Mutah University

Faculty of Engineering
Department of Chemical Engineering

Unit Operations Lab 0404533

A Report About Size Reduction by Using a Jaw Crusher

Experiment no. 3

Instructors: Prof. Dr. Nabeel Al Jarrah

Eng. Saja Al Awasa

Date of submission: 13th of April 2025

Student Name Student Number
Arwa Musallam Lassassmeh 120210414019
Rayan Othman Al Masri 120210414078
Ro’a Baker Al Btoush 120210414050
Sarah Muneer Abu Alkhair 120210414081
• Abstract

This experiment investigates the performance of a jaw crusher in the primary

stage of size reduction, using limestone as the feed material. The objective was
to analyse the crusher's efficiency in reducing large feed particles to smaller,
more manageable sizes and to evaluate the energy required for the process
using Bond’s law. Limestone with an average initial particle size of 37.06 mm
was crushed, and the product size at 80% passing was found to be 1.75 mm.
Sieve analysis was conducted to determine the particle size distribution of the
crushed material. The power requirement for the process was calculated to be
0.2179 kW. The results confirmed that the jaw crusher is a reliable and
efficient mechanical device suitable for handling hard and abrasive materials.
It offers advantages such as high throughput, simple operation, and ease of
maintenance, making it ideal for industrial applications in mining,
construction, and aggregate processing. The experiment also emphasized the
relevance of theoretical size reduction laws in predicting energy requirements
and guiding equipment selection.

Possible sources of error include inaccuracies in measuring particle sizes

during sieve analysis, inconsistent feed size due to irregular particle shapes,
potential material loss during handling and sieving, mechanical vibration
affecting uniform crushing, and timing errors when measuring feed duration.
These factors may lead to slight deviations in the calculated mass flow rate,
power requirement, and particle size distribution.
• Introduction
Size reduction is a critical operation in many industries such as mining,
cement, and chemical manufacturing. It involves decreasing the size of solid
particles to enhance handling, reactivity, and downstream processing. The
jaw crusher is one of the most common machines for primary crushing due
to its robustness and ability to handle hard, abrasive materials.
This experiment aims to analyse the performance of a jaw crusher in
reducing the particle size of limestone. By examining feed characteristics,
power consumption, and final particle size distribution, we evaluate the
efficiency of the crushing process. The experiment also involves using
theoretical energy laws—namely Kick’s, Rittinger’s, and Bond’s—to
understand and estimate the power requirements. Given that jaw crushers are
typically applied in coarse crushing, Bond’s law is used for power
calculations in this setup.

• Objectives
1. Investigate how different materials break down when subjected to a
primary crusher (Jaw Crusher) under varying operating conditions.
2. Gain a fundamental understanding of the operating principles of jaw
crushers.
3. Determine the power requirements necessary to achieve size reduction for
a specific material.
• Theory
Size reduction, also known as comminution, is a fundamental operation in
many industries such as mining, chemical processing, metallurgy, and
material science. It involves the mechanical breakdown of large solid
particles into smaller, more manageable sizes. The goal is to enhance surface
area, improve material handling, or prepare feed for further processing.

Purpose of Size Reduction

▪ Increase surface area for reaction or mixing,
▪ Achieve desired particle size for downstream processing,
▪ Improve material flow and handling,
▪ Facilitate separation processes such as flotation or leaching.

A jaw crusher is a widely used piece of equipment for primary crushing. It

is particularly effective for breaking hard and abrasive materials, making it
suitable for the initial stage of comminution.

Working Mechanism of a Jaw Crusher

The jaw crusher operates based on repetitive compressive force. It comprises
two main components:
1. A fixed jaw mounted in a “V” alignment, which remains stationary
during operation.
2. A moving jaw that oscillates in a reciprocating back and forth motion
relative to the fixed jaw powered by an eccentric shaft and toggle
mechanism.

Material is fed into the crushing chamber from the top and is progressively
reduced in size as it moves downward. The reduction occurs when the
movable jaw closes against the fixed jaw, compressing the material. Once
the particles are small enough to pass through the narrow opening at the
bottom (called the discharge gap), they exit the crusher.
The motion of the movable jaw is typically driven by a toggle mechanism
or an eccentric shaft, which imparts a mechanical advantage and allows the
application of high pressure to the feed material.

