Comminution Theory

The Siam Cement Industry Co.,Ltd.

Content
Principle of Size Reduction
Reduction Ratio
Law of Comminution

The Siam Cement Industry Co.,Ltd.

Process to break solid particle into

small pieces
Need many kind of equipment
e.g.crusher for coarse particle and
grinding mill for fine particle

The Siam Cement Industry Co.,Ltd.

Tensile
Stress

Compressive
Stress

The Siam Cement Industry Co.,Ltd.

Stress

Stress - Strain Curve according to Hookes Law

Yield Point

Fracture
(Ultimate Tensile Strength)

Elastic Limit

dl

Deformation
(Plastic Material)
d stress

Strain (or elongation)

The Siam Cement Industry Co.,Ltd.

Comminution Process

Crushing: rock (1-1.5 m) to raw material (<100 mm)

Grinding : raw mat to raw meal (<2% R200um)
Grinding (and mixing) : clinker and gypsum (<25 mm)

to cement (fineness defined by standard or customer

requirement)
Grinding : raw coal (20 mm) to coal powder

The Siam Cement Industry Co.,Ltd.

Comminution Process
Specific Power Consumption

Raw material crushing

Raw material grinding
Coal grinding
Cement Grinding
Cement plant total
7

1-2
5 - 15
2-4
30 - 60
90 -130

kWh/t clinker
kWh/t clinker
kWh/t clinker
kWh/t clinker
kWh/t clinker

The Siam Cement Industry Co.,Ltd.

Breaking Forces

Impact Forces
Compressive Forces
Shear/Friction Forces
Interparticle contact Forces

The Siam Cement Industry Co.,Ltd.

The Siam Cement Industry Co.,Ltd.

Particle
Size
Before
Reduction
Red. Ratio =
Particle Size After Reduction

10

The Siam Cement Industry Co.,Ltd.

1. Limiting Reduction Ratio

=

11

Top Size of Feed

Top Size of Product
Size of Screen which Feed passes
Size of Screen which Product passes

The Siam Cement Industry Co.,Ltd.

2. Apparent Reduction Ratio

=

Size of Feed Opening

Size of Product Opening
Gap

Set
12

The Siam Cement Industry Co.,Ltd.

3. Working Reduction Ratio

13

Feed Thickness
Set

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4. Medium Reduction Ratio

d50 of Feed
d50 of Product

50

14

Fe
ed

Pro
du
ct

Cumulative % Passing

100

Log Size

The Siam Cement Industry Co.,Ltd.

5. 80% Passing Reduction Ratio

d80 of Feed
d80 of Product

Fe
ed

80

Pro
du
ct

Cumulative % Passing

100

15

b
Log Size
The Siam Cement Industry Co.,Ltd.

1. Rittinger (1867) First Law of Comminution

The energy consumed in the size reduction of

solid is proportional to the surface produced.

16

The Siam Cement Industry Co.,Ltd.

1. Rittinger (1867) First Law of Comminution

1
1
ER = KR [ Xp - Xf ]
Kr = Rittingers Constant
Xf = initial size of the particle
Xp = final size of the particle
Energy input ,ER , is inversely proposional to
the decrease in particle size
17

The Siam Cement Industry Co.,Ltd.

2. Kick (1885) Second Law of Comminution

Deformation energy of a body or work

required for size reduction is
proportional to its volume.

18

The Siam Cement Industry Co.,Ltd.

2. Kick (1885) Second Law of Comminution

Xf
EK = KK log [ Xp ]
Kk = Kicks Constant
Xf = original avg. particle size in unit volume
Xp = final size in unit volume
Energy input is proportional to particle volume reduction
19

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

The energy consumed in size reduction is

proportional to square root of particle
size to be reduced.

20

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

1 1
EB = KB[ X - X ]
P
F
KB = Bonds Constant
XF = particle size of feed
XP = particle size of product
21

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

1 1
EB = KB[ P - F ]
80
80
KB = Bonds Constant
F80 = particle size of feed at 80% pass (in micron)
P80 = particle size of product at 80% pass (in micron)
22

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

1 1
EB = KB[ P - F ]
80
80
KB = 10 Wi
10 10
EB = Wi[ P - F ]
80
80
23

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

Wi is called WORK INDEX

and unit of energy is kWh/ton

24

The Siam Cement Industry Co.,Ltd.

3. Bond (1952) Third Law of Comminution

Wi means energy consumed for size

reduction from very large particle size
down to 100 micron.

25

The Siam Cement Industry Co.,Ltd.

(n = 4)

1010

Grinding Practice

106

n=
er (
ting
Rit

104

Bond

102
1
10-2
10-4

26

(n =

2)

Energy Input, kWh/t

10

1.5)

Crushing Practice

Kick (n = 1)
Possible Plastic
Deformation
Unit Crystal (Quarts)

10-2

102

104

106

Particle Size(10-6 m.)

The Siam Cement Industry Co.,Ltd.

Energy Utilization

EU

S
=
W s 3.6

[cm/J]

S = SSB Pr od SSB Feed [cm 2 / g ]

Ws = specific energy used [kWh/t]

SSB = Specific Surface according to Blaine
27

The Siam Cement Industry Co.,Ltd.

Energy Efficiency

c = Ei / EP
Ei = theoretical energy input
EP = actual energy input
Energy efficiency is relation between theoritical energy input
and actual process input energy
28

The Siam Cement Industry Co.,Ltd.