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2.

Unit -introduction to solid handling systems (Size reduction, 7 lectures


operat theory behind size reduction, various equipment)
ions -screening, types of screening equipment, methods to find
associ
out size distribution of particles
ated
with -types of Solid storage (bulk storage, silos, hoppers, bins)
Power and Conveyers
plant -2nd Assignment project: Performing experiments related
to size reduction, and screening (student will use
equipment available in lab, and some experiments using
mixer grinder)
-3rd Assignment project: Experiments to evaluate the types
of flow out of silos, hoppers and bins
PPMO 4-0-4
Particulate Solids
The three most important characteristics of an individual particle are its composition, its
size and its shape.
• Composition determines such properties as density and conductivity, provided that the
particle is completely uniform. In many cases, however, the particle is porous or it may
consist of a continuous matrix in which small particles of a second material are distributed.
• Particle size is important in that this affects properties such as the surface per unit volume
and the rate at which a particle will settle in a fluid.
• A particle shape may be regular, such as spherical or cubic, or it may be irregular as, for
example, with a piece of broken glass. Regular shapes are capable of precise definition by
mathematical equations. Irregular shapes are not and the properties of irregular particles
are usually expressed in terms of some particular characteristics of a regular shaped
particle.

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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

How close the irregular particle is to a spherical particle

De = equivalent diameter = diameter of a sphere of equal volume


Sp = surface area of particle
vp = volume of particle
For a perfectly spherical particle ϕ = 1

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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:
4 
(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

(b) Sphericity of cylinder: Volume of cylinder = volume of sphere


 
so,  r 2 h  D 2 h  2.356 cm3  D3p 1 cm
4 6 Dp
3 cm
6  2.356
 De  3  1.650 cm

 D
Surface area of cylinder  D  h    11cm 2
 2
6v p 6  2.356
    0.7778
De S p 1.650 11 6
PPMO 4-0-4
(c) Sphericity of rectangular cuboid: Volume of rectangle = volume of sphere
 2
so, l  b  h  48cm3  D3p Dp
6 4
6  48 6
 Dp  3  4.51 cm

Surface area of rectangular cuboid = 2  lb  lh  bh   88cm 2
6v p 6  48
    0.725
De S p 4.51 88

7
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

Sieving (>50 μm)

Microscopic analysis (1–100 μm)

Sedimentation and elutriation methods (>1 μm)

Permeability methods (>1 μm)

Electron Microscopy (0.0005-5 µm)


Size Reduction
In the materials processing industry, size reduction or
also known as comminution is usually carried out in order
to increase the surface area because,
in most reactions involving solid particles,
the rate of reactions is directly proportional to the area
of contact with a second phase.

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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  CL2  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

Since the surface of unit mass of material is proportional to 1/L, the


interpretation of this law is that the energy required for size
reduction is directly proportional to the increase in surface.

16
For Kick’s law: p = −1
for Kick law C = K K f c , 
dE  
so  CL1  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 

• This supposes that the energy required is directly related to the


reduction ratio L1/L2
• which means that the energy required to crush a given amount of
material from a 50 mm to a 25 mm size is the same as that required to
reduce the size from 12 mm to 6 mm
• Neither of these two laws permits an accurate calculation of the
energy requirements 17
• Rittinger’s law is applicable mainly to that part of the process where
1. new surface is being created
2. holds most accurately for fine grinding where the increase in
surface per unit mass of material is large

• Kick’s law, more closely relates to


1. the energy required to effect elastic deformation before fracture
occurs
2. is more accurate than Rittinger’s law for coarse crushing where
the amount of surface produced is considerably less

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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  CL3/2
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.

Example 1: A material is crushed in a Blake jaw crusher such that the


average size of particle is reduced from 5 cm to 1.3 cm with the
consumption of energy at the rate of 37 W.hr/metric tonn. What would be
the consumption of energy needed to crush the same material of average
size 8 cm to an average size of 3 cm:
a) assuming Rittinger’s law applies?
b) assuming Kick’s law applies?

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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.

Solution: Bond’s Law:  1


P 1 
 0.3162Wi   
m  L1 
 L2
L2 = 0.03 cm L1 = 3.75

Wi = 12.74, m = 100 tons/hr

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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.

Solution: Rate of crushing = fc = 20,000 kg/hr = 20 tonn/hr


Let, E = power consumption for crushing only =E1 − E2
E1 = Power consumption by the mill during crushing
E2 = Power consumption by the mill to run it empty
So, E = (684−35) = 649 kgf.m/sec = 649/76 = 8.54 HP

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Methods of feeding Crushers

There are two distinct methods of feeding material to a crusher.

• Free Crushing: involves feeding the material at a comparatively low rate so that the

product can readily escape.

• Its residence time in the machine is therefore short and the production of appreciable

quantities of undersize material is avoided

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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.

Classification of size reduction equipment

Feed size Product size

Coarse crushers 1500–50 mm 50–5 mm

Intermediate crushers 50–5 mm 5–0.1 mm

Fine crushers 5–2 mm 0.1 mm

Colloid mills 0.2 mm down to 0.01 μm


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Grinding may be carried out either wet or dry, although wet grinding is generally

applicable only with low speed mills. The advantages of wet grinding are

(a) The power consumption is reduced by about 20–30 per cent.

(b) The capacity of the plant is increased.

(c) The removal of the product is facilitated and the amount of fines is reduced.

(d) Dust formation is eliminated.

(e) The solids are more easily handled.