Key variables influencing performance include:

▪ Jaw gap setting which controls output size.
▪ Feed characteristics (size, hardness, moisture content).
▪ Crusher speed and angle of nip, which affect throughput and
efficiency.

Power Considerations and Laws of Size Reduction

The power required to reduce the size of particles depends on the material
properties and the extent of size reduction. Several empirical laws have been
developed to estimate this energy requirement.
Each law is best suited to specific size ranges:
1. Kick’s Law (Best for Coarse Crushing)
Kick’s law is particularly suitable for coarse crushing, where the change
in surface area is relatively small. It postulates that the energy required
for size reduction is proportional to the logarithm of the ratio between the
initial and final particle sizes. In other words, it assumes that equal energy
is required to achieve the same ratio of size reduction, regardless of the
absolute sizes of the particles. This law is generally applied when dealing
with large feed sizes.
𝑃 1 1
= 𝑘𝑘 ( − )
𝑚̇ 𝐷2 𝐷1
Where:
- 𝑃: Power required for crushing (kW)
- 𝑚̇: Mass flow rate of the material (tons/hour)
- 𝐷1 : Initial average particle diameter (mm)
- 𝐷2 : Final average particle diameter (mm)
- 𝑘𝑘 : Kick’s constant (depends on material properties)

2. Rittinger’s Law (Best for Fine Grinding)

Rittinger’s law is applicable in fine grinding operations. It assumes that
the energy required for size reduction is directly proportional to the
increase in surface area. As the particle size decreases, the surface area
increases significantly, and so does the energy consumption. This law is
most appropriate when fine particles are desired, such as in
pharmaceutical or pigment production.
𝑃 1 1
= 𝑘𝑅 ( − )
𝑚̇ 𝑙2 𝑙1
Where:
- 𝑃: Power required for crushing (kW)
- 𝑚̇: Mass flow rate of the material (tons/hour)
- 𝑙1 : Feed particle diameter (mm)
- 𝑙2 : Product particle diameter (mm)
- 𝑘𝑅 is Rittinger’s constant.
3. Bond’s Law (Best for Intermediate Crushing)
Bond’s law provides a middle-ground approach between Kick’s and
Rittinger’s laws and is most widely used in practical applications,
especially for intermediate size reduction processes. Bond’s law suggests
that the energy required is inversely proportional to the square root of the
particle diameter. This makes it more accurate for medium crushing and
grinding processes, such as those in mineral and cement industries.

𝑃 1 1
= 0.316 𝑤𝑖 ( − )
𝑚̇ √𝑙2 √𝑙1
Where:
- 𝑃: Power required for crushing (kW)
- 𝑚̇: Mass flow rate of the material (tons/hour)
- 𝑤𝑖 : Bond’s Work Index (kWh/ton), a material-specific constant
- 𝑙1 : Feed particle diameter (mm)
- 𝑙2 : Product particle diameter (mm)

Bond’s Work Index is defined as the energy required to reduce a very large
feed to a size such that 80% of the product passes through a 100 µm screen.
It gives a practical measure of material hardness.

Below are typical values for some materials:

Materials Work Index (kWh/ton)

Limestone 12.74
Phosphate Rock 9.92
Cement Clinker 13.45
Industrial applications
1. Mining & Metallurgy
Primary crushing of ores (e.g., iron, copper) to prepare for grinding
and mineral separation.
2. Construction & Recycling
Crushing concrete, bricks, and asphalt into reusable aggregates for
sustainable construction.
3. Cement & Chemical Industries
Reducing raw materials (like limestone or chemicals) for efficient kiln
feeding or reactions.
4. Power & Waste Management
Crushing coal for combustion and reducing industrial waste volume
for disposal or recycling.

In this experiment, the jaw crusher is used to investigate the crushing

behaviour of different materials under controlled conditions. Kick’s Law
is the most applicable, as jaw crushers are typically used for coarse size
reduction. However, understanding Rittinger’s and Bond’s laws
provides a complete theoretical framework for analysing the energy
efficiency of crushing operations across various particle sizes.
• Apparatus & Materials
- Apparatus
1. Laboratory Jaw Crusher
▪ A jaw crusher operates on the compression principle, where the
material is crushed between two jaws—one fixed and the other
moving.
▪ The fixed jaw remains stationary and serves as a rigid support surface.
▪ The swing jaw (or movable jaw) pivots to exert compressive force on
the feed material.
▪ The angle between the two jaws (called the jaw angle) typically ranges
from 20° to 40°, allowing material to be efficiently crushed as it
moves downward.
▪ The swing jaw operates at speeds between 250 to 400 strokes per
minute, depending on the crusher’s design and material characteristics.
▪ It is widely used in laboratories and industries due to its simplicity,
rugged design, and efficiency in breaking down hard and abrasive
materials.
2. Digital Electronic Weighing Balance
▪ A precision digital balance is used to weigh the feed and the crushed
product before and after the crushing process.
▪ Accurate mass measurements are essential for calculating energy
consumption and efficiency.

