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Summary of Calculation:: Part 1: Size Reduction Result
Summary of Calculation:: Part 1: Size Reduction Result
Reduction energy
prediction:
Rittinger Bond Kick
13743.72 0.00405
Reduction energy (kJ/kg) 1 2 8.673
Appendix
Part A
B)
Table 1: Feed size distribution
Average size (µm) 6 5 4 3 2 1
Fraction 0.18 0.42 0.3 0.06 0.04 0
Table 2: Specific rate of breakage and breakage distribution for ball mill (5 mins grinding
time)
Average size (µm) 6 5 4 3 2 1
Interval no (j) 1 2 3 4 5 6
Sj 0.7 0.6 0.5 0.35 0.3 0
b(1,j) 0 0 0 0 0 0
b(2,j) 0.32 0 0 0 0 0
b(3,j) 0.29 0.4 0 0 0 0
b(4,j) 0.14 0.2 0.5 0 0 0
b(5,j) 0.13 0.2 0.25 0.6 0 0
b(6,j) 0.12 0.2 0.25 0.4 1 0
Assume that S is a rate of breakage. The following equation expresses the rate of change of
the mass of particles in size interval i with time:
d mi j=i −2
= ∑ [ b(i , j) S j m j ] −S i mi
dt j=1
j =i−2
Where ∑ [ b (i , j ) S j m j ]=mass brokeninto interval i¿ all intervals of j>i ¿
j=1
Since mi= y i M ∧m j= y j M , we can write a similar expression for the rate of change of mass
fraction of material in size interval i with time:
d y i j=i−2
= ∑ [ b(i , j) S j y j ] −S i y i
dt j=1
Where M is the total mass of feed material and y iis the mass fraction in size interval i
New y 1=0.054
New y 2=0.2083
New y 3=0.2873
New y 4=0.1820
Change of fraction in interval 5:
d y5
=b ( 5,1 ) s 1 y 1 +b ( 5,2 ) s 2 y 2 +b ( 5,3 ) s3 y 3+ b(5,4)s 4 y 4 −S 5 y5
dt
d y5
=0.13 ( 0.7 )( 0.18 )+ 0.2 ( 0.6 )( 0.42 ) +0.25 ( 0.3 ) ( 0.5 ) +0.6 ( 0.35 )( 0.06 )−0.3(0.04 )
dt
d y5
=0.1049
dt
New y 5=0.04+ 0.1049
New y 5=0.1449
New y 6=0.1234
Assumption made:
1. This calculation is assumed to be able to use the values of S and b determined from
small-scale tests for the prediction of product size distributions on a large scale for
industry purpose.
2. This method is assumed to give fairly reliable predictions.
C)
Find the average size for feed, x 1 :
x 1=0.18 ( 6 ) +0.42 ( 5 ) +0.3 ( 4 ) +0.06 ( 3 ) +0.04 ( 2 ) +0
x 1=4.64 µm
x 1=4.64 ×10−6 m
Find the average size for product, x 2 based on the new fraction in each interval calculated:
x 2=0.054 ( 6 )+ 0.2083 (5 )+ 0.2873 ( 4 ) + 0.182 ( 3 ) +0.1449 ( 2 ) +0.1234 (1)
x 2=3.474 µm
x 2=3.474 ×10−6 m
E=C R ( x1 − x1 )
2 1
Given C R =190,
1 1
E=190
(
3.474 ×10−6
−
4.64 ×10−6 )
E=13743721 J /kg
b) Bond’s Law
The total work input represented by a given weight of crushed product is inversely
proportional to the square root of the diameter of the product particles.
1 1
E=C B
(√−
x2 √ x1 )
Given C B=120 ,
1 1
E=120
(√ 3.474 × 10−6
−
√ 4.64 × 10−6 )
E=8673.68 J /kg
c) Kick’s Law
The energy required in comminution process is directly proportional to the ratio of the
volume of the feed particle to the product particle.
Based on stress analysis theory for plastic deformation, Kick’s Law states that
“energy required for comminution process is direction proportional to the reduction ratio”. It
means that the comminution energy required depends only on the reduction ratio and is
independent of the original size of the feed. For an example, this proposal predicts that same
energy is required to reduce 10mm particle to 1mm as is required to reduce 1m boulders to
10cm block since the reduction ratio is same. However, it is very obvious that more energy is
required for the reduction of 10mm to 1mm particle since higher reduction energy is required
for reduction of small particle size to further smaller size. Thus, Kick’s Law is applicable for
large particle size.
Rittinger’s Law states that “reduction energy required is directly proportional to the
area of new surface created”. Rittinger’s Law is for the fine grinding where the increase in
surface area of particles is large. Thus, Rittinger’s Law is applicable when we deal with fine
material since there is more chances to create new surfaces.
Bond’s Law states that “The total work input represented by a given weight of
crushed product is inversely proportional to the square root of the diameter of the product
particles”. Bond’s formula is more suitable for intermediate particle size, the most common
range for many industrial grinding processes.
Kick’s Law is not suitable for fine grinding compared with Rittinger’s Law. Bond’s
Law is an intermediate and more realistic method for prediction of reduction energy.
However, this law is more suitable for intermediate particle size and not applicable for flour.
Thus, Rittinger’s Law is the best prediction method since it is suitable to reduce a small
particle size to a further smaller size.