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TYPES OF CRUSHING EQUIPMENT
Coarse crusher
Intermediate crusher
•Blake jaw crusher
•Crushing rolls Fine crusher
•Dodge jaw crusher

•Gyratory crusher •Disc crusher


•Roller mill
•Edge runner mill
•Ball mill
•Hammer mill
•Tube mill
•Single roll crusher
•Ring roller mill
•Pin mill
•Hardinge mill
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Coarse Crushers

(i) Blake Jaw Crusher

(ii) Dodge Jaw Crusher

(iii) Gyratory Crusher

(iv) Other Coarse crushers

Rotary coal breaker

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(i) Blake Jaw Crusher

Typical cross-section of Stag jaw crusher


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(i) Blake Jaw Crusher
• The Stag jaw crusher has a fixed jaw and a moving jaw pivoted at the top
with the crushing faces formed of manganese steel.
• maximum movement of the jaw is at the bottom (minimum at the top),
there is little tendency for the machine to clog.
• maximum pressure is exerted on the large material which is introduced at
the top.
• The speed of operation should not be so high that a large quantity of fines
is produced as a result of material being repeatedly crushed because it
cannot escape sufficiently quickly.
• The angle of nip, the angle between the jaws, is usually about 30◦.
• The power requirements of the crusher depend upon size and capacity and
vary from 7 to about 70 kW, at a feed rate of 10 kg/s.
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(ii) Dodge Jaw Crusher

The Dodge jaw crusher 33


(ii) Dodge Jaw Crusher
•In the dodge jaw crusher, the moving jaw is pivoted at the bottom.
•The minimum movement is thus at the bottom and a more uniform product is
obtained.
•The crusher is less widely used because of its tendency to choke.
•The large opening at the top enables it to take very large feed and to effect a
large size reduction.

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
37
(iv) Other coarse crushers

• Friable materials, such as coal, may be


broken up without the application of
large forces, and therefore less robust
plant may be used.
• A common form of coal breaker consists
of a large hollow cylinder with
perforated walls.
• The coal breaks by impact and passes
through the perforations as soon as the
size has been sufficiently reduced. Rotary coal breaker

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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.

• Material is fed in, either at the top or at the


centre, and it is thrown out centrifugally
and crushed by being beaten between the
hammer bars, or against breaker plates
fixed around the periphery of the
cylindrical casing.
• The material is beaten until it is small
enough to fall through the screen which
forms the lower portion of the casing.
• Since the hammer bars are hinged, the presence of any hard material does not cause
damage to the equipment.

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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

• For steel rolls, the angle of nip


is not greater than about 32◦.
• Crushing rolls are extensively used for crushing oil seeds and in the
gunpowder industry and they are also suitable for abrasive materials. They
are simple in construction and do not give a large percentage of fines

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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.

Solution: Angle of nip = 30o = 2α cos   r1  b


r1  r2
2b = space between the rolls
50  0.625
so, cos15o   r2  2.41 cm  Maximum permissible size of feed = 4.82 cm dia
50  r2

Theoretical capacity of a set of crushing rolls is q = 60×2b×πND×w


q = volumetric capacity (cm3/hr); 2b = roll spacing, cm
N = rpm; D = roll diameter
w = width face

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So, q = 60 × 1.25 × (π × 100 ×100) × 38 = 8.954 × 107 cm3/hr

Density of material = ρs = 2.35 gm/cm3

8.954 107  2.35


Theoretical capacity= q × ρs =  210.4 tonn/hr
6
10
Actual capacity = 12% of the theoretical capacity
Hence, actual capacity of the rolls = 25.25 tons/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.

52
(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.

53
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.

54
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

55
The two forces acting on the ball while at hanging mω2(R−r)

Gravitational force = Centrifugal force


r
Centrifugal force
α
R  r R
mg
 m 2
where  (rad/s)  2 n, n = rotational speed
The component of the gravitational force

mg cos  = opposes the centrifugal force

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 Rr

The speed of ball mill is 60-80% of critical speed


NOTE: The ratio of tangential force to the normal force is the coefficient of friction.
So tanα = µ (where µ is known as the coefficient of friction) 56
Example 6: What rotational speed , in rpm, would you suggest for a
ball mill 1200 mm diameter charged with 75 mm balls.

Solution:

1 g 1 9.81 1 9.81 (m s 2 )
nc   nc  
2 Rr 2 600 mm  37.5 mm 2 0.6  0.0375 (m)
 0.664 rps  39.84 rpm

Rotational speed = 80% of nc

So, recommended nc = 39.84 × 0.8 = 31.872 rpm

57
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

For a roll crusher cos   r1  b  cos15.64  0.7  b


r1  r2 0.7  0.3
 b  0.262
 2b  0.526  space between rolls

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

Similarly find the out taking µ = 0.32


Advantages of the ball mill
(i) The mill may be used wet or dry although wet grinding facilitates the removal of
the product.
(ii) The costs of installation and power are low.
(iii) The ball mill may be used with an inert atmosphere and therefore can be used
for the grinding of explosive materials. Why?
(iv) The grinding medium is cheap.
(v) The mill is suitable for materials of all degrees of hardness.
(vi) It may be used for batch or continuous operation.
(vii) It may be used for open or closed circuit grinding. With open circuit grinding,
a wide range of particle sizes is obtained in the product. With closed circuit grinding,
the use of an external separator can be obviated by continuous removal of the product
by means of a current of air or through a screen.
Forces on the Crushers
Crusher
(Compression is the characteristic action of all crushers)

Coarse Crusher Jaw Crusher − Compression


Gyratory crusher − Compression, impact

Intermediate Crusher Smooth roll Crusher− Compression

Tooth Roll Crusher−compression, Impact and shear


Hammer mill−Impact

Fine Crusher Roller mill− Compression


Ball mill−Attrition

60

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