Crushing Theory

Crushing Theory

• When solid particles of feed material are being reduced in size, they are first
distorted by straining and mechanical energy is stored in the solid in a similar
manner to energy stored in a coil spring.
• As more energy is applied, the material is distorted beyond their ultimate
strength, thus causing them to rupture and thereby creating new surface.
• Since a unit area of a solid has a definite amount of surface energy, the
creation of new surface requires energy which is released as the particle
breaks.
• Energy used in crushing is measured in terms of new surface produced.
Crushing Theory

• By the law of conservation of energy, all energy in excess of that required

to create new is converted into heat.
• Efficiency of crushing is the ratio of the surface energy created to the
energy absorbed by the solid.
• Crushing efficiencies are low, ranging from 0.1 to 2%, but the accuracy of
the calculations is poor due to the uncertainties in determining surface
area.
Crushing Theory

• The amount of power required for crushing is a major consideration in

selecting crushing equipment.
• The greatest problems lies is the fact that most of the energy input to a
crushing and grinding is absorbed by the machine itself, and only a small
fraction of the total energy is available for breaking the material.
• All the theories of comminution assume that the material is brittle, so that
no energy is absorbed in the process such as elongation or contraction
which is not finally utilized in breakage.
Rittinger’s Law

• It states that the work required in crushing is proportional to the new

surface created.
• The surface area of a known weight of particles of uniform diameter is
inversely proportional to the diameter, hence Rittinger's law equates to;
𝑊 1 1
=K −
𝑇 𝐷𝑝 𝐷𝑓
Where: W is the Hp required, T is the feed rate in tpm, and Df and Dp are the
mean volume surface diameters of the feed and product .
Rittinger’s Law

• This law applies reasonably well under conditions where energy input per
unit mass of solids is not great. It can be used as a first approximation to
calculate the energy required for an actual crushing processes where the
constant K is determined experimentally in a test on a machine of the type
to be used and with the material to be crushed.
Bond’s Law

• This law states that the total useful work required to reduce in size very large particles of
feed is inversely proportional to the square root of the diameter of the product particles.
• Bond’s law is written as:
10 𝑊𝑖 10𝑊𝑖
𝑊= −
𝑃 𝐹
Where:
W is the gross power input in kwp per ton, F and P are the square-mesh aperatures in
passing through which 80% of the feed and the product pass, and Wi is a work index or
comminution parameter expressed as the gross power in kwh required to reduce one ton
of material from a size to 80% passing 100 microns square mesh aperature.
Bonds Law

• The work index is the comminution parameter which expresses the

resistance of the material to crushing and grinding; numerically it is the
kilowatt hours per short ton required to reduce the material from
theoretically infinite feed size to 80% passing 100 microns.
• Representative screen analyses of the feed and crushed product of a
coarse crushing operation are difficult to obtain. Samples vary widely with
the character of the material, condition of the mine or quarry, and the
amount of finished size material contained in the feed at the time the
sample was taken.
Bond’s Law

• The 80% passing size of the product may be calculated from the following
Bond equation:
𝑃 in. = 𝑶33 𝑋 0.04 𝑊𝑖 + 0.40
In which the characteristics of the material are taken into consideration by
the work index factor Wi and O33, the open side setting of the crusher at the
bottom of the crushing chamber in inches.
Bond’s Law

• As the feed and product sizes of coarse crushers are large and usually
measured in inches the given constants may be substituted and equation
as follows:
1 1
𝑀𝑜𝑡𝑜𝑟 𝑖𝑛𝑝𝑢𝑡 ℎ𝑝 = 𝑇 𝑥 𝑊𝑖 𝑥 0.084( − )
𝑃 𝐹

In which T is the feed rate in short tons per hour, Wi in the work index is the
constants from the table given, and F and P are the square mesh aperature
sizes in inches through which 80% of the feed and product will pass.
Work Indices of Common Rocks
Material Work Index, Wi
andesite 18.25
basalt 17.10
bauxite 8.78
coal 13.0
Copper ore 12.73
dolomite 11.27
gabbro 18.45
granite 15.13
hematite 12.87
Nickel ore 13.65
Trap rock 19.32