Example 2.1 A material is crushed in a Blake jaw crusher such that the average size of particle is reduced from 50 mm to 10 mm with the consumption of energy of 13.0 kW/(kgis). What would be the consumption of energy needed to crush the same material of average size 75 mm to an average size of 25 mm: a) assuming Rittinger’s law applies? 'b) assuming Kick’s law applies? Which of these results would be regarded as being more reliable and why? Solution a) Rittinger’s law. This is given by: E = Kg f.l(1/L2) — (1/L)) (equation 2.3) ‘Thus: 18.0 Kg f.l(1/10) — 1/50)] and: Ka f. = (13.0 x 50/4) = 162.5 kWikg mm) Thus the energy required to crush 75 mm material to 25mm is: 162.5[(1/25) — (1/75)] = 3 kik. b) Kick's law. This is given by: E= Keg f.ln(Li/L2) (equation 2.4) Thus: 13.0 = Kx f.In(50/10) and: Kx fo = (13.0/1.609) = 8/08 kW/(kg/s) ‘Thus the energy required to crush 75 mm material to 25 mm is given by: E = 8.08 In(75/25) = 8.88 kW/ke. ‘The size range involved by be considered as that for coarse crushing and, because Kick’s law ‘more closely relates the energy required to effect elastic deformation before fracture occurs, this would be taken as given the more reliable result. Example 2.2 If crushing rolls, 1 m in diameter, are set so that the crushing surfaces are 12.5 mm apart and the angle of nip is 31°, what is the maximum size of particle which should be fed to the rolls? Tf the actual capacity of the machine is 12 per cent of the theoretical, calculate the throughput in kg/s when cunning at 2.0 Hz if the working face of the rolls is 0.4 m long and the bulk density of the feed is 2500kg/m*.Solution ‘The particle size may be obtained from: cose = (n+ BY +12) (equation 2.7) In this case: 2a = 31° and cose = 0.964, b = (12.5/2) = 6.25 mm or 0.00625 m and: n= (102) =05 m 0.964 = (05 +0.00625)/(05 +n) ry = 0.025 m of25.mm The cross sectional area for flow = (0.0125 x 0.4) = 0.005 m? and the volumetric flowrate = (2.0 x 0.005) = 0.010 m°/s. ‘Thus, the actual throughput = (0.010 x 12)/100 = 0.0012 m*/s or: (0.0012 x 2500) = 3.0 ke/s Example 2.3 A ball mill, 1.2 m in diameter, is run at 0.80 Hz.and itis found that the mill is not working properly. Should any modification in the conditions of operation be suggested? Solution ‘The angular velocity is given by: a= Vein, (equation 2.10) In this equation, r = (radius of the mill — radius of the particle). For small particles, r =0.6 m and hence: @.= V9.81/06) = 4.04 rads ‘The actual speed = 2 x 0.80) = 5.02 rad's ud hence it may be concluded that the speed of rotation is too high and that the balls are being carried round in contact with the sides of the mill with litle relative movement or grinding taking place. ‘The optimum speed of rotation lies in the range (0.5-0.75)e.. say 0.6.» of: (0.6 x 404) = 2.42 rads ‘This is equivalent to: (2.42/2x) = 0.39 Hz, or, in simple terms: the f should be halved.