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Energy Analysis in Size Reduction Unit

The document discusses size reduction equipment and analysis of energy required for size reduction. It covers objectives of size reduction, sieve analysis including particle size distribution and fineness modulus. It also discusses the mesh number system. Finally, it describes mathematical models for energy analysis including Rittinger's law, Kick's law, and Bond's law along with examples of calculations using Bond's law to determine power requirements for size reduction equipment.

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Kyla Marie Plaza
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87 views

Energy Analysis in Size Reduction Unit

The document discusses size reduction equipment and analysis of energy required for size reduction. It covers objectives of size reduction, sieve analysis including particle size distribution and fineness modulus. It also discusses the mesh number system. Finally, it describes mathematical models for energy analysis including Rittinger's law, Kick's law, and Bond's law along with examples of calculations using Bond's law to determine power requirements for size reduction equipment.

Uploaded by

Kyla Marie Plaza
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Energy Analysis in Size

Reduction Equipments

Dr. J. Badshah
Dairy Engineering Department
Sanjay Gandhi Institute of Dairy
Technology
Objectives of Size Reduction Units

Size
reduction
causing
Increase
in surface
Area
Sieve Analysis
 Particle size distribution in granular materials :
Sieving or screening
 Classification in course, medium and fine grains
 Uniformity Index= Course : Medium : Fine grains
 If it is 1: 3 : 6, then Course grain = 1/10, edium = 3/10
and Fine grains = 6/10
 Fineness Modulus: Defined as the sum of the percent
weight fraction retained above each sieve divided by
100.
 Average size of particles in inches = D p = 0.0041 (2) F.M.

 Average Size of Particles in mm, Dp = 0.135 (1.366)F.M.


Sieve Stack arranged in increasing order
of mesh size
• 7 3/8 Mesh weight fraction% w1
• 6 4 Mesh w2
• 5 8 w3 F.M. = (w1x7+ w2x6+ w3 x5
• 4 14 w4 + w4x4+ w5x3+ w6 x2
• 3 28 w5 w7x1+ w8 x0 )/100
• 2 48 w6
• 1 100 w7
• 0 Pan w8
Mesh Number System
• The mesh number system is a measure of how many
openings there are as per linear inch in a screen.
• Sieving is a method of separating a mixture or grains
into two or more size fractions. The oversize materials
are trapped above the screen, while undersize materials
can pass though the screen. In stacks, sieve divides
samples into various size fractions.
• There are two mesh sizes 9I) US Sieve size and Tyler
equivalent size or Tyler Mesh Size. Table is available for
ex. 10 Us sieve = 9 Tyler mesh = 2 mm,
• 40 US Sieve = 35 Tyler mesh = 0.420 mm and 100 US
sieve = 100 Tyler Mesh = 0.149 mm particle size opening
eyc.
Energy Analysis of Size Reduction Unit
 Mathematical Models for energy dE required to produce small
change dx in the size of a unit mass of material
i. General Model : dE/dx = - K /xn

 Rittinger’s Law:
i. Energy required is proportional to the new surface area
produced, i.e. n=2
ii. dE/dx= - K /x2
iii. On Integration E = KR [1/x2 – 1/x1]
iv. x1 and x2 are the average size of feed and product particles
v. E is the energy per unit mass required to produce this increase
in surface area and KR is Rittinger’s constant
vi. It is found to hold better for fine grinding where greater
change in surface area is required.
Energy Analysis of Size Reduction Unit
 Kick’s Law:
i. Energy required is proportional to size reduction ratio i.e. n=1
ii. dE/dx= - K /x1 ∫dE = - ∫ K /x for limit x1 to x2
iii.On Integration E = Kk ln (x1 / x2 )
iv. x1 and x2 are the average size of feed and product particles
v. E is the energy per unit mass required to produce this increase in size and K k is
Kicks’ constant
vi. Kick’s law has been found to apply best to coarse crushing
 Bond’s Law:
i. Energy required is proportional to the square root of the surface to volume
ratio of the product and n = 3/2
ii. dE/dx= - K /x3/2 ∫dE = - ∫ K /x3/2 for limit x1 to x2
iii. On Integration E = 2 KB [ 1/√x2 - 1/√x1 ]
iv. x1 and x2 are the average size of feed and product particles
v. E is the energy per unit mass required to produce this increase in size and K B is
Bonds’ constant
vi. Bond’s law has been found to apply best to variety of materials undergoing
coarse, intermediate and fine grinding
Bonds’law in terms of Bond Work Index
• Energy Required in KW hr per unit mass in ton
Ranges from 10 -20 KWhr/ton
• Dp and Df are size such that 80 % of the sample
passed through mesh of diameter Dp and Df in mm
respectively.
• Wi Bond work index in (2000 lb) is the work
required to reduce from a very size to that size in
which 80% passing through the 100 micron screen
• P= kilowatt and m = ton/ hr Kb = √(100x10 -3
) wi =
0.3162 wi
• P/m= 0.3162 wi [1/ √Dp - 1/√Df ]
Numericals on Bonds’ law
 What is the power required to crush 100 tons /hr of limestone
if 80 per cent of the feed passes a 2 – in screen and 80% of
the product a 1/8 –in screen? Given index for limestone is
12.74
 Solution: M = 100 tons /hr
 Dpa = 2 inch = 2x 25.4 = 50.8 mm
 Dpb = 1/8 inch = 1/8x 25.4 = 3.175 mm
 The Power Required P/m = 0.3162 wi [1/ √Dp - 1/√Df ]
 Therefore, P = 100 x 0.3162 x12.74 (1/ √3.175 – 1/ √ 50.8)
 Therefore P = 169.6 KW = 227 hp
Numericals on Bonds’ Law
 Sugar is ground from crystal of which 80%
pass 30 mesh screen down to a size in which
80% pass a 200 mesh sieve and 5 h.p. metor is
sufficient for required throughput. If the
requirement is changed such that the
grounding is only down to 80% through a 150
mesh sieve but the throughput is to be
increased by 80%. Would the existing motor
has the sufficient power to operate the
grinder. Assume Bond Equation.
Numericals on Bonds’ Law
 Df = 30 mesh = 0.595 mm
 Dp1 = 200 mesh = 0.074 mm
 Dp2 = 150 mesh = 0.110 mm
 M1 = m
 M2 = 1.8 m
 P1 = 5 h.p. = 5 x 0.746 = 3.730 Kw
 Using Bonds’ Law
 The Power Required P/m = 0.3162 wi [1/ √Dp - 1/√Df ]
 3.73/m = 0.3162 wi [1/ √0.074 - 1/√0.595 ] ---------(1)
 Similarly P2/ 1.8 m = 0.3162 Wi [ 1/ √0.110 - 1/√0.595 ]----(2)
 On solution P2 = 6.55 h.p. ( Not Sufficient)

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