BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

Private Mail Bag 16

Palapye, Botswana
BIUST Website: www.biust.ac.bw Tel: (+267)4900117
Fax: (+267)4900102

UNIT OPERATIONS 1, CHEE 220

TUTORIAL 1 MEMO

QUESTION 1

The energy dE required to effect a small change dx in the size of unit mass of material is a simple power
function of the size.
𝑑𝐸 = −𝐾𝑥 −𝑛 𝑑𝑥
The integration gives:
𝑃
𝐸 = −𝐾 ∫ 𝑥 −𝑛 𝑑𝑥
𝐹

Where n (1, 2 or 3/2) and K are constants

F – Feed particle diameter
P – Product particle diameter

Given the above information, derive Kick’s law and Rittinger’s Law.

Solution:

By using integration

Kick’s law, n = 1

𝐹
𝐸𝐾 = 𝐾 ln ( )
𝑃

Rittinger’s law, n = 0

1 1
𝐸𝑉𝑅 = 𝐾 ( − )
𝑃 𝐹
 BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

QUESTION 2

a) A certain crusher accepts a feed material having an average size of 19mm and gives a product of
5mm. The power required to crush 15 tonnes per hour is 7.5 kW. What will be the power
consumption if the capacity is reduced to 12 tonnes per hour?

b) What will be the power required to crush 150 tonnes per hour of limestone if 80 percent of the
feed passes 50 mm screen and 80 percent of the product a 3.125 mm screen?

Solution:

a) We have:
𝑃 1 1
= 𝐾( − )
𝑚̇ 𝑝 𝐹

Where: P is the power consumption in kW

ṁ is the feed rate in tonnes per hour

7.5 1 1
= 𝐾( − )
15 0.005 0.019
Therefore:
𝐾 = 3.4 𝑋 10−3

Power consumption for crushing 12 tonnes per hour is:

𝑃 1 1
= 3.4 𝑋 10−3 ( − )
12 0.005 0.019

𝑃 = 6 Kw

b) We have:

𝑃 1 1
= 0.3162 𝑊𝑖 ( − )
𝑚̇ √𝑃80 √𝐹80

The work index for limestone, Wi = 12.74

 BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

𝑃 1 1
= 0.3162 𝑋 12.74 ( − )
150 √3.125 √50

𝑃 = 256.4 kW

QUESTION 3

A material consisting originally of 20 mm particle was crushed to an average size of 5 mm and it required
30 kJ/kg for this size reduction. Determine the energy required to crush the material from 20 mm to 3 mm
assuming

(a) Rittinger’s law,

(b) Kick’s law and

(c) Bond’s Law.

Solution:
a) Von Rittinger’s law:
1 1
𝐸𝑉𝑅 = 𝐾 ( − )
𝑃 𝐹
1 1
30 = 𝐾 ( − )
5 20
Therefore:
30
𝐾 = 1 1 = 200 kW/(kg mm)
( − )
5 20
Energy required to crush from 20 mm to 3 mm is:
1 1 1 1
𝐸𝑉𝑅 = 𝐾 ( − ) = 200 ( − )
𝑃 𝐹 3 20
𝐸𝑉𝑅 = 56.67 kW/kg

b) Kick’s law:
𝐹
𝐸𝐾 = 𝐾 ln ( )
𝑃
20
30 = 𝐾 ln ( )
5
Therefore:
30
𝐾 = 20 = 21.64 kW/kg
ln( )
5
Energy required to crush from 20 mm to 3 mm is:
 BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

𝐹 20
𝐸𝐾 = 𝐾 ln ( ) = 21.64 ln ( )
𝑃 3
𝐸𝐾 = 41.05 kW/kg

c) Bond’s law:
To get the energy (kWh/ton) required, there is need for a conversion:
𝑃𝑜𝑤𝑒𝑟 𝑃
𝐸𝑛𝑒𝑟𝑔𝑦(𝑊) = =
𝑚̇𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑚̇
𝑘𝐽
( )(3600𝑠) 3600𝑘𝐽
𝑠
𝑊(𝑘𝑊ℎ/𝑡𝑜𝑛) = = 1000𝑘𝑔 = 3.6 kJ/kg
1000𝑘𝑔

So:
30
𝑊 = 3.6 = 8.33 kWh/ton

Also:
F = 20 mm = 20 000 µm and P = 5 mm = 5 000 µm

And:
1 1
𝑊 = 10 × 𝑊𝑖 ( − )
√𝑃80 √𝐹80
1 1
8.33 = 10 × 𝑊𝑖 ( − )
√5000 √20000
Therefore:
8.33
𝑊𝑖 = 1 1 = 117.85 kWh/ton
10( − )
√5000 √20000

Now:
F = 20 mm = 20 000 µm and P = 3 mm = 3 000 µm

So, energy required to crush from 20 mm to 3 mm is:

1 1 1 1
𝑊 = 10 × 𝑊𝑖 ( − ) = 10 × 117.85 ( − )
√𝑃80 √𝐹80 √3000 √20000
𝑊 = 13.18 kWh/ton = 13.18𝑥3.6 = 47.46 kW/kg
 BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

QUESTION 4
A crusher was used to crush a material. The size of the feed was minus 50 mm, plus 40 mm. The screen
analysis of the product was:

Size of aperture (mm) Amount of product (%)

through 6.0 mm All
On 4.0 mm 26
On 2.0 mm 18
On 0.75 mm 23
On 0.50 mm 8
On 0.25 mm 17
On 0.125 mm 3
On 0.125 mm 5

What power is required to crush the material using (a) Von Rittinger’s law, (b) Kick’s law and (c)
Bond’s law from a feed of minus 45 mm, plus 40 mm to a product passing 80% if Kvr = 0.56 kJ/kg; Kk =
0.239 kJ/kg and Wi = 18 kJ/kg.

Solution:

50+40
Mean diameter of feed: = = 45 mm
2

Mean diameter of product passing 80%:

Size of aperture (mm) Amount of Cumulative (%)

product (%)
through 6.0 mm All -
on 4.0 mm 26 26
on 2.0 mm 18 44
on 0.75 mm 23 67
on 0.50 mm 8 75
on 0.25 mm 17 92
on 0.125 mm 3 95
on 0.125 mm 5 100

From the tabulated data, 80% of the product in the distribution passes a 0.25 mm sieve
and therefore P = 0.25 mm
 BOTSWANA INTERNATIONAL UNIVERSITY OF SCIENCE AND TECHNOLOGY

Therefore:
a) Energy consumption using von Rittinger’s law:

1 1 1 1
𝐸𝑉𝑅 = 𝐾𝑉𝑅 ( − ) = 0.56 ( − )
𝑃 𝐹 0.25 45
𝐸𝑉𝑅 = 2.215 kJ/(kg/s)

b) Energy consumption using Kick’s law:

𝐹 45
𝐸𝐾 = 𝐾 ln ( ) = 0.239 ln ( )
𝑃 0.25
𝐸𝐾 = 1.24 kW/(kg/s)

c) Energy consumption using Bond’s law:

Bond work index, Wi = 18/3.6 = 5 kWh/ton
Also:
F = 45 mm = 45 000 µm and P = 0.25 mm = 250 µm

So:
1 1 1 1
𝑊 = 10 × 𝑊𝑖 ( − ) = 10 × 5 ( − )
√𝑃80 √𝐹80 √250 √45000
𝑊 = 2.93 kWh/ton = 10.54 kJ/kg