3. Stopwatch
▪ Used to measure the exact time taken for the crushing operation,
which is vital for calculating the feed rate and energy consumption
per unit time.

4. Sieve Shaker with Sieve Set

▪ A set of sieves with different mesh sizes is used to classify the
crushed material.
▪ The sieve shaker facilitates uniform and consistent particle separation
based on size.
▪ It helps in determining the size distribution of the product and
calculating parameters such as 𝑙2 (product size diameter).

- Materials
▪ In this experiment, limestone was selected as the feed material due to
its moderate hardness and relevance in cement and construction
industries.
▪ The feed material is weighed, and its average particle diameter is
measured before and after crushing.
• Procedure
1. Sample Preparation
Select samples of various particle sizes and accurately weigh the
required quantity for testing.
2. Feed Characterization
Measure the average particle size of the feed and record the initial
mass of the feed material.
3. Crusher Setup
Adjust the jaw gap to a predetermined setting and load the sample into
the jaw crusher.
4. Crushing Operation
Start the crusher and operate it for a specified duration or until the
entire sample has been fully processed.
5. Product Collection
Collect the crushed material from the output tray.
6. Product Weighing
Weigh the total mass of the crushed material to ensure mass balance.
7. Sieving Analysis
Arrange the test sieves in the correct order and sieve the crushed
product to separate particle size fractions.
8. Data Recording
Record the mass of material retained on each sieve for subsequent
analysis.

• Safety Precautions
1. Always wear protective safety goggles when operating the jaw
crusher.
2. Ensure that only trained personnel operate the equipment.
3. Be cautious of operational hazards, such as high noise levels and
flying debris.
4. Strictly follow the manufacturer's safety instructions and operational
procedures.
• Data & Calculations
- Experimental Data

Mass of
Mesh
Mesh Sieves & Sieves Mass Accumulative
Diameter Particles Mass
Diameter Particles mass Fraction Fraction
(mm)
(g)
2 mm 2 879.70 381.02 498.68 0.49497 1
1.4 mm 1.4 469.66 372.00 97.66 0.09693 0.50503
710 μm 0.71 480.60 344.04 136.56 0.13554 0.40810
500 μm 0.5 362.54 313.66 48.88 0.04851 0.27256
250 μm 0.25 365.90 288.50 77.40 0.07682 0.22405
125 μm 0.125 368.70 275.96 92.74 0.09205 0.14723
63 μm 0.063 319.22 275.10 44.12 0.04379 0.05518
45 μm 0.045 271.38 260.36 11.02 0.01093 0.01139
Pan Pan 244.72 244.30 0.42 0.00416 0.00046
∑ 𝑚𝑝 : 1007.48

- Given Data

Feed Mass (mF ) 1017.28 g

Feed Average Particles Diameter (𝑙1 ) 3.30625 cm
Time (t) 40 s
Work Index of Limestone ( wi ) 12.74 kW ∙ h⁄ton
Graph

Accumulative Fraction Vs. Mesh Diameter

1.2

1
Accumulative Fraction

0.8

0.6

0.4

0.2

0
0 0.5 1 1.5 𝒍𝟐 2 2.5
Mesh Diameter (mm)

- The value of 𝑙2 at 80% of the product passing through a 100 μm is

1.75 mm.

