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COMMINUTION
By:
Engr: Raheel Memon

Department of Mining Engineering, MUET.

 Sampling
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 Sampling: The removal of a convenient part from

the bulk of the material for testing.
 Sampling
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 Objective of sampling in mineral processing is to estimate

grades and contents of Ore with an acceptable and affordable
degree of precision.
 It should be done before the material is subject to grind or

crushed in the mill.

 The samples should be totally representative of the bulk

material.
Purpose Of Sampling:
1. To have information of the feed ore for its further treatment.
2. To make the process more efficient.
3. To calculate recovery and losses.
4. To understand methods to improve recovery and reduce losses.
 Sampling
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Errors Reduction can be made by;

1. Appropriate methods and quantities of sampling to be done.
2. Samples should be taken at the appropriate points of
operation.
3. Automatic sample cutters may be used.
4. Larger samples at prefixed intervals may be collected.
5. The larger size samples may be reduced to intermediate sizes.

Types of Error:
1. Accidental- cannot be predicted.
2. Systamatic- leads to cummulative errrors
3. Observation – misreading a signal or a measuring index,
4. Personal – carelessness.
 Sampling
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 Sampling Division Methods
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 Some of the common methods of sample divisions

are;
1. Grab Sampling.
2. Coning and Quartering.
3. Table Sampling
4. Sample splitter.
 1.Grab Sampling
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 This is the simplest quickest, and most flexible method, as it can

be carried out on small quantities using spatulas, or on large
quantities using shovels, and can divide the material into many
samples are desired.
 The material is first homogenized by thorough mixing on a
rolling mat.
 then divided into samples randomly, grabbing small amounts
from the homogenized pile on the cloth.
 2. Coning and Quartering
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 This method is well suited for large lots of material, and can be
conveniently done by shovels.
 First material is mixed, and transformed into uniform conical
pile, then tip of the cone flattened.
 Then divided into quarters using perpendicular boards.
 One pair of opposite quarters is removed, then other pair
used as a sample.
 2. Coning and Quartering
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 3. Table sampler
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 4. Sample Splitter
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 Sample Splitters: These are often called riffle or chute splitters.

 This consists a series of chutes that run in alternating direction,
so that when material is poured into the top of the splitter, it
flows through the chutes and is randomly divided into equal
sized fractions.
 One of the fraction can be split again, and the procedure
repeats until the required size is obtained.
 3. Sample splitter
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 John Riffle Splitter

 COMMINUTION
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 Comminution in the mineral processing plant or mill,

takes place as a sequence of crushing and grinding
processes.
 Crushing reduces the particle size of ROM ore to such a
level that grinding can be carried out until the mineral
and gangue are separated.
 Crushing is accomplished by Compression and impact of
ore against rigid surfaces.
 Grinding is accomplished by Abrasion/Attrition and
impact of the ore by the free motion of unconnected
media, such as rods, balls or pebbles.
 COMMINUTION
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 Crushing is usually a dry processes, and is

performed in several stages, with small reduction
ratio from 3-6 (3:1 to 6:1) in each stage.

 Reduction ratio: The ratio of Feed to discharge size

particles in crusher.

 Grinding is usually performed “Wet” to provide a

slurry feed to the concentration process, although
Dry grinding has limited application.
 COMMINUTION
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 Objectives of Size Reduction:

1. Reduction of large lumps into small pieces.
2. Production of solids of desired size ranges or
specific surfaces.
3. Liberation of valuables from gangue.
4. Convenience in handling and transportation.
5. Preparation of feed material for different ore
processing methods
 COMMINUTION
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 Stages Of Size Reductions:

Explosive Shattering Reduce to -1m

Primary Crushing From -1m to 100mm
Secondary Crushing From -100mm to 10mm
Coarse Grinding From -10mm to 1mm
Fine Grinding From -1mm to 100m
Very Fine Grinding From -100m to 10m
Super Fine Grinding From -10m to 1m
 COMMINUTION
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 Primary Crushers:
1. Jaw Crusher.
2. Gyratory Crusher.
3. Hammer mill crusher.
 Secondary Crushers:
1. Cone Crusher &
2. Roll Crusher.
 Grinding mills or Machine:
1. Ball mill,
2. rod mill, Tumbling mills
3. Tube mills,
4. SAG Mill 50% efficient than conventional Ball mills
5. Stirred mill 20-50 % efficient than conventional cruhers and mills
5. HPGR (High pressusre grinding rolls), etc
 Principles/Mechanism of Comminution
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 Most minerals are crystalline materials in which the atoms are

regularly bonded and arranged in three dimension arrays.
 These bonds are effective only over small distances/
displacement, and it can be broken if extended by tensile
stress.
 Such stresses may be generated by tensile or compressive
loading.
 Principle of Comminution
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 The distribution of stress depends upon the

mechanical properties of the individual minerals.
 It has been shown that the increase in stress at such
a site/location is directly proportional to the
square root of the crack length perpendicular to the
stress direction. (Inglis, 1913)
 Principles of Comminution
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 Under loading, Crystals can store energy without

breaking, and release this energy when stresses is
removed. Such behavior is known as elastic.
 When fracture does occur, some of the stored energy is
transformed into free surface energy, which is the
potential energy of atoms at newly produced surfaces.
 Principles of Comminution
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 Real particles are irregularly shaped, and loading

is not uniform, but is achieved through points or
small areas of contact.
 Breakage is achieved mainly by crushing, impact
and attrition.
 All three modes of fracture (compressive, tensile
and shear) depends on the rock mechanics and type
of loading.
 Comminution Theory
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 Comminution theory is concerned with the relation-

ship between energy input and the particle size
made from a given feed size.
 The greatest problem lies in the fact that, most of
the energy input to a crushing or grinding machine
is absorbed by the machine itself.
 Only small fraction of the total energy is available
for breaking the material.
 In Ball mill, less than 1% of the total energy input is
available for actual size reduction, the remaining
being utilized in the production of heat.
 Comminution Theory
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 Another factor is that a material which is plastic will

consume energy in changing shape , a shape which
it will retain without creating significant new
surfaces.

