Problem Set for ChE 154 2nd Long Exam

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 energy of 13.0 kW/(kg/s). What would be the power consumption (in kW assuming a flowrate of 1 kg/s) needed to
crush the same material of average size 75 mm to an average size of 25 mm, assuming
a. Rittinger’s law applies?
𝑃 1 1
= 𝐾𝑟 ( − )
𝑚 𝐷𝑝 𝐷𝑓
13.0 𝑘𝑊 1 1
= 𝐾𝑟 ( − )
𝑘𝑔/𝑠 10 𝑚𝑚 50 𝑚𝑚
𝑘𝑊 − 𝑚𝑚
𝐾𝑟 = 162.50
𝑘𝑔/𝑠
𝑘𝑊 − 𝑚𝑚 1 1
𝑃 = (162.50 ) (1 𝑘𝑔/𝑠) ( − )
𝑘𝑔/𝑠 25 𝑚𝑚 75 𝑚𝑚

𝑃 = 𝟒. 𝟑𝟑𝟑𝟑 𝒌𝑾

b. Kick’s law applies?

𝑃 𝐷𝑓
= 𝐾𝑘 𝑙𝑛
𝑚 𝐷𝑝
13.0 𝑘𝑊 50 𝑚𝑚
= 𝐾𝑘 𝑙𝑛
𝑘𝑔/𝑠 10 𝑚𝑚
𝑘𝑊
𝐾𝑘 = 8.0774
𝑘𝑔/𝑠

𝑘𝑊 75 𝑚𝑚
𝑃 = (8.0774 ) (1 𝑘𝑔/𝑠) 𝑙𝑛
𝑘𝑔/𝑠 25 𝑚𝑚

𝑃 = 𝟖. 𝟖𝟕𝟑𝟗 𝒌𝑾

2. Gideonski is applying as a process engineer to RAM Corp. In the final interview, the executive president opened to him their
plan to expand the operation by adding new equipment including a ball mill. A test will be conducted to simulate an actual
operation of a ball mill. A steel cylinder with dimension 3’ x 6’ is available for the test. There are 2446 balls that can be used with
40% void fraction. When the balls were put in the cylinder, about half of the container was filled. The president asked Gideonski
about the following:
a. Volume of the slurry fed to the simulated ball mill.
𝜋 𝜋
𝑉𝑚𝑖𝑙𝑙 = 𝐷2 𝐿 = (3 𝑓𝑡)2 (6 𝑓𝑡) = 42.4115 𝑓𝑡 3
4 4
42.4115 𝑓𝑡 3
𝑉𝑐𝑜𝑛𝑡𝑒𝑛𝑡 𝑜𝑓 𝑚𝑖𝑙𝑙 = = 21.2058 𝑓𝑡 3 *Content of Mill = Slurry + 2446 balls
2

𝑉𝑠𝑙𝑢𝑟𝑟𝑦 = 21.2058 𝑓𝑡 3 × 0.4 = 𝟖. 𝟒𝟖𝟐𝟑𝒇𝒕𝟑

b. Diameter of a single ball.

𝑉𝑏𝑎𝑙𝑙𝑠 = 21.2058 𝑓𝑡 3 × (1 − 0.4) = 12.7235 𝑓𝑡 3

12.7235 𝑓𝑡 3 12 𝑖𝑛 3
𝑉𝑠𝑖𝑛𝑔𝑙𝑒 𝑏𝑎𝑙𝑙 = ×( ) = 𝟖. 𝟗𝟖𝟖𝟔 𝒊𝒏𝟑
2446 𝑏𝑎𝑙𝑙𝑠 1 𝑓𝑡

𝜋 3
𝑉𝑠𝑖𝑛𝑔𝑙𝑒 𝑏𝑎𝑙𝑙 = 8.9886 𝑖𝑛3 = 𝐷
6

3 8.9886 𝑖𝑛3
𝐷𝑠𝑖𝑛𝑔𝑙𝑒 𝑏𝑎𝑙𝑙 = √ 𝜋 = 2.5797 𝑖𝑛
6

c. Critical speed
76.65
𝑁= = 𝟒𝟓. 𝟗𝟑𝟎𝟏 𝒓𝒑𝒎
1 𝑓𝑡
√3 𝑓𝑡 − (2.5797 𝑖𝑛 ×
12 𝑖𝑛)