Calculation Samples:

- All diameters should be in mm:

1. Convert the Feed Average Particles Diameter 𝑙1 from cm to mm
using:
1 cm
10 mm
For 𝑙1 = 3.30625 cm
10 mm
𝑙1 = 3.30625 cm × = 37.0625 mm
1 cm

2. Convert the Mesh Diameter from 𝜇𝑚 to 𝑚𝑚 using:

1000 𝑚𝑚
106 𝜇𝑚
For 710 𝜇𝑚
1000 𝑚𝑚
710 𝜇𝑚 × = 0.71 𝑚𝑚
106 𝜇𝑚
- To calculate the mass flowrate ṁ ( ton⁄h ):
1. Convert the mass of the feed from g to ton using:

1000 g
0.001 ton

2. Convert the time from s to h using:

1h
3600 s

For mF = 1017.28 g and t = 40 s

1017.28 g 0.001 ton 3600 s

ṁ = × × = 0.0915 ton⁄h
40 s 1000 g 1h

- To calculate the Power of Jaw Crusher required for crushing use Bond’s
Law:
1 1
P = 0.316 wi × ṁ × ( − )
√𝑙2 √𝑙1

Given that the Work Index of Limestone is wi = 12.74 kW ∙ h⁄ton

and 𝑙2 = 1.75 mm:
kW ∙ h ton 1 1
P = 0.316 × 12.74 × 0.0915 ×( − )
ton h √1.75 mm √37.0625 mm

P = 0.2179 kW
• Results
The following outcomes were obtained from the experiment:
- Feed Mass: 1017.28 g
- Average Feed Size (𝑙₁): 3.30625 cm (converted to 37.0625 mm)
- Time: 40 seconds
- Mass Flowrate: 0.0915 ton/h
- Product Size (𝑙₂ at 80% passing): 1.75 mm
- Power Consumption (Bond’s Law):
kW ∙ h ton 1 1
P = 0.316 × 12.74 × 0.0915 ×( − )
ton h √1.75 mm √37.0625 mm

P = 0.2179 kW

• Discussion
The results of the experiment demonstrated the effectiveness of the jaw
crusher in reducing the average feed particle size of limestone from 37.06 mm
to 1.75 mm at 80% passing. The power required for the process, calculated
using Bond’s law, was 0.2179 kW. This value is consistent with expectations
for materials of moderate hardness and reflects the relatively low energy
consumption of jaw crushers for coarse crushing applications.
The sieve analysis revealed a wide range of particle sizes in the crushed
product, with nearly 50% of the mass retained above the 2 mm mesh and the
rest distributed across finer sieves. This variability is typical of jaw crushing
processes, which produce both coarse fragments and fines due to random
fracture patterns.
The experiment confirms the jaw crusher’s suitability for primary crushing,
offering benefits such as mechanical simplicity, ease of maintenance, and high
throughput. These features make it especially valuable in mining and
construction where bulk material handling is essential.
▪ Sources of Error
Despite the overall success, several sources of error may have influenced
the results:
- Inconsistent feed size due to non-uniform particle shapes.
- Material loss during transfer and sieving, leading to slight mass
imbalances.
- Timing inaccuracies when recording the duration of the crushing
process.
- Vibration or uneven wear in the jaw mechanism affecting uniformity.
- Sieving inefficiencies, especially for finer particles, possibly skewing
size distribution data.

Such factors may result in minor deviations in calculated parameters like

power requirement, mass flow rate, and size reduction ratio. Future studies
could benefit from automated feeding systems, controlled feed shapes, and
repeat trials to minimize variability.

• Conclusion

This experiment successfully demonstrated the principles and performance of

a jaw crusher in primary size reduction. Limestone, a moderately hard
material, was effectively reduced from a feed size of 37.06 mm to 1.75 mm at
80% passing. The calculated power requirement of 0.2179 kW validated the
application of Bond’s law for intermediate size reduction.

The jaw crusher proved to be an efficient and practical device, operating on the
compression principle to break down large particles between a fixed and a
moving jaw. Its high throughput capacity, simple design, and ease of
maintenance make it a reliable choice in industries such as mining,
construction, and aggregate processing.

Additionally, the crusher offers the critical benefit of preparing feed material
for subsequent processing stages such as secondary crushing, grinding, or
chemical treatment. While minor experimental errors were observed, the
overall results reinforce the importance of jaw crushers in industrial material
preparation and the value of theoretical models in estimating energy
requirements.
• References
- Instructor Notes
- Laboratory Manual
- McCabe, W. L., Smith, J. C., & Harriott, P. (2005). Unit Operations of
Chemical Engineering (7th ed.). McGraw-Hill.
- Wills, B. A., & Finch, J. (2016). Wills' Mineral Processing Technology
(8th ed.). Butterworth-Heinemann.
- Bond, F. C. (1952). “The Third Theory of Comminution,” Transactions
on AIME, 193:484–494.