Particle Technology

Size Reduction Equipments

Submitted to: Mam Tajwer Sultana An Effort by: Ahmad Sharjeel (08-Chem-53) Abdul Hakeem (08-Chem-83) Ahmad Bilal (08-Chem-137) Naeem Nazir (08-Chem-63) DEPARTMENT OF CHEMICAL ENGINEERING UET LAHORE

Grinders
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It is actually a size reduction machine for intermediate duty. The product which is obtained from the crusher is often fed to grinder in which it is reduced to powder form. The size of particle should be less than 2 mm for the proper grinding.

Types of Grinders:
Hammer mills & Impactors Rolling compression mills i. Bowl mills ii. Roller mills Attrition mills Tumbling mills i. Rod mills ii. Ball mills iii. Tube mills

Hammer Mill
Principle:
In this type of grinder the feed is dropped into the top of casing it is broken and falls out of the bottom opening. Particles are broken by the sets of swing hammers connected to rotor disk.

Importance:
Hammer mills are used for fine grinding. They can grind almost every thing like tough fibrous solid, like bark or leather steel turning, soft wet paste, sticky clay, hard rock. For fine reduction of soft material hammer mill is very prominent.

Construction:
It contains cylindrical casing in which turning rotor is provided. Usually shaft is horizontal. The shaft contain several rotor disk 150 t0 450 mm (6 to 18 inch) in diameter and each carrying 4 to 8 swing hammer. The hammer may be the straight bars of metal
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with plane or enlarged end or end with sharpened cutting edge. The feed inlet is at the top and discharge outlet is at the bottom of the casing. There is anvil inside the casing around the beater and screen is provided behind the anvil. Working: First feed is dropped into the top of the casing and it is broken by sets of swing hammers connected to rotor disk. In the grinding zone the broken particles can not be escape being struck by the hammer. It shatters into the pieces which fly against a stationary anvil plate inside the casing and break into still smaller fragments. These in turn are rubbed into powder form by the hammer and pushed through a grate or screen that covers the discharge opening. Intermediate hammer mills yield a product 25 mm (1 inch) to 20 meshes in particle size. In the hammer mills for the fine reduction the peripheral speed of hammer tips may reach 110 m/s (360 Ft/sec). They reduce .1 to 15 tons per hour to size fine than 200 meshes. Commercial mill typically reduce 60 to 240 Kg of the solid per kilowatt hour of energy consumed. Applications:

Ethanol plants Grinding used shipping pallets Saw mills (size reduction of trim scrape) A farm machine Shredding paper
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Cement industry Milling grain

Advantages: Produce a wide range of particle sizes Work with any friable material and fiber Less initial purchase cost compared to roller mills Offer minimal expense for maintenance Generally feature uncomplicated operation Disadvantages: Provide less efficient use of energy compared to the roller mill May generate heat (source of energy loss) May create noise and dust pollution Produce greater particle size variability (less uniform)

Impactors
It resembles a heavy duty hammer mill but it does not contain grate or screen. In the impactor the particles are broken by impact force alone without the rubbing action (Characteristic of hammer mill).These are commonly used as primary reduction machines for rock and ores. Its working power range is up to 600 Ton/hr. The particles obtained from the Impactors are more equidimensional (more cubical) than the slab shaped particles obtained from a jaw crusher or gyratory crusher. The rotor in the impactor, as in many hammer mills may be turn in either direction to prolong the life of hammer.

Rolling Compression Machines

In this type of mill solid particles are caught and crushed between a rolling member and the face of a ring or casing. The most common types are Rolling-ring pulverizer Bowl mills Roller mills

Roller Mills
Construction:

There is a delivery device to supply a constant and uniform amount of material A pair of rolls mounted horizontally in a rigid frame One roll is fixed in position and the other can be moved closer to or further from the fixed roll The rolls counter rotate either at the same speed or one may rotate faster Roll surface may be smooth or have various grooves or corrugations Pairs of rolls may be placed on top of one another in a frame.

Working:

In the roller mill vertical cylindrical rollers press outward with great force against a stationary anvil or bull ring. They are driven at moderate speeds in a circular path. Plow lift the solid lumps from the floor of the mill and direct them between the ring and the rolls, where the reduction rakes place, product is swept out of the mill by a stream of air to a classifier separator. From which oversize particles are returned to the mill for further reduction, in a bowl mill and some roller mills the bowl or ring is driven: the roller rotate on stationary axes , which may be vertical or horizontal, mills of this kind find most application in the reduction lime stone, cement clinker, and coal. The rolls that make up a pair will be 9 to 12 inches (23 to 30.5 cm) in diameter, and their ratio of length to diameter can be as great as 4:1. It is very important to maintain the alignment between the roll pairs. Sizing of The material is dependent upon the gap between the rolls along their length. If this gap is not uniform, mill performance will suffer, leading to increased maintenance reduced output and overall increased operation costs. The gap may be adjusted manually or automatically through the use of pneumatic or hydraulic cylinders operated through a computer or programmable controller. They pulverize up to 50 ton/h. when classification is used; the product may be as fine as 99 percent through a 200-mesh screen.

Applications and Importance:

These have been used for many years for the less exacting rawmilling process, but recently roller mills, in combination with highefficiency separators, have been used for cement grinding. The
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grinding action employs much greater stress on the material than in a ball mill, and is therefore more efficient. Energy consumption is typically half that of a ball mill. However, the narrowness of the particle size distribution of the cement is problematic, and the process has yet to receive wide acceptance.

Advantages:

Energy efficient Uniform particle-size distribution Little noise and dust generation Little or no effect on fiber Particles tend to be irregular in shape and dimension May have high initial cost (depends on system design) When required, maintenance can be expensive

Disadvantages: