MECHANICAL SIZE REDUCTION

GROUP MEMBERS :
KHAIRU
L AZWAN BIN MOHAMED DAUD (2011887244)
MOHD ADIE FIQRIE BIN MARIUS (2014295054)
MUHAMMAD NUR AKMAL BIN MOHAMMAD (2014211422)
MUHAMMAD AZIZI BIN MOHD ZULKIFLI (2014248582)

14.5A INTRODUCTION TO MECHANICAL SIZE REDUCTION

Purpose
To reduce the size of the solid particles before being used .
To carried out separation of various ingredients
Crushing & Grinding
General term for diving large solid particles to smaller particles.

Crushing & Grinding technique

 Applications
Food processing industry
Roller mills to grind wheat and corn
Grinding soybeans to produce oil and flour
Hammer mills to produce potato flour, tapioca

Roller Mill for food processing

 Ore processing and cement mills industries

Grinding of copper, nickel and cobalt ores
Lime, alumina, and silica are ground as for
cement raw materials

Grinding in cement industry

Methods
Compression or crushing ( Hard solids to coarses sizes)
Impact for coarse, medium, or fine sizes
Attrition or Rubbing for fine products
Cutting for definite sizes

Particle-size Measurement

 The feed-to-size reduction processes and the product are defined in

terms of the particle-size distribution.
To plot particle sizes particle diameter vs the cumulative percent
retained at that size.
Example :-

 As the cumulative amount as percent smaller than the stated size

versus particle size :-

(A)Cumulative percent versus particle size

 The same data are plotted as a particle-distribution curve :-

(B)percent by weight per m versus particle size

The ordinate is obtained by taking the slopes of the 5-m intervals of
figure A and converting to percent by weight per m
Complete particle-size analysis is necessary for most comparisons
and calculations.

Energy and Power Required in Size

Reduction

Introduction
In reducing the size of solids, mechanical action are needed.
The feed particles are distorted and strained by the action of size-reduction machine.
The energy to strain the particles are first stored temporarily in the solids as strain energy.

 As additional force is added to the stressed particles, the strain energy exceeds, and
material fractures.

 New surface area is created when materials fractures.

Each unit area requires a certain amount of energy.
Some of the added energy is used to create new surface, a large portion of it appears as
heat.

Factors affecting the extent of size-reduction process

The magnitude of the mechanical force
The duration
The type of force
Compression force
Shear force
Impact
Important factors in this process include the amount of energy or power used and the
particle size and new surface formed.

Power required in size reduction

There are theories that are derived based upon the assumption that energy, E required to
produce a change dX in a particle of size X. This include;

Where X is size or diameter of particle in mm, and n and C are constants depending upon
type and size of material and type of machine.

Rittingers proposed law

Rittinger proposed a law which states the work in crushing is
proportional to the new surface created.
From the previous equation, integrate it.

X2 is mean diameter of feed and X2 is mean diameter of product.

n=2, we get;

Kicks equation
Kick assumed that the energy required to reduce a material in size
was directly proportional to the size-reduction ratio.
Implying n=1 from equation 14.5-1;

Where KK is a constant

Bonds equation
Recent data by Bond(B3) on correlating exensive experimental data suggest that work
required using large-size feed is proportional to square root of the surface/volume ratio of
product.
Implying n=1.5;

Where KB is a constant.

 To use Eq. 14.4-5, Bond proposed a work index(kW.h/ton) needed

to reduce from 100% to 80% passing a 100 micro meter.
E = gross work required to reduce a unit weight of feed with 80%
passing diameter XF to a product with 80% passing Xp.
Bonds final equation will be;

Where P = hp, T = feed rate (tons/min) and DF = feed size (ft).

JAW CRUSHER

HAMMER MILL
GRINDERS

EQUIPMENT FOR SIZE

REDUCTION

ROLL CRUSHER

GRYATORY
CRUSHER

J AW C R U S H E R

A jaw or toggle crusher consists of a set of vertical jaws, one jaw being fixed and the other being
moved back and forth relative to it by a cam or pitman mechanism.
The jaws are farther apart at the top than at the bottom, forming a tapered chute so that the
material is crushed progressively smaller and smaller as it travels downward until it is small
enough to escape from the bottom opening.
Jaw crushers commonly used in mines and in quarries.
Theres are few types of jaw crushers which are classified based on the basis position of the
pivoting of the swing jaw :
1. Blake crusher-the swing jaw is fixed at the upper position
2. Dodge crusher-the swing jaw is fixed at the lower position

J AW C R U S H E R

Types of jaw crushers:

1. Blake Jaw Crusher:
In the Blake or jaw crusher the moveable is pivoted at top. The gretest amount of motion is
at the bottom which means it has the little tendency to choke.

J AW C R U S H E R

2. Dodge Jaw Crusher

In the dodge jaw crusher the moving jaw is pivoted at the bottom. as minimum movement is
at the bottom it has a greater tendency to choke.

J AW C R U S H E R

Principle Of Jaw Crusher

This jaw crusher uses motor as its power. Through the motor's wheels, the eccentric shaft is
driven by the triangle belt and slot wheel to make the moveable jaw plate move by a regulated
track. Therefore, the materials in the crushing cavity composed of fixed jaw plate, moveable jaw
plate and side-lee board cn be crushed and discharged through the discharging opening.

Working Of Jaw Crusher

G YR AT O R Y C R U S H E R

A gyratory crusher have the similar concept as jaw crusher. It consisting of a concave surface
and a conical head and 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.
Material is fed through a feed plate that distributes the particles evenly into the chamber between
the mantle and the concave casing. The mantle oscillates, causing a decrease in the volume
between the mantle and the concave casing and crushing the material. The crushed material then
exits freely from the apparatus.
A gyratory crusher is one of the main types of primary crushers in a mine or ore processing
plant.

G YR AT O R Y C R U S H E R

Principle Of Gyratory Crusher

1. 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.
2. 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.
3. The gap is opened and closed by an eccentric on the bottom of the spindle that causes the
central vertical spindle to gyrate.
4. 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.

G YR AT O R Y C R U S H E R