Variations of Particle Fracture

Abrasion
"

Comminution

"

Localized stresses at the surface

Occurs when insufficient energy is applied to
cause significant fracture of the particles

Rittinger s, Kick s and Bond s Laws

Crushing and Grinding

Variations of Particle Fracture

!

Cleavage
"
"

Slow compression
Occurs when energy applied
is just sufficient to load
comparatively few regions of
the particles to the fracture
point

Variations of Particle Fracture

!

Shatter
"
"

"

Impact
The applied energy is well in
excess of which is required for
fracture
Comparatively large number of
particles with a wide range of
sizes

Stages of Comminution
!

Primary Crushing
"
"
"
"
"

Jaw Crusher
Gyratory Crusher
Cone Crusher
Roll Crusher
Impactor

Secondary Grinding
"
"
"
"

Operation

Ball Mill
Rod Mill
Autogenous / SemiAutogenous Mill
Tower Mill

Reduction Ratio

Rr =

Stages of Size Reduction

Explosive Shattering
10 Crushing
20 Crushing
Coarse Grinding
Fine Grinding
Very Fine Grinding
Superfine Grinding

Jaw Crusher

d feed
d product

For crushing, it is often taken as the ratio of

the feed opening (gape) to the discharge
opening (set) of equipment
Maximum particle sizes are used
sometimes

Consists of 2 crushing
faces or jaws:
"
"

one stationary and

rigidly mounted
one moving, swinging
relative to the fixed jaw

Size Range
< x 1m
1m < x 100mm
100mm < x 10mm
10mm < x 1mm
1mm < x 100m
100m < x 10m
10m < x 1m

Types of Jaw Crushers

!

Blake
"

Movable jaw is pivoted at the top

Gyratory Crushers
!

Relative motion of the

crushing faces is due to
gyration motion of an
eccentrically mounted
cone
Crushes on full cycle

Types of Jaw Crushers

!

Dodge Type
"

The movable jaw is fixed at the bottom

Cone Crusher
!

!
!
!

Modified gyratory
crusher
Smaller product
Fast discharge
Non-choking

Types of Cone Crushers

STANDARD

SHORT HEAD

Roll Crushers
!

Consists of two horizontal cylinders revolving

towards each other

Impactors
!

Comminution by impact; sharp blows on freefalling rock

Grinding
!

Size reduction by impact + abrasion

Motion of Charge in TM s
!

Cascading
"
"

!
!
!

Done either wet or dry

Performed primarily on rotating cylindrical steel
vessels (tumbling mills)
May or may not use grinding medium (balls or rods)

Motion of charge in tumbling mills

Cataracting
"
"

Rolling motion of the charge down to the toe

Leads to finer grinding by abrasion
Parabolic path taken by charge as projected by
lifting of the mill
Coarse grinding by impact

Centrifuging
"

Charge is carried around in a fixed position

Rod Mill
!
!

Uses cast iron rods as grinding medium

Length is 1.5-2.5x the diameter

Discharge types

Ball Mill
!
!

Uses forged steel balls as grinding medium

Length is 1-1.5x the diameter

Autogenous / SAG Mills

!
!

!
!

The action of the ore

grinding upon itself
Uses tumbling to effect
grinding; little or no
medium!
Length is of diameter
Semi-Autogenous
Grinding (SAG) Mill
uses 6%-10% mill
volume ball charge

Tower Mill
Alternative to ball
mills for very fine
grinding
Steel balls or
pebbles in a
vertical grinding
chamber with
internal screw