 All theories of comminution assume that the material

is brittle, so that no energy is adsorbed in processes,
such as elongation or contraction which is not finally
utilised in breakage.
 Comminution Theory
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Rittinger’s Law (1867):

 The oldest theory states that; the energy consumed
in size reduction is directly proportional to the new
surface area produced.
 The surface area of known weight of particles is
inversely proportional to the diameter of particles.
1 1
𝐸 = 𝑘 −
𝐷2 𝐷1
 Where; E = Energy input
D1 = Initial particle size
D2 = Final particle size
k = Constant
 Comminution Theory
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Kick’s Law (1885):

 He stated that “The work required is proportional to

the reduction in the volume of particles concerned.

 The energy required for comminution is proportional
to log to (LogR /Log2).

 Where; R = Reduction ratio (R=f/p)

f = feed size
p = Product size
 Comminution Theory
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Bond’s Theory (1952):

 The work input is proportional to the new crack tip
length produced in particle breakage.
 In particles of similar shape, “The surface area of unit
volume of material is inversely proportional to the
diameter”.
1 1
𝑊 = 10𝑊𝑖 −
𝑃 𝐹
 Where; W = Work input in kwh/short ton
Wi = Work index
P = Product size (80% Passing 100m)
F = 80% Passing Feed size (m)
 Comminution Theory
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Hukki’s Law (1975):

 He suggests that the relationship between energy and
particle size is a composite form of the three laws.
 The probability of breakage in comminution is high for
large particles, and rapidly diminishes for fine sizes.

 He shows that:
1. Kick's law is reasonably accurate in the crushing
range above about 1 cm in diameter.
2. Bond’s Theory applies reasonably in the range of
conventional rod and ball mill grinding.
3. Rittinger's law applies fairly well in the fine grinding
range of 10-1000m.
 Comminution Theory
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 On the basis of Hukki's evaluation, Morrell (2004) has

proposed a modification to Bond's equation.
𝐾𝑀𝑖 𝐾𝑀𝑖
𝑊 = 𝑓(𝑃) − 𝑓(𝐹)
𝑃 𝐹
 where
Mi = the material index related to the breakage
property of the ore
K = a constant chosen to balance the units of the
equation.
 The application of the new energy-size relation has been
shown to be valid across the size range covered by most
modern grinding circuits, i.e. 0.1-100mm
 Grindability
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 Ore grindability is defined as “Ease with which

materials can be comminuted.”
 The data from grindability tests are used to evaluate
crushing and grinding efficiency.
 Probably the most widely used parameter to measure
ore grindability is the Bond work index Wi.
 If the breakage characteristics of a material remain
constant over all size ranges, then the calculated work
index would be expected to remain constant.
 However, for most naturally occurring raw materials,
differences exist in the breakage characteristics
depending on particle size, which can result in
variations in the work index
 Grindability
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 For instance, when a mineral breaks easily at the

boundaries. but individual grains are tough, then
grindability increases with fineness of grind.
 Consequently work index values are generally obtained
for some specified grind size.
 Grindability
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 Example#01: Calculate the work input and

reduction ratio of the crusher, crushed the bauxite
ore; if
 Workindex of bauxite = 8.78
 80% passing of feed size = 50.8mm
 80% passing of product size = 3.175mm.
 Grindability
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 Example#02: Limestone is subject to ground in ball

mill which is mounted at the processing plant. The work
index of material is 12 and average size fraction of
feed is 50.8mm. The analysis of product from mill are
as follow,
Size fraction: (mm) Weight (g) Weight (%) Cumulative wt: (%)
3.65 0.2 20 20
1.76 0.3 30 50
0.87 0.3 30 80
0.44 0.15 15 95
0.22 0.05 5 100

 Calculate work input of limestone by using bond’s

equation?
 Grindability
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 Example#03: Rock goes through the two successive

grinders mounted at the plant, which draws a total
power input of 15kwh/t. The average feed size of
50.8mm. Calculate the work index of rock and work
input of each grinders separately? The analysis of the
product from the two grinders shown in plots;
4 0.5
0.45
y = -0.18ln(x) + 0.8483

Size Fraction (mm)

3.5
y = -2.08ln(x) + 9.8962
Size Fraction (mm)

0.4
3
0.35
2.5 0.3
2 Primary Grinding 0.25 Secondary Grinding
1.5 0.2
0.15
1
0.1
0.5 0.05
0 0
0 20 40 60 80 100 120 0 20 40 60 80 100 120

Cummulative Mass Passing (%) Cummulative Mass Passing (%)