the feed passes through a screen 3.75 cm aperture
and 80% of the product passes through a screen with 0.03 cm aperture.
The work index for limestone is 12.74.
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Example 3: A certain crusher takes rock whose average particle diameter is 0.025 m
and crushes it to a product whose average particle diameter is 0.018 m, at the rate of
20,000 kg/hr. At this rate, the mill takes 684 kgf.m/sec of power and 35 kgf.m/sec
power is required to run it empty.
(i) What would be the power consumption for same capacity, if the average particle
diameter in the product is 0.008 m.
(ii) How much power would be required under condition (i) by Kick’s law.
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Methods of feeding Crushers
• Free Crushing: involves feeding the material at a comparatively low rate so that the
• Its residence time in the machine is therefore short and the production of appreciable
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Choke Feeding: the machine is kept full of material and discharge of the product
is impeded so that the material remains in the crusher for a longer period.
•This results in a higher degree of crushing
• The capacity of the machine is reduced
• Energy consumption is high.
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• If the plant is operated, as in choke feeding, so that the material is passed only
once through the equipment, the process is known as open circuit grinding.
• If, on the other hand, the product contains material which is insufficiently crushed,
it may be necessary to separate the product and return the oversize material for a
second crushing. This system which is generally to be preferred, is known as closed
circuit grinding.
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• The desirability of using a number of size reduction units when the particle size
is to be considerably reduced arises from the fact that it is not generally
economical to effect a large reduction ratio in a single machine.
• The desirability of using a number of size reduction units when the particle size
is to be considerably reduced arises from the fact that it is not generally
economical to effect a large reduction ratio in a single machine.
applicable only with low speed mills. The advantages of wet grinding are
(c) The removal of the product is facilitated and the amount of fines is reduced.
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TYPES OF CRUSHING EQUIPMENT
Coarse crusher
Intermediate crusher
•Blake jaw crusher
•Crushing rolls Fine crusher
•Dodge jaw crusher
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(i) Blake Jaw Crusher
Pivot
Pivot
Pivot
Stag/Blake Dodge Universal
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(iii) The Gyratory Crusher
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(iii) The Gyratory Crusher
• The gyratory crusher employs a crushing head, in the form of a truncated
cone, mounted on a shaft, the upper end of which is held in a flexible bearing,
whilst the lower end is driven eccentrically so as to describe a circle.
• The crushing action takes place round the whole of the cone.
• Since the maximum movement is at the bottom, the characteristics of the
machine are similar to those of the Stag/Blake crusher.
• It does not, take such a large size of feed as a jaw crusher, although it gives a
rather finer and more uniform product.
• Because the capital cost is high, the crusher is suitable only where large
quantities of material are to be handled.
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Sample
Sample
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(iv) Other coarse crushers
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Intermediate crushers
(i) The edge runner mill
• In the edge runner mill, a heavy cast iron or granite wheel, or muller as it is
called, is mounted on a horizontal shaft which is rotated in a horizontal plane
in a heavy pan.
• Material is fed to the center of the pan
and is worked outwards by the action of
the muller, whilst a scraper continuously
removes material that has adhered to the
sides of the pan, and returns it to the
crushing zone.
• The mill may be operated wet or dry
and it is used extensively for the grinding
of paints, clays and sticky materials.
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(ii) The hammer mill
• The hammer mill is an impact mill employing a high speed rotating disc, to which are
fixed a number of hammer bars which are swung outwards by centrifugal force.
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(iii) Crushing rolls
• Two rolls, one in adjustable bearings, rotate in opposite directions, and the clearance
between them can be adjusted according to the size of feed and the required size of
product.
• Both rolls may be driven, or one directly and the other by friction with the solids.
• The crushing rolls, which may vary from a few centimeters up to about 1.2 m in
diameter, are suitable for effecting a small size reduction ratio, 4:1 in a single operation
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• A system where a spherical or cylindrical particle of radius r2 is being fed to
crushing rolls of radius r1
• 2α = angle of nip, the angle between the two common tangents to the
particle and each of the rolls
• 2b = distance between the rolls,
• Angle of nip can be written as
r b
cos 1
r1 r2
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Example 4: A certain set of crushing rolls has rolls of 100 cm diameter by 38 cm width face.
They are set so that the crushing surfaces are 1.25 cm apart at the narrowest point. The
manufacturer recommends that they may run a 50-100 rpm. They are likely to crush a rock
having a specific gravity of 2.35, and the angle of nip is 30o. What are the maximum
permissible size of feed and the maximum actual capacity in tons/hr, if the actual capacity is
12% of the theoretical.
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So, q = 60 × 1.25 × (π × 100 ×100) × 38 = 8.954 × 107 cm3/hr
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Example 5: A certain set of roll crusher has rolls of 150 cm in diameter by 50 cm width of
face. They are set so that the crushing surfaces are 1.25 cm apart at the narrowest point. The
manufacturer recommends 100 rpm, as the roll speed. They are to crush a rock having
specific gravity of 2.35 and the angle of nip is 30o.
(a) What are the permissible size of feed and the maximum actual capacity in metric tons
per hour if the actual capacity is 12% of the theoretical?
(b) After long use, the tires on the rolls of the mill have become roughened so that the angle
of nip is 32o . What will now be the maximum permissible size of feed and the capacity of
the rolls.
