Ch.E.

507
PARTICULATE
TECHNONOLOGY

Serj Abalos
 SIZE
REDUCTION
 SIZE REDUCTION
Unit operation that converts
larged size particles into
smaller ones
How to reduce particle size?

COMPRESSION
ATTRITION

IMPACT
CUTTING
 COMMINUTION
• Generic term for size reduction
• Comminuting equipment: Crushers & grinders
CRITERIA:
1. Large capacity
2. Small power input per unit of product
3. Yields a product of single size or the desired size distribution
COMPRESSION
“Size can be reduced
by exerting pressure to
the particle in between
two materials”
 Coarse reduction of hard
solids.

ROLLER MILL
IMPACT
“materials will
crush, shatter, or
pulverize upon
impact”
 Gives coarse, medium or fine
products for hard, heavy and/or
abrasive materials such as glass,
stone, metals and aggregates.

HAMMER MILL
ATTRITION “sizes of materials
can be reduced by
rubbing or
through friction ”
 Ideal for producing very fine
products of considerably
same size. Generally used for
soft, non-abrasive materials.

DOUBLE-DISC GRINDER
CUTTING “materials can be
cut to an ideal size
and shape by taking
advantage of shear
deformation”

 Cutting tool must be

CUTTER harder than the material.
 SIZE REDUCTION
•Done to produce smaller particles
from larger ones
•Why smaller particles?
• Large surface area
• Size
• Shape
• Number
 SIZE REDUCTION
• Actual crusher or grinder does not yield uniform
products
• Products range from very small to the maximum
size
• Ratio of the diameters of the largest to the
smallest particle of the product is of the order
104
• Because of the intense size variation, several
averaging methods are defined
 PARTICLE SIZE
AVERAGING METHODS
DSA (ADJUSTED for size
DSA range increment)
 PARTICLE SIZE
AVERAGING METHODS
CSAS
 PARTICLE SIZE
AVERAGING METHODS
Review:

(The volume of any particle is proportional to the cube of it’s diameter)

a – volume shape factor
 PARTICLE SIZE
AVERAGING METHODS
Review:

(The volume of any particle is proportional to the cube of it’s diameter)

a – volume shape factor
 PARTICLE SIZE
AVERAGING METHODS
For a mixture of uniform particle diameter, Dp;
• Number of particles in a sample:

• Total surface area

 PARTICLE SIZE
AVERAGING METHODS
For a mixture of non-uniform particle diameter,
• Specific Surface Area – suface area of all particles per unit mass of a sample

*
 PARTICLE SIZE
AVERAGING METHODS
For a mixture of non-uniform particle diameter,
• Volume Surface Mean Diameter:

OR
 PARTICLE SIZE
AVERAGING METHODS
For a mixture of non-uniform particle diameter,
• Arithmetic Mean Diameter:

NT – total number of samples

 PARTICLE SIZE
AVERAGING METHODS
For a mixture of non-uniform particle diameter,
• Mass Mean Diameter:

• Volume Mean Diameter

 PARTICLE SIZE
AVERAGING METHODS
For a mixture of non-uniform particle diameter,
• Nw – Total Population per unit mass of sample

v
 EQPT.
POWER
REQUIRMENT
POWER REQUIREMENT
𝑃𝑜𝑤𝑒𝑟 𝑃
𝑊𝑜𝑟𝑘 = =
𝐹𝑒𝑒𝑑 𝑅𝑎𝑡𝑒 𝑚ሶ
Work is proportional to the new surface area created:
𝑃
𝑑 ∞𝐴𝑤 𝑛 (−𝑑𝐷𝑠)
𝑚ሶ

∞
𝑛
𝑃 6 𝑑𝐷𝑠
𝑑 = −k
𝑚ሶ Φs𝜌𝑝 𝐷𝑠 𝑛
POWER REQUIREMENT

a. RITTINGER’S LAW
• n=2
2
𝑃 6 𝑑 𝐷ഥ𝑠
න𝑑 = −k න
Φs𝜌𝑝 𝐷ഥ𝑠 2
𝑚ሶ
POWER REQUIREMENT

a. RITTINGER’S LAW
• Therefore:
POWER REQUIREMENT

b. KICK’s LAW
• n=1
1
𝑃 6 𝑑 𝐷ഥ𝑠
න𝑑 = −k න
Φs𝜌𝑝
𝑚ሶ 𝐷ഥ𝑠
POWER REQUIREMENT

b. KICK’s LAW
• Therefore:
 POWER REQUIREMENT
c. BOND’s LAW
• n = 3/2 3ൗ
6 𝑃 2 𝑑 𝐷ഥ𝑠
න𝑑 = −k න
𝑚ሶ Φs𝜌𝑝 𝐷ഥ𝑠 3 Τ 2

𝐾𝐵 = 100 × 103 𝑊𝑖 = 0.3162𝑊𝑖

Work Index, 𝑾𝒊 : gross energy reqt. In kWh per ton of feed needed to reduce the feed to a size where 80% of it passes the 100-micron screen. Perry’s HB 8th ed. Table 21-8.
POWER REQUIREMENT
c. BOND’s LAW
• Therefore:

Dpb is the equivalent size of the mesh wherein 80% of the feed passed through it
 PROBLEM
Bauxite is crushed in a jaw crusher and the average size of the particle
is reduced from 5 cm to the 1st crusing DSA table, with consumption of
energy at a rate of 37 Wh/ton. What will be the consumption of energy
necessary to crush the same material from the 1st crushing DSA to the
secong crushing DSA. The efficiency remains the same.
a. Using Rittinger
b. Using Kicks
c. Using Bond
MESH 𝑫𝒑, 𝒎𝒎 After 1st After 2nd
Crushing Crushing
20/28 0.2945 7.07 0
28/35 0.503 16.6 0
35/48 0.356 14.02 0
48/65 0.2515 11.82 2.32
65/100 0.1775 9.07 14.32
100/150 0.1255 7.62 13.34
150/200 0.089 33.8 70.02