FLUID FLOW

Mechanical Size Reduction

Asst.Prof.Dr. Sirirat Wacharawichanant
Department of Chemical Engineering
Faculty of Engineering and Industrial Technology
Introduction to Size Reduction
The ways in which particles of solids are cut or
broken into smaller pieces.
Many solid materials occur in sizes that are too large Many solid materials occur in sizes that are too large
to be used and must be reduced.
Solids may be broken in many different ways, but
only four are commonly used in size reduction
machine: compression, impact, attrition or rubbing,
cutting.
A t ke h mme file d i f he
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A nutcracker, a hammer, a file and a pair of shears.
Sometime size reduction results from the attrition of
a particle by one or more other particles or from
intense shear in the supporting fluid.
Introduction to Size Reduction
Compression or crushing is used for coarse reduction
of hard solids, to give relatively few fines.
Impact gives coarse medium or fine products
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Impact gives coarse, medium, or fine products.
Attrition yields very fine products from soft,
nonabrasive materials.
Cutting gives a definite particle size and sometimes a
definite shape.
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Equipments for Size
Reduction
Classification of Equipment
Size reduction equipment is divided into crushers,
grinders, fine grinders and cutters.
These machines do their work in distinctly different These machines do their work in distinctly different
ways.
Compression is the characteristic action of crushers.
Grinders employ impact and attrition, sometimes
combined with compression; fine grinders operate by
attrition.
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A cutting action is of course characteristic of cutters,
dicers and slitters.
Jaw Crushers
Crushers are slow-speed machines
for coarse reduction of large
quantities of solids.
The main types are jaw crushers The main types are jaw crushers,
gyratory crushers, smooth-roll
crushers and toothed-roll
crushers.
The material is fed between two
heavy jaws or flat plates.
One jaw is fixed and the other
reciprocating and movable on a
i i h b
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pivot point at the bottom.
The jaw swings back and forth,
pivoting at bottom of the V.
The material is worked down into a
narrow space, being crushed as it
moves.
Dodge type.
Jaw Crushers
The pivot point is at the top of the
movable jaw.
Jaw crushers are used mainly for
primary crushing of hard materials
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primary crushing of hard materials
and are usually followed by other
types of crushers.
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Blake type.
Dodge Crusher
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Gyratory Crushers
It has to a large extend taken over in the field of large hard-ore and
i l hi li ti
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mineral crushing applications.
The movable crushing head is shaped like an inverted truncated cone
and it inside a truncated cone casting.
The crushing head rotates eccentrically and the material being crushed
is trapped between the outer fixed cone and the inner gyrating cone.
Roll Crushers
The rolls are rotated toward
each other at the same of
different speeds.
f h ll Wear of the rolls is a serious
problem.
The reduction ratio varies
from about 4:1 to 2.5:1.
Single rolls are often used,
rotating against a fixed
surface, and corrugated and
toothed rolls are also used.
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Smooth-roll crusher.
Single Roll Crusher
The single roll crusher
consists of a toothed
crushing roll which rotates
close to the breaker plate close to the breaker plate.
The material is crushed by
compression and shearing
between the two surfaces.
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Rotary Coal Breaker
A common form of coal breaker
consists of a large hollow
cylinder with perforated walls.
h ll l The axis is at a small angle to
the horizontal and feed is
introduced at top.
The cylinder is rotated and coal
is lifted by means of arms
attached to the inner surface
and then falls against the
cylindrical surface.
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The coal breaks by impact and
passes through the perforations
as soon as the size has been
sufficiently reduced.
Swing Claw Hammer Mill
The hammer mill is an impact
mill employed a high speed
rotating disc, to which are fixed
a number of hammer bars which a number of hammer bars which
are swung outward by
centrifugal force.
Material is fed in, either at the
top or centre, and is thrown out
centrifugally and crushed by
being beaten between the
hammer bars, or against breaker
plates fixed around the
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plates fixed around the
periphery of cylindrical easing.
The material is beaten until it is
small enough to fall through the
screen which forms the lower
portion of the easing.
Alpine Pin Mill
It is a form of pin mill and
consists of two horizontal steel
plates with vertical projectors
on their near faces on their near faces.
The upper disc is stationary
whist the lower disc is rotated at
high speed.
Material is fed in through a
hopper to the centre of the
upper disc, and is thrown
outwards by centrifugal action
d b k h
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and broken against the
projections
The mill gives a fairly uniform
fine product.
Alpine Universal Mill
The Alpine universal mill with
turbine beater and grinding
track is suitable for both brittle
and tough materials and tough materials.
The high airflow from the
turbine keeps the temperature
rise to a minimum.
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Grinders
The term grinder refers to a variety of size reduction
machines for intermediate duty.
Product from a crusher is often fed to a grinder for Product from a crusher is often fed to a grinder for
further reduction.
Commercial grinders are hammer mills and
impactors, rolling-compression machines, attrition
mills and tumbling mills.
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Impactor
A impactor resembles a
heavy-duty hammer mill
except that it contains no
grate or screen.
Particles are broken by
impact alone, without the
rubbing action characteristic
of a hammer mill.
Impactors are often primary
reduction machines for rock
and ore processing up to
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and ore, processing up to
600 tons/h.
The rotor in an impactor, as
in many hammer mills, many
be run in either direction to
prolong the life of hammers.
Attrition Mills
In an attrition mill particles
of soft solids are rubbed
between the grooved flat
faces of rotating circular
disks.
In a single-runner mill one
disk is stationary and one
rotates; in a double-runner
machine both disks are
driven at high speed in
opposite directions.
Feed enters through an
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Feed enters through an
opening in hub of one of
disks; it passes outward
though the narrow gap
between disks and discharge
from the periphery into a
stationary casting.
Conical Ball Mill
Feed enters from the left
through a 60 cone into the
primary grinding zone, where
diameter of shell is a d a ete o s e s a
maximum.
Product leaves through 30
cone to the right.
A mill of this kind contains
balls of different sizes, all of
which wear and become
smaller as mill is operated.
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Ch i i f S lid Characterization of Solid
Particles
Particle Shape
The shape of an individual particle is conveniently
expressed in terms of sphericity u
s
, which is independent
of particle size. For a spherical particle of diameter Dp, p p p p,
us=1; for a nonspherical particle, the sphericity is defined
by the relation
(5-1)
p p
p
s
s
D 6
v
= u
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D
p
: Nominal diameter of particle
s
p
: Surface area of one particle
v
p
: Volume of one particle
Mixed Particle Size and Size Analysis
In a sample of uniform particles of diameter D
p
the total
volume of the particles is m/
p
, where m and
p
are the
total mass of the sample and the density of particles. Since
the volume of one particle is v
p
, the number of particles in
sample N is
p p
m
N
v
=
(5-2)
The total surface area of the particles is
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The total surface area of the particles is
p p s
p
D
m 6
Ns A
u
= = (5-3)
Specific Surface of Mixture
If the particle density
p
, and sphericity u
s
, are know,
the surface area of the particles in each fraction may be
calculated from Eq.(9-2) and results for all fractions
dd d t i A th ifi f If d u added to give A
w
, the specific surface. If
p
, and u
s
, are
constant, A
w
is given by
(5-4)
3 p
p s
3
2 p
p s
2
1 p
p s
1
w
D
x 6
...
D
x 6
D
x 6
A
u
+ +
u
+
u
=
(5-5)
=
n
i
x 6
A
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( )

= u 1 i
pi
p s
w
D
A
x
i
: Mass fraction in a given increment
n : Number of increment
D
pi
: Average particle diameter
Average Particle Size
The average particle size for a mixture of particles is
defined in several different ways. The volume-surface
mean diameter D
s
is related to the specific area A
w
.
(5-6)
Substitution Eq.(9-5) in Eq.(9-6) gives
p w s
s
A
6
D
u
=
6
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(5-7)
( )
=
=
n
1 i
pi i
s
D x
6
D
Average Particle Size
Other average are sometimes useful. The arithmetic
mean diameter D
N
is
(5 8)
n
i
n
i D N D N
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(5-8)
The mass mean diameter D
w
is found from the equation
T
1 i
pi
i
n
1 i
i
1 i
pi
i
N
N
D N
N
D N
D

=
=
=
= =
n
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(5-9)

=
=
n
1 i
pi
i
w D x D
Average Particle Size
The volume mean diameter D
V
is
3 1
(
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(5-10)
( )
n
1 i
3
pi
i
V
D x
1
D
(
(
(

=
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Particle Size Analysis
The feed-to-size reduction processes and the
product are defined in terms of particle-size
distribution.
A particle size analysis is tabulated to show the mass
or number fraction in each size increment as a
function of the average particle size (or size range). It
is called a differential analysis.
A second way to present the information is a
cumulative analysis obtained by plotting the
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cumulative analysis obtained by plotting the
cumulative sums against the particle size.
Particle Size Analysis
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Particle size distribution for powder.
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Differential analysis. Cumulative analysis.
Screen Analysis
Standard screens are used to measure the size and
size distribution of particles in the size range.
Testing sieves are made of woven wire screens the Testing sieves are made of woven wire screens, the
mesh and dimensions of which are carefully
standardized.
The openings are square.
Each screen is identified in meshes per inch.
In making an analysis, a set of standard screens is
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arranged serially in a stack, with the smallest mesh at
the bottom and the largest at the top.
The sample is placed on the top screen and the stack
shaken mechanically for a definite time.
Screen Analysis
The particles retained on each screen are removed
and weighed, and the masses of the individual screen
increments are converted to mass fractions or mass
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percentages of the total sample.
Any particles that pass the finest screen are caught in
a pan at the bottom of the stack.
The results of a screen analysis are tabulated to show
the mass fraction of each screen increment as a
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the mass fraction of each screen increment as a
function of the mesh size range of the increment.
Screen Analysis
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