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Factors influencing the size of the product in the roll crusher
(a) The rate of feed. With high rates of feed, less size reduction is effected since
the material is in the mill for a shorter time.
(b) The properties of the feed material. The larger the feed the larger is the
product under given operating conditions. A smaller size reduction is obtained with
a hard material.
(c) Weight of rolls
(d) The diameter and width of the rolls
(e) Discharge freedom. Increasing the freedom of discharge of the product has the
same effect as increasing the slope or decreasing the tendency to choke.
Types of roll crushers
A. Crusher with two rolls moving in opposite direction
towards each other
(A)
B. Single roll crusher
C. Smooth roll crusher
D. Toothed roll crusher
(D)
(B)
(C)
Fine crusher
Ball Mill
• Consists of a rotating hollow cylinder, partially filled with balls,
with its axis either horizontal or at a small angle to the horizontal
• The ball mill is used for the grinding of a wide range of materials, including coal,
pigments, and felspar for pottery, and it copes with feed up to about 50 mm in
size.
• The efficiency of grinding increases with the hold-up in the mill, until the voids
between the balls are filled.
• The balls are usually made of flint or steel and occupy between 30 and 50 per
cent of the volume of the mill. Why?
• The diameter of ball used will vary between 12 mm and 125 mm and the
optimum diameter (de) is approximately proportional to the square root of the
size of the feed (Df), with the proportionality constant being a function of the
nature of the material.
db C D f
• Sometimes instead of same size of balls, it is used multiple sized balls for better
crushing.
Compound ball mill
In the compound mill, the cylinder is divided into a number of compartments
by vertical perforated plates.
The material flows axially along the mill and can pass from one compartment
to the next only when its size has been reduced to less than that of the
perforations in the plate.
• Each compartment is supplied with balls of a different size. The large balls
are at the entry end and thus operate on the feed material, whilst the small
balls come into contact with the material immediately before it is
discharged.
Advantages of compound ball mill over simple ball mill
• This results in economical operation and the formation of a uniform
product.
•It also gives an improved residence time distribution for the material, since
a single stage ball mill approximates closely to a completely mixed system.
• It reduces the need of screens or separator Feed in
Product out
Factors influencing the size of the product in the Ball Mill
(a) The rate of feed. With high rates of feed, less size reduction is effected since
the material is in the mill for a shorter time.
(b) The properties of the feed material. The larger the feed the larger is the
product under given operating conditions. A smaller size reduction is obtained with
a hard material.
(c) Weight of balls. A heavy charge of balls produces a fine product. The weight of
the charge can be increased, either by increasing the number of balls, or by using a
material of higher density. Since optimum grinding conditions are usually obtained
when the bulk volume of the balls is equal to 50 per cent of the volume of the mill,
variation of the weight of balls is normally effected by the use of materials of
different densities.
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(d) The diameter of the balls. Small balls facilitate the production of fine
material although they do not deal so effectively with the larger particles in the
feed. The limiting size reduction obtained with a given size of balls is known as
the free grinding limit. For most economical operation, the smallest possible
balls should be used.
e) The slope of the mill. An increase in the slope of the mill increases the
capacity of the plant because the retention time is reduced, although a coarser
product is obtained.
(f) Discharge freedom. Increasing the freedom of discharge of the product has
the same effect as increasing the slope. In some mills, the product is
discharged through openings in the lining.
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g) The speed of rotation of the mill. At low speeds of rotation, the balls simply roll
over one another and little crushing action is obtained. At slightly higher speeds,
the balls are projected short distances across the mill, and at still higher speeds
they are thrown greater distances and considerable wear of the lining of the mill
takes place. At very high speeds, the balls are carried right round in contact with
the sides of the mill and little relative movement or grinding takes place again. The
minimum speed at which the balls are carried round in this manner is called the
critical speed of the mill and, under these conditions, there will be no resultant
force acting on the ball when it is situated in contact with the lining of the mill in
the uppermost position, that is the centrifugal force will be exactly equal to the
weight of the ball.
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Operating speed must be less than critical speed
• The speed at which the outermost balls loose contact with the wall of the mill
depends on the balance between the gravitational and centrifugal force.
• Consider a ball at point A on the periphery of the mill. Let the radii of the mill
and the ball be R and r respectively.
• The center of the ball is then at R − r distance from the axis of the mill.
• Let the ball is at an angle α with the vertical.
α R
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The two forces acting on the ball while at hanging mω2(R−r)
As long as the centrifugal force > centripetal force: the ball does not break contact with the wall
When the forces are equal, the ball falls down. So the angle at which this occur is,
At critical speed, α = 0, cos α = 1, so
mg cos m 2 R r
2 R r 4 2 n 2 R r
cos nc
1 g
g g 2 Rr
Solution:
1 g 1 9.81 1 9.81 (m s 2 )
nc nc
2 Rr 2 600 mm 37.5 mm 2 0.6 0.0375 (m)
0.664 rps 39.84 rpm
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Ex 7: What should be the maximum product sixe obtained from a feed size of 60 cm,
using a double-roll crusher having rolls of 140-cm diameter and 50-cm width of face, if
the coefficient of friction is 0.28? Compare the result when the coefficient of friction is
0.32?
Solution
tan tan 1 15.64o
Since Angle of nip = 2α = 31.28o
The space between two rolls is also same as the maximum product size. So the
maximum product size would be 0.526 m=52.6